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.
SKIDSTEER LOADER
3TS-8T, 3TS-8W Contents
01 - Machine
03 - Attachments, Couplings and Load

Handling
EN - 9813/7400
ISSUE 1 - 03/2017 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
This manual contains original instructions, verified by
the manufacturer (or their authorized representative). 27 - Driveline
30 - Hydraulic System
33 - Electrical System
Copyright 2017 © JCB SERVICE
All rights reserved. No part of this publication may 72 - Fasteners and Fixings
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means, 75 - Consumable Products
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
78 - After Sales
www.jcb.com
Notes:
9813/7400-1
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
3TS-8T, 3TS-8W 3TS-8T, 3TS-8W

EN 9813/7400 EN 9813/7400
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
3TS-8T, 3TS-8W 3TS-8T, 3TS-8W

EN 9813/7400 EN 9813/7400
9813/7400-1
Notes:
9813/7400-1
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
01-03-15 Safety Practice ................................................................................................................. 01-8
01-03-18 Operating Safety .............................................................................................................. 01-9
01-03-21 Worksite Safety .............................................................................................................. 01-11
01-03-24 Risk Assessment ............................................................................................................ 01-12
01-03-27 Maintenance Positions ................................................................................................... 01-13
01-06 About this Manual
01-06-03 Model and Serial Number .............................................................................................. 01-19
01-06-06 Using the Manual ........................................................................................................... 01-20
01-09 Description
01-09-12 Main Component Locations ........................................................................................... 01-23
01-09-15 Service Point Locations ................................................................................................. 01-25
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-33
9813/7400-1
2017-02-07
Acronyms Glossary
PIL Parts Identification List
9813/7400-1
2017-02-07
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
01-03-15 Safety Practice ................................................................................................................. 01-8
01-03-18 Operating Safety .............................................................................................................. 01-9
01-03-21 Worksite Safety .............................................................................................................. 01-11
01-03-24 Risk Assessment ............................................................................................................ 01-12
01-03-27 Maintenance Positions ................................................................................................... 01-13
01 - 1 9813/7400-1 01 - 1
Notes:
01 - 2 9813/7400-1 01 - 2
01 - Machine
03 - Safety
03 - Safety - Yours and Others
03 - Safety - Yours and Others
Introduction
All machinery can be hazardous. When a machine

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

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

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

the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
01 - 3 9813/7400-1 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
In this manual and on the machine, there are safety

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

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

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

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

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

important safety messages in this manual and on the
machine. When you see this symbol, be alert, your
safety is involved, carefully read the message that
follows, and inform other operators.
Figure 1. The safety alert system
01 - 4 9813/7400-1 01 - 4
01 - Machine
03 - Safety
09 - General Safety
09 - General Safety Lifting Equipment

You can be injured if you use incorrect or faulty lifting
Introduction equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
Training equipment is in good condition and complies with all
To operate the machine safely you must know the local regulations.
machine and have the skill to use it. You must abide Raised Equipment
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The Never walk or work under raised equipment unless
operator's manual instructs you on the machine, its it is supported by a mechanical device. Equipment
controls and its safe operation; it is not a training which is supported only by a hydraulic device can
manual. If you are a new operator, get yourself drop and injure you if the hydraulic system fails
trained in the skills of using a machine before trying or if the control is operated (even with the engine
to work with it. If you don't, you will not do your job stopped).
well, and you will be a danger to yourself and others. Make sure that no-one goes near the machine while
In some markets and for work on certain jobsites you you install or remove the mechanical device.
may be required to have been trained and assessed
in accordance with an operator competence scheme. Raised Machine
Make sure that you and your machine comply with Never position yourself or any part of your body
relevant local laws and jobsite requirements - it is under a raised machine which is not correctly
your responsibility. supported. If the machine moves unexpectedly you
Care and Alertness could become trapped and suffer serious injury or be
killed.
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always Lightning
be alert for hazards. Lightning can kill you. Do not use the machine if there
Clothing is lightning in your area.
You can be injured if you do not wear the correct Machine Modifications
clothing. Loose clothing can get caught in the This machine is manufactured in compliance with
machinery. Keep cuffs fastened. Do not wear a prevailing legislative requirements. It must not be
necktie or scarf. Keep long hair restrained. Remove altered in any way which could affect or invalidate its
rings, watches and personal jewellery. compliance. For advice consult your JCB dealer.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
01 - 5 9813/7400-1 01 - 5
01 - Machine
03 - Safety
12 - Maintenance Safety
12 - Maintenance Safety Hydraulic Pressure

Hydraulic fluid at system pressure can injure you.
Introduction Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
Raised Machine service line has been vented before connecting or
Never position yourself or any part of your body removing hoses. Make sure the engine cannot be
under a raised machine which is not correctly started while the hoses are open.
supported. If the machine moves unexpectedly you 'O' rings, Seals and Gaskets
could become trapped and suffer serious injury or be
killed. Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
Air Conditioning Maintenance accidents. Renew whenever disturbed unless
The air conditioning system is a closed loop system otherwise instructed. Do not use Triochloroethane or
and contains pressurised refrigerant. No part of the paint thinners near 'O' rings and seals.
system should be disconnected until the system Arc Welding
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely To prevent the possibility of damage to electronic
frostbitten or injured by escaping refrigerant. components, disconnect the battery and the
alternator before arc-welding on the machine or
Compressed Air attached implements.
Compressed air is dangerous. Wear personal If the machine is equipped with sensitive electrical
protective equipment. Never point a compressed air equipment, i.e. amplifier drivers, electronic control
jet at yourself or others. units (ECUs), monitor displays, etc., then disconnect
Springs them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Always wear personal protective equipment when
irreparable damage to these components.
dismantling assemblies containing components
under pressure from springs. This will protect against Parts of the machine are made from cast iron, welds
eye injury from components accidentally flying out. on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
Metal Splinters
or apply any weld to any part of the engine.
You can be injured by flying metal splinters when
Always connect the welder earth (ground) cable to
driving metal pins in or out. Use a soft faced hammer
the same component that is being welded to avoid
or copper drift to remove and install metal pins.
damage to pivot pins, bearings and bushes. Attach
Always wear personal protective equipment.
the welder earth (ground) cable a distance from the
Communications part being welded no more than 0.6m.
Bad communications can cause accidents. If two Counterweights
or more people are working on the machine, make
Your machine may be installed with counterweights.
sure each is aware of what the others are doing.
They are extremely heavy. Do not attempt to remove
Before starting the engine make sure the others are
them.
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the Accumulators
attachments and linkages, and anywhere beneath or The accumulators contain hydraulic fluid and gas at
behind the machine. People can be killed or injured high pressure. Prior to any work being carried out
if these precautions are not taken. on systems incorporating accumulators, the system
Repairs pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
If your machine does not function correctly in
cause serious injury or death.
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect Hot Components
your health. Do not try to do repairs or any other Touching hot surfaces can burn skin. The engine and
type of maintenance work you do not understand. To machine components will be hot after the unit has
avoid injury and/or damage get the work done by a been running. Allow the engine and components to
specialist engineer. cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
01 - 6 9813/7400-1 01 - 6
01 - Machine
03 - Safety
12 - Maintenance Safety
Working Under the Machine

Make the machine safe before getting beneath it.
Make sure that any attachments on the machine are
correctly attached. Engage the park brake, remove
the ignition key, disconnect the battery. If the machine
has wheels use blocks to prevent unintentional
movement.
Lifting the Machine
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
Chemicals
Certain seals and gaskets (e.g. crankshaft oil
seal) on JCB machines contain fluoroelastomeric
materials such as Viton®, FluorelTM and
Technoflon®. Fluoroelastomeric materials subjected
to high temperatures can produce highly
corrosive hydrofluoric acid. This acid can severely
burn. New fluoroelastomeric components at
ambient temperature require no special safety
precautions. Used fluoroelastomeric components
whose temperatures have not exceeded 300°C
(571.6°F) require no special safety precautions. If
evidence of decomposition (e.g. charring) is found,
refer to the next paragraph for safety instructions.
Do not touch component or surrounding area.
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (571.6°F) (e.g.
engine fire) must be treated using the following
safety procedure. Make sure that heavy duty gloves
and special safety glasses are worn: Thoroughly
wash contaminated area with 10% calcium hydroxide
or other suitable alkali solution, if necessary use
wire wool to remove burnt remains. Thoroughly
wash contaminated area with detergent and water.
Contain all removed material, gloves etc. used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations. Do not
burn fluoroelastiometric materials.
Hydraulic Hoses
Never re-use hydraulic hose end crimps or use
reusable hose end crimps.
Personal Protective Equipment
Use the appropriate personal protective equipment
before performing maintenance on the machine,
otherwise you could be injured.
Working at Height
Use appropriate access equipment such as ladders
or a working platform if it is necessary to work at
height to perform maintenance tasks on the machine.
If you do not use suitable access equipment there is
a risk of falling, resulting in personal injury or death.
01 - 7 9813/7400-1 01 - 7
01 - Machine
03 - Safety
15 - Safety Practice
15 - Safety Practice 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.
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 - 8 9813/7400-1 01 - 8
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 - 9 9813/7400-1 01 - 9
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. Firefighters must use self-
and repair before resuming work. contained breathing apparatus.
Hot Components Roll Over Protection
Touching hot surfaces can burn skin. The engine and If the machine starts to roll over, you can be crushed
machine components will be hot after the unit has if you try to leave the cab. If the machine starts to roll
been running. Allow the engine and components to over, do not try and jump from the cab. Stay in the
cool before servicing the unit. cab, with your seat belt fastened.
Travelling at High Speeds Confined Areas
Travelling at high speeds can cause accidents. Pay extra attention to proximity hazards when
Always travel at a safe speed to suit working operating in confined areas. Proximity hazards
conditions. include buildings, traffic and bystanders.
Hillsides Safe Working Loads
Operating the machine on hillsides can be Overloading the machine can damage it and make it
dangerous if the correct precautions are not taken. unstable. Study the specifications in the Operator's
Ground conditions can be changed by rain, snow, ice Manual before using the machine.
etc. Check the site carefully. When applicable, keep
all attachments low to the ground. Lightning
Visibility If you are inside the machine during a lightning storm
stay in the machine until the storm has passed. If
Accidents can be caused by working in poor visibility. you are outside of the machine during a lightning
Use your lights to improve visibility. Keep the road storm stay away from the machine until the storm
lights, windows and mirrors clean. has passed. Do not attempt to mount or enter the
Do not operate the machine if you cannot see clearly. machine.
Modification of the machine's configuration by the If the machine is struck by lightning do not use the
user (e.g. the fitting of large and non-approved machine until it has been checked for damage and
attachments) may result in a restriction of the malfunction by trained personnel.
machine visibility.
01 - 10 9813/7400-1 01 - 10
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.
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.
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 - 11 9813/7400-1 01 - 11
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 - 12 9813/7400-1 01 - 12
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-13 Make the machine safe before you start a
Health and Safety .......................................... 01-16 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.
If you raise the lift arm to get access for maintenance,

you must install the maintenance strut on the lift arm.
If the cab is to be lifted to get access for

maintenance, you must raise the lift arm and install
the maintenance strut on the lift arm.
Release the hydraulic pressure.
Figure 2.
A B C
A Lift arm lowered B Lift arm raised

C Lift arm and cab raised
Lift Arm Lowered Lift Arm Raised

1. Park the machine on level, solid ground. Refer to If you raise the lift arm to get access for maintenance,
(PIL 01-03). you must install the lift arm maintenance strut on the
lift arm.
2. Lower the lift arm.
3. Put the attachment flat on the ground.
4. Stop the engine and remove the ignition key. If
the keyless ignition option is installed stop the
engine and wait
Duration: 15s
5. Disconnect the battery to prevent accidental
operation of the engine. Refer to (PIL 33-03).
6. If necessary, put blocks against the two sides of
the wheels before you get below the machine.
01 - 13 9813/7400-1 01 - 13
01 - Machine
03 - Safety
Installing the Lift Arm Maintenance Strut 3. Remove the lift arm strut from its stowage
position.
Figure 3. Stowage Radial Lift
4. Raise the lift arm just far enough to install the lift
arm strut.
the keyless ignition option is fitted stop the engine
and wait for the time specified.
Duration: 15s
6. Place the lift arm strut around the lift ram piston
rod. Secure it in position with the strap.
Figure 5.
C Stowage position
Figure 4. Stowage Vertical Lift
A Lift arm strut

B Lift arm strap
7. To prevent any chance of the lift arm creeping
down and trapping your fingers, the lift arm
should be lowered onto the lift arm strut. Lower
the arm carefully, to prevent possible damage to
C the lift arm strut. Stop as soon as the weight of
the lift arm is on the lift arm strut.
8. Disconnect the battery to prevent accidental
operation of the engine.
9. If necessary, put blocks against the two sides of
the wheels before you get below the machine.
C Stowage position
1. Remove the shovel or attachment. Removing the Lift Arm Maintenance Strut
2. Park the machine on level, solid ground. Stop the 1. Raise the lift arm to take the weight off of the lift
engine. arm strut.
01 - 14 9813/7400-1 01 - 14
01 - Machine
03 - Safety

the keyless ignition option is fitted stop the engine
and wait for the time specified.
Duration: 15s
3. Remove the lift arm strut.
4. Secure the lift arm strut in its stowage position.
Refer to Figure 3. Refer to Figure 4.
5. Lower the lift arm to the ground.
01 - 15 9813/7400-1 01 - 15
01 - Machine
03 - Safety
Health and Safety

WARNING Maintenance must be done only by
suitably qualified and competent persons.
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
the ignition key. Disconnect the battery when you
are not using electrical power. If you do not take
these precautions you could be killed or injured.
WARNING Make the machine safe before getting
beneath it. Make sure that any attachments on
the machine are correctly attached. Engage the
park brake, remove the ignition key, disconnect
the battery.
01 - 16 9813/7400-1 01 - 16
01 - Machine
06 - About this Manual
Contents Page No.
01-06-03 Model and Serial Number .............................................................................................. 01-19

01-06-06 Using the Manual ........................................................................................................... 01-20
01 - 17 9813/7400-1 01 - 17
Notes:
01 - 18 9813/7400-1 01 - 18
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:
3TS-8T 2475701
3TS-8W 2475701
01 - 19 9813/7400-1 01 - 19
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 - 20 9813/7400-1 01 - 20
01 - Machine
09 - Description
09 - Description
Contents Page No.
01-09-12 Main Component Locations ........................................................................................... 01-23

01-09-15 Service Point Locations ................................................................................................. 01-25
01 - 21 9813/7400-1 01 - 21
Notes:
01 - 22 9813/7400-1 01 - 22
01 - Machine
09 - Description
12 - Main Component Locations
Introduction
The illustration shows a typical machine model. Your

machine may look different from the one shown.
Figure 6.
J D
F
C
A ROPS/FOPS cab B Fuel tank filler point

C Lift arm/boom D Front working lights
E Quickhitch F Rubber tracks
G Engine top cover H Wheels/tyres
01 - 23 9813/7400-1 01 - 23
01 - Machine
09 - Description
J Exhaust
01 - 24 9813/7400-1 01 - 24
01 - Machine
09 - Description
15 - Service Point Locations
Introduction
Wheeled Machines
Figure 7.
M
L
K
D
G
J H
A Coolant expansion bottle B Fuel sedimenter

C Air intake D Engine oil filler cap
01 - 25 9813/7400-1 01 - 25
01 - Machine
09 - Description
E Engine oil dipstick F Hydraulic oil level indicator, Hydraulic oil filler
cap
G Battery isolator H Battery
J Radiator K Radiator cap
L Window washer fluid bottle M Chain case oil port
01 - 26 9813/7400-1 01 - 26
01 - Machine
09 - Description
Tracked Machines
Figure 8.
M N
K
D
H
J
A Coolant expansion bottle B Fuel sedimenter

C Air intake D Engine oil filler cap
E Engine oil dipstick F Hydraulic oil level indicator, Hydraulic oil filler
cap
G Battery isolator H Battery
J Radiator K Radiator cap
L Window washer fluid bottle M Track tensioner
01 - 27 9813/7400-1 01 - 27
01 - Machine
09 - Description
N Track Sprocket
01 - 28 9813/7400-1 01 - 28
01 - Machine
09 - Description
Service Label The number next to each symbol cross refers to the
service schedule in this manual.
The service label is located inside the rear door. It
is a visual representation of the daily, weekly and The number of grease points on each machine model
six monthly service checks. The label serves as a is indicated at the bottom of the label.
reminder of these service checks and their intervals.
Use the label and the service schedule in this manual Figure 9.
to perform the service checks on time.
The 1,000h and 2,000h checks which are

represented by the outer track are described in this
manual only.
The label shows a picture of the machine. On the

machine are marked the positions of the service
items to check. Surrounding the machine are four
'tracks'. The tracks represent the 10h, 50h, 500h,
1,000h and 2,000h checks. The symbols of each A
check are marked on the corresponding track B
depending on their frequency. A Grease points
B Machine model
01 - 29 9813/7400-1 01 - 29
01 - Machine
09 - Description
Figure 10. 250, 260, 300, 3TS-8W, 330
01 - 30 9813/7400-1 01 - 30
01 - Machine
09 - Description
Figure 11. 225T, 260T, 300T, 320T, 325T, 3TS-8T
01 - 31 9813/7400-1 01 - 31
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-33
01 - 32 9813/7400-1 01 - 32
01 - Machine
33 - Cleaning
00 - General
00 - General Introduction
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-33 or other chemicals, you must adhere to
Preparation .................................................... 01-34 the manufacturer's instructions and safety
precautions.
CAUTION To avoid burning, wear personal
protective equipment when handling hot
components. To protect your eyes, wear goggles
when using a brush to clean components.
Notice: Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
Notice: The efficiency of the rams will be affected
if they are not kept free of solidified dirt. Clean dirt
from around the rams regularly. When leaving or
parking the machine, close all rams if possible to
reduce the risk of weather corrosion.
Notice: Never use water or steam to clean inside
the operator station. The use of water or steam
could damage the machine electrics and render
the machine inoperable. Remove dirt using a
brush or damp cloth.
Clean the product with water and/or steam. Do not

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

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

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

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

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

CAUTION When using a steam cleaner, wear
safety glasses or a face shield as well as
protective clothing. Steam can cause personal
injury.
01 - 33 9813/7400-1 01 - 33
01 - Machine
33 - Cleaning
00 - General
Notice: The engine and other components could Preparation

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

after pressure washing or steam cleaning.
01 - 34 9813/7400-1 01 - 34
03 - Attachments, Couplings and Load Handling
Contents Page No.
03-00 Attachments
03-00-00 General ............................................................................................................................. 03-3
03-09 Lift Arm Quickhitch
03-09-00 General ............................................................................................................................. 03-7
03-09-09 Electronic Quickhitch ...................................................................................................... 03-11
03-30 Shovel
03-30-00 General ........................................................................................................................... 03-15
03-33 Fork
03-33-00 General ........................................................................................................................... 03-19
9813/7400-1
2016-12-21
Notes:
9813/7400-1
2016-12-21
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9813/7400-1 03 - 1
Notes:
03 - 2 9813/7400-1 03 - 2
00 - Attachments
00 - General
Introduction ...................................................... 03-3 A wide range of optional attachments are available
Health and Safety ........................................... 03-4 to increase the versatility of your machine. Only JCB
approved attachments are recommended for use
with your machine. Consult your JCB Distributor for
the full list of approved attachments available.
Some attachments are supplied complete with

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

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

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

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

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

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

until the machine hydraulic oil has reached its normal
working temperature.
03 - 3 9813/7400-1 03 - 3
00 - Attachments
00 - General
Health and Safety

Attachments
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or others.
The use of non-approved attachments could
invalidate your warranty.
Attachments
If you have an attachment which is not covered in the
Operator's Manual do not install it, use it or remove
it until you have obtained, read and understood the
pertinent information. Install attachments only on the
machines for which they were designed.
WARNING! Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
DANGER! Before lowering the attachments to the
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or
close to the machine could fall and be crushed by the
attachments, or get caught in the linkages.
DANGER! Using the forks alone as a working
platform is hazardous; you can fall off and be killed
or injured. Never use the forks as a working platform.
03 - 4 9813/7400-1 03 - 4
09 - Lift Arm Quickhitch
Contents Page No.
03-09-00 General ............................................................................................................................. 03-7

03-09-09 Electronic Quickhitch ...................................................................................................... 03-11
03 - 5 9813/7400-1 03 - 5
Notes:
03 - 6 9813/7400-1 03 - 6
00 - General
Introduction ...................................................... 03-7 Quickhitches are used on machines to allow the rapid
Health and Safety ........................................... 03-8 change of buckets, shovels and other attachments
Remove and Install ......................................... 03-9 on the machine.
Quickhitches do not normally have a specific function

themselves in that they do not carry out handling or
digging operations, but when installed on a machine
they become a part of the overall machine system.
They are usually mounted on the machine by means
of pins that would otherwise be the mountings for the
shovel or attachment.
03 - 7 9813/7400-1 03 - 7
00 - General
Health and Safety

WARNING Do not lean out of the cab to operate
the quickhitch levers. If the controls are moved
accidentally you could be killed or injured.
WARNING Always install the quickhitch latch
hook locking pin (mechanical only). Failure to
install the pin will result in possible failure of the
latching mechanism. Such a failure would result
in the sudden release of an attachment from the
machine and you or others could be killed or
seriously injured.
WARNING The attachment will move when
released. Stand clear and to one side when
releasing the attachment.
WARNING Attachments that are installed with the
use of loader or excavator quickhitches must not
be used to transport or lift persons if the machine
is not designed and equipped to do so.
CAUTION When the quickhitch is attached to the
machine, allowance must be made for the weight
of the quickhitch on the rated operating load. The
mass of the Quickhitch is stamped on the data
plate.
03 - 8 9813/7400-1 03 - 8
00 - General
Remove and Install
Special Tools 3. Discharge the hydraulic pressure. Refer to (PIL

Description Part No. Qty. 30-00).
Slide Hammer Kit 993/68100 1 4. Disconnect the electrical harness from the
quickhitch.
Remove
5. Remove the locking bolt.
1. Make the machine safe. Refer to (PIL 01-03).
2. Tilt the quickhitch fully forward and lower the lift
arm.
Figure 12.
C A
C
D E A
E A
D
H G F
A Locking bolt B Crowd ram pivot pin

C Bolt (x2) D Washer (x2)
E Tapered pivot pin (x2) F Pivot pin
G Quickhitch H Lift arm
6. Remove the pivot pin securing the crowd ram to 9. Remove the bolt.
the quickhitch.
10. Remove the tapered pivot pins.
Special Tool: Slide Hammer Kit (Qty.: 1)
11. Remove the pivot pin.
7. Loosen the bolts but do not fully remove.
12. Remove the quickhitch from the machine.
8. Strike the head of the bolts with a suitable soft
faced hammer to break the tapered pivot pins
free.
03 - 9 9813/7400-1 03 - 9
00 - General
Install
1. Align the quickhitch with the lift arm on the
machine.
2. Install the pivot pin. Make sure that the pivot pin
is within the specified dimension.
Length/Dimension/Distance: 302–305mm
2.1. If the pivot pin is not within the specified
dimension, replace the pivot pin.
3. Install the tapered pivot pins. Use a suitable soft
faced hammer to seat the pivot pins correctly.
4. Install the bolts and washers (x2). Tighten the
bolts by hand to seat the tapered pivot pins.
5. Tighten the bolts to the correct torque value.
6. Install the crowd ram pivot pin.
7. Install the locking bolt.
8. Connect the electrical harness to the quickhitch.
9. Grease the pivot pins. Refer to (PIL 06-12-00).
Table 3. Torque Values

Item Nm
C 562
03 - 10 9813/7400-1 03 - 10
09 - Electronic Quickhitch
09 - Electronic Quickhitch Introduction

Introduction .................................................... 03-11 The electronic powered quickhitch can be used for
Disconnect and Connect ............................... 03-12 faster attachment changeover, it has the following
advantages:
• Positive Engagement
• No risk of hydraulic leaks or loosening in the
event of hydraulic failure
• No risk of going over relief if the pins become
clogged.
03 - 11 9813/7400-1 03 - 11
Disconnect and Connect 6. Lower the lift arm fully to bring the quickhitch
plate attachment bracket below the level of the
lips of the attachment interface.
Disengaging the Attachments 7. Operate the lift arm joystick control lever as if to
1. Stop and park the machine on level ground. roll forward the attachment. When the quickhitch
plate attachment bracket has disengaged from
2. Lower the shovel/attachment to the ground. the lips on the attachment interface, reverse the
machine clear.
2.1. If applicable close the grapple or clam of the
attachment. Figure 14.
3. Press and hold the unlock switch located in the

left hand panel.
Figure 13.
ISO
Engaging the Attachments

1. Align the machine square to the attachment.
2. Verify that the quickhitch locking pins are fully
retracted and the red quickhitch indicator is
A Unlock switch visible prior to engaging the quickhitch plate
B Lock switch attachment bracket into the attachment interface.
4. Verify that the quickhitch locking pins are fully 3. Lower the lift arm fully to bring the quickhitch
retracted from the attachment interface and the plate attachment bracket below the level of the
red quickhitch indicator is fully visible. lips on the attachment interface.
5. If the attachment has connected auxiliary 4. Drive the machine slowly forward. Stop when the
hydraulic couplings, stop the engine. quickhitch plate attachment bracket just touches
the attachment interface.
5.1. Remove the ignition key or if the keyless
ignition option is installed wait. 5. Raise the lift arm and engage the quickhitch plate
Duration: 15s attachment bracket in the lips on the attachment
interface. Stop the movement as soon as the
5.2. Raise the safety control locks and dismount quickhitch plate attachment bracket is engaged
the machine. with the attachment interface.
5.3. Relieve the auxiliary circuit pressure and
disconnect the attachment tail hoses from
the lift arm couplings. Refer to (PIL
30-00-00.
5.4. Return to the cab seat, lower the safety
control locks and start the engine.
03 - 12 9813/7400-1 03 - 12
Figure 15.
6. Move the lift arm joystick control lever to roll back

the attachment slightly.
7. Once the quickhitch plate attachment bracket
is engaged with the attachment interface, press
and hold the lock switch.
8. Verify that the quickhitch locking pins are fully
extended into the attachment interface and the
red quickhitch indicator is not visible.
9. If the attachment has connected auxiliary
hydraulic couplings, stop the engine.
9.1. Remove the ignition key or if the keyless
ignition option is installed wait.
Duration: 15s
9.2. Raise the safety control locks and dismount
the machine.
9.3. Relieve the auxiliary circuit pressure and
connect the attachment tail hoses lift arm
pipework. Refer to (PIL 30-00-00).
9.4. Route the hoses and wires to prevent
chafing and pinching.
9.5. Return to the cab seat, lower the safety
control locks and restart the engine.
9.6. Start the engine and slowly cycle the
attachment cylinders several times to purge
the system of air.
9.7. Check for proper electrical and hydraulic
connections, routings, lengths and
hydraulic leaks.
10. The attachment is now ready for use.
03 - 13 9813/7400-1 03 - 13
30 - Shovel
30 - Shovel
Contents Page No.
03-30-00 General ........................................................................................................................... 03-15
03 - 14 9813/7400-1 03 - 14
30 - Shovel
00 - General
Introduction .................................................... 03-15 A shovel can be installed on many different types of
Health and Safety .......................................... 03-16 earthmoving machines. The shovel can be directly
mounted on to a lift arm assembly or mounted to the
lift arm via a quickhitch assembly.
There are a vast amount and size of shovels used for

numerous applications.
A shovel can be used to scoop up loose material

from the ground, such as dirt, sand or gravel, and
move it from one place to another without pushing
the material across the ground. It is commonly used
to move stockpiled material from ground level and
deposited into a dump truck or into an open trench
excavation.
03 - 15 9813/7400-1 03 - 15
30 - Shovel
00 - General
Health and Safety

CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
03 - 16 9813/7400-1 03 - 16
33 - Fork
33 - Fork
Contents Page No.
03-33-00 General ........................................................................................................................... 03-19
03 - 17 9813/7400-1 03 - 17
Notes:
03 - 18 9813/7400-1 03 - 18
33 - Fork
00 - General
Introduction .................................................... 03-19 Forks can be installed on many different types of
Health and Safety .......................................... 03-20 agricultural or construction machines. Forks can be
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 - 19 9813/7400-1 03 - 19
33 - Fork
00 - General
Health and Safety

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.
WARNING Loads can fall off incorrectly spaced
forks. Always space the forks correctly for the
load. Make sure the forks are completely under
the load before lifting.
WARNING If the fork/locking pin is not fully
engaged, the fork could become unintentionally
disengeged.
WARNING Do not try to correct the alignment
of the fork tips by bending the forks or adding
shims. Never repair damaged forks by heating or
welding. Forks are made of special steel using
special procedures. Always replace the damaged
forks.
WARNING Overloaded scaffolding can collapse.
Never load scaffolding beyond the regulation
capacity.
WARNING The forks project in front of the
machine. Make sure there is enough clearance
for the forks when making turns.
CAUTION A load lifted on one fork can slip off.
Never lift a load with one fork.
CAUTION Never unload the forks by stopping the
machine suddenly. Follow the procedures in the
Operator Manual for unloading.
CAUTION The forks are heavy. Make sure
suitable lifting equipment is used to support and
transport them.
CAUTION Do not exceed the total rated load
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 - 20 9813/7400-1 03 - 20
06 - Body and Framework
Contents Page No.
06-06 Moveable Panel and Cover

06-06-00 General ............................................................................................................................. 06-3
06-06-06 Engine Compartment ....................................................................................................... 06-4
06-06-14 Rear Cover ....................................................................................................................... 06-5
06-12 Lift Arm
06-12-00 General ............................................................................................................................. 06-7
06-12-03 Outer Arm ...................................................................................................................... 06-11
06-12-06 Inner Arm ....................................................................................................................... 06-16
06-12-30 Wear Pads ..................................................................................................................... 06-19
06-12-33 Stop Pad ........................................................................................................................ 06-23
06-27 Transportation Lock
06-27-00 General ........................................................................................................................... 06-27
06-30 Pivot Pins
06-30-00 General ........................................................................................................................... 06-29
06-63 Identification Label
06-63-00 General ........................................................................................................................... 06-33
06-63-03 Machine .......................................................................................................................... 06-34
06-66 Tools
06-66-00 General ........................................................................................................................... 06-37
06-69 Maintenance Strut
06-69-00 General ........................................................................................................................... 06-39
06-75 Fire Extinguisher
06-75-00 General ........................................................................................................................... 06-41
06-90 Door Guard
06-90-09 Rear Cover ..................................................................................................................... 06-43
9813/7400-1
2017-03-11
Acronyms Glossary
PIN Product Identification Number
9813/7400-1
2017-03-11
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ............................................................................................................................. 06-3

06-06-06 Engine Compartment ....................................................................................................... 06-4
06-06-14 Rear Cover ....................................................................................................................... 06-5
06 - 1 9813/7400-1 06 - 1
Notes:
06 - 2 9813/7400-1 06 - 2
00 - General
00 - General
Introduction
Access panels provide easy access to the machine

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

of the access panels are in their operation position
and secure.
06 - 3 9813/7400-1 06 - 3
06 - Engine Compartment
06 - Engine Compartment
Open and Close
Access to the engine compartment is provided by a Maintenance Position

hinged top cover and a hinged rear cover.
1. Make the machine safe with the arm lowered.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine 2. Unlock the rear cover (if lock is installed).
compartment. Do not use the machine with the
engine cover open. 3. Pull the handle. Refer to Figure 19.
Figure 19.
A
C
A Handle B Locking pin

C Locking position
4. Swing the door open to the left. Operation Position

5. Remove the locking pin from its stowage 1. Remove the locking pin from the locking position.
position. Refer to Figure 20. Refer to Figure 19.
Figure 20. 2. Install it in the stowage position. Refer to Figure
B 20.
A 3. Swing the door to the right and push it closed.

4. Lock the rear cover (if lock is installed).
A Locking pin
B Stowage position
6. Install it in the locking position.
06 - 4 9813/7400-1 06 - 4
14 - Rear Cover
14 - Rear Cover
Remove and Install

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 also provided

by the rear cover on the underside of the chassis at
the rear of the machine.
Remove
The front three holes are slotted. Do not fully remove
the bolts, this will aid re-assembly.
1. Remove the bolts that secure the rear cover and

remove the rear cover.
Figure 21.
A Rear cover
Install
1. Position the rear cover and secure it with the
bolts.
06 - 5 9813/7400-1 06 - 5
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ............................................................................................................................. 06-7

06-12-03 Outer Arm ...................................................................................................................... 06-11
06-12-06 Inner Arm ....................................................................................................................... 06-16
06-12-30 Wear Pads ..................................................................................................................... 06-19
06-12-33 Stop Pad ........................................................................................................................ 06-23
06 - 6 9813/7400-1 06 - 6
12 - Lift Arm
00 - General
Introduction ...................................................... 06-7 The lift arm on this machine is a one piece assembly.
Health and Safety ........................................... 06-8 The assembly is a heavy item, you must not
Check (Condition) ............................................ 06-8 attempt to lift this component without suitable lifting
Lubricate .......................................................... 06-9 equipment.
06 - 7 9813/7400-1 06 - 7
12 - Lift Arm
00 - General
Health and Safety Check (Condition)

Lifting Equipment 1. Make sure that the bushes and the pivot pins
You can be injured if you use incorrect or faulty lifting are within the permitted tolerances. Replace the
equipment. You must identify the weight of the item to pivot pin or bushes as necessary.
enough and suitable for the job. Make sure that lifting 2. Examine the lift arm structure for wear, damage
equipment is in good condition and complies with all or corrosion. Replace as necessary.
local regulations. 3. Examine the pivot levers for wear, damage or
WARNING! Do not work under raised lift arms unless corrosion. Replace as necessary.
they are adequately supported by stands and/or
slings.
CAUTION! The lift arm pivot levers are potentially
dangerous, when pivoting about their centre they
form a scissor point with the lift arm. Make sure the
pivot levers are securely blocked when working in the
lift arm area.
CAUTION! This component is heavy. It must only be
removed or handled using a suitable lifting method
and device.
06 - 8 9813/7400-1 06 - 8
12 - Lift Arm
00 - General
Lubricate
In the following illustrations, the grease points are Quickhitch Pivot Pins
numbered. Count off the grease points as you grease
each one. Lower the lift arm as far as it will go. Switch off the
engine and ensure it cannot be started while you are
doing this job.
Total of 4 grease points. Refer to Figure 22.
Figure 22.
1 4
2 3
Lift Arm and Ram Pivot Points Table 4.

Total Grease Points
Switch off the engine and ensure it cannot be started
while you are doing this job. Vertical Lift 6, Refer to Figure 23.
Radial Lift 3, Refer to Figure 24.
06 - 9 9813/7400-1 06 - 9
12 - Lift Arm
00 - General
Figure 23. Vertical Lift
6 5
4
1 3
Figure 24. Radial Lift
06 - 10 9813/7400-1 06 - 10
12 - Lift Arm
03 - Outer Arm
03 - Outer Arm
Remove and Install
Special Tools 6. Position the hoses over the loader tower at the
Description Part No. Qty. rear of the machine out of the way.
Grease Gun 892/00913 1 7. Support the rod end of the lift ram then remove
Attachment the nut and bolt and drive out the pivot pin. Lower
Slide Hammer Kit 993/68100 1 the lift ram on to the mainframe.
Consumables Special Tool: Slide Hammer Kit (Qty.: 1)
Description Part No. Size 8. Use suitable lifting equipment and a sling to lift
Special MPL-EP 4003/1501 0.4kg the arm as shown. Take the weight of the arm on
Grease 4003/1506 12.5kg the lifting equipment.
4003/1510 50kg Figure 29.
Lifting Equipment
equipment. You must identify the weight of the item to
equipment is in good condition and complies with all
local regulations.
Remove
1. Make the machine safe with the lift arm lowered.
Refer to (PIL 01-03).
2. Chock all four wheels to prevent accidental
machine movement (wheeled machines).
3. Remover the inner lift arm. Refer to (PIL
06-12-06).
9. To remove the tapered pin from the lift arm. Do
4. Remove the bolts (x6) and remove the side cover the step from 9.1 to 9.6.
from the lift arm.
9.1. Loosen the lift arm tapered pins locking bolt
Figure 28. until it can be turned by hand.
B 9.2. Loosen the locking bolt two full turns.
9.3. Hit the locking bolt with a suitable hammer
until the left side tapered pin is loose.
9.4. Remove the locking bolt and the left side
tapered pin.
A 9.5. Use a suitable punch to remove the right
B side tapered pin.
9.6. If necessary, remove the grease nipple from
the tapered pins.
A Side cover
B Bolts (x6)
5. Label the auxiliary hydraulic hoses (if installed)
and disconnect them from the metal pipework on
top of the carriage.
06 - 11 9813/7400-1 06 - 11
12 - Lift Arm
03 - Outer Arm
Figure 30. Figure 31. Pivot Pins
F E
E
C
E Lift arm tapered pins

F Locking bolt
10. Use the lifting equipment to remove the lift arm
from the machine. Place the lift arm on a clean
dry surface.
11. Check all bushes, pivot pins and wear pads for
wear and replace as required.
D
C Extend ram pivot pin
D Lift ram pivot pin
E Lift arm tapered pivot pins
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Grease all pins and bolts with JCB Special
MPL grease. Reconnect all hoses and bleed the
hydraulic system.
Special Tool: Grease Gun Attachment (Qty.: 1)
Consumable: Special MPL-EP Grease
3. Check the lift arm functions correctly.
4. If necessary adjust the lift arm tapered pivot pins.
4.1. Make sure that the lines on the pins face
directly upwards.
06 - 12 9813/7400-1 06 - 12
12 - Lift Arm
03 - Outer Arm
Figure 32.
G H
G Right side tapered pivot pin H Left side tapered pivot pin
4.2. If the left side of the quickhitch is too high,

rotate the left side tapered pivot pin until
the quickhitch is level or up to the specified
amount.
Angle: 180°
06 - 13 9813/7400-1 06 - 13
12 - Lift Arm
03 - Outer Arm
Figure 33. Figure 34.
180°
180°
4.3. If the right side of the quickhitch is too high, 4.4. If the lift arm is too close to the operator
rotate the right side tapered pivot pin until station, rotate the left side tapered pivot
the quickhitch is level or up to the specified pin until the lift arm is straight or up to the
amount. specified amount.
Angle: 180° Angle: 90°
06 - 14 9813/7400-1 06 - 14
12 - Lift Arm
03 - Outer Arm
90° -90°
4.5. If the lift arm is too far away from the 5. Tighten the locking bolt in three stages to the
operator station, rotate the left side tapered correct torque value.
pivot pin until the lift arm is straight or up to
the specified amount. 5.1. Tighten the locking bolt to the first stage
Angle: -90° torque value.
5.2. Hit the head of the locking bolt with a
suitable hammer to seat the tapered pins in
the taper.
5.3. Tighten the locking bolt to the second stage
torque value.
5.4. Hit the head of the locking bolt with a
suitable hammer to seat the tapered pins in
the taper.
5.5. Tighten the locking bolt to the final stage
torque value.

Item Description Nm
F First stage 400
F Second stage 562
F Final stage 562
06 - 15 9813/7400-1 06 - 15
12 - Lift Arm
06 - Inner Arm
06 - Inner Arm Lubricate

Consumables
Lubricate ........................................................ 06-16
Description Part No. Size
Remove and Install ....................................... 06-17
Waxoyl 4004/0501A 0.4L
4004/0502 5L
4004/0505 200L

2. Fully extend the inner lift arm.
3. Apply Waxoyl evenly over all the sliding surfaces
of the inner and outer boom sections. Allow
the Waxoyl to dry for the specified time before
retracting the lift arm.
Duration: 2h
Consumable: Waxoyl
Figure 37.
06 - 16 9813/7400-1 06 - 16
12 - Lift Arm
06 - Inner Arm
Remove and Install 6. Remove the crowd ram. Refer to (PIL 30-15-11).
Special Tools 7. Remove the nut and bolt from the rod end of the
Description Part No. Qty. extend ram. Drive out the pivot pin using the slide
hammer kit.
Grease Gun 892/00913 1
Attachment Special Tool: Slide Hammer Kit (Qty.: 1)
Slide Hammer Kit 993/68100 1 8. Use suitable lifting equipment to support the
inner lift arm.
Consumables
Description Part No. Size 9. Switch on the engine and fully retract the extend
Special MPL-EP 4003/1501 0.4kg ram.
Grease 4003/1506 12.5kg 10. Switch off the engine.
4003/1510 50kg
Waxoyl 4004/0501A 0.4L 11. The lift arm can now be manoeuvred from the
machine using the lifting tackle. Place the lift arm
4004/0502 5L on a clean dry surface.
4004/0505 200L
12. Check all bushes, wear pads and pivot pins for
Lifting Equipment wear and replace as required.
You can be injured if you use incorrect or faulty lifting Figure 39. Pivot Pins
local regulations.
Remove
1. Make the machine safe with the lift arm lowered
and the inner lift arm fully extended. Refer to (PIL
01-03).
2. Chock all four wheels to prevent accidental
machine movement (wheeled machines).
E
3. Remove the bolts (x6) and remove the side cover
from the lift arm.
Figure 38. D
B
A
B
C
C Quickhitch pivot pin
D Crowd ram pivot pin
E Lift arm extend ram pivot pin
A Side cover Install

B Bolts (x6)
4. Label the auxiliary hydraulic hoses (if installed)
and disconnect them from the inner lift arm.
steps.
5. Remove the quickhitch assembly. Refer to (PIL
03-09-00).
06 - 17 9813/7400-1 06 - 17
12 - Lift Arm
06 - Inner Arm
2. Grease all pins and bolts with JCB Special

MPL grease. Reconnect all hoses and bleed the
hydraulic system.
Special Tool: Grease Gun Attachment (Qty.: 1)
Consumable: Special MPL-EP Grease
3. Apply Waxoyl evenly over all the sliding surfaces
of the inner lift arm.
Consumable: Waxoyl
4. Check the lift arm functions correctly.
06 - 18 9813/7400-1 06 - 18
12 - Lift Arm
30 - Wear Pads
30 - Wear Pads Introduction

Introduction .................................................... 06-19 Wear pads can be used in many different
Remove and Install ....................................... 06-20 applications on a machine. They are designed to
wear so that they protect the major component they
are installed in.
When the wear pads are worn below the specified

values, they must be renewed.
06 - 19 9813/7400-1 06 - 19
12 - Lift Arm
30 - Wear Pads
Remove and Install Figure 41.

D
Consumables
B
JCB High Strength 4102/0551 0.05L
Threadlocker
Inner Boom Wear Pads

Remove
2. Remove the top and left side wear pads as
follows:
2.1. Unscrew the wear pad assembly.
Figure 40.
C
B Locking plug
C Adjuster
A D Wear pad
2.3. Remove the wear pad from the adjuster.
3. Remove the bottom and right side wear pads as
follows:
3.1. Remove the inner lift arm to gain access to
the wear pads. Refer to (PIL 06-12-06).
A
A Wear pad assembly (x8)

2.2. Remove the locking plug.
06 - 20 9813/7400-1 06 - 20
12 - Lift Arm
30 - Wear Pads
Figure 42. 3.3. Remove the wear pad.

4. Remove the rear wear pad as follows:
4.1. Remove the inner lift arm to gain access to
the wear pads. Refer to (PIL 06-12-06).
E 4.2. Remove the screw and washer.

Figure 44.
H
J
E Wear pad (x8)

3.2. Remove the screws (x2) and washers (x2).
Figure 43.
F H Bolt
J Wear pad
4.3. Remove the wear pad.
Install
G 1. The installation procedure is the opposite of the
steps.
2. For the bottom and right side wear pads:
2.1. Apply threadlocker before you install
screws.
K Consumable: JCB High Strength
Threadlocker
2.2. Tighten the screws to the correct torque
F Screws (for right side wear pad) (x2)
value.
K Screws (for bottom wear pads) (x2)
G Washers (x2) 3. For the top and left side wear pads:
06 - 21 9813/7400-1 06 - 21
12 - Lift Arm
30 - Wear Pads
3.1. Install the wear pad on to the adjuster.

3.2. Install the locking plug.
3.3. Install the wear pad assembly to the
machine.
3.4. Tighten the adjusters to the correct torque
value.
3.5. Fully extend and retract the lift arm twice.
3.6. Tighten the adjusters to the correct torque
value.
3.7. Fully extend and retract the lift arm twice.
3.8. Repeat 3.5 to 3.7 until the adjusters are fully
seated.
3.9. Loosen the adjusters 1/4 turn for final
setting.

Item Description Nm
C Adjusters 68
F Screw (for right side wear 30
pad)
K Screw (for bottom wear pad) 47
06 - 22 9813/7400-1 06 - 22
12 - Lift Arm
33 - Stop Pad
33 - Stop Pad Adjust

Adjust ............................................................ 06-23 1. Remove any attachment installed on the lift arm.
2. Raise then lower the lift arm fully. Make sure that
the stop pad on the lift arm contacts the chassis
at the same time as the centring cup.
Figure 45.
E
D
D Chassis
E Centring cup
3. If the stop pad on the lift arm does not contact
the chassis at the same time as the centring cup,
add or remove shims from the stop pad.
Figure 46.
C
A
A Stop pad
B Bolts (x2)
C Shims
4. Repeat 2 and 3.
06 - 23 9813/7400-1 06 - 23
12 - Lift Arm
33 - Stop Pad
Remove and Install
Remove
1. Remove any attachment from the lift arm.
2. Make the machine safe with the lift arm raised.
3. Remove the bolts.
4. Remove the stop pad.
Figure 47.
A Stop pad
B Bolts
Install
steps.
2. Adjust the stop pad. Refer to (PIL 06-12-33).

Item Nm
B 47
06 - 24 9813/7400-1 06 - 24
27 - Transportation Lock
Contents Page No.
06-27-00 General ........................................................................................................................... 06-27
06 - 25 9813/7400-1 06 - 25
Notes:
06 - 26 9813/7400-1 06 - 26
00 - General
00 - General
Introduction
Make sure that all machine locks are in the transport

position before you transport the machine.
06 - 27 9813/7400-1 06 - 27
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ........................................................................................................................... 06-29
06 - 28 9813/7400-1 06 - 28
30 - Pivot Pins
00 - General
Introduction .................................................... 06-29 Pivot pins are a short shaft or pin that supports
Remove and Install ....................................... 06-30 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 - 29 9813/7400-1 06 - 29
30 - Pivot Pins
00 - General
Remove and Install Figure 48. 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.
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 - 30 9813/7400-1 06 - 30
63 - Identification Label
Contents Page No.
06-63-00 General ........................................................................................................................... 06-33

06-63-03 Machine .......................................................................................................................... 06-34
06 - 31 9813/7400-1 06 - 31
Notes:
06 - 32 9813/7400-1 06 - 32
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 - 33 9813/7400-1 06 - 33
03 - Machine
03 - Machine
Introduction
Machine Identification Plate power, year of manufacture and serial number of the
machine are shown on the identification plate.
Your machine has an identification plate. The
PIN (Product Identification Number), weight, engine The serial number is also permanently stamped into
the chassis.
Figure 49.
A
A Identification plate (location) B Serial number (stamped)
Typical Product Identification Number Digit Description

9 Generated Check Letter. The random check
The machine model and build specification are letter is used to verify the authenticity of a
indicated by the PIN. The PIN has 17 digits and must machine's PIN.
be read from left to right.
10 to Machine serial number 02196001.
Table 9. Typical PIN 17
GE0 260 WV H 02196001
Table 10. Explanation of the PIN

Digit Description
1 to 3 World manufacturer identification. For ex-
ample, JCB = UK Build. GE0 = USA Build
4 to 6 Machine type. For example, 260 = 260
7 to 8 Machine model. For example, W = Wheeled
T = Tracked V = Vertical Lift R = Radial Lift
06 - 34 9813/7400-1 06 - 34
66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ........................................................................................................................... 06-37
06 - 35 9813/7400-1 06 - 35
Notes:
06 - 36 9813/7400-1 06 - 36
66 - Tools
00 - General
00 - General
Introduction
When you carry tools onto the machine, you must

keep three points of contact with the machine at all
times. If necessary, lift the tools on to the machine in
intervals. Put the tools down before you adjust your
grips on the machine. Do not try to adjust your grips
on the machine while holding tools.
06 - 37 9813/7400-1 06 - 37
69 - Maintenance Strut
Contents Page No.
06-69-00 General ........................................................................................................................... 06-39
06 - 38 9813/7400-1 06 - 38
00 - General
00 - General
Introduction
Before you start any service procedures on the

machine, make sure that the relevant maintenance
strut is installed in its correct position and secure.
Refer to (PIL 01-03-27).
06 - 39 9813/7400-1 06 - 39
75 - Fire Extinguisher
Contents Page No.
06-75-00 General ........................................................................................................................... 06-41
06 - 40 9813/7400-1 06 - 40
00 - General
00 - General
Introduction
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 50.
A Gauge
B Safety Pin
06 - 41 9813/7400-1 06 - 41
90 - Door Guard
90 - Door Guard
Contents Page No.
06-90-09 Rear Cover ..................................................................................................................... 06-43
06 - 42 9813/7400-1 06 - 42
90 - Door Guard
09 - Rear Cover
09 - Rear Cover Introduction

Introduction .................................................... 06-43 A guard can be installed on the rear of the machine
Remove and Install ....................................... 06-44 to protect the rear door. The guard pivots on one side
and is locked using two hitch pins.
Figure 51.
A
B
A Hitch pin
B Door guard
06 - 43 9813/7400-1 06 - 43
90 - Door Guard
09 - Rear Cover
Remove and Install
Remove
1. Remove the hitch pins to release the door guard
at one side.
2. Remove the nuts and bolts, remove the door
guard.
Figure 52.
A
B
C
A Hitch pin
B Door Guard
C Nut
D Bolt
Install
1. Replacement is the reversal of the removal
procedure.
06 - 44 9813/7400-1 06 - 44
Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-09 Window
09-09-00 General ............................................................................................................................. 09-9
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-17
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-19
09-18 Door
09-18-00 General ........................................................................................................................... 09-21
09-18-03 Lock ................................................................................................................................ 09-23
09-18-06 Latch ............................................................................................................................... 09-25
09-18-09 Hinge .............................................................................................................................. 09-26
09-18-12 Handle ............................................................................................................................ 09-27
09-27 Controls
09-27-00 General ........................................................................................................................... 09-29
09-27-36 Accelerator Pedal ........................................................................................................... 09-30
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-35
09-81 Mount
09-81-00 General ........................................................................................................................... 09-39
9813/7400-1
2017-01-10
Notes:
9813/7400-1
2017-01-10
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3
09 - 1 9813/7400-1 09 - 1
Notes:
09 - 2 9813/7400-1 09 - 2
00 - General
Introduction ...................................................... 09-3 Some service procedures will need the operator
Health and Safety ........................................... 09-4 station to be raised into the service position.
Remove and Install ......................................... 09-5
Service position
2. Remove the two rear mounting nuts and
compression plates that secure the cab at the
rear.
Figure 53.
B A
A Mounting nuts
B Compression Plates
3. Raise the cab by lifting the corner of the cab
behind the operator’s door. Do not try to raise the
cab by pulling on the front of the cab.
Figure 54.
09 - 3 9813/7400-1 09 - 3
00 - General
4. Unfold the safety strut from the stowed position. Health and Safety
Position the cab safety strut to support the cab
into the service position.
Raised Equipment
Figure 55. 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
local regulations.
09 - 4 9813/7400-1 09 - 4
00 - General
Special Tools
Lifting Brackets 892/01160 1
Lifting Equipment
local regulations.
The procedure for cab and canopy models is the

same.
Remove
2. Remove the two rear mounting nuts and
compression plates that secure the cab at the
rear.
Figure 59.
4. Unfold the safety strut from the stowed position.
B A Position the cab safety strut to support the cab.
Figure 61.
A Mounting nuts
B Compression plates
3. Raise the cab by lifting the corner of the cab
behind the operator’s door. Do not try to raise the
cab by pulling on the front of the cab.
5. Disconnect the cab harness connection(s).

6. Mark and disconnect the servo lines at the servo
manifold.
09 - 5 9813/7400-1 09 - 5
00 - General
7. Disconnect the air conditioning and heater hoses Table 11. Torque Values
(if fitted).
Item Nm
8. Install the lifting eyes to the cab. A 205
Special Tool: Lifting Brackets (Qty.: 1)
9. Install a sling through the lifting eyes and
carefully support the weight of the cab.
10. Remove the gas struts and safety cable.
11. Carefully lower the cab back into position.
12. Remove the two front cab mounting nuts, bolts
and washers.
Figure 62.
A
C
B
A Nuts
B Washers
C Bolts
13. Carefully lift the cab clear of the machine.
Install
1. Installation is a reversal of the removal
procedure.
2. Tighten the front and rear mounting nuts to the
correct torque value.
3. After cab replacement, check the function of all
controls and cab mounted electrical equipment.
09 - 6 9813/7400-1 09 - 6
09 - Window
09 - Window
Contents Page No.
09-09-00 General ............................................................................................................................. 09-9
09 - 7 9813/7400-1 09 - 7
Notes:
09 - 8 9813/7400-1 09 - 8
09 - Window
00 - General
Introduction ...................................................... 09-9 The service procedures, explain how to correctly
Health and Safety .......................................... 09-10 remove and install panes of glass that are directly
Preparation .................................................... 09-10 bonded to the cab frame apertures. When you carry
Remove and Install ....................................... 09-12 out any service procedure, you must always refer to
the relevant safety precautions, Health and Safety
(PIL 09-09).
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 - 9 9813/7400-1 09 - 9
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 - 10 9813/7400-1 09 - 10
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 66.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 64.
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 - 11 9813/7400-1 09 - 11
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 67.
Consumables
Black Polyurethane 4102/2310 0.31L
Sealant
A Black Primer/Activator 4104/2304 0.1L
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
B JCB Glass Cleaner 4006/3175 0.75L
A 12.5mm
B 9mm
Removal
6. Apply the pre-heated adhesive to the glass (do
not start in a corner). Keep the nozzle guide 1. Position the machine on level ground and apply
against the edge of the glass and make sure the park brake. Stop the engine. Put protective
that the adhesive forms a continuous pyramid' covers over the cab seat and control pedestals.
shape. Note: Once the pre-heated adhesive has
2. If a laminated pane breaks it will stay in one piece
been applied to the glass, install the glass in the
even though the glass is cracked. A toughened
aperture as soon as possible. If you wait too long
pane will shatter and fall apart. The method of
then the sealant will form a skin, this will prevent
removal of the glass depends upon which type
the glass from bonding.
it is.
Duration: 10min
2.1. Laminated glass - leave installed until the
Figure 68. 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 - 12 9813/7400-1 09 - 12
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 70.

the sealant will melt.
Figure 69.
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 71.
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 - 13 9813/7400-1 09 - 13
09 - Window
00 - General
Figure 72. 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 74. 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 75.
face of the cab frame aperture.
Figure 73.
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 - 14 9813/7400-1 09 - 14
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 - 15 9813/7400-1 09 - 15
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-17
09 - 16 9813/7400-1 09 - 16
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 - 17 9813/7400-1 09 - 17
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-19
09 - 18 9813/7400-1 09 - 18
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 - 19 9813/7400-1 09 - 19
18 - Door
18 - Door
Contents Page No.
09-18-00 General ........................................................................................................................... 09-21

09-18-03 Lock ................................................................................................................................ 09-23
09-18-06 Latch ............................................................................................................................... 09-25
09-18-09 Hinge .............................................................................................................................. 09-26
09-18-12 Handle ............................................................................................................................ 09-27
09 - 20 9813/7400-1 09 - 20
18 - Door
00 - General
00 - General Component Identification

Component Identification ............................... 09-21 The door assembly consists of the following
Remove and Install ....................................... 09-22 components:
Figure 76.
5
4
9
7
1
8
6 2
3
1 Door frame (PIL 09-18)
2 Exterior door handle (PIL 09-24)
3 Lock (PIL 09-20)
4 Latch (PIL 09-22)
5 Interior door handle (PIL 09-24)
6 Latch cover
7 Hinge (PIL 09-23)
8 Gasket
9 Checkstrap
09 - 21 9813/7400-1 09 - 21
18 - Door
00 - General
Consumables B
Extreme Performance 4003/1327 0.4kg
Moly Grease 4003/1326 12.5kg
CAUTION This component is heavy. It must only A

method and device.
Remove
2. Remove one end of the gas strut from the door.
If necessary, remove the gas strut completely.
C
3. Unhook the check strap.
A Setscrew
Figure 77.
B Hinge pin
C Door
6. Lift the door off its hinges and move to a safe
place.
D
7. If the hinge pins are worn they must be replaced.
Install
step.
2. Apply a smear of grease to the hinge pins.
Consumable: Extreme Performance Moly
D Check strap
Grease
4. Remove the setscrew from the upper and lower
hinges.
5. Remove the hinge pin from the upper and lower
hinges.
09 - 22 9813/7400-1 09 - 22
18 - Door
03 - Lock
03 - Lock Check (Condition)

Check (Condition) .......................................... 09-23 Check the condition of the door locks and access
Remove and Install ....................................... 09-24 covers locks as follows:
• Check the operation of the locks. Make sure all

applicable keys are available.
• Lubricate the locks with light lubricating oil.
• If a lock fails to operate correctly, replace it with
a new one.
09 - 23 9813/7400-1 09 - 23
18 - Door
03 - Lock
Remove and Install
Remove
2. Remove the screws, remove the inside door latch
cover.
3. Remove the screws, remove the door latch.
4. Remove the screws, remove the exterior door
handle.
5. Remove the door lock from the door handle.
Figure 79.
E
C
D
F
A B
G
A Door latch cover
B Exterior door handle
C Door latch
G Door Lock
Install
1. Replacement is a reversal of the removal
procedure.
09 - 24 9813/7400-1 09 - 24
18 - Door
06 - Latch
06 - Latch
Remove and Install
Remove
Refer to Maintenance, Prepare the Machine for
Maintenance.
cover.
3. Remove the screws, remove the door latch.
Figure 80.
E
C
D
F
A B
G
A Door latch cover
C Door latch
Install
procedure.
09 - 25 9813/7400-1 09 - 25
18 - Door
09 - Hinge
09 - Hinge
Remove and Install
Remove
Refer to Maintenance, Prepare the Machine for
Maintenance.
2. Remove the door. Refer to (PIL 09-18-00).
3. Remove the nuts (x2) and remove the hinge from
the operator station.
Figure 81.
A
C
A Nuts (x2)
B Hinge (operator station side)
C Bolts (x3)
D Hinge (Door side)
4. Remove the bolts (x3) and remove the hinge from
the door.
Install
removal procedure.
09 - 26 9813/7400-1 09 - 26
18 - Door
12 - Handle
12 - Handle 2. Remove the screws, remove the inside door latch

cover.
Remove and Install 3. Remove the screws, remove the door latch and
interior door handle.
Interior Door Handle 4. Remove the screws, remove the exterior door
handle.
Remove Figure 83.
cover.
3. Remove the screws, remove the door latch and
interior door handle.
Figure 82.
E
C
D
F
A B
E
C
D
G
A Door latch cover
F B Exterior door handle
A B C Door latch
E Interior door handle
Install
removal procedure.
G
A Door latch cover
C Door latch
E Interior door handle
Install
removal procedure.
Exterior Door Handle

Remove
09 - 27 9813/7400-1 09 - 27
27 - Controls
27 - Controls
Contents Page No.
09-27-00 General ........................................................................................................................... 09-29

09-27-36 Accelerator Pedal ........................................................................................................... 09-30
09 - 28 9813/7400-1 09 - 28
27 - Controls
00 - General
00 - General
Introduction
The main controls inside the operator station are

covered in detail in the relevant operator manual.
09 - 29 9813/7400-1 09 - 29
27 - Controls
36 - Accelerator Pedal
36 - Accelerator Pedal Component Identification

Component Identification ............................... 09-30
Figure 84.
C
E
H
G
A Accelerator pedal mounting B Accelerator pedal

C Washer 1 (x3) D Rivet nut (x3)
E Setscrew (x3) F Harness
G Self locking nut (x2) H Washer 2 (x2)
09 - 30 9813/7400-1 09 - 30
27 - Controls
Remove and Install
Remove 4. Remove the accelerator pedal with the

accelerator pedal mounting from the machine.
Refer to (PIL 01-03). 5. Remove the self locking nut (x2) and the washer
2 (x2) from the accelerator pedal.
2. Disconnect the accelerator harness from the
accelerator pedal. 6. Remove the accelerator pedal from the
accelerator pedal mounting.
3. Remove the setscrew (x3) and the washer 1 (x3)
from the accelerator pedal mounting.
Figure 85.
C
E
H
G
A Accelerator pedal mounting B Accelerator pedal

C Washer 1 (x3) D Rivet nut (x3)
E Setscrew (x3) F Harness
G Self locking nut (x2) H Washer 2 (x2)
09 - 31 9813/7400-1 09 - 31
27 - Controls
Install
1. Installation is the opposite of the removal
procedure.
09 - 32 9813/7400-1 09 - 32
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-35
09 - 33 9813/7400-1 09 - 33
Notes:
09 - 34 9813/7400-1 09 - 34
00 - General
Introduction .................................................... 09-35 The safety labels are strategically placed around the
Health and Safety .......................................... 09-36 product to remind you of possible hazards.
If you need eye-glasses for reading, make sure you

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

Replace a lost or damaged safety label. Make
sure the replacement parts include the safety labels
where necessary. Each safety label has a part
number printed on it, use this number to order a new
safety label from your JCB dealer.
09 - 35 9813/7400-1 09 - 35
00 - General
Health and Safety

WARNING Safety labels on the machine warn
you of particular hazards. You can be injured if
you do not obey the safety instructions shown.
09 - 36 9813/7400-1 09 - 36
81 - Mount
81 - Mount
Contents Page No.
09-81-00 General ........................................................................................................................... 09-39
09 - 37 9813/7400-1 09 - 37
Notes:
09 - 38 9813/7400-1 09 - 38
81 - Mount
00 - General
Introduction .................................................... 09-39 There are four rubber mounts, they are located under
Remove and Install ....................................... 09-40 each corner of the operator station.
Figure 86.
A Mount
09 - 39 9813/7400-1 09 - 39
81 - Mount
00 - General
Remove and Install
The procedure is the same for all four operator

station mounts.
Remove
2. Remove the Operator Station. Refer to (PIL
09-00).
3. Remove the nut, bolt, mount and washer.
Figure 87.
C
A Mount
B Nut
C Bolt
D Washer
Install
step.
2. Tighten the nuts to the correct torque value.
09 - 40 9813/7400-1 09 - 40
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
12-03-03 Evaporator ...................................................................................................................... 12-21
12-03-09 Expansion Valve ............................................................................................................. 12-23
12-09 Compressor
12-09-00 General ........................................................................................................................... 12-27
12-12 Receiver Drier
12-12-00 General ........................................................................................................................... 12-31
12-15 Condenser
12-15-00 General ........................................................................................................................... 12-35
12-18 Filter
12-18-00 General ........................................................................................................................... 12-39
12-18-06 Fresh Air ........................................................................................................................ 12-40
12-18-09 Recirculation ................................................................................................................... 12-42
12-21 Heater Valve
12-21-00 General ........................................................................................................................... 12-45
12-96 Pipe
12-96-00 General ........................................................................................................................... 12-49
9813/7400-1
2016-03-16
Acronyms Glossary
HVAC Heating Ventilation Air Conditioning
9813/7400-1
2016-03-16
12 - Heating, Ventilating and Air-Conditioning (HVAC)
Contents Page No.
12-00-00 General ............................................................................................................................. 12-3
12 - 1 9813/7400-1 12 - 1
Notes:
12 - 2 9813/7400-1 12 - 2
00 - General
Introduction ...................................................... 12-3 To maintain optimum operator comfort in warm
Health and Safety ........................................... 12-4 climates or during seasons of high ambient
Technical Data ................................................. 12-5 temperature, the air conditioning system delivers
Component Identification ................................. 12-6 cool, dehumidified air into the cab. Cooling is
provided by passing the warm ambient air, together
Operation ......................................................... 12-8 with recirculated air, over an evaporator matrix in the
Diagram ........................................................... 12-9 air conditioning unit.
Fault-Finding .................................................. 12-13
Discharge and Pressurise ............................. 12-15 The air conditioning system is a closed circuit
through which the refrigerant is circulated, its state
Check (Leaks) ............................................... 12-18 changing from gas to liquid and back to gas again,
Check (Level) ................................................ 12-18 as it is forced through the system. The major
Check (Operation) ......................................... 12-19 components of the system are the:
• Compressor
• Condenser matrix
• Receiver drier
• Expansion valve
• Evaporator matrix
12 - 3 9813/7400-1 12 - 3
00 - General
Health and Safety • DO NOT steam clean refrigerant system

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

is used and that charging is done only by
qualified personnel. It is illegal to discharge
the refrigerant into the atmosphere but as
a precaution in case of accidental leakage,
discharging and charging of the vehicle
refrigerant system must be conducted in a well-
ventilated area.
• Containers of refrigerant should be stored in a
cool environment away from direct sunlight.
• DO NOT perform welding operations close to
refrigerant hoses (maintain a distance of at least
0.5m from hoses).
12 - 4 9813/7400-1 12 - 4
00 - General
Technical Data
Table 12. HVAC System

Description Charge Weight Refrigerant
Double con- 1.13kg (2.49lb) R134a
denser fan
Single con- 0.75kg (1.65lb) R134a
denser fan
Table 13. Compressor

Item Data
Clutch voltage 11.5 Volts dc
Clutch coil resistance 2.2 and 4.4 ohms
12 - 5 9813/7400-1 12 - 5
00 - General
Component Identification
Figure 89. Location
B C
E
F
D
G
A
A Compressor B Condenser matrix

C Receiver drier D Evaporator with built in Thermal Expansion
Valve (TEV)
E Air Vents F Re-circulation filter
G Water valve and Refrigerant service ports
12 - 6 9813/7400-1 12 - 6
00 - General
Figure 90. Basic Circuit
F G
A Compressor B Condenser matrix

C Receiver drier D Expansion valve
E Evaporator matrix F Air conditioning switch (On/Off)
G Temperature control H Blower switch
X Charging connector (High pressure) Y Charging connector (Low pressure)
12 - 7 9813/7400-1 12 - 7
00 - General
Operation The low temperature, low pressure, high heat

content refrigerant gas, is now drawn by suction back
to the compressor, where the cycle is completed.
To operate the air conditioning, press the air
conditioning switch to switch the system on. Press Service connection points adjacent to the
the heater switch to operate the 3-speed heater fan. compressor are provided for connecting the pressure
Rotate the temperature switch to select the desired gauge manifold, when charging or testing the
temperature. Some machines have an option that refrigerant.
enables the operator to select either recirculating air
or fresh air from outside the machine. Note: The high pressure connection is coloured red,
the low pressure connection is coloured blue.
The Air conditioning system power is generated
from the engine, via an electromagnetic clutch
to the compressor. Three 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 the refrigerant pressure through
compression. This process also increases the
refrigerant temperature.
The 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 reservoir for 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 expansion
valve, which meters the amount of refrigerant
entering the evaporator. In the expansion valve the
refrigerant 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
matrix by the blowers. Heat is transferred from
the ambient and recirculated 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 via condensate.
Cool de-humidified air is emitted through the air vents

into the cab.
12 - 8 9813/7400-1 12 - 8
00 - General
Diagram
Figure 91. HVAC Circuit
12 - 9 9813/7400-1 12 - 9
00 - General
A Blower Switch B A/C Switch

C Temperature Control Switch D Condensor Fan Relay
E Condensor Fan F Blower Resistor
G Blower Fan H Coolant Valve
J Compressor Relay K Compressor Clutch
L Ground M Cold Control
N Pressure Switch 000 Ground (Black)
002 12V DC Positive (Red) 003 Blower Low Speed (Yellow)
004 Blower Medium Speed (Red) 005 Blower High Speed (Orange)
006 12V DC to A/C Switch (Blue) 007 A/C Signal to Condensor and Compressor
(Black/White)
008 Temperature Switch Signal (Purple) 009 A/C Circuit from Cold Control (White)
010 A/C Circuit from Pressure Switch (Black/ 011 12V DC to Compressor (Green)
White)
12 - 10 9813/7400-1 12 - 10
00 - General
Figure 92. Heater only Circuit
A Blower Switch B Temperature Control Switch

C Blower Resistor D Blower Fan
E Coolant Valve F Ground
000 Ground (Black) 002 12V DC Positive (Red)
003 Blower Low Speed (Yellow) 004 Blower Medium Speed (Red)
12 - 11 9813/7400-1 12 - 11
00 - General
005 Blower High Speed (Orange) 006 Temperature Switch Signal (Purple)
12 - 12 9813/7400-1 12 - 12
00 - General
Fault-Finding
Fault
Inadequate Cooling (Discharge air from A/C vents is only slightly cool) Table 14. Page 12-13
Inadequate cooling during hot part of the day. Table 15. Page 12-13
Gradual loss over time of cooling and air flow during A/C operation. Table 16. Page 12-14
Compressor clutch cycles too rapidly or discharge air warms excessively Table 17. Page 12-14
during compressor clutch “OFF” cycle.
Inadequate or no heat. (Discharge air only slightly warm, or neutral). Table 18. Page 12-14
Table 14. Inadequate Cooling (Discharge air from A/C vents is only slightly cool)
Cause Remedy
HVAC Unit air intake filters clogged with dirt / debris. Clean and/or replace air filters.
Misadjusted or leaking hot water valve (Cooling may Refer to Water Valve-Check Operation. NOTE:
be diminished at engine idle. Increased engine and Complete all remaining A/C system checks before
compressor speed will improve A/C cooling). Clamp Water Valve-Check Operation. Keep supply hose to
off the heater hose supplying the coolant valve valve clamped shut during remaining checks.
and retest the air conditioning. If the performance
improves, the valve may be leaking.
Incorrect refrigerant charge in system. If charge is Install manifold gauge set on to high side and low
excessively low or high, the compressor clutch will side service ports and operate A/C. Observe for low
not engage, or remain engaged. pressures. If low pressures are observed, check all
A/C components for leaks as required. If excessive
oil loss is suspected, check oil level in compressor,
evacuate, and recharge.
Moisture or air present in system. Discharge and recover refrigerant. Replace receiver
drier. Add 2 ounces of oil, to replace oil removed with
the old receiver-drier evacuate and recharge.
Restriction in receiver-drier or liquid line resulting in a If low and high side readings are excessively low
starved evaporator. and/or the liquid line at the expansion valve is cool to
the touch and showing signs of sweating or frosting,
discharge and recover the refrigerant. Replace the
receiver-drier, liquid lines or any other defective
parts. Add 2 ounces of oil, to replace oil removed
with the old receiver drier, evacuate and recharge.
Defective expansion valve restricting flow. Symptoms are the same as receiver-drier restriction.
Discharge and recover refrigerant. Remove and
replace expansion valve. Check oil level in the
compressor, evacuate and recharge.
Defective, worn or leaking compressor. Low side gauge reading too high and high side
gauge reading too low. Discharge and recover
refrigerant. Remove and replace compressor and
receiver-drier. Add 2 ounces of oil to replace oil
removed with the old receiver-drier evacuate and
recharge.
Table 15. Inadequate cooling during hot part of the day.

Cause Remedy
Excessive moisture in system freezing in expansion Discharge and recover refrigerant. Replace receiver
valve and restricting refrigerant flow. drier, check oil level in compressor, evacuate and
recharge.
12 - 13 9813/7400-1 12 - 13
00 - General
Table 16. Gradual loss over time of cooling and air flow during A/C operation.
Cause Remedy
Defective evaporator frost prevention thermostat, Examine capillary tube of thermostat to ensure that
causing continuous operation of the compressor it is inserted into the evaporator fins. If the core still
thereby freezing condensate within the evaporator freezes and the compressor clutch doesn’t cycle off,
core. replace the thermostat.
Table 17. Compressor clutch cycles too rapidly or discharge air warms excessively during compressor
clutch “OFF” cycle.
Cause Remedy
Defective evaporator frost prevention thermostat Replace thermostat
Table 18. Inadequate or no heat. (Discharge air only slightly warm, or neutral).
Cause Remedy
Engine cooling system is low on coolant. Check the engine coolant level per the
manufacturer’s recommendations. Add coolant as
required.
Water valve stuck closed. Refer to Water Valve-Check Operation.
Pinched heater hose or other system flow restriction. Examine heater hoses from the engine cooling
system to the heater core for pinches and kinks.
Repair or replace as required. Visually examine the
heater core for dented tubes. Check the core for free
flow by circulating an outside water source through it.
Replace the heater core if a restriction is observed.
Engine running cold. Engine thermostat stuck open. Check machine engine coolant temperature
specifications according to the manufacturer’s
recommendation. Repair if required.
12 - 14 9813/7400-1 12 - 14
00 - General
Discharge and Pressurise Figure 93.
IMPORTANT: This procedure requires specialist air

conditioning equipment for refrigerant charging and
discharging and must only be carried out by qualified
service personnel who have received specialist
training on the air conditioning system. Refer to
the Health and Safety section (PIL 12-00) Refer to:
Health and Safety (Page 12-4).
Refrigerant Recovery
The recovery process clears the system refrigerant,
prior to servicing or for refrigerant renewal.
Note: Do not re-use refrigerant unless you are aware

of its purity.
Note: 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.
1. Make sure that the engine is OFF and the engine

is cool.
2. Remove the ignition key.
A Low pressure hose (blue)
3. Connect the manifold to the system with the blue B High pressure hose (red)
hose connected to the system low pressure port. C Hose (yellow)
Do not connect the red hose. Make sure that both D Filter
valves are closed. E Javac unit
F Empty receiver bottle
4. Connect the yellow hose to the Javac unit filter.
Evacuate
5. Connect the filter to the Javac unit.
6. Connect the Javac unit to an empty receiver This procedure follows on from the Recovery
bottle. Weigh the bottle before and after filling to process and is necessary to make sure that the
assess the system capacity. Note: Do not fill the system is correctly refilled with refrigerant. To avoid
receiver bottle to more than 80% by weight. leakage in the vacuum system itself, Do not use
extensions to the yellow hose (use standard 2 metre
7. Switch on Javac unit and open the low pressure length).
manifold valve. Note: If the high pressure
warning light on the Javac unit comes on, throttle 1. Recover all refrigerant from the system, refer to
back the manifold low pressure valve to provide Refrigerant recovery.
a restriction.
2. Close all valves and connect the manifold.
8. The Javac unit will automatically switch off when Connect the blue hose to the system low
a pressure balance exists between the system pressure port and the red hose to the high
and the receiver bottle. Switch off Javac unit at pressure port.
main switch, but leave the system connected.
3. Connect the yellow hose to the vacuum pump.
Switch on after 10 minutes, the Javac unit will
Note: If the Electronic vacuum gauge is used
restart if residual pressure remains.
connected as shown. Refer to Electronic Vacuum
9. Close the valves and remove all equipment. Gauge for further information.
4. Open the manifold valves.
5. Switch on the vacuum pump until 740mm (29
in) mercury vacuum reads on both gauges.
Note: achievable vacuum will vary with altitude.
12 - 15 9813/7400-1 12 - 15
00 - General
Maximum gauge reading will be 25mm (1 in) less 7. Unscrew the oil injector cap and add the specified
for every 305 metres (1000 feet) above sea level. quantity of refrigerant oil.
6. Maintain suction for approximately 30 minutes. 8. When 740mm (29 in) mercury shows on the
Note: If the vacuum falls rapidly the system is vacuum gauge, open the oil injector valve to
leaking. Check all connections and reseal. If the allow the oil into the system.
point of leakage is not obvious, recharge the
system and test again. 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:
Use only PAG oil in R-134a systems.
Figure 94.
Figure 95.
A Low pressure hose (blue)

B High pressure hose (red)
C Hose (yellow) F
D Vacuum pump
E Electronic vacuum gauge A Low pressure hose (blue)
B High pressure hose (red)
Re-lubricate C Hose (yellow)
D Vacuum pump
Pre-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- Charge
lubricating.
This procedure is the industry recommended
1. Make sure that the engine is OFF and the engine practice for refilling air conditioning systems with
is cool. refrigerant. Evacuate the system beforehand to
2. Remove the starter 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.
Be sure to connect to the liquid port when
6. Switch on the vacuum pump and open the high following the above procedure. Note: Refrigerant
pressure side valve. can be used either in gas or liquid form. If
12 - 16 9813/7400-1 12 - 16
00 - General
recharging with gas follow the manufacturers Figure 97.

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 96.
A396790
Table 19.
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 - Possi-
ble system leakage.
8000 8.0mm (0.31 in)Hg. Par-
tial vacuum - If the read-
ing does not progress
A Low pressure hose (blue) the system may have a
B High pressure hose (red) slow leak.
C Hose (yellow) 1000 1.0mm (0.039 in)Hg.
D Refrigerant cylinder Deeper vacuum.
E Scales 600 0.6mm (0.023 in)Hg.
F Thermal blanket Deep vacuum.
400 0.4mm (0.015 in)Hg.
Electronic Vacuum Gauge Deep vacuum.
200 0.2mm (0.0078 in)Hg.
The CPS VG100 vacuum gauge is an electronic type
Deep vacuum.
using LED's to indicate various states of vacuum. It
is used in place of or to supplement the gauge on the 25 0.025mm (0.00098
vacuum pump. Before connecting into the system, in)Hg. Pump Test. Max-
switch on to check that the first LED lights to show imum sustainable vacu-
that the battery is in good condition. um.
Note: The indicator lights show pressure in inches of

mercury (Hg) and vacuum in microns (0.001mm Hg).
12 - 17 9813/7400-1 12 - 17
00 - General
Check (Leaks) Check (Level)
The refrigerant is heavier than air and will leak A correct refrigerant charge is necessary to achieve
downwards from the defective component. Check in optimum performance from an air conditioning
still conditions but in a well ventilated area. system.
Hose or pipe connections are likely leakage points of Some refrigerant loss is expected over the years,
any refrigerant circuit. and is considered normal, given vibration at the fitting
connections, hose permeation, etc.
It is essential that an electronic leak detector is used
to locate leaks accurately. However, if a leak detector If the system is suspected of not having a complete
is not available, an approximate source can be found charge, check the refrigerant charge level.
by applying a soap solution to the suspect area.
Refrigerant Charge Level
To test for leaks in the high pressure side of
the system i.e. from the compressor output to the The pressure in the system, i.e. the refrigerant
expansion valve, run the air conditioning for a few charge level can be determined by checking the state
minutes then switch off the engine and test for of refrigerant at the receiver drier sight glass.
leakage using an electronic leak detector or soapy
water. If the level of charge is correct the sight glass will
be clear. If the charge is low, bubbles will be seen.
To test for leakage in the low pressure side of the Bubbles may also be an indication of inadequate
system, switch off the air conditioning and leave for cooling, due to a restriction of air flow around the
a few minutes before testing. condenser coil.
Leaking Hoses Check the refrigerant charge level as follows:
The refrigerant hoses have crimped ferrule end Note: When R-134a refrigerant is used slight
fittings. The hose connectors have an O-ring seal bubbling will be seen at the system sight glass. This
which compresses when the connection is tight, is normal for this type of refrigerant. If the system is
creating an air tight seal. not providing adequate cooling.
Hoses are used to connect the inlets and outlets 1. Park the machine on firm, level ground. Lower
of the compressor, condenser, receiver drier and the lift arm to the ground.
expansion valve (the evaporator coil is connected to
the expansion valve within the air conditioning unit 2. Remove the ignition key.
using rigid pipes).
3. Open the rear access cover.
If leakage is detected from a hose connector, either 4. Start the engine and run at idle. Switch the air
by means of an electronic leak detector or soapy conditioning ON to circulate refrigerant.
water, tighten the connector up and repeat the
leakage test. If leakage is still evident, it will be 5. Check the refrigerant charge level at the receiver
necessary to discharge the system and renew the drier sight glass.
connector O-ring seal. Refer to (PIL 12-00).
If the level of charge is incorrect, recharge the
system, this must be carried out by an air
conditioning engineer.
12 - 18 9813/7400-1 12 - 18
00 - General
Check (Operation)
The air conditioning system needs to be checked 8. Make sure the condenser’s cooling air paths are
regularly to ensure efficient and safe operation. free of debris or obstructions.
Before commencing any service operations, carry
out a basic service check as described below: 9. Allow 3-5 minutes for the system to run before
recording temperatures. The system is now
1. Switch the ignition off, stabilised and ready for the System Operational
Test.
2. Make the machine safe with the cab tilted
forward. 10. Stop the engine when the tests are complete.
3. Attach the manifold gauges to the Air System Operational Test

conditioning system and purge the air from the
hoses. Make sure that all the test hoses, gauges The general operating condition of the air
and other test equipment is away from all moving conditioning system can be examined after the
engine parts. system has been stabilised. The refrigerant gauge
pressures along with the system inlet and outlet
4. Start the engine and operate at fast idle speed
air temperatures will be the prime indicators of the
(1000 RPM).
system’s operation.
5. Switch on the air conditioning and set to
maximum cooling. Set the blower fan to the 1. Measure the temperature and humidity of the air
highest speed. Note: The cab temperature needs entering the fresh and recirculation inlet air vents
to be above 20°C. At low ambient temperatures it and record the average of the values.
may be necessary to operate the heating system 2. Measure the temperature of the air discharging
to prevent the air conditioning system switching the vent closest to the air conditioning unit and
off. record.
6. Operate the engine at operating temperature for 3. Record the high and low side refrigerant gauge
five to ten minutes. pressures.
7. Open the door(s) and/or window(s) to allow the 4. Compare your record with the air conditioning
passenger compartment temperature to stabilize unit’s Pressure / Temperature Performance
with the ambient temperature and humidity. Chart for expected performance.
Table 20. Air Conditioning Performance Chart

Air Temperature Inlet-Outlet Air Inlet-Outlet Air A/C System Op- A/C System Op-
Entering A/C Unit- Temperature Dif- Temperature erating Refriger- erating Refriger-
Average Inlet (°F) ferential (°F)-Inlet Differential(°F)-In- ant Pressures-Low ant Pressures-High
Air Humidity (Be- let Air Humidity Side Pressure Side Pressure
low 50%) (Above 50%) (Psig) (Psig)
50 5 – 10 5 – 10 5 – 15 75 – 125
60 10 – 20 10 – 15 5 – 15 100 – 150
70 20 – 25 15 – 20 10 – 20 125 – 175
80 25 – 30 20 – 25 10 – 20 175 – 250
90 25 – 35 20 – 30 15 – 25 175 – 250
100 30 – 35 25 – 30 15 – 25 200 – 275
110 35 – 40 30 – 35 15 – 30 225 – 325
Off-Season Operation 1. Engine idle speed is greater than 1000 RPM.
During the off-season, the air conditioning system 2. Ambient temperature is greater than 0°C.
should be operated for at least five minutes every 3. Cab temperature is greater than 20°C.
month to circulate the oil in the system to lubricate
the fittings and seals. 4. The engine is at normal operating temperature.
When operating the system, ensure that:
12 - 19 9813/7400-1 12 - 19
03 - HVAC Unit
03 - HVAC Unit
Contents Page No.
12-03-03 Evaporator ...................................................................................................................... 12-21

12-03-09 Expansion Valve ............................................................................................................. 12-23
12 - 20 9813/7400-1 12 - 20
03 - HVAC Unit
03 - Evaporator
03 - Evaporator Introduction
Introduction .................................................... 12-21 The evaporator in the air conditioning system allows
Remove and Install ....................................... 12-22 the compressed cooling chemical to evaporate from
liquid to gas while absorbing heat in the process. It is
also used to remove water or other liquids from the
mixture.
Refer to Component Identification (PIL 12-00) Refer

to: Component Identification (Page 12-6).
12 - 21 9813/7400-1 12 - 21
03 - HVAC Unit
03 - Evaporator
Remove and Install

12 - 22 9813/7400-1 12 - 22
03 - HVAC Unit
09 - Expansion Valve
09 - Expansion Valve Introduction

Introduction .................................................... 12-23 The thermal expansion valve (TEV or TXV) is
Check (Operation) ......................................... 12-24 a component in the air conditioning system that
controls the amount of refrigerant flow into the
evaporator thereby controlling the heating at the
outlet of the evaporator.
Thermal expansion valves are often referred to

generically as metering devices. Flow control, or
metering, of the refrigerant is accomplished by use
of a temperature sensing bulb, filled with a similar
gas as in the system, that causes the valve to open
against the spring pressure in the valve body as the
temperature on the bulb increases. As the suction
line temperature decreases, so does the pressure
in the bulb and therefore on the spring causing the
valve to close.
Refer to Component Identification (PIL 12-00) Refer

to: Component Identification (Page 12-6).
12 - 23 9813/7400-1 12 - 23
03 - HVAC Unit
09 - Expansion Valve
Check (Operation)
1. Make sure that the air conditioning system is fully
charged.
2. Set the blower motor to high speed.
3. Switch the air conditioning system on to engage
the compressor.
4. Allow the system to stabilise.
Duration: 5–10min
5. When the system has stabilised, observe the low
side refrigerant operating pressures and record.
6. Change the blower motor speed to low and
continue to watch the low side pressure. The
pressure should drop depending on the heat
load.
Pressure: 0.2–0.28bar (2.9–4.1psi)
Duration: 1–2min
7. Repeat steps 1 to 6 three more times.
8. If the low side pressure can be influenced
by changing the blower motor speed then the
valve is responding and operating correctly,
and changing the evaporator’s heat load as
designed.
12 - 24 9813/7400-1 12 - 24
09 - Compressor
09 - Compressor
Contents Page No.
12-09-00 General ........................................................................................................................... 12-27
12 - 25 9813/7400-1 12 - 25
Notes:
12 - 26 9813/7400-1 12 - 26
09 - Compressor
00 - General
Introduction .................................................... 12-27 The compressor is located at the front of the engine,
Check (Operation) ......................................... 12-28 it is the heart of the air conditioning system since it
Remove and Install ....................................... 12-28 produces the refrigerant flow.
The compressor is driven by the engine drive belt,

refer to (PIL 15-18).
Refer to Component Identification (PIL 12-00).
12 - 27 9813/7400-1 12 - 27
09 - Compressor
00 - General
Check (Operation) Remove and Install
Make sure that the compressor clutch is engaged IMPORTANT: This procedure requires specialist air
and rotating and the compressor is operating conditioning equipment for refrigerant charging and
correctly, refer to Check Operation (PIL 12-00) Refer discharging and must only be carried out by qualified
to: Check (Operation) (Page 12-19). service personnel who have received specialist
Check that the engine drive belt is in good condition the Health and Safety section (PIL 12-00) Refer to:
and tightened to the correct tension. Check the belt Health and Safety (Page 12-4).
when the engine is off and the belt is still warm,
refer to Check Operation (PIL 15-18) Refer to: Check
(Condition) (Page 15-91).
Do not replace the compressor unless its function

has been properly tested, refer to Compressor Test.
Compressor Test
This is a quick and simple test to see if the
compressor has the capacity to build pressure and
pump the refrigerant.
1. Restrict the inlet air flow to the condenser with

a piece of cardboard to increase the high side
refrigerant pressure.
2. Monitor the high side pressure gauge to see if the
pressure rises to 300-350 Psig. If the pressure
does rise to this level then remove the cardboard.
3. If it does not achieve that high pressure range
then check the items below:
3.1. Low refrigerant charge.
3.2. High side refrigerant blockage (i.e. kinked
hose).
3.3. Ambient temperature is below 50°F.
3.4. Clutch slippage or low voltage.
3.5. Inspect the compressor front seal and
pressure relief valve for leaks.
3.6. Check the clutch voltage and clutch coil
resistance, refer to Technical Data.
Refer to: Technical Data (Page 12-5).
3.7. Check the compressor rotation for
smoothness.
12 - 28 9813/7400-1 12 - 28
12 - Receiver Drier
12 - Receiver Drier
Contents Page No.
12-12-00 General ........................................................................................................................... 12-31
12 - 29 9813/7400-1 12 - 29
Notes:
12 - 30 9813/7400-1 12 - 30
12 - Receiver Drier
00 - General
Introduction .................................................... 12-31 The Receiver/Drier is a device that removes
Remove and Install ....................................... 12-32 moisture from the refrigerant as well as filtering any
contaminants or particulates from it. It also acts as a
tank to store excess coolant.
12 - 31 9813/7400-1 12 - 31
12 - Receiver Drier
00 - General
Remove and Install

12 - 32 9813/7400-1 12 - 32
15 - Condenser
15 - Condenser
Contents Page No.
12-15-00 General ........................................................................................................................... 12-35
12 - 33 9813/7400-1 12 - 33
Notes:
12 - 34 9813/7400-1 12 - 34
15 - Condenser
00 - General
Introduction .................................................... 12-35 The condenser is a device used to condense a
Remove and Install ....................................... 12-36 substance from its gaseous to its liquid state, the
refrigerant changes state to a high pressure, high
temperature liquid but with a lower heat content.
Refer to HVAC (Heating Ventilation Air Conditioning)

Component Identification (PIL 12-00).
12 - 35 9813/7400-1 12 - 35
15 - Condenser
00 - General
Remove and Install

12 - 36 9813/7400-1 12 - 36
18 - Filter
18 - Filter
Contents Page No.
12-18-00 General ........................................................................................................................... 12-39

12-18-06 Fresh Air ........................................................................................................................ 12-40
12-18-09 Recirculation ................................................................................................................... 12-42
12 - 37 9813/7400-1 12 - 37
Notes:
12 - 38 9813/7400-1 12 - 38
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 - 39 9813/7400-1 12 - 39
18 - Filter
06 - Fresh Air
06 - Fresh Air Clean

Clean ............................................................. 12-40 1. Make the machine safe with the lift arm raised,
Remove and Install ....................................... 12-41 refer to (PIL 01-03).
2. Remove the filter, refer to (PIL 12-18).
3. Knock any loose dust off the filter. Carefully
blow compressed air through all the folds of the
filter, blow in the opposite direction to the arrows
marked on the filter. Note: The compressed air
must be set at a pressure no greater than 7 bar
(100 lb/in2).
4. Install the filter, refer to (PIL 12-18).
12 - 40 9813/7400-1 12 - 40
18 - Filter
06 - Fresh Air
Remove and Install
The filter is located between the lift arm and the

outside of the cab on the right hand side of the
machine.

2. Remove the screws that secure the air vent.
3. Remove the vent.
4. Remove the filter, Clean or replace the filter as
necessary.
Refer to: Clean (Page 12-40).
Install
procedure.
Important: Do not use the machine without the filter

installed.
Figure 98.
A B
A Filter
B Air vent
C Nuts
12 - 41 9813/7400-1 12 - 41
18 - Filter
09 - Recirculation
09 - Recirculation
Remove and Install
The filter is located inside the cab next to the operator

seat.

2. Remove the clip that secures the air vent.
3. Remove the vent.
4. Remove the filter, Clean or replace the filter as
necessary.
Install
procedure.
Important: Do not use the machine without the filter

installed.
Figure 99.
A Filter
B Air vent
C Clip
12 - 42 9813/7400-1 12 - 42
21 - Heater Valve
21 - Heater Valve
Contents Page No.
12-21-00 General ........................................................................................................................... 12-45
12 - 43 9813/7400-1 12 - 43
Notes:
12 - 44 9813/7400-1 12 - 44
21 - Heater Valve
00 - General
Introduction .................................................... 12-45 The heater water valve allows the flow of coolant
Check (Operation) ......................................... 12-46 through the heater core to be controlled, and
Remove and Install ....................................... 12-46 switched on and off without affecting the operation of
the rest of the cooling system.
Engine coolant leaking into a hot water valve into the

heater core will increase the outlet air temperature
and thus decrease the expected air conditioning
performance.
If the refrigerant operating pressures are within the

range for the given inlet air temperature, then check
to make sure that the heater coolant valve is closed,
and the heater core tubes are neutral or cool to the
touch. If this is not the case then refer to Water Valve-
Check Operation (PIL 12-21).
12 - 45 9813/7400-1 12 - 45
21 - Heater Valve
00 - General

Hot Components
There are three common symptoms of an improperly
operating electronic coolant control system: Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
• No heat in the heat mode. been running. Allow the engine and components to
• Unable to control the temperature in any cool before servicing the unit.
operating mode.
• Poor cooling, no cooling, or even heat while Removal of the coolant valve should be performed
operating in full cooling mode. when the engine is cold. Removing the valve from
the system when the engine is hot could result in
1. Make sure that the heating system hoses have burns and/or serious injury due to extremely hot
been properly installed: coolant escaping under pressure. Do not start the
engine while the coolant lines are disconnected as
1.1. Make sure that the heater supply hose the engine will quickly pump the system dry, which
installed to the coolant valve is actually the could result in damage to the engine.
hose coming from the supply port on the
engine. A flow direction indicator is located
on the side of the valve to help distinguish Remove
inlet and outlet ports. The inlet side of the
1. Make the machine safe with the cab raised, refer
valve is always on the same side as the
to (PIL 01-03).
harness connector. New valves also have
tape wrapped around the inlet port that 2. Remove the electrical connector from the hot
clearly identifies the inlet port. water valve actuator.
2. The electronic coolant valve is a directional flow 3. Use a spring hose clamp tool to remove the
valve, and must be correctly installed, or it will supply coolant line at the water valve.
not function properly. Coolant valves installed
with the coolant flow reversed, will leak coolant 4. Tightly clamp both supply and return lines to
past the valve cylinder resulting in poor air reduce the amount of coolant leakage when
conditioning performance. If it is determined that the valve is removed. Note: Some coolant will
the coolant supply line to the valve has been reside within the unit’s heating coil, use a suitable
reversed, the valve should be replaced. Refer to container to catch the liquid when you remove
Water Valve Removal. the supply coolant line from the valve assembly.
3. If the system is correctly installed and the 5. Remove the valve assembly mounting bracket
problem still exists, perform a heating system from the bottom of the cab to free the valve
verification test. assembly and allow better access to the short
outlet hose.
6. Remove the valve assembly from its outlet
coolant hose, cap the ports.
Install
procedure.
2. Check and fill the system with the correct fluid to
the correct level.
12 - 46 9813/7400-1 12 - 46
96 - Pipe
96 - Pipe
Contents Page No.
12-96-00 General ........................................................................................................................... 12-49
12 - 47 9813/7400-1 12 - 47
Notes:
12 - 48 9813/7400-1 12 - 48
96 - Pipe
00 - General
Introduction .................................................... 12-49 The refrigeration pipes are responsible for carrying
Remove and Install ....................................... 12-50 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 - 49 9813/7400-1 12 - 49
96 - Pipe
00 - General
Remove and Install
This procedure requires specialist air conditioning

equipment for refrigerant charging and discharging
and must only be carried out by qualified service
personnel who have received specialist training on
the air conditioning system. Refer to the Health
and Safety section (PIL 12-00) Refer to: Health and
Safety (Page 12-4).
12 - 50 9813/7400-1 12 - 50
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-03 Crankcase
15-03-00 General ........................................................................................................................... 15-39
15-06 Cylinder Head
15-06-00 General ........................................................................................................................... 15-43
15-09 Bedplate
15-09-00 General ........................................................................................................................... 15-49
15-12 Crankshaft
15-12-00 General ........................................................................................................................... 15-57
15-12-03 Main Bearing .................................................................................................................. 15-66
15-12-06 Front Oil Seal ................................................................................................................. 15-70
15-12-09 Rear Oil Seal ................................................................................................................. 15-73
15-12-12 Pulley .............................................................................................................................. 15-77
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-79
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-87
15-18-03 Drive Belt ....................................................................................................................... 15-90
15-18-21 Tensioner ........................................................................................................................ 15-94
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-97
15-24 Air Filter
15-24-00 General ......................................................................................................................... 15-105
15-27 Crankcase Ventilation Filter
15-27-00 General ......................................................................................................................... 15-109
15-30 Valve
15-30-00 General ......................................................................................................................... 15-113
15-30-12 Valve Spring ................................................................................................................. 15-122
15-30-24 Stem Seal .................................................................................................................... 15-123
15-33 Connecting Rod
15-33-00 General ......................................................................................................................... 15-125
15-33-06 Big-End Bearing ........................................................................................................... 15-129
15-36 Piston
15-36-00 General ......................................................................................................................... 15-135
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-147
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-149
15-42-06 Rocker Cover ............................................................................................................... 15-158
15-42-09 Push Rod ..................................................................................................................... 15-160
15-42-21 Tappet ........................................................................................................................... 15-162
9813/7400-1
2017-03-28
15-42-24 Tappet Cover ................................................................................................................ 15-164
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-167
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-173
15-51-03 Crankshaft Gear ........................................................................................................... 15-178
15-51-06 Camshaft Gear ............................................................................................................. 15-181
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-182
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-185
15-51-22 Rear Case .................................................................................................................... 15-188
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-193
15-54-03 Housing ........................................................................................................................ 15-196
15-54-09 Gear Ring ..................................................................................................................... 15-199
15-54-12 Drive Plate .................................................................................................................... 15-200
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-203
15-63 Mount
15-63-00 General ......................................................................................................................... 15-211
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-215
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-221
15-72-03 Pulley ............................................................................................................................ 15-227
15-72-06 Voltage Regulator ......................................................................................................... 15-229
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-231
15-75-03 Solenoid ....................................................................................................................... 15-239
15-75-06 Brush Gear ................................................................................................................... 15-240
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-243
15-84-03 Crankshaft Position ...................................................................................................... 15-253
15-84-06 Camshaft Position ........................................................................................................ 15-257
15-84-09 Knock ........................................................................................................................... 15-261
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-264
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-267
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-270
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-273
15-84-19 Exhaust Temperature ................................................................................................... 15-276
15-84-21 Engine Oil Pressure ..................................................................................................... 15-279
15-84-24 Fuel Temperature ......................................................................................................... 15-282
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-285
15-84-33 Coolant Temperature .................................................................................................... 15-287
15-84-42 Engine Oil Temperature ............................................................................................... 15-290
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-293
15-84-51 Nitrogen Oxide (NOx) .................................................................................................. 15-296
15-90 Air Intake
15-90-00 General ......................................................................................................................... 15-301
9813/7400-1
2017-03-28
Acronyms Glossary
CAN Controller Area Network

DC Direct Current
DCU Dosing Control Unit
DEF Diesel Exhaust Fluid
DTC Diagnostic Trouble Code
DTI Dial Test Indicator
ECM Engine Control Module
ECU Electronic Control Unit
EGR Exhaust Gas Recirculation
ESOS Engine Shut-Off Solenoid
FEAD Front End Accessory Drive
HPV High Pressure Valve
IMV Inlet Metering Valve
MAF Mass Air Flow
NOx Nitrogen Oxide
PTO Power Take-Off
RPM Revolutions Per Minute
SCR Selective Catalytic Reduction
TDC Top Dead Centre
TMAF Temperature and Mass Air Flow
TMAP Temperature Manifold Air Pressure
VGT Variable Geometry Turbocharger
9813/7400-1
2017-03-28
Notes:
9813/7400-1
2017-03-28
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9813/7400-1 15 - 1
Notes:
15 - 2 9813/7400-1 15 - 2
15 - Engine
00 - Engine
00 - General
Introduction ...................................................... 15-3 This section contains information about the complete
Health and Safety ........................................... 15-7 engine assembly. For specific engine technical
Technical Data ................................................. 15-8 information refer to the technical data section.
Component Identification ................................. 15-9
Make sure that the correct engine service tools,
Operation ....................................................... 15-14 consumables and torque figures are used when you
Fault-Finding .................................................. 15-18 perform service procedures.
Clean ............................................................. 15-28
Check (Pressure) .......................................... 15-29 Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or
Remove and Install ....................................... 15-31 damage is expected as a matter of course.
Store and Recommission .............................. 15-35
It is expected that components will be cleaned and
lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
excessive loss of hydraulic fluid, engine oil and
ingress of dirt.
Basic Description
The JCB ecoMax engine is a 4 cylinder diesel engine
in which the fuel is ignited by compression ignition.
The engine operates on a four stroke cycle.
The engine is started by an electric starter motor. The

starter motor turns the engine via a pinion and teeth
on the engine flywheel, refer to (PIL 15-75).
When the engine runs the crankshaft drives the

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

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

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

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

coolant circulation pump, alternator, radiator cooling
fan and other ancillaries such as an air conditioning
compressor.
15 - 3 9813/7400-1 15 - 3
15 - Engine
00 - Engine
00 - General
Figure 100.
8
5
3
1
10
1 Flywheel 2 Crankshaft
3 Camshaft 4 Inlet valves (x8)
5 Exhaust valves (x8) 6 Push rods (x8)
7 High pressure fuel pump drive gear 8 Turbocharger
9 Lubrication oil pump 10 Front end drive belt
15 - 4 9813/7400-1 15 - 4
15 - Engine
00 - Engine
00 - General
Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
Figure 101.
1 Rocker assembly 2 Valve bridge piece (x8)

3 Valve spring (x16) 4 Inlet valve (x8)
5 Exhaust valve (x8) 6 Piston assembly (x4)
6a Piston ring - top compression (x4) 6b Piston ring - 2nd compression (x4)
6c Piston ring - oil control (x4) 6d Gudgeon pin (x4)
7 Connecting rod assembly (x4) 8 Crankshaft
9 Main bearing - crankshaft (x5) 10 Big end bearing - crankshaft / connecting rod
(x4)
11 Front crankshaft oil seal 12 Flywheel
13 High duty PTO (Power Take-Off) idler gear (if
installed)
15 - 5 9813/7400-1 15 - 5
15 - Engine
00 - Engine
00 - General
Figure 102.
11
10 5
1a
6 7 4 3
1 Flywheel 1A Flywheel - crankshaft fixing bolts (x8)

2 Fuel injector (atomiser) (x4) 3 Flywheel hub
4 Crankshaft drive gear 5 High duty PTO idler gear (if installed)
6 Camshaft drive gear 7 Lubrication oil pump
8 High pressure fuel pump drive gear 9 Camshaft
10 Tappet (x8) 11 Push rod (x8)
15 - 6 9813/7400-1 15 - 6
15 - Engine
00 - Engine
00 - General
Health and Safety accordance with local regulations. Use authorised

waste disposal sites.
Hot Components
Touching hot surfaces can burn skin. The engine and
been running. Allow the engine and components to
cool before servicing the unit.
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.
Switch off the engine before working in the engine
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job.Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
15 - 7 9813/7400-1 15 - 7
15 - Engine
00 - Engine
00 - General
Technical Data
Table 21.
Description SJ Engine DJ Engine
Engine Variants Turbocharged with intercooler and Turbocharged with intercooler and
exhaust after treatment system exhaust after treatment system
Emission compliance US-EPA Tier 4 Final, EU Stage IV US-EPA Tier 4 Final, EU Stage IV
Rated speed 2200 rpm 2200 rpm (108kW), 2050 rpm
(129kW)
Weight (Dry) (Dry weight-No cooling fan drive) (Dry weight-No cooling fan drive)
496kg 496kg
Number of cylinders 4 4
Nominal bore size 103mm 106mm
Stroke 132mm 135mm
Cylinder arrangement In line In line
Combustion Cycle 4-stroke 4-stroke
Firing order 1-3-4-2 1-3-4-2
Displacement 4.399L 4.765L
Compression ratio 16.7: 1 16.7: 1
Engine Compression Compression variance between Compression variance between
each cylinder should be no greater each cylinder should be no greater
than 3.5bar (50.7psi) than 3.5bar (50.7psi)
Direction of rotation (viewed from Clockwise Clockwise
front {crankshaft pulley} end)
Valves 4 per cylinder 4 per cylinder
Valve clearances measured at the
tappet end of the rockers (mea-
sured cold)
- Inlet 23–0.04mm 23–0.04mm
- Exhaust 0.6–0.04mm 0.6–0.04mm
Lubricating oil pressure (Depen- 1.6–6.5bar (23.2–94.2psi) 1.6–6.5bar (23.2–94.2psi)
dent on engine temperature and
speed)
Fuel filter type Screw-on canister (with drain facil- Screw-on canister (with drain facil-
ity) ity)
Oil pressure relief valve setting 6bar (87.0psi) 6bar (87.0psi)
Oil pressure switch setting 0.6bar (8.7psi) falling 0.6bar (8.7psi) falling
Oil pump
(1)
Integral unit with relief valve Integral unit with relief valve
Combustion system Common rail direct Injection Common rail direct Injection
High pressure fuel pump High pressure with electronically High pressure with electronically
controlled fuel metering controlled fuel metering
(1) The oil pump is a non-serviceable part
15 - 8 9813/7400-1 15 - 8
15 - Engine
00 - Engine
00 - General
External
The following identifies the main components of a
typical engine assembly visible from the exterior.
Some variants may differ in detail.
Figure 103. Left hand Side
24
23 9
2
8
1
15
10
4
20
17
14 5
13 16
19
12
11
21
7
18
22 6
1 Rocker cover 2 Fuel injectors and high pressure fuel pipes

3 Lubrication oil filler cap 4 Timing gear case
15 - 9 9813/7400-1 15 - 9
15 - Engine
00 - Engine
00 - General
5 Flywheel housing 6 Bedplate

7 Lubrication oil sump 8 EGR (Exhaust Gas Recirculation) cooler
9 Air inlet manifold 10 High pressure fuel pump
11 Fuel filter 12 Lubrication oil filler cap
13 Lubrication oil filter 14 Lubrication oil cooler housing
15 Lubrication oil dipstick 16 Low duty PTO (Power Take-Off) (blanking
cover if no device is installed)
17 Low pressure fuel line (to tank) 18 Oil drain plug (sump)
19 Oil filter housing drain plug 20 IMV (Inlet Metering Valve)
21 ECM (Engine Control Module) 22 Crankcase ventilation filter assembly
23 Inlet manifold induction heater (if installed) 24 Intake throttle
15 - 10 9813/7400-1 15 - 10
15 - Engine
00 - Engine
00 - General
Figure 104. Right Hand Side

6
11 14
8
2
16
3
17
10
9
4
12 15 13
1 EGR valve heatshield 2 Timing gear case
3 Flywheel housing 4 Bedplate
5 Lubrication oil sump 6 VGT (Variable Geometry Turbocharger) (not
installed on <55kW Engines)
7 Exhaust manifold 8 Alternator
9 Coolant pump housing (crankcase) 10 Coolant inlet/radiator hose connector
11 Heavy duty PTO (blanking cover if no device 12 Starter motor assembly
is installed)
13 Turbocharger oil drain pipe 14 Turbocharger oil feed pipe
15 - 11 9813/7400-1 15 - 11
15 - Engine
00 - Engine
00 - General
15 Oil drain plug (sump) 16 Coolant take off for cab heater
17 Coolant take off for SCR (Selective Catalytic
Reduction) system (not installed on <55kW
Engines)
Figure 105. Front End

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

3 Crankcase 4 Bedplate
5 Lubrication oil sump 6 Crankshaft pulley
7 FEAD (Front End Accessory Drive) tensioner 8 Coolant pump and drive pulley assembly
9 Alternator and drive pulley assembly 10 Coolant thermostat housing/radiator hose
connector
11 VGT (not installed on <55kW Engines) 12 Coolant temperature sensor
15 - 12 9813/7400-1 15 - 12
15 - Engine
00 - Engine
00 - General
Figure 106. Rear End
1 Rocker cover 2 Cylinder head

3 Flywheel 4 High pressure fuel pump drive gear cover
5 Flywheel housing 6 Engine electrical harness
7 VGT linkage (not installed on <55kW Engines) 8 VGT actuator (not installed on <55kW
Engines)
9 Turbocharger 10 EGR valve
11 EGR co-axial cooler 12 EGR plate cooler
13 EGR water cooler pipe 14 Low pressure return pipe to tank
15 - 13 9813/7400-1 15 - 13
15 - Engine
00 - Engine
00 - General
Operation
The Four Stroke Cycle - 4 Cylinder It is important to note that number 1 cylinder is firing
Engine and about to start its power stroke. Rotating the
crankshaft a further full rotation would position the
This section describes the cycle sequence, for the 4 pistons as described but the engine would be at a
cylinder engine. different stage in its four stroke cycle, with number 1
cylinder about to start its Induction stroke.
With the crankshaft positioned as shown, the pistons
in numbers 1 and 4 cylinders are at top dead centre The stages in the four stroke cycle for each cylinder
and pistons in numbers 2 and 3 cylinders are at are as follows:
bottom dead centre.
Table 22. The Four Stroke Cycle

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

number 1 cylinder will be next to fire. Number 3
A cylinder is said to be firing, when the fuel / air cylinder is starting its compression stroke and is next
mixture ignites and the piston is about to start its in the cycle, followed by cylinders 4 and 2.
power stroke.
The firing order is therefore; 1, 3, 4, 2.
15 - 14 9813/7400-1 15 - 14
15 - Engine
00 - Engine
00 - General
Figure 107.
CYL1 CYL2 CYL3 CYL4
1 2
C B C B C B C B
G H J K
4
3
745620
745620
G H J K
C B
B C
A A A A
C B
B C
CYL1 Cylinder number 1 CYL2 Cylinder number 2

CYL3 Cylinder number 3 CYL4 Cylinder number 4
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation F Front of engine
1 Exhaust valves 2 Inlet valves
3 Crankshaft 4 Crankshaft gear
5 Camshaft drive gear
15 - 15 9813/7400-1 15 - 15
15 - Engine
00 - Engine
00 - General
Four Stroke Cycle revolution of the crankshaft, thus, in one cycle of a

four stroke engine, the crankshaft revolves twice.
Induction
Figure 108.
As the piston travels down the cylinder, it draws
filtered air through inlet valves into the cylinder.
Compression
When the piston reaches the bottom of its stroke the 3

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

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

both temperature and pressure. The high pressure 746030
generated propels the piston downward turning the 1 Induction stroke
crankshaft and producing energy. 2 Compression stroke
3 Power stroke
Exhaust 4 Exhaust stroke
A Camshaft
Once the piston has reached the bottom of its travel, B Camshaft lobe - Inlet valve operation
the exhaust valves open and momentum stored C Camshaft lobe - Exhaust valve operation
in the flywheel forces the piston up the cylinder BDC Bottom dead centre
expelling the exhaust gases. TDC TDC (Top Dead Centre)
In a running engine these four phases are
continuously repeated. Each stroke is half a
15 - 16 9813/7400-1 15 - 16
15 - Engine
00 - Engine
00 - General
Figure 109.
717620
1 2 3 4
B C
A A A A
C B B C B
C
1 Induction stroke 2 Compression stroke

3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation
15 - 17 9813/7400-1 15 - 17
15 - Engine
00 - Engine
00 - General
Fault-Finding
Fault
Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Table 23. Page 15-18
Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Table 24. Page 15-19
Engine - Will Not Crank or Cranks Slowly Table 25. Page 15-19
Engine - Starts Then Stops Table 26. Page 15-20
Engine - Poor Running Table 27. Page 15-20
Engine - Poor Running at Idle Table 28. Page 15-21
Engine - Noise Excessive Table 29. Page 15-22
Engine - Compression Knocks Table 30. Page 15-22
Engine - Reduced Power Output Table 31. Page 15-23
Engine - Will Not Reach Maximum RPM Table 32. Page 15-24
Engine - RPM Surges Table 33. Page 15-24
Engine - Vibration Excessive Table 34. Page 15-25
Engine - Exhaust Smoke Excessive (Black Smoke) Table 35. Page 15-25
Engine - Exhaust Smoke Excessive (White/Blue Smoke) Table 36. Page 15-26
Engine - Will Not Shut Off Table 37. Page 15-26
Lubricating Oil - Consumption Excessive Table 38. Page 15-26
Lubricating Oil - Contaminated Table 39. Page 15-27
Lubricating Oil - Pressure Low Table 40. Page 15-27
Lubricating Oil - Pressure High Table 41. Page 15-27
Table 23. Engine - Will Not Start or Difficult to Start (No Exhaust Smoke)
Cause Remedy
No fuel in supply tank. Check the level in the fuel tank, use sight gauge or
dipstick. Replenish as required.
Starter switch or starter electrical system failure. Check the operation of the starter switch. Check the
correct electrical wires for open or short circuits.
Improper starting procedure. Verify proper starting procedure.
Fuel Filter blocked with water or other contamination. Drain fuel/water separator or replace fuel filter.
Defective fuel lift pump (fuel supply inadequate). Check that the lift pump operates and delivers fuel
to the high pressure fuel pump. Check the correct
electrical wires for open or short circuits. Check
fuses.
Fuel is aerated. Check the fuel system for loose connections and
possible air ingress points. Rectify and bleed the fuel
system.
Fuel inlet restriction. Maximum inlet restriction to fuel lift pump must not
exceed 100mm Hg.
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction. Remove as required. Check
the air filter elements for signs of blocking. Replace
as required.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
properly. connected to the top of the fuel tank.
One or more fuel injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
connections at the injectors.
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Do all the
necessary fault finding checks before removal of the
high pressure fuel pump.
Injectors Contaminated. Check the injectors. Use the Servicemaster test
procedure in Servicemaster Tools Actuator Test. Test
and replace as required.
15 - 18 9813/7400-1 15 - 18
15 - Engine
00 - Engine
00 - General
Table 24. Engine - Will Not Start or Difficult to Start (Exhaust Smoke)
Cause Remedy
Starting procedure incorrect. Verify proper starting procedure.
Air intake system blocked or restricted. Visually check the air intake for blockage or
obstruction, remove as required. Check the air filter
elements for signs of blocking, replace as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
Fuel is contaminated or incorrect grade diesel fuel STOP THE ENGINE. Replace the fuel filters.
used. Operate the engine with a temporary supply of
the correct grade of clean fuel. Monitor the engine
performance. Dirty fuel will cause damage to the high
pressure fuel pump and injectors.
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). Check fuel lines for
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
Check fuel inlet restriction. Maximum inlet restriction to fuel transfer pump must
not exceed 100 mm Hg
Inlet and exhaust valve clearances set incorrectly. Set the valve clearances to the recommended
clearances.
Engine compression low in one or more cylinders. Check the engine compression.
Cranking speed too slow. See Also: Table 25. Engine - Will Not Crank or
Cranks Slowly
ECM or electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at the ECM and sensors.
Table 25. Engine - Will Not Crank or Cranks Slowly

Cause Remedy
Starting electrical circuit connections loose or Clean and tighten connections.
corroded.
Battery charge low. Check battery voltage, charge the battery or
replace as required. Make sure that the alternator is
functioning correctly and charging the battery.
No electrical connection to starter solenoid. Check voltage to solenoid.
Crankshaft rotation restricted. Use special tool 892/01147 (crankshaft turning tool)
to manually turn the engine and check for any severe
rotational resistance.
Solenoid or starter motor fault. Replace starter motor.
Starter motor operating but not cranking. Remove the starter motor and check for broken teeth
on the ring gear or broken starter motor spring.
15 - 19 9813/7400-1 15 - 19
15 - Engine
00 - Engine
00 - General
Table 26. Engine - Starts Then Stops

Cause Remedy
Engine starting under load. Check for added loading from malfunctioning
accessories or driven units, brakes dragging and
other changes in vehicle loading. Disengage the
hydraulic controls.
blockage or obstruction - remove as required. Check
the air filter elements for signs of blocking - replace
as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump is operating and delivering
inadequate). fuel to the injection pump.
Fuel is waxing due to extremely cold weather. Verify by inspecting the fuel filter. Clean the system
and use acclimatised fuel.
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return lines are not obstructed and
ECM or Electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at theECM and sensors.
Table 27. Engine - Poor Running

Cause Remedy
Condition only occurs at idle. For possible poor running at idle faults.
See Also: Table 28. Engine - Poor Running at Idle
Engine is cold, coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
Check the correct electrical wires for open or short
circuits.
Fuel injection lines leaking. Replace defective high pressure fuel lines. DO
NOT repair defective fuel lines. If there is a fuel leak
remove and discard the necessary components and
install new ones.
system
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
restriction.
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15 - Engine
00 - Engine
00 - General
Cause Remedy
Engine is cold - Thermostat fault. Drain Coolant, Remove and replace Thermostat.
Low Power (particularly at high speed) Exhaust back pressure high, Catalyst problem,
Check Servicemaster Diagnostics.
clearances.
Camshaft damaged. Inspect camshaft.
Tappets damaged. Inspect tappets.
Table 28. Engine - Poor Running at Idle

Cause Remedy
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
install new ones.
system.
inadequate). fuel to the injection pump.
restriction.
clearances.
15 - 21 9813/7400-1 15 - 21
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Table 29. Engine - Noise Excessive

Cause Remedy
Drive belt squeal, insufficient tension or abnormally Check the tensioner and inspect the drive belt for
high loading. loading. deterioration, Make sure water pump,
tensioner pulley, fan, alternator turn freely. Check
for paint/oil or other material on pulleys. Check the
tension of accessory drive belts.
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Air intake or exhaust leaks. See Also: Table 35. Engine - Exhaust Smoke
Excessive (Black Smoke)
clearances.
Turbocharger noise. Check turbocharger impeller and turbine wheel for
housing contact.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Worn crank/connecting rod bearings (knocking under Check/replace rod and main bearings.
load).
Excessive camshaft bearing wear. Check bearings (engine overhaul required).
Worn or damaged pistons and/or piston rings. Check piston assemblies (engine overhaul required).
Gear train noise. Visually inspect and measure gear backlash.
Replace gears as required.
Loss of Pilot injection on one or more cylinders. Use service master to disable pilot injections to
identify audibly if they are still present.
Table 30. Engine - Compression Knocks

Cause Remedy
system.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Coolant operating temperature incorrect. Check and if necessary replace engine thermostat.
15 - 22 9813/7400-1 15 - 22
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Table 31. Engine - Reduced Power Output

Cause Remedy
Oil level incorrect. Check oil level.
Engine overload. Check for added loading from malfunctioning
hydraulic controls.
Throttle position sensor (TPS) system defective. Check the throttle assembly. Check the electronic
fault codes.
Turbocharger boost control pipe leaking or damaged, Check boost control pressure. Inspect and tighten
or wastegate diaphragm ruptured. fittings, repair pipes, replace wastegate assembly.
install new ones.
restriction.
system.
inadequate). fuel to the injection pump. Check fuses.
as required.
Exhaust leak at the manifold or turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Extra injector sealing washer installed under injector. Remove extra injector sealing washer.
clearances.
high pressure fuel pump
Engine in reduced torque or limp home mode. Check the electronic fault codes.
Excessive exhaust back pressure Inspect Catalyst. Check Exhaust pressure readings
using Servicemaster.
Low DEF (Diesel Exhaust Fluid) Level. Fill the DEF Tank with clean DEF
15 - 23 9813/7400-1 15 - 23
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Table 32. Engine - Will Not Reach Maximum RPM

Cause Remedy
Tachometer faulty. Verify engine speed with hand tachometer. Repair as
required.
Engine overloaded. Verify high idle speed without load. Investigate
operation to be sure correct gear is being used.
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
system.
inadequate). fuel to the injection pump. Check fuses.
restriction.
Turbocharger wastegate actuator diaphragm Repair or replace turbocharger.
ruptured.
Table 33. Engine - RPM Surges

Cause Remedy
Fuel level low. Check the level in the fuel tank, use sight gauge or
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
install new ones.
Fuel tank cap vent/breather blocked. Inspect and rectify as required. Replace cap if
necessary.
system.
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00 - Engine
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Table 34. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. See Also: Table 28. Engine - Poor Running at Idle
Fan damaged or accessories faulty. Check/replace the vibrating component. Refer to the
machine's service manual for correct installation and
torque figures.
Fan hub faulty. Inspect/replace the fan hub. Refer to the machine's
service manual for correct installation and torque
figures.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
clearances.
Alternator bearing worn or damaged. Check/replace the alternator.
Flywheel housing misaligned. Check/repair flywheel alignment.
Drive line components worn or unbalanced. Check and inspect drive line components such as
propshafts. Refer to the machine's service manual for
correct installation and torque figures.
Table 35. Engine - Exhaust Smoke Excessive (Black Smoke)

Cause Remedy
Engine being lugged down. Check for added loading from malfunctioning
hydraulic controls.
as required.
Air leak between the turbocharger and the intake Check/repair leaks in the air crossover tube, hoses,
manifold. or manifold cover. Visually inspect MAF (Mass Air
Flow) sensor tube
Intercooler faulty. Check for blocked cooler matrix.
Exhaust leak at the manifold or turbocharger Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Turbocharger wastegate faulty. Repair or replace turbocharger.
Turbocharger malfunction. Replace turbocharger.
connections at the ECM and sensors
Smokes under load at all speeds, but mainly low to
mid speed range.
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00 - Engine
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Table 36. Engine - Exhaust Smoke Excessive (White/Blue Smoke)

Cause Remedy
Improper starting procedure. Verify proper starting procedure.
Diesel or hydraulic oil in sump. Check oil consistency. If oil contamination is
suspected check equipment such as PTO (Power
Take-Off) pump for hydraulic oil leaks past the seal
into the engine. Drain, flush and fill with clean oil.
Coolant temperature too low (over-cooling) - light Check the thermostat and replace if necessary.
blue or white high speed/light load.
One or more engine injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
- white/ blue smoke at operating temperature. connections at the injectors.
Coolant leaking into combustion chamber. Check the EGR (Exhaust Gas Recirculation) Cooler
for leaks. Replace Cylinder head gasket if necessary.
Leaking valve stem seals - evident after long idle Replace valve seals.
period and then acceleration.
Piston rings not sealing - evident with persistent blue Check the engine compression.
smoke at all speeds/load.
Table 37. Engine - Will Not Shut Off

Cause Remedy
Stop switch or stop switch electrical system failure. Check the operation of the stop switch. Check the
correct electrical wires for open or short circuits.
Table 38. Lubricating Oil - Consumption Excessive

Cause Remedy
Oil leaks. Inspect the engine for visible signs of leaks. Pay
particular attentions to seals, gaskets oil cooler and
external connections.
Oil level over-full. Check oil level.
Incorrect lubricating oil (specification of viscosity). Make sure the correct lubricating oil is being used.
Tier 4 Final Engines require a special oil grade. Refer Check for reduced viscosity from dilution with fuel.
to (PIL 75-03). Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review/reduce the lubricating oil change intervals.
Crankcase ventilation (CCV) system blocked. Check the breather tube area for signs of lubricating
oil loss. Check and if necessary replace the CCV
filter.
Lubricating oil cooler leak. Check for lubricating oil in the coolant.
Turbocharger leaking lubricating oil to the air intake Inspect the air crossover tube for evidence of
or exhaust. lubricating oil transfer.
Valve guide seals are leaking. Replace valve guide stem seals as required.
Piston rings not sealing - lubricating oil being Check the engine compression
consumed by the engine (blue smoke from exhaust).
Worn cylinder bores - lubricating oil being consumed Check the engine compression.
by the engine (blue smoke from exhaust).
Glazed cylinder bores. De-glaze bores as required.
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00 - Engine
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Table 39. Lubricating Oil - Contaminated

Cause Remedy
Coolant in the lubricating oil, internal engine Check oil cooler O-rings. If necessary change the oil
component leaks. cooler.
Lubricating oil sludge excessive. Change oil and filter. Review oil and filter change
period. If operating in arduous applications, change
more frequently. Make sure the correct lubricating oil
is being used.
Fuel in the lubricating oil, engine operating too cold. Review the operation for excessive idling resulting in
the engine running below normal temperature.
Table 40. Lubricating Oil - Pressure Low

Cause Remedy
Check for reduced viscosity from dilution with fuel.
Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review oil and filter change period. If operating in
arduous applications, change more frequently.
Pressure switch or gauge fault. Verify the pressure switch is functioning correctly.
Lubricating oil filter blocked. Change lubricating oil filter. Review oil and filter
change period. If operating in arduous applications,
change more frequently.
Lubricating oil filter drain down valve not installed. Change lubricating oil filter.
Suction pump pressure relief valve stuck open. Check/replace seal.
Oil pump pressure relief valve stuck open. Replace oil pump assembly.
Lubricating oil pump worn. Replace oil pump assembly.
Table 41. Lubricating Oil - Pressure High

Cause Remedy
Pressure switch or gauge fault. Verify the pressure switch is functioning correctly.
Engine running too cold. Check and if necessary replace the engine
thermostat.
Oil pump pressure relief valve stuck closed. Replace oil pump assembly.
15 - 27 9813/7400-1 15 - 27
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 - Clean (PIL 18-00).
Before carrying out any service procedures that

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

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

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

2. Make sure that all electrical connectors are
correctly coupled. If connectors are open fit the
correct caps or seal with water proof tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and soft bristle
brush to soak off caked mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical connectors and
electronic components such as ECU (Electronic
Control Unit)'s, alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine or exhaust
system.
Length/Dimension/Distance: 600mm
15 - 28 9813/7400-1 15 - 28
15 - Engine
00 - Engine
00 - General
Check (Pressure) • The correct engine oil has been used, refer to
Consumable Products, Oil (PIL 75-03).
Special Tools • The engine oil level is correct, refer to Oil Filter,
Description Part No. Qty. Check Level (PIL 15-21).
Servicemaster 721/10855 1 1. Make sure that the engine is safe to work on. If
Electronic Test Cable the engine has been running, let it cool before
Pressure Gauge (0-40 892/00278 1 you start the service work.
Bar)
Servicemaster 892/01033 1* 2. Get access to the engine.
Electronic Test Kit 892/01174
3. Disconnect the electrical connector to the oil
Data Link Adaptor
pressure switch, remove the switch from the oil
(DLA) Kit
cooler housing.
Digital Hydraulic 998/11051 1
Pressure Test Kit 4. Install a suitable adaptor into the vacant pressure
*Unless otherwise stated, you can use any of the switch port (M10 x 1.5mm thread) and a pressure
tools shown. test gauge. Make sure that the gauge has a
sealing washer as shown.
This test is used to diagnose suspected poor Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
compression in one or more of the engine cylinders. Special Tool: Digital Hydraulic Pressure Test Kit
Use ServiceMaster to control the test. (Qty.: 1)
Engine Compression Test

1. Connect the Servicemaster tool to the machine,
Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
Special Tool: Servicemaster Electronic Test
Cable (Qty.: 1)
2. Access the engine compression test and follow
the on screen commands.
3. There is a 5 second delay before the test starts.
4. The test disables the injectors and requests the
tester to crank the engine.
5. Crank the engine for at least 5 seconds, but no
longer than 10 seconds.
6. The engine ECU measures the variation in
engine cranking speed to determine if one
or more cylinders have lower than expected
compression values.
7. Turn off the ignition after the test.
Note: The engine cranking speed must be greater

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

Use the following procedures to measure the engine
oil pressure. Refer to Oil Sump (PIL 15-45) for a
full explanation of the lubricating oil circuit. Several
factors can influence the engine oil pressure, the
following conditions are assumed:
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15 - Engine
00 - Engine
00 - General
Figure 110. High Lubrication Oil Pressure

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

temperature is achieved, check the oil level, if this is
correct, suspect the oil pump relief valve is at fault.
Low Lubrication Oil Pressure
A Several factors can be the cause of low lubricating

oil pressure:
• Low oil level - typically evident as a loss of

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

B Sealing washer
5. Start the engine and allow a few seconds to
gain oil pressure, increase the engine revs to
the rated speed. Record the pressure gauge
reading, refer to Technical Data (PIL 15-00), for
the recommended circuit pressure.
6. Remove the pressure gauge and install the
pressure switch.
15 - 30 9813/7400-1 15 - 30
15 - Engine
00 - Engine
00 - General
Remove and Install
Special Tools recommended lifting equipment is shown. Use a

Description Part No. Qty. spreader bar when lifting the engine. Never attempt
Lifting Bracket Front 320/09062 1 to manually lift heavy components on your own.
Always use lifting equipment, or obtain the help of
Lifting Bracket Rear 320/09063 1 an assistant. Inspect the lifting brackets for signs
Engine Lifting Spreader 892/01382 1 of damage. The brackets must be correctly torqued
Bar to the crankcase. Make sure the lifting equipment
does not damage any of the engine dressing and the
Lifting Equipment rocker cover.
equipment. You must identify the weight of the item to Component Identification
enough and suitable for the job. Make sure that lifting The following component identification is for a typical
equipment is in good condition and complies with all engine installation. There will be some component
local regulations. differences depending on the machine variant.
Before attempting to remove the engine ensure that
The lifting equipment used must be an approved all the necessary components have either been
type and capable of lifting the engine safely. The removed, or safely disconnected from the engine.
Figure 111.
14 25 22 15
6
7
8
10 23
17
16
18
21
24
12 19
11
20
6 Engine mounting bolts 7 Lifting bracket- front

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

16 Electrical sensor- engine oil level 17 Electrical connections- starter motor
18 Lifting bracket- rear 19 Lifting bracket fixing bolts
20 Fixing bolts- gearbox to engine 21 Electrical connector- engine harness
22 Top hose 23 Bottom hose
24 Air inlet hose 25 Exhaust pipe
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00 - Engine
00 - General
Before Removal 16. Disconnect and plug the hoses at the hydraulic
pump.
1. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before 17. Disconnect the wiring to the hydraulic pump.
you start the service work.
18. Remove the gearbox to engine retaining bolts,
2. Position the machine on firm level ground. Make pull the transmission and converter clear of
the machine safe, refer to (PIL 01-03). the engine, make sure that the converter stays
mounted on the gearbox shaft.
3. Get access to the engine.
19. Attach slings to the engine lifting eyes.
Remove Special Tool: Lifting Bracket Front (Qty.: 1)
Special Tool: Lifting Bracket Rear (Qty.: 1)
1. Disconnect and remove the battery. Refer to (PIL Special Tool: Engine Lifting Spreader Bar (Qty.:
33-03). 1)
2. Drain the engine oil. Refer to (PIL 15-21). 20. Take the weight of the engine on the hoist and
remove the engine mounting bolts.
3. Drain the engine coolant, remove the cooling
pack. Refer to (PIL 21-03). 21. Withdraw the engine in a level attitude until the
hydraulic pump is clear of the chassis. Raise the
4. Discharge the hydraulic pressure. Refer to (PIL engine to lift it clear of the machine.
30-00).
22. Lower the engine into a suitable stand that is
5. Drain the hydraulic tank. Disconnect and plug capable of supporting the weight of the engine.
the hydraulic suction and delivery lines at the
transmission pump and gear pump. Label the
hoses to ensure correct reassembly. Refer to
(PIL 30-00).
6. Disconnect and plug the hydraulic cooler hoses.
Label the hoses to ensure correct reassembly.
7. Disconnect the exhaust system.
8. Label the cab heater hoses at the engine block
connectors. Release the hose clips and remove
the hoses.
9. Disconnect the wiring connections from the
starter motor. Refer to (PIL 15-75).
alternator. Refer to (PIL 15-72).
engine sensors and actuators. Refer to (PIL
15-84).
12. Disconnect the fuel supply line at the fuel lift
pump and the spill line at the fuel injection pump.
Cap all hoses and ports to prevent ingress of dirt.
13. Disconnect the electrical harness at the engine
harness.
14. Uncouple the electrical harness at the
ECM (Engine Control Module) machine side
connector. Important: Do not touch the connector
pins on the ECM or harness connectors. Cover
the connectors to prevent contamination.
15. Ensure that all relevant harnesses and hoses are
unclipped from the engine and tied out of the way.
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00 - Engine
00 - General
Figure 112. 3. Fill the cooling system with the correct mix of
coolant fluid. Refer to (PIL 21-00).
4. Fill and Check the hydraulic fluid level. Refer to
B (PIL 30-00).
5. Fill and Check the engine oil level. Make sure the
correct oil is used. Refer to (PIL 75-03).
6. On completion, check the hydraulic and cooling
system for leakage and levels.
7. Check the function of the drive and loader
services.

C Item Nm
A 47
A Lifting bracket mounting bolts

B Lifting equipment
C Spreader bar
Install
procedure. Note the following:
2. Important: It is vitally important that the torque
converter is installed at the gearbox and engine
flywheel correctly. Failure to locate the converter
correctly will result in damage to the gearbox oil
pump on engine start up.
15 - 34 9813/7400-1 15 - 34
15 - Engine
00 - Engine
00 - General
Store and Recommission
Engines should be stored in the original shipping If an engine is to be placed into storage, all external
packaging. Damaged or disturbed packaging should signs of surface coating damage or corrosion should
be made weatherproof immediately. be cleaned and re-coated. Electrical connectors and
components should be coated with a protective
If an engine is shipped with oil, it should be stored in spray.
the correct (upright) position.
Capping Engine Openings
If an engine is shipped dry of oil, after 6 months it
should be filled with oil to the correct level and re- All openings on the engine must be suitably capped
inhibited, refer to hot test description. to prevent ingress of water and contamination by
foreign particles.
All floor stock engines should be stored under cover
in dry conditions and not subjected to extreme
variations in temperature or humidity.
Figure 113.
13
5
3
4
14
16
12
11
2
10
8 15
1 Top hose cap 2 Bottom hose cap

3 Turbocharger intake cap 4 Turbocharger compressor outlet cap
5 Turbocharger exhaust outlet cap 6 Inlet manifold cap
7 Dipstick plug 8 ECM (Engine Control Module) machine
harness connector cap
15 - 35 9813/7400-1 15 - 35
15 - Engine
00 - Engine
00 - General
9 Fuel spill back line cap 10 Low duty PTO (Power Take-Off) (if installed)
cap
11 Heavy duty PTO (if installed) cap 12 Cab heater feed and return spigots
13 Coolant circuit de-gas spigot 14 CCV canister outlet on the closed loop
breathing circuit (55kW)
15 Low pressure fuel filter inlet spigot 16 SCR (Selective Catalytic Reduction) coolant
feed spigot (if installed)
12 Month Revalidation Procedure Table 43. Oil Pressure Switch Set Points
1. Pre-inspection: Oil pressure switch >0.6bar (8.7psi)

closed
1.1. Inspect packaging for signs of damage. Oil pressure switch open <0.6bar (8.7psi)
1.2. Inspect the caps for signs of damage.
OEM Commissioning Check on Engine
1.3. Inspect openings for signs of water or dirt Installation After More Than 12 Months
ingress.
1.4. Inspect the engine for signs of external 1. Flush the coolant system with proprietary
corrosion. flushing solution.
1.5. Inspect the engine for signs of fluid leaks. 2. Refill the coolant system with 50/50 mix of long
life antifreeze mixture.
2. From storage:
3. Hot test engine according to the hot test profile.
2.1. Remove the air intake caps. Refer to Table 44.
2.2. Make sure the engine oil level is correct. 4. Drain engine oil and replace engine oil filter.
2.3. Using a suitable power supply at the correct
voltage, crank the engine over. 5. Refill with the correct oil and inhibit the cooling
system using the correct product.
2.4. During cranking, check that the oil pressure
switch opens using a multimeter. The switch 6. Record details of work as required.
is closed when there is no or low oil
pressure and opens when oil pressure Hot Test Description
reaches a set point. After three separate 20
WARNING When using cleaning agents, solvents
second cranking periods, If the oil pressure
or other chemicals, you must adhere to
switch does not open (indicating no, or
the manufacturer's instructions and safety
low oil pressure), contact your JCB engine
precautions.
dealer.
2.5. Recap all engine openings. All engines despatched from JCB will have been
2.6. Coat any exposed bare metal with a subjected to a hot test (checking items such as oil
suitable product. pressure, engines speeds, torque values etc.) and
therefore the interior surfaces will have been coated
2.7. Electrical connectors and components with engine oil.
should be coated with a protective spray if
exposed. All coolant galleries are coated with CRODAFLUID
2.8. Cover in weatherproof packaging. PA75 corrosion inhibitor.
2.9. Place in storage, under cover on level Stored engines will require re-inhibiting every 12
ground or shelving. months, this will include hot testing the engine using
2.10. Record details of work as required. a dynamometer. The hot test profile is:
2.11. Do not expose to extremes of temperature Table 44. Hot Test Profile
or humidity. Stage Mode Speed Torque Time
Notice: Do not operate the starter motor for more (rpm) (Nm) (secs)
than 20s at one time. Let the starter motor cool for 1 Speed/ 830 0 50
at least 2min. Torque
2 Speed/ 1300 50 60
Torque
3 Speed/ 2500 0 60
Torque
15 - 36 9813/7400-1 15 - 36
15 - Engine
00 - Engine
00 - General
Stage Mode Speed Torque Time

(rpm) (Nm) (secs)
4 Speed/ 1300 0 25
Torque
5 Speed/ 800 0 35
Torque
15 - 37 9813/7400-1 15 - 37
15 - Engine
03 - Crankcase
03 - Crankcase
Contents Page No.
15-03-00 General ........................................................................................................................... 15-39
15 - 38 9813/7400-1 15 - 38
15 - Engine
03 - Crankcase
00 - General
Introduction .................................................... 15-39 The crankcase is the housing for the crankshaft.
Technical Data ............................................... 15-40 The enclosure forms the largest cavity in the engine
and is located below the cylinders. It is integral with
the cylinder bank and forms an engine block. It has
an opening in the bottom to which an oil sump is
attached with a gasket and bolted joint.
The crankcase protects the crankshaft and

connecting rods from foreign objects it also keeps
the engine oil contained and allows the oil to be
pressurised and also provide the rigid structure with
which to join the engine to the transmission.
Figure 114.
A
A Crankcase
B Crankshaft
15 - 39 9813/7400-1 15 - 39
15 - Engine
03 - Crankcase
00 - General
Technical Data
Table 45. Crankcase and Bedplate Data

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

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

Diameter of second oversize bore 104–104.02mm
Main bearing bore (without bear-
ings)
Numbers 1 to 4 92–92.02mm 92–92.02mm
Number 5 105–105.02mm 105–105.02mm
Main bearing bore (with bearings)
Numbers 1 to 4 88.047–88.09mm 88.047–88.09mm
Number 5 100.047–100.09mm 100.047–100.09mm
Camshaft bore
Numbers 1 to 4 60.04–60.07mm 60.04–60.07mm
Number 5 (bush) 60.29–60.32mm 60.29–60.32mm
Permissible wave profile wt < 10m (2.5 distance) wt < 10m (2.5 distance)
(1) Nominal diameter to be measured 63mm below the cylinder head face.
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures
may result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
(3) The crankcase to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
15 - 40 9813/7400-1 15 - 40
15 - Engine
06 - Cylinder Head
06 - Cylinder Head
Contents Page No.
15-06-00 General ........................................................................................................................... 15-43
15 - 41 9813/7400-1 15 - 41
Notes:
15 - 42 9813/7400-1 15 - 42
15 - Engine
06 - Cylinder Head
00 - General
Introduction .................................................... 15-43 The cylinder head is located above the cylinders
Technical Data ............................................... 15-44 on top of the crankcase. It closes in the top of the
Remove and Install ....................................... 15-45 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 - 43 9813/7400-1 15 - 43
15 - Engine
06 - Cylinder Head
00 - General
Technical Data
Table 46. Cylinder Head Data

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

- Side to side 0.03mm
Valve recess depth
- Inlet 0.85mm
- Exhaust 0.85mm
Valve seat angle
- Inlet 120(inclusive)
- Exhaust 90(inclusive)
Cylinder head bolts tourque
(2)
- First stage 40
- Second stage 75
- Third stage Repeat75
- Fourth stage Torque angle + 90
- Final stage Torque angle + 180
Surface finish for cylinder head joint Rz < 15 Rmax < 20
Permissible wave profile wt < 10m 2.5 distance
(1) The block to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct remove, install, disassemble and assemble procedure may
result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
15 - 44 9813/7400-1 15 - 44
15 - Engine
06 - Cylinder Head
00 - General
Remove and Install
Special Tools 2. Make sure that the engine is safe to work on. If
Description Part No. Qty. the engine has been running, let it cool before
Torque Wrench 993/70111 1 you start the service work.
(10-100Nm) 3. Get access to the engine.
Consumables 4. Remove the thermostat, refer to (PIL 21-12).
Cleaner/Degreaser 4104/1557 0.4L 5. Remove the fuel pipes, refer to (PIL 18-96).
- General purpose 6. Remove the rocker cover, refer to (PIL 15-42).
solvent based parts
cleaner 7. Remove the fuel injectors, refer to (PIL 18-18).
Before Removal 8. Remove the rocker assembly, refer to (PIL

15-42).
1. This procedure requires service parts. Make sure
9. Remove the exhaust manifold, refer to (PIL
you have obtained the correct parts before you
18-24).
start, refer to Parts Catalogue.
10. Remove the inlet manifold, refer to (PIL 18-24).
15 - 45 9813/7400-1 15 - 45
15 - Engine
06 - Cylinder Head
00 - General
Figure 115.
21
22
20
19
18 14 10 6 2 3 7 11
15
16
17 13 9 5 1 4 8 12
0° +90° +180°
1-18 Cylinder head fixing bolts (x18) 19 Cylinder head

20 Crankcase 21 Location dowels (x2)
22 Cylinder head gasket
15 - 46 9813/7400-1 15 - 46
15 - Engine
06 - Cylinder Head
00 - General
Remove Special Tool: Torque Wrench (10-100Nm)

(Qty.: 1)
1. Progressively remove the cylinder head bolts in
4.2. Then, further tighten the bolts, starting with
reverse order, starting at bolt 18. Note that the
the middle pair and working outwards (in
bolts MUST NOT be re-used. Discard the bolts.
sequence 1- 18) to the 2nd stage pre-
2. Carefully lift the cylinder head from the torque.
crankcase. If necessary use a soft face hammer. 4.3. Then, re-tighten the bolts, starting with
DO NOT use a lever to separate the cylinder the middle pair and working outwards (in
head from the crankcase. Discard the head sequence 1-18) to the 3rd stage pre-torque.
gasket.
4.4. Use the angle gauge to angle tighten the
3. Using a suitable cleaning agent, carefully remove bolts, starting with the middle pair and
all traces of the head gasket material from the working outwards (in sequence 1-18) to the
cylinder head and crankcase mating faces. 4th stage pre-torque. As a visual check,
Consumable: Cleaner/Degreaser - General matchmark the bolts to the cylinder head
purpose solvent based parts cleaner before you start. When the bolts have
been angle tightened, the matchmarks will
4. Check the cylinder head and crankcase mating appear as shown at Y.
faces for signs of damage and distortion, refer to 4.5. Finally, angle tighten the bolts, starting with
Technical Data (PIL 15-06). the middle pair and working outwards (in
sequence 1- 18) for the final stage torque.
Before Assembly
Table 47.
1. Obtain the correct new cylinder head bolts. Note
that the original bolts MUST NOT be re-used. Description Torque Value
Cylinder head to
2. Obtain the correct replacement head gasket. crankcase bolts 1-18
Note the number of identification holes as shown - first stage torque 40N·m
at X.
- second stage torque 75N·m
3. Make sure that all items are clean and free from - third stage torque 75N·m
damage and corrosion. - fourth stage torque 90°
- final stage torque 180°
Assemble
The cylinder head bolts are tightened using a torque
and angle method, refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).

procedure.
2. Make sure that the location dowels are correctly
installed into the crankcase. Use a dowel punch
to install the dowels as required.
3. Position a new head gasket on to the crankcase
mating face. Make sure that the gasket is
installed the correct way around and correctly
located over the dowels.
4. Lower the cylinder head on to the crankcase.
Make sure that the cylinder head is correctly
located on the dowels. Install new cylinder head
bolts. Tighten the bolts in five stages, use the
torque and angle method, refer to Fasteners and
Fixings, General, Introduction (PIL 72-00).
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-18) to the 1st stage pre-torque.
15 - 47 9813/7400-1 15 - 47
15 - Engine
09 - Bedplate
09 - Bedplate
Contents Page No.
15-09-00 General ........................................................................................................................... 15-49
15 - 48 9813/7400-1 15 - 48
15 - Engine
09 - Bedplate
00 - General
Introduction .................................................... 15-49 The bedplate acts as the main strength component
Remove and Install ....................................... 15-50 of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 116.
1
1 Bedplate
2 Crankcase
15 - 49 9813/7400-1 15 - 49
15 - Engine
09 - Bedplate
00 - General
Remove and Install
Special Tools 10. Remove the rocker assembly including the push
Description Part No. Qty. rods, refer to (PIL 15-42).
Template for Sealant 892/12356 1 11. It is not necessary to remove the cylinder head
Bedplate to Crankcase assembly to remove the crankshaft. If however
(4 Cyl) the cylinder head needs to be removed for other
Torque Wrench 993/70111 1 reasons (for piston and connecting rod removal
(10-100Nm) for example) remove it now, refer to (PIL 15-06).
Consumables 12. Remove the fuel injection pump, refer to (PIL
Description Part No. Size 18-18).
Cleaner/Degreaser 4104/1557 0.4L 13. Remove the starter motor, refer to (PIL 15-75).
- General purpose
solvent based parts 14. Remove the high duty PTO (Power Take-Off)
cleaner device (if installed).
CAUTION This component is heavy. It must only 15. Position the engine upside down in a suitable jig
be removed or handled using a suitable lifting or fixture, supported at the front of the cylinder
method and device. block.
16. Remove the flywheel, refer to (PIL 15-54).
Before Removal
17. Remove the flywheel housing, refer to (PIL
1. This procedure requires service parts. Make 15-54).
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue. 18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
the engine has been running, let it cool before 19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
3. Remove the engine, refer to (PIL 15-00). installed), refer to (PIL 15-51).
4. Remove the drive belt, refer to (PIL 15-18). 21. Remove the crankshaft drive gear, refer to (PIL
15-51).
5. Remove the crankshaft pulley, refer to (PIL
15-12). 22. Remove the camshaft, refer to (PIL 15-15).
6. Remove the oil sump, refer to (PIL 15-45). 23. Remove the rear timing case, refer to (PIL
15-51).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
8. Remove the rocker cover, refer to (PIL 15-42). caps, refer to (PIL 15-12).
9. Remove the fuel injectors, refer to (PIL 18-18).
15 - 50 9813/7400-1 15 - 50
15 - Engine
09 - Bedplate
00 - General
Figure 117.
4 1 5
11
8 9
7 10
3 P3 2 6
X
12 18
18
18
18
18
13
18
1-10 Main bearing bolts (x10) 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Upper bearing shell (x5) P3 O-ring (if installed)
T1 Lifting bolts (obtain locally)
15 - 51 9813/7400-1 15 - 51
15 - Engine
09 - Bedplate
00 - General
Remove suitable lifting equipment (if the bedplate is lifted

manually, two people will be required). DO NOT
1. Remove the bedplate peripheral bolts. use a lever to separate the bedplate.
2. Progressively remove the main bearing bolts in 4. Remove and discard the O-ring.
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts. 5. Carefully remove the upper bearing shells from
the bedplate, remove the bedplate.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
Figure 118.
Y P2 Y A (T5) T4
T4
P2
P3
B (T5)
Y Y P2 T6
18
18 18
X
18
T6 18
4 1 5 T6
11
8 9
W
18
12
T6
7 10
3 2 6
13
1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Lower bearing shells (x5) A Left side template
B Right side template T3 Angle Gauge (obtain locally)
15 - 52 9813/7400-1 15 - 52
15 - Engine
09 - Bedplate
00 - General
T4 Guide pins (x2 obtain locally) T5 Sealant template

T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal
W Bearing tab X Rear main bearing
Y Bearing location tab P2 Anaerobic sealant
P3 O-ring
15 - 53 9813/7400-1 15 - 53
15 - Engine
09 - Bedplate
00 - General
Before Installation as a guide apply beads of sealant P2 around the

crankcase/bedplate mating face as shown to the
1. Clean off all traces of the old sealant compound dimension specified.
from the crankcase and bedplate mating faces.
Length/Dimension/Distance: 1.5mm
2. Use a suitable degreasing agent to carefully
9. Remove the four fixing bolts at positions Y.
clean the main bearing saddles in the bedplate
Remove the templates A and B, make sure
and crankcase. Take care not to block the oil
you do not smudge the sealant. Discard the
ways or the piston cooling jets.
templates.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner 10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
Important: Anaerobic sealant will not start to cure beads as shown at X.
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 11. Make sure that the location guide pins T4 are in
put together) it will immediately start to harden. Make position in the crankcase. Assemble the bedplate
sure that all the necessary tools, bolts etc. are readily to the crankcase use the alignment guide pins.
available prior to assembling the components. The 12. Note: The bedplate is heavy. Two people will
parts must be installed and tightened to the correct be required to lift and rotate the bedplate safely
torque value within 5 minutes (with a maximum on to the crankcase. Install new main bearing
permissible time of 15 minutes). bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
Important: BEFORE installing the bedplate: DO NOT
outwards (in sequence 1-10) to the 1st stage pre-
rotate the crankshaft. Make sure that the upper main
torque.
bearing shells are flush with the bottom face of the
crankcase. Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Install 13. Install the bedplate peripheral bolts. Tighten the
1. The installation procedure is the opposite of the bolts to the correct torque value.
14. After installation and tightening the bedplate
steps.
peripheral bolts, further tighten the main bearing
2. Make sure that all items are clean and free from bolts in pairs, starting in the centre and working
damage and corrosion. outwards (in sequence 1-10) to the 2nd stage
pre-torque.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown. 15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
4. Install the four lifting bolts T6 to the bedplate as (in sequence 1-10) for the final stage torque. Use
shown. the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
5. Install a new O-ring at the bedplate.
Important: If the parts have not been tightened to the
6. Use a suitable degreasing agent to clean both correct torque value within the maximum 15 minute
sides of the lower bearing shells. Assemble the time period, then the parts must be separated,
lower bearing shells into the bedplate. Lubricate thoroughly cleaned and fresh sealant applied.
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
After Installation
Consumable: Cleaner/Degreaser - General 1. Check that the crankshaft can be freely rotated
purpose solvent based parts cleaner by hand. Remove the bedplate lifting bolts T6.
7. Note: The sealant template T5 is used on 2. Carry out the procedures listed, Before removal
the crankcase, NOT the bedplate. The sealant in reverse order.
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Table 48. Torque Table
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1) Item Torque Value
1-10 (1st Stage) 50N·m
8. Locate the holes in the templates A and B using 1-10 (2nd Stage) 115N·m
four fixing bolts at positions Y. Use the templates
15 - 54 9813/7400-1 15 - 54
15 - Engine
09 - Bedplate
00 - General
Item Torque Value

1-10 (Final Stage) 180°
11 24N·m
15 - 55 9813/7400-1 15 - 55
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-00 General ........................................................................................................................... 15-57

15-12-03 Main Bearing .................................................................................................................. 15-66
15-12-06 Front Oil Seal ................................................................................................................. 15-70
15-12-09 Rear Oil Seal ................................................................................................................. 15-73
15-12-12 Pulley .............................................................................................................................. 15-77
15 - 56 9813/7400-1 15 - 56
15 - Engine
12 - Crankshaft
00 - General
Introduction .................................................... 15-57 The crankshaft is housed inside the crankcase.
Technical Data ............................................... 15-58 It is connected to the piston via a connecting
Component Identification ............................... 15-59 rod, they form a simple mechanism that converts
Operation ....................................................... 15-60 reciprocating motion into rotating motion. Refer to
Engine- General, Operation, The Four Stroke Cycle
Check (Condition) .......................................... 15-61 (PIL 15-00).
15 - 57 9813/7400-1 15 - 57
15 - Engine
12 - Crankshaft
00 - General
Technical Data
Table 49.
Main bearing journal diameter (x4)
- min 87.98mm
- max 88mm
Main rear bearing journal diameter (x1)
- min 99.98mm
- max 100mm
Connecting rod bearing journal diameter
- min 72.98mm
- max 73mm
Maximum wear and ovality on journals
(1)
Crankshaft induction hardness 55 HRc min on surface

Thrust washer width
- min 2.44mm
- max 2.5mm
Crankshaft end float
- min 0.05mm
- max 0.28mm
(1) No visible damage/wear or marks
15 - 58 9813/7400-1 15 - 58
15 - Engine
12 - Crankshaft
00 - General
Figure 119.
A
A Crankcase
B Crankshaft
15 - 59 9813/7400-1 15 - 59
15 - Engine
12 - Crankshaft
00 - General
Operation
Refer to Camshaft-Operation (PIL 15-15). diameter of the upper main bearing shell allows oil
transfer to cross drillings in the crankshaft to feed
Lubrication each of the big end bearings. Crankshaft gear is
'splash' lubricated. Front and rear crankshaft oil seals
Oil is fed from the main gallery via five drillings, one prevent oil leakage from, and dirt ingress to, the
to each of the main bearings. A groove around the engine.
Figure 120.
1 Main gallery 2 Drillings (x5)

3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal 8 Crankshaft oil seal
15 - 60 9813/7400-1 15 - 60
15 - Engine
12 - Crankshaft
00 - General
Check (Condition) Figure 123.
1. Check the main bearing surfaces for damage and

excessive wear.
Figure 121.
C
D
A
C J-jets
D Fixing screws
A Main bearing shells

2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 122.
B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.
15 - 61 9813/7400-1 15 - 61
15 - Engine
12 - Crankshaft
00 - General
Remove and Install
Consumables reasons (for piston and connecting rod removal

Description Part No. Size for example) remove it now, refer to (PIL 15-06).
Cleaner/Degreaser 4104/1557 0.4L 12. Remove the fuel injection pump, refer to (PIL
- General purpose 18-18).
solvent based parts
cleaner 13. Remove the starter motor, refer to (PIL 15-75).
CAUTION This component is heavy. It must only 14. Remove the high duty PTO device (if installed).
method and device. 15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
Before Removal
16. Remove the flywheel, refer to (PIL 15-54).
1. This procedure requires service parts. Make
sure you have obtained the correct service parts 17. Remove the flywheel housing, refer to (PIL
before you start, refer to Parts Catalogue. 15-54).
2. Make sure that the engine is safe to work on. If 18. Remove the fuel injection pump drive gear, refer
the engine has been running, let it cool before to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
3. Remove the engine, refer to (PIL 15-00).
20. Remove the high duty PTO idler drive gear (if
4. Remove the drive belt, refer to (PIL 15-18). installed), refer to (PIL 15-51).
5. Remove the crankshaft pulley, refer to (PIL 21. Remove the crankshaft drive gear, refer to (PIL
15-12). 15-51).
6. Remove the oil sump, refer to (PIL 15-45). 22. Remove the camshaft, refer to (PIL 15-15).
7. Disconnect and remove the fuel pipes from the 23. Remove the rear timing case, refer to (PIL
injectors, refer to (PIL 18-96). 15-51).
8. Remove the rocker cover, refer to (PIL 15-42). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
9. Remove the fuel injectors, refer to (PIL 18-18). caps, refer to (PIL 15-12).
10. Remove the rocker assembly including the push 25. Remove the bedplate, refer to (PIL 15-09).
rods, refer to (PIL 15-42).
Remove
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however 1. Remove the thrust washers between the
the cylinder head needs to be removed for other crankshaft and crankcase rear main bearing.
15 - 62 9813/7400-1 15 - 62
15 - Engine
12 - Crankshaft
00 - General
Figure 124.
A
A
A Thrust Washers B Crankshaft

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

that they are installed in the correct positions
during assembly. 1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft 2. Use a suitable degreasing agent to carefully
is lifted manually, two people will be required). clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
4. Carefully lift out the bearing shells. ways or the piston cooling jets.
Figure 125. Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
D
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
steps.
2. Make sure that all items are clean and free from
damage and corrosion.
3. If removed or a new crankcase is being installed
D Main bearing shells then install cooling J jets as follows:
5. It is recommended that the bearing shells are

replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
15 - 63 9813/7400-1 15 - 63
15 - Engine
12 - Crankshaft
00 - General

G
D
E
F
D Main bearing shells

G Bearing location tab
E J jets (x4)
F Fixing screws 4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
3.1. Insert the cooling jets into the crankcase. shells are clean.
3.2. Note: There are different types of cooling Consumable: Cleaner/Degreaser - General
jets installed depending on the engine purpose solvent based parts cleaner
application. The jets are colour coded. 4.2. Assemble the bearing shells into the
3.3. Be sure to install the correct jets. Refer to crankcase bearing saddles. Make sure that
the relevant parts catalogue for the correct the location tab engages into the slot as
cooling jet identification. shown.
3.4. Tighten the retaining screws to the correct 4.3. Important: Make sure that the oil-way holes
torque value. in the bearing saddles align with the holes
in the bearing shell. If the holes are even
4. Install the upper bearing shells as follows: partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:
15 - 64 9813/7400-1 15 - 64
15 - Engine
12 - Crankshaft
00 - General
Figure 128.
B H
A
A
A Thrust washers B Crankshaft

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

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

Item Nm
F 24
15 - 65 9813/7400-1 15 - 65
15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing Introduction

Introduction .................................................... 15-66 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-67 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 129.
A Main bearing
B Crankshaft
15 - 66 9813/7400-1 15 - 66
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 Technical Data
(PIL 15-12). Before Removal
3. Renew any parts that are worn or not within the 1. This procedure requires service parts. Make
specified tolerances. sure you have obtained the correct service parts
before you start. Refer to Parts Catalogue.
the engine has been running, let it cool before
injectors. Refer to (PIL 18-96).
5. Remove the rocker cover. Refer to (PIL 15-42).
6. Remove the fuel injectors. Refer to (PIL 18-18).
7. Drain the oil from the engine. Refer to (PIL
15-21).
8. Remove the oil sump. Refer to (PIL 15-45).
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
The connecting rod and the big-end bearing cap

have been fracture split and must be kept together
as a set. Care must be taken to avoid contamination
and or damage to the fracture split surfaces.
Remove
1. It is recommended that the big-end bearing caps
are removed in pairs, cylinders 1 and 4 and
cylinders 2 and 3. Rotate the crankshaft so that
the big-end bearing caps on cylinders 2 and 3 are
positioned as shown.
2. Remove the bolts and lift off the big-end bearing
caps from the connecting rods. The bolts must
not be re-used, discard the bolts.
15 - 67 9813/7400-1 15 - 67
15 - Engine
12 - Crankshaft
03 - Main Bearing
Z
X 3
1 2
1 Big-end bearing caps

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

with the bolt to avoid damaging the screw 1 Big-end bearing cap
thread. 2 Bolts
3 Connecting rod
3. Lift out the bearing shells from the bearing caps. 4 Piston
Carefully rotate the crank to disengage from the 5 Piston rings
connecting rods and get access to the upper 6 Big end bearing shells
bearing shells. Lift out the upper bearing shells. Z Fracture split surfaces
It is recommended that the bearing shells are
renewed. If they are to be reused, label the 4. Carefully rotate the crankshaft to position the big-
bearing shells to make sure that they are installed end bearing caps of cylinders 1 and 4. Make
in their original positions on assembly. sure that the crank does not foul the connecting
rods of cylinders 2 and 3. Remove the bearing
caps and bearing shells as described in previous
steps.
5. Inspect the big-end bearings for signs of damage
and excessive wear. Refer to Check Condition
(PIL 15-12).
Install
steps.
3. Install the upper bearing shell to the connecting
rod. Lubricate the bearing shell with clean engine
oil.
15 - 68 9813/7400-1 15 - 68
15 - Engine
12 - Crankshaft
03 - Main Bearing
4. Install the lower bearing shell to the big-end

bearing cap. Lubricate the bearing shell with
clean engine oil. Install the big-end bearing cap
to the connecting rod. Make sure that the cast
notch on the bearing cap faces to the front of the
engine. Use compressed air to clean the fracture
surfaces before assembly.
5. Install new fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Figure 132.
T3
T3 Angle gauge (obtain locally)

5.1. Make sure that the tool is kept in inline
with the bolt to avoid damaging the screw
thread.
6. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
Figure 133.
0° +90°
After Installation
1. Carry out the procedures listed in Before
Removal in reverse order.
Table 51.
Item Torque Value
2 - 1st Stage 35N·m
2 - 2nd Stage 65N·m
2 - Final Stage 90°
15 - 69 9813/7400-1 15 - 69
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Remove and Install
Special Tools Figure 134.

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

5. Remove the crankshaft pulley, refer to (PIL
15-12-12).
A Crankshaft oil seal
Remove B Crankcase
C Crankshaft hub
1. Use a suitable lever behind the lip of the
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not Install
to scratch or damage the counterbore or the 1. Make sure that the counterbore and the
crankshaft hub. Damaged or dirty sealing faces crankshaft hub are clean and free from damage
will cause the oil seal to fail. and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 135.
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
135.
15 - 70 9813/7400-1 15 - 70
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 135.
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 136.
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
136. 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 - 71 9813/7400-1 15 - 71
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
After Installation
1. Install the crankshaft pulley, refer to (PIL
15-12-12).
2. Install the drive belt, refer to (PIL 15-18).
15 - 72 9813/7400-1 15 - 72
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
09 - Rear Oil Seal
Remove and Install
Special Tools Figure 138. 15mm Hub

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

B Flywheel housing
4. Remove the flywheel, refer to (PIL 15-54). C Flywheel hub
E Fixing bolt
Remove
Install (24mm Hub)
1. Use a suitable lever behind the lip of the seal
to carefully prise out the rear oil seal from the 1. Make sure that the counterbore and the flywheel
counterbore in the flywheel housing. Take care hub are clean and free from damage and
not to scratch or damage the counterbore or the corrosion.
flywheel hub. Damaged or dirty sealing faces will
cause the oil seal to fail.
Figure 137. 24mm Hub
C B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
15 - 73 9813/7400-1 15 - 73
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 139.
B
D
A
C
A Crankshaft rear oil seal B Flywheel housing

C Flywheel hub D Oil seal alignment tool
2. To prevent the seal lip rolling over and becoming Special Tool: Crankshaft Rear Oil Seal Alignment
damaged, make sure that you use the oil seal Tool (Qty.: 1)
alignment tool to initially install the oil seal on to
the flywheel hub. Locate the alignment tool over 3. Apply lubricant P80 around the seal outer rubber
the end of the hub, then carefully push the oil seal diameter.
over the alignment tool and on to the crankshaft
diameter. Make sure that the oil seal is installed 4. Dismantle the oil seal installation tool. Bolt the
the correct way around. centre body to the flywheel hub, using the two
flywheel bolts. Assemble the outer sleeve on to
Special Tool: Crankshaft Rear Oil Seal the centre body and install the screw.
Installation Tool (Qty.: 1)
Figure 140.
F
B
E
A C H
H
G
G F

C Outer sleeve E Oil seal installation tool
F Flywheel bolts G Centre body
H Flywheel hub J Screw
5. Turn the screw to push the seal squarely into 6. Remove the oil seal installation tool.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. Install (15mm Hub)
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore 1. Make sure that the counterbore and the hub are
within the tolerance specified. clean and free from damage.
15 - 74 9813/7400-1 15 - 74
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 141.
B
D
A
C

C Flywheel hub D Oil seal alignment tool
2. Install the new hub on to the crankshaft gear and Special Tool: Crankshaft Rear Oil Seal
install the old hub on the outside of the new hub Installation Tool (Qty.: 1)
to create a double thickness flywheel hub, install Special Tool: Crankshaft Rear Oil Seal Alignment
the fixing bolt as shown at A. Do not touch the Tool (Qty.: 1)
PTFE seal lips of the crankshaft oil seal.
4. Apply the lubricant P80 around the seal outer
3. Make sure that you use the oil seal alignment tool rubber diameter.
to initially install the oil seal on to the flywheel
hub to prevent damage to the seal lip. Locate the 5. Dismantle the oil seal installation tool. Use the
alignment tool over the end of the hub, carefully two flywheel bolts to attach the centre body on to
push the oil seal over the alignment tool as far the flywheel hub. Assemble the outer sleeve on
on to the crankshaft hub as possible. Make sure to the centre body include the extension ring and
that the seal is installed the correct way around. install the screw.
Figure 142.
B F
G
A C1 K C2
H
L
K
J

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

the counterbore so that the screw will not turn.
15 - 75 9813/7400-1 15 - 75
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
7. Remove the oil seal installation tool, remove the

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

Item Nm
E 47
15 - 76 9813/7400-1 15 - 76
15 - Engine
12 - Crankshaft
12 - Pulley
12 - Pulley Install
Remove and Install removal procedure. Additionally do the following
steps.
Special Tools
Description Part No. Qty. 2. Make sure that all items are clean and free from
Torque Wrench 993/70111 1 damage and corrosion.
(10-100Nm)
3. Renew the fixing bolts. Tighten the new bolts in
Before Removal
1. This procedure requires service parts. Make 1)
before you start, refer to Parts Catalogue. 4. The bolts are tightened using a torque and
2. Make sure that the engine is safe to work on. If General, Introduction (PIL 72-00).
you start the service work. Figure 144.

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 143.
C Angle gauge (obtain locally)
After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
A
Table 53.
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 - 77 9813/7400-1 15 - 77
15 - Engine
15 - Camshaft
15 - Camshaft
Contents Page No.
15-15-00 General ........................................................................................................................... 15-79
15 - 78 9813/7400-1 15 - 78
15 - Engine
15 - Camshaft
00 - General
Introduction .................................................... 15-79 The camshaft is an important component in an
Technical Data ............................................... 15-80 internal combustion engine.
Operation ....................................................... 15-82 The relationship between the rotation of the camshaft
and the rotation of the crankshaft is of critical
Check (Condition) .......................................... 15-83 importance. Since the valves control the flow of the
Remove and Install ....................................... 15-83 air/fuel mixture intake and exhaust gases, they must
be opened and closed at the appropriate time during
the stroke of the piston. For this reason, the camshaft
is connected to the crankshaft directly, via a gear
mechanism.
When the engine runs the crankshaft drives the

camshaft via gears. The camshaft opens and closes
the inlet and exhaust valves and via push rods in time
with the four stroke cycle, refer to Engine-Operation
(PIL 09-00).
15 - 79 9813/7400-1 15 - 79
15 - Engine
15 - Camshaft
00 - General
Technical Data
Table 54. Camshaft Data

Camshaft journal diame-
ter
- 4 off 59.99–59.97mm
- 1 off 60.25–60.22mm
Camshaft lobe wear lim-
its
Inlet lift 7.161–7.271mm
Exhaust lift 7.2–7.31mm
Camshaft bore diameter
- 4 off 60.07–60.04mm
- 1 off 60.32–60.29mm
Camshaft gear
(1)
104 teeth
(1) The camshaft gear is not available as a separate
item. The gear must be heated on to the camshaft
in the correct timed position. Specialist fixtures are
used during the production process to achieve the
correct timing.
15 - 80 9813/7400-1 15 - 80
15 - Engine
15 - Camshaft
00 - General
Figure 145.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700
1 Camshaft drive gear 2 Crankshaft gear

3 Camshaft 3a Camshaft lobes
4 Tappets 5 Push rods
15 Inlet valves 16 Exhaust valves
15 - 81 9813/7400-1 15 - 81
15 - Engine
15 - Camshaft
00 - General
Operation
As the crankshaft rotates the camshaft also rotates, during the cycle it follows that the camshaft is driven
driven by a gear on the crankshaft. The inlet and at half crankshaft (engine) speed.
exhaust valves are opened by lobes on the camshaft
in time with the cycle. Lubrication
The diagrams show the position of the camshaft at Oil is fed from the main gallery via a drilling to the
each part of the four stroke cycle, refer to Engine- camshaft bearing. A groove around the diameter of
General, Operation. Refer to (PIL 15-00). the bearing and connecting the cross drilling ensures
that oil is always fed to the centre drilling. Oil is then
It can be seen that for a complete cycle the camshaft transferred to the remaining camshaft bearings by
revolves once. Since the crankshaft revolves twice further cross drillings in the shaft. The cam lobes and
tappets are 'splash' lubricated.
Figure 146.
1 Main gallery 2 Camshaft bearing

3 Groove 4 Centre drilling
15 - 82 9813/7400-1 15 - 82
15 - Engine
15 - Camshaft
00 - General

1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
Before Removal
1. Drain the oil from the engine.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting. 2. Disconnect and remove the fuel pipes from the
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the 3. Remove the rocker cover. Refer to (PIL 15-42).
dimensions are within service limits.
4. Remove the fuel injection pump. Refer to (PIL
4. Inspect the cam bearing surfaces inside the 18-18).
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within 5. Remove the rocker assembly and push rods.
service limits. Refer to (PIL 15-42).
5. Inspect the bearing surfaces of the tappets for 6. Remove the starter motor. Refer to (PIL 15-75).
signs of excessive wear or damage. Check that
the dimensions are within service limits. 7. Remove the oil sump. Refer to (PIL 15-45).
6. Inspect the tappet bores inside the crankcase for 8. Remove the flywheel. Refer to (PIL 15-54).
the dimensions are within service limits. 9. Remove the flywheel housing. Refer to (PIL
15-54).
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries 10. Rotate the crankshaft until the camshaft timing
in the crankcase and camshaft may be blocked. pin can be inserted through the gear and into the
Make sure all oil ways are clear and free from aligning hole in the rear gear case.
debris. Figure 147.
A Timing pin- camshaft

11. Remove the taper blanking plug and insert
crankshaft locking pin. The camshaft and
crankshaft locking pins must be in position to lock
the crankshaft and camshaft before removing the
camshaft assembly.
15 - 83 9813/7400-1 15 - 83
15 - Engine
15 - Camshaft
00 - General
Figure 148. 3. Access the tappets through the apertures in

the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a
suitable magnetic probe. Label the tappets to
ensure replacement in their original positions.
B
Figure 150.
C
B Timing pin- crankshaft E
C Blanking plug
E
12. Remove the fuel injection pump drive gear. Refer
to (PIL 15-51).
Remove
The engine must be inverted. Do not attempt to
remove the camshaft and its drive gears with the
engine upright. The tappets and push rods will
fall into the engine and further dismantling will be
required to retrieve them.
1. Remove the camshaft timing pin.

2. Carefully withdraw the camshaft and gear
assembly from the crankcase. Make sure that
you fully support the camshaft to prevent the
lobes contacting the bearing surfaces in the
crankcase. The bearing surfaces can easily be
damaged by the sharp hard edges on the cam
lobes.
Figure 149. E Tappet
F Magnetic probe
Inspection
1. Refer to Camshaft- Check Condition (PIL 15-15).
Install
1. Lubricate the tappets and tappet bores inside the
A crankcase with clean engine oil.
2. Insert the tappets in their original positions in the
crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
preventing the lobes contacting the bearing
D surfaces in the crankcase. Before meshing the
camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
A Timing pin - camshaft aligns with the dowel hole in the gear casing.
D Camshaft and drive gear Insert the timing pin T1 to lock the camshaft in
this position.
15 - 84 9813/7400-1 15 - 84
15 - Engine
15 - Camshaft
00 - General
After Installation
1. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
injection pump replacement procedure. Refer to
(PIL 18-18).
2. Do the procedures in Before Removal in reverse
order.
15 - 85 9813/7400-1 15 - 85
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-87

15-18-03 Drive Belt ....................................................................................................................... 15-90
15-18-21 Tensioner ........................................................................................................................ 15-94
15 - 86 9813/7400-1 15 - 86
15 - Engine
18 - Engine Belt
00 - General
Introduction .................................................... 15-87 A crankshaft pulley is used to drive a FEAD
Health and Safety .......................................... 15-88 (Front End Accessory Drive) belt. The belt drives
Component Identification ............................... 15-88 the coolant pump. Depending on the machine
application, the belt is configured to drive engine
mounted accessories, such as the alternator, cooling
fan and air conditioning compressor.
Some applications have a second pulley on the

crankshaft which drives a dedicated fan belt. The belt
drives an engine mounted cooling fan.
15 - 87 9813/7400-1 15 - 87
15 - Engine
18 - Engine Belt
00 - General
Health and Safety Component Identification

Turning the Engine Figure 151. A - With air condition-
Do not try to turn the engine by pulling the fan or fan ing compressor, no cooling fan
belt. This could cause injury or premature component
failure. A
4
Switch off the engine before working in the engine 5
engine cover open.
3
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts. 7
Figure 152. B - Without air condi-

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

2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
7 Air conditioning compressor drive pulley
15 - 88 9813/7400-1 15 - 88
15 - Engine
18 - Engine Belt
00 - General
Figure 153. C - With air conditioning com-

pressor, cooling fan pulley installed
C
6
4
5
3
7
Figure 154. D - Without air conditioning

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

2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
6 Cooling fan drive pulley
7 Air conditioning compressor drive pulley
15 - 89 9813/7400-1 15 - 89
15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Introduction

Introduction .................................................... 15-90 The crankshaft pulley is used to drive the coolant
Health and Safety .......................................... 15-91 pump via a FEAD (Front End Accessory Drive) belt.
Check (Condition) .......................................... 15-91 In addition to the coolant pump the drive belt can
Adjust ............................................................ 15-92 also be configured to drive the engine mounted
accessories.
The belt is maintained at a constant tension by a
spring loaded tensioner. To achieve the necessary
belt/pulley contact area the belt is routed around
idler wheels as required. The configuration varies
depending on the accessories installed.
15 - 90 9813/7400-1 15 - 90
15 - Engine
18 - Engine Belt
03 - Drive Belt

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

Refer to: Safety (Page 01-1).
2. Stop the engine and let it cool down.
3. Renew the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Figure 155.
B
A
C
A Crack in belt
B Missing piece of belt
C Frayed belt
15 - 91 9813/7400-1 15 - 91
15 - Engine
18 - Engine Belt
03 - Drive Belt
Adjust Remove and Install
Adjustment is not possible with this drive belt. A Remove

spring loaded tensioning unit ensures that the FEAD
(Front End Accessory Drive) belt is kept at the correct 1. Make the machine safe. Refer to (PIL 01-03).
tension.
3. Use a socket of the specified size to locate
on to the hexagon spigot nut, carefully rotate
the tensioner against the spring force in the
direction shown. Do not use excessive force or
the tensioner will be damaged.
Dimension: 16mm
4. Keep holding the tensioner against the spring
force and lift the belt off the drive tensioner pulley.
5. Slowly release the spring force by rotating the
tensioner unit in the opposite direction.
15 - 92 9813/7400-1 15 - 92
15 - Engine
18 - Engine Belt
03 - Drive Belt
Figure 156.
A Spring loaded tensioner

B Drive belt
C Example of frayed drive belt (refer to Check
Condition)
D Spigot nut
Install
step.
2. Before you install the new belt, check that the
tensioner roller and the fan pulley rotate smoothly
and that there is no play in the bearings.
15 - 93 9813/7400-1 15 - 93
15 - Engine
18 - Engine Belt
21 - Tensioner
21 - Tensioner Install
steps.
Before Removal 2. Tighten the bolts to the correct torque value.
1. Make the machine safe. Refer to (PIL 01-03). 3. Install the drive belt, refer to (PIL 15-18).
2. Make sure that the engine is safe to work on. If 4. Make sure that the drive belt is under tension
the engine has been running, let it cool before and the locking pin is removed before starting the
you start the service work. engine. Refer to Drive Belt - Adjust (PIL 15-18).
3. Get access to the engine. Table 55. Torque Values

4. Remove the drive belt, refer to (PIL 15-18). Item Nm
2 24
Figure 157.
3 2 1
2
X
T3
1 Drive belt tensioner pulley
2 Fixing bolts (x3)
3 Drive belt
T3 Locking pin
X Spigot nut
Remove
The drive belt tensioner is a non-serviceable item.
If the drive belt tensioner or the idler wheel is faulty
or damaged it must be renewed as a complete
assembly.
1. To remove the tensioner assembly, remove the

bolts and lift the tensioner pulley from the cylinder
block.
15 - 94 9813/7400-1 15 - 94
15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ........................................................................................................................... 15-97
15 - 95 9813/7400-1 15 - 95
Notes:
15 - 96 9813/7400-1 15 - 96
15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................... 15-97 The oil filter is a spin on type which screws on and
Health and Safety .......................................... 15-98 off the oil filter head. For details on the oil cooler and
Component Identification ............................... 15-99 filter assembly, refer to (PIL 15-69).
Operation ..................................................... 15-101
Check (Level) .............................................. 15-101
Remove and Install ..................................... 15-102
15 - 97 9813/7400-1 15 - 97
15 - Engine
21 - Oil Filter
00 - General
Health and Safety

Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
accordance with local regulations. Use authorised
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove
the plug.
CAUTION! The oil filter canister will contain some oil
which could spill out when you remove the canister.
15 - 98 9813/7400-1 15 - 98
15 - Engine
21 - Oil Filter
00 - General
Figure 158.
1
13
A
16
5 6
14
4
19
15
18 8
10
10
3 9 9
11
13
B
16 11 1
14
19
15
18
12 17
3 3 8
1 Oil cooler and filter housing 2 Oil filler cap (not shown)
3 Oil filter head 4 Oil gallery - from pump to cooler
5 Oil cooler matrix 6 Sealing gasket - housing to crankcase
7 Coolant gallery 8 Oil filter drain down plug
9 Oil gallery - from cooler to filter head 10 Oil gallery - from filter head to main oil gallery
15 - 99 9813/7400-1 15 - 99
15 - Engine
21 - Oil Filter
00 - General
11 Oil filler port 12 Oil pressure switch

13 Oil filter 14 Filter element
15 Anti-drain seal 16 Spring
17 Oil Temperature Sensor 18 O-ring
19 Anti-drain pipe A Oil filter state - engine running
B Oil filter state - engine stopped
15 - 100 9813/7400-1 15 - 100

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

completed in accordance with the service schedules.
The oil pump delivers oil at pressure to the oil filter Failure to replace the oil and filter at the
via a port. The anti-drain seal is forced off its seat and recommended interval could cause serious engine
oil flows through a large area paper element. Filtered failure.
oil enters the inner part filter before leaving the filter
head via a port. 1. Make the machine safe, refer to (PIL 01-03).
At Engine Stopped
3. Check that the oil level is between the two marks
With the engine stopped oil pressure in the galleries on the dipstick.
and filter decays. The anti-drain seal falls on
its seat and oil is prevented from draining from 4. If necessary, add recommended oil through one
the filter assembly. The anti-drain pipe prevents of the filler points.
approximately half the filters oil capacity from
Figure 159.
draining. These features help protect the engine from
oil starvation on start up. B
A Dipstick
B Oil filler point
15 - 101 9813/7400-1 15 - 101

15 - Engine
21 - Oil Filter
00 - General
Remove and Install
Special Tools 9. If the engine has a dead crank feature, carry out
Description Part No. Qty. the following procedure.
Oil Filter Removal Tool 892/00292 1 9.1. Turn the ignition key to the on position.
Data Link Adaptor 892/01174 1
(DLA) Kit 9.2. Turn the ignition key to the off position.
9.3. Repeat steps 9.1 and 9.2 5 times.
Drain the oil when the engine is warm as
contaminants held in suspension will then be drained 9.4. Wait for the ECU (Electronic Control Unit) to
with the oil. shutdown.
Duration: 30s
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove 9.5. Turn the ignition key to the start position.
the plug. The engine will crank for an extended time
period before starting.
1. Place a container of suitable size beneath the
Duration: 10s
drain plug.
10. If the engine does not have a dead crank feature,
2. Remove the oil sump drain plug and 'O' ring. Let
carry out the following procedure.
the oil drain out, then clean and install the drain
plug with a new 'O' ring. Tighten the plug to the 10.1. Connect a laptop to the engine with a data
correct torque value. link adapter and open Servicemaster.
3. Loosen and remove the filter housing drain plug. Special Tool: Data Link Adaptor (DLA) Kit
Let the oil fully drain. Install the plug. Tighten the (Qty.: 1)
plug to the correct torque value. 10.2. Perform the IMV (Inlet Metering Valve)
4. Unscrew the filter canister, use special tool if Override test.
necessary. 10.3. The IMV Override test will allow the engine
Special Tool: Oil Filter Removal Tool (Qty.: 1) to be cranked for a set time period without
starting allowing sufficient time to prime
5. Clean the seal face of the filter head. the oil pressure.
6. Smear the seal on the new filter canister with Duration: 10s
clean engine oil. 11. Operate the engine at idle, make sure that the
7. Screw in the new filter canister (hand tight only). oil pressure low warning light is extinguished
immediately after the engine starts. If it does not
8. Through one of the filler points, fill the engine with extinguish, stop the engine and investigate the
the recommended oil to the MAX mark on the cause.
dipstick. Wipe off any spilt oil, install the filler cap
and make sure it is secure. 12. Check for oil leakage. When the oil has cooled,
check the oil level again, and if necessary top up
with clean engine oil.
15 - 102 9813/7400-1 15 - 102

15 - Engine
21 - Oil Filter
00 - General
Figure 160.
B
A Dipstick B Oil filler points

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

Item Description Nm
C Oil sump drain plug 40
E Filter housing drain plug 40
15 - 103 9813/7400-1 15 - 103

15 - Engine
24 - Air Filter
24 - Air Filter
Contents Page No.
15-24-00 General ......................................................................................................................... 15-105
15 - 104 9813/7400-1 15 - 104

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

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

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

installed.
15 - 105 9813/7400-1 15 - 105

15 - Engine
24 - Air Filter
00 - General

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

with a vacuum switch. The switch will detect if there
is a restriction on the air intake, and activate warning
indicators such as an audible alarm and/or a visual
indicator.
15 - 106 9813/7400-1 15 - 106

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

every other time the outer element is changed. As
a reminder, mark the inner element with marker pen
each time the outer element is changed.
F
Remove E
D
3. Depress the clips and lift off the cover.
4. Remove the outer element. Take care not to tap
or knock the element.
5. If the inner element is to be changed, lift up pulls
and remove the inner element.
G
C
B Clips
C Cover
D Outer element
E Inner element
F Housing
G Air holes
Install
steps.
2. Clean inside the housing, and cover, make sure
that the air holes are clear.
3. Install the cover and fasten the latch. Make sure
that dust valve is at the bottom.
15 - 107 9813/7400-1 15 - 107

15 - Engine
27 - Crankcase Ventilation Filter
Contents Page No.
15-27-00 General ......................................................................................................................... 15-109
15 - 108 9813/7400-1 15 - 108

15 - Engine
00 - General
Introduction .................................................. 15-109 The engine is installed with a filtered open loop
Component Identification ............................. 15-110 crankcase ventilation (CCV) system.
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 crankcase ventilation
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.
The ventilation circuit incorporates a pressure relief

valve. If the filter element becomes blocked the valve
opens bypassing the filter and preventing a build up
of pressure in the crankcase. Although this prevents
serious engine damage it must be remembered
that the filtration system does not function when
bypassed. The filter element must be renewed at the
intervals specified to ensure a bypass condition is
avoided.
15 - 109 9813/7400-1 15 - 109

15 - Engine
00 - General
Figure 162.
C
H
D
G
A
A Crankcase vapour B Pressure relief valve

C Transfer hose D Filter element - second stage
E Filter element - first stage F Filtered vapour vent to atmosphere
G Oil droplets - return to sump H Crankcase ventilation filter assembly
15 - 110 9813/7400-1 15 - 110

15 - Engine
00 - General
Remove and Install
The filter element must be changed at the

recommended maintenance interval. Refer to (PIL
78-24).

2. Get access to the engine. Refer to (PIL 06-06).
3. Rotate the filter cover anti-clockwise and
remove.
4. Lift out the filter element and discard it.
5. Clean the inside of the filter housing. Remove all
oil and sludge contamination.
6. Make sure that the oil drain in the bottom of the
filter housing is not blocked with sludge.
7. Install a new filter element. Make sure that the
correct type of filter element is installed.
8. Align the arrows on both parts to install the filter
cover.
Figure 163.
A Filter cover
B Filter element
C Filter housing
15 - 111 9813/7400-1 15 - 111

15 - Engine
30 - Valve
30 - Valve
Contents Page No.
15-30-00 General ......................................................................................................................... 15-113

15-30-12 Valve Spring ................................................................................................................. 15-122
15-30-24 Stem Seal .................................................................................................................... 15-123
15 - 112 9813/7400-1 15 - 112

15 - Engine
30 - Valve
00 - General
Introduction .................................................. 15-113 The valve train system opens and closes the
Technical Data ............................................. 15-114 valves with correct timing in relation to the piston
Component Identification ............................. 15-115 movements.
Operation ..................................................... 15-117
Each push rod has one end in a valve tappet and the
Adjust .......................................................... 15-117 other end under a rocker arm, or as applicable. The
Remove and Install ..................................... 15-120 adjusting screw has a ball shaped end that locates in
the push rod. The adjusting screw is used for setting
the valve clearance.
The valves extend through the cylinder head. There

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

head. The seat inserts are also made from a special
metal to provide for a long service life. Damaged or
worn seat inserts can be removed and replaced with
new ones.
15 - 113 9813/7400-1 15 - 113

15 - Engine
30 - Valve
00 - General
Technical Data
Table 57. Inlet and Exhaust Valve Data

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

valve rockers.
15 - 114 9813/7400-1 15 - 114

15 - Engine
30 - Valve
00 - General
Figure 164.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700
1 Camshaft drive gear 2 Crankshaft gear

3 Camshaft 3a Lobes
4 Tappets (x8) 5 Push rods (x8)
6a Rockers - inlet (x4) 6b Rockers - exhaust (x4)
6c Adjusting screws (x8) 6d Swivel tip - rockers
7 Rocker shaft 8 Wave washers (x8)
9 Bridge pieces (x8) 10 Valve springs (x16)
11 Retainer (x16) 12 Collets (x32)
13 Oil seal - valve stems (x16) 14 Valve seat inserts (x16)
15 - 115 9813/7400-1 15 - 115

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

17 Valve stem
Cross Sectional View
Figure 165.
17
6c 11 12
8 10
6a 6b 13
6d
745930
14
6a Rockers - inlet (x4) 6b Rockers - exhaust (x4)

6c Adjusting screws (x8) 6d Swivel tip - rockers
8 Wave washers (x8) 9 Bridge pieces (x8)
10 Valve springs (x16) 11 Retainer (x16)
12 Collets (x32) 13 Oil seal - valve stems (x16)
14 Valve seat inserts (x16) 17 Valve stem
15 - 116 9813/7400-1 15 - 116

15 - Engine
30 - Valve
00 - General
Operation Adjust
Special Tools
The camshaft drive gear is driven by the crankshaft Description Part No. Qty.
gear at half the speed of the crankshaft. Camshaft Crankshaft Turning Tool 892/01147 1
lobes, two for each cylinder, (operating exhaust and (95.25mm PCD)- JCB
inlet valves) actuate the valve tappets. 4 Cylinder Ecomax and
Dieselmax
When the camshaft rotates the cam lobes act on the
tappets. The push rods act on the rockers which pivot Valve Clearance 892/01380 1
on the camshaft, depressing two valves at the same Service Kit
time via the bridge piece.
Engine Position
The screw is self locking in the rocker by means of
a tapered thread. Wave washers act like springs to The engine needs to be set to two different positions
keep the rockers in their correct positions along the to measure and adjust all of the valves. The graphics
camshaft and prevent them contacting one another. show which valves are applicable at which engine
The rockers incorporate a swivel tip to ensure position.
alignment with the bridge piece. This prevents
excessive wear. 1. Make sure that the engine is safe to work on. If
Each valve has a compression spring. The function you start the service work.
of the spring is to close the valve and at the same
time return the rocker arm and push rod to ensure 2. Get access to the engine.
that the tappets follow the camshaft lobes. The spring
is located on the valve stem by a retainer and split 3. Remove the tappet covers. Refer to (PIL 15-42).
collets.
4. Put the indicator pins into the holes inside the
tappet adjusters for cylinder number 4. Make
sure that the pins do not fall into the engine.
5. Use the crankshaft turning tool to turn the engine
crankshaft clockwise. Stop turning the crankshaft
when one indicator pin starts to move up after the
other pin has moved down. This is the position
where the exhaust valve is almost closed and the
inlet valve is just starting to open.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax
(Qty.: 1)
Special Tool: Valve Clearance Service Kit (Qty.:
1)
6. Put a mark on the crankshaft pulley at the 12
o'clock position.
15 - 117 9813/7400-1 15 - 117

15 - Engine
30 - Valve
00 - General
Figure 166. Figure 168. 360 Degree Position

A
360
T7
2B 4B
1A 2A
1A Exhaust valve-Cylinder 1
2A Exhaust valve-Cylinder 2
2B Inlet valve-Cylinder 2
T8 T8 Valve Clearances
The procedure describes how to measure and,
if necessary, adjust one valve clearance. The
procedure for all the valves is the same. Do the
A 12 o'clock position procedure for the correct valves at each of the two
T7 Crankshaft turning tool engine positions. Remember you must remove the
T8 Indicator pins (obtain locally) valve clearance service tools before you turn the
engine crankshaft.
7. Turn the engine crankshaft 90 degrees
clockwise. Important: The engine must be cold before you
8. Measure and, if necessary, adjust the clearances measure or adjust the valve clearances.
for the correct valves.
1. Install the adaptor plate in the correct position on
Figure 167. 90 Degree Position the rocker cover using the screws A.
2. Make sure that the crankshaft is in the correct
position.
3. Put the adaptor sleeve on the correct valve
tappet adjuster screw.
90 4. Push the lock bar into the correct valve tappet
adjuster screw.
1B 3B 5. Tighten the lock bar by turning it with your hand.
3A 4A
6. Assemble the DTI support and DTI.
3A Exhaust valve-Cylinder 3 7. Push and then pull the lock bar in the direction of
3B Inlet valve-Cylinder 3 the arrows X and Y. Do this until you are sure that
4A Exhaust valve-Cylinder 4 the lock bar is correctly installed and oil is moved
away from the cam follower and push rod.
9. Remove the valve clearance service tools. Turn
the engine crankshaft 360 degrees clockwise. 8. Important: Apply a side force on the lock bar
Use the mark on the crankshaft pulley as a at the same time as pushing and pulling. This
reference. prevents the rocker moving along the rocker
shaft and giving a false reading on the DTI. Apply
10. Measure and, if necessary, adjust the clearances a force to the left on the exhaust valve tappets
for the correct valves. and to the right on the inlet valve tappets.
15 - 118 9813/7400-1 15 - 118

15 - Engine
30 - Valve
00 - General
T1
C
T5
X A
T4 Y B
A
T3
T2
T6
A Screws B Tappet adjusters
T1 Dial Test Indicator (DTI)(obtain locally) C Rockers
T2 Adaptor plate (part of valve clearance service T6 Spanner open ended (obtain locally)
kit)
T3 Adaptor sleeve (part of valve clearance service
kit)
T4 Lock bar (part of valve clearance service kit)
T5 DTI Support (obtain locally)
9. Pull the lock bar in the direction of arrow Y and
turn the DTI to zero.
10. Push the lock bar in the direction of arrow X and
record the DTI indication.
11. Compare the valve clearance measurement with
the correct clearances. If an adjustment is
necessary:
11.1. Turn the tappet adjuster using an open
ended spanner on the adaptor sleeve.
Turn the sleeve clockwise to reduce
the clearance and counterclockwise to
increase the clearance.
11.2. Important: The tappet adjusters are set in
position by thread friction with the rockers.
Make sure that the torque to turn the
tappet adjusters is more than the minimum
necessary. If any of the adjusters show a
lower torque value then the adjuster and
its related rocker must be replaced.
15 - 119 9813/7400-1 15 - 119

15 - Engine
30 - Valve
00 - General
Remove and Install Figure 171. Valve Stand
Special Tools
Valve Stem Seal 892/01152 1
Installation Tool
(444/448/762 Engine)
EXHAUST
EXHAUST
EXHAUST
INLET
INLET
INLET
Before Removal
1. This procedure requires service parts. Make CYL. 1 CYL. 2 CYL. 3

2. Make sure that the engine is safe to work on. If Remove
you start the service work. 1. Use a spring compressor tool to compress each
valve spring and remove the collets. Make sure
3. Get access to the engine. that the springs are compressed squarely.
4. Remove the thermostat, refer to (PIL 21-12). Figure 172.
5. Remove all of the fuel injector pipes, refer to (PIL
18-96). B
6. Remove the rocker cover, refer to (PIL 15-42).

7. Remove the fuel injectors, refer to (PIL 18-18).
8. Remove the rocker assembly, refer to (PIL
15-42).
9. Remove the exhaust manifold, refer to (PIL A
18-24).
10. Remove the inlet manifold, refer to (PIL 18-24).
11. Remove the cylinder head assembly from the
cylinder block, refer to (PIL 15-06). A Spring compressor tool
12. Measure the valve recession with a suitable DTI B Collets
(Dial Test Indicator). Clean the carbon deposits 2. Remove the spring compressor tool and lift off
from a small area of the valve heads for location the retainer and valve spring.
of the DTI probe. If the valve recession is outside
the serviceable limits, it is advisable to obtain Figure 173.
a new or reconditioned cylinder head assembly,
refer to Technical Data (PIL 15-06). C
13. To aid removal and replacement, use a wooden

valve stand to retain the valves after removal. D
Add labels to make sure that the valves are
correctly replaced.
C Retainer
D Valve spring
3. Turn the cylinder head on its side and withdraw
the inlet valves and exhaust valves as shown.
15 - 120 9813/7400-1 15 - 120

15 - Engine
30 - Valve
00 - General
Figure 174. If there is evidence of wear or damage to the valves,

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

F Inlet valves
G Exhaust valves 1. The installation procedure is the opposite of the
4. When removing, note the respective position of steps.
each valve. Use a suitable valve stand to keep
the valves together and identify them with their 2. Install the new valve stem seals as shown. Use
respective cylinder. Note: The exhaust valves the installation tool to avoid damaging the seals.
have smaller diameter heads. Pre-assemble the seal into the tool. Locate the
tool over the valve guide and gently press the
5. Remove the valve stem seals. Discard the seals. seal into place. Lubricate the seal with P80 fluid.
Figure 175. Special Tool: Valve Stem Seal Installation Tool
(444/448/762 Engine) (Qty.: 1)
3. With the cylinder head on its side, insert the
J H inlet valves and exhaust valves as shown. Make
sure that the valves are installed in the correct
positions. Lubricate the valve stems with clean
engine oil before assembly. Carefully push the
end of the valve stem through the stem seals.
4. Install the valve springs on to the valve
stems, together with a retainer. Use the spring
compressor tool to compress each valve spring
and insert the collets. Make sure that the collets
are correctly seated in the valve stem grooves,
before you remove the spring compressor tool.
H Valve stem seals After Installation

J Punch tool
1. Tap the valve stems in turn using a rubber mallet
top fully seat the valves.
Inspection
1. Carefully clean the carbon deposits from the
valves, take care not to damage the valve seats.
2. Check that the valves and valve seats are not
cracked, burnt or damaged.
3. Check the valve stems and valve guides for wear,
refer to Technical Data (PIL 15-30).
15 - 121 9813/7400-1 15 - 121

15 - Engine
30 - Valve
12 - Valve Spring
12 - Valve Spring
Remove and Install
Refer to Valve, General, Remove and Install (PIL

15-30-00).
15 - 122 9813/7400-1 15 - 122

15 - Engine
30 - Valve
24 - Stem Seal
24 - Stem Seal
Remove and Install
Refer to Valve, General, Remove and Install (PIL

15-30-00).
15 - 123 9813/7400-1 15 - 123

15 - Engine
33 - Connecting Rod
33 - Connecting Rod
Contents Page No.
15-33-00 General ......................................................................................................................... 15-125

15-33-06 Big-End Bearing ........................................................................................................... 15-129
15 - 124 9813/7400-1 15 - 124

15 - Engine
33 - Connecting Rod
00 - General
Introduction .................................................. 15-125 The connecting rod connects the piston to the
Technical Data ............................................. 15-126 crankshaft. They form a simple mechanism that
Component Identification ............................. 15-126 converts reciprocating motion into rotating motion.
Check (Condition) ........................................ 15-127
Connecting rods are usually made of high strength
Remove and Install ..................................... 15-127 steel. They are not rigidly fixed at either end, so that
Disassemble and Assemble ........................ 15-128 the angle between the connecting rod and the piston
can change as the rod moves up and down and
rotates around the crankshaft.
The small end of the connecting rod attaches to the

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

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

the big end of the connecting rod so that pressurised
lubricating engine oil squirts out on to the thrust
side of the cylinder wall to lubricate the travel of the
pistons and piston rings.
15 - 125 9813/7400-1 15 - 125

15 - Engine
33 - Connecting Rod
00 - General
Technical Data Component Identification
Table 58. Connecting Rods Data Refer to Piston- Component Identification (PIL
15-36).
Connecting rod type
(1)
Split fracture
Connecting rod bore di- 77–77.01mm
ameter
Connecting rod side
clearance
min 0.05mm
max 0.4mm
Big end bearings
Width 32.5–33mm
Thickness (at centre) 1.99–1.981mm
Small end bearings
Inside diameter 40.034–40.02mm
(1) Split fracture type connecting rods MUST NOT be
dot punched or etched in anyway during disassembly
- refer to relevant service procedures.
15 - 126 9813/7400-1 15 - 126

15 - Engine
33 - Connecting Rod
00 - General

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

renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a
complete assembly.
15 - 127 9813/7400-1 15 - 127

15 - Engine
33 - Connecting Rod
00 - General
Disassemble and Assemble
The disassemble and assemble procedure for one

piston and connecting rod assembly is exactly the
same. Refer to Piston - Disassemble and Assemble
(PIL 15-36).
15 - 128 9813/7400-1 15 - 128

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

Introduction .................................................. 15-129 In a piston engine, the big-end bearings are the
Check (Condition) ........................................ 15-130 bearings at the big-end of the connecting rod.
15 - 129 9813/7400-1 15 - 129

15 - Engine
33 - Connecting Rod

Special Tools
1. Check the bearing shell surfaces for signs of Description Part No. Qty.
2. Measure the crank pin diameters to confirm they (10-100Nm)
are within service limits, refer to Technical Data
(PIL 15-33). Before Removal
3. Renew any parts that are worn or not within the 1. This procedure requires service parts. Make
specified tolerances. sure you have obtained the correct service parts
6. Remove the fuel injectors. Refer to (PIL 18-18).
7. Drain the oil from the engine. Refer to (PIL
15-21).
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
The connecting rod and the big-end bearing cap

have been fracture split and must be kept together
as a set. Care must be taken to avoid contamination
and or damage to the fracture split surfaces.
Remove
1. It is recommended that the big-end bearing caps
are removed in pairs, cylinders 1 and 4 and
cylinders 2 and 3. Rotate the crankshaft so that
the big-end bearing caps on cylinders 2 and 3 are
positioned as shown.
2. Remove the bolts and lift off the big-end bearing
caps from the connecting rods. The bolts must
not be re-used, discard the bolts.
15 - 130 9813/7400-1 15 - 130

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

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

with the bolt to avoid damaging the screw 1 Big-end bearing cap
thread. 2 Bolts
3 Connecting rod
3. Lift out the bearing shells from the bearing caps. 4 Piston
Carefully rotate the crank to disengage from the 5 Piston rings
connecting rods and get access to the upper 6 Big end bearing shells
bearing shells. Lift out the upper bearing shells. Z Fracture split surfaces
It is recommended that the bearing shells are
renewed. If they are to be reused, label the 4. Carefully rotate the crankshaft to position the big-
bearing shells to make sure that they are installed end bearing caps of cylinders 1 and 4. Make
in their original positions on assembly. sure that the crank does not foul the connecting
rods of cylinders 2 and 3. Remove the bearing
caps and bearing shells as described in previous
steps.
5. Inspect the big-end bearings for signs of damage
and excessive wear. Refer to Check Condition
(PIL 15-12).
Install
steps.
3. Install the upper bearing shell to the connecting
rod. Lubricate the bearing shell with clean engine
oil.
15 - 131 9813/7400-1 15 - 131

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

bearing cap. Lubricate the bearing shell with
clean engine oil. Install the big-end bearing cap
to the connecting rod. Make sure that the cast
notch on the bearing cap faces to the front of the
engine. Use compressed air to clean the fracture
surfaces before assembly.
5. Install new fixing bolts. Tighten the new bolts in
1)
Figure 178.
T3
T3 Angle gauge (obtain locally)

5.1. Make sure that the tool is kept in inline
with the bolt to avoid damaging the screw
thread.
6. The bolts are tightened using a torque and
Figure 179.
0° +90°
After Installation
1. Carry out the procedures listed in Before
Removal in reverse order.
Table 59.
Item Torque Value
2 - 1st Stage 35N·m
2 - 2nd Stage 65N·m
2 - Final Stage 90°
15 - 132 9813/7400-1 15 - 132

15 - Engine
36 - Piston
36 - Piston
Contents Page No.
15-36-00 General ......................................................................................................................... 15-135
15 - 133 9813/7400-1 15 - 133

Notes:
15 - 134 9813/7400-1 15 - 134

15 - Engine
36 - Piston
00 - General
Introduction .................................................. 15-135 The piston is acted upon by the pressure of the
Technical Data ............................................. 15-136 expanding combustion gases in the combustion
Component Identification ............................. 15-137 chamber space at the top of the cylinder. This force
Operation ..................................................... 15-138 then acts downwards through the connecting rod and
on to the crankshaft.
Check (Condition) ........................................ 15-139
Remove and Install ..................................... 15-140 The pistons are cast from aluminium alloys for
Disassemble and Assemble ........................ 15-143 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 - 135 9813/7400-1 15 - 135

15 - Engine
36 - Piston
00 - General
Technical Data
Table 60.
Engine 444 - SE Engine 444 - excluding SE en- 448, 672
gine
Gudgeon pin bore diame-
ter
- min. 4.0008mm 40.01mm 42.008mm
- max. 40.013mm 40.015mm 42.013mm
Piston ring clearance
- Top ring Half keystone ring Full keystone ring Full keystone ring
- Middle ring 0.11–0.07mm 0.125–0.08mm 0.125–0.08mm
- Bottom (oil) ring 0.09–0.05mm 0.09–0.05mm 0.09–0.05mm
Piston ring gap
- Top ring 0.3–0.5mm 0.3–0.4mm 0.3–0.4mm
Piston height above 0.0375–0.3385mm 0.00025–0.36825mm
(1)
0.00025–0.36825mm
(1)
crankcase (cold)
Piston groove width
- Top ring 3.108–3.133mm 3.114–3.134mm 3.114–3.134mm
Piston skirt - 102.853–102.871mm 105.851–105.869mm
Piston pin - 39.994–40mm 41.994–42mm
(1) Nominal measurement is 0.03325mm
15 - 136 9813/7400-1 15 - 136

15 - Engine
36 - Piston
00 - General
Figure 180.
C
D
E
A F
F
A Piston
B Connecting rod
C Oil control ring
D Piston ring - compression No.1
E Piston ring - compression No.2
F Retaining circlips
G Piston pin
15 - 137 9813/7400-1 15 - 137

15 - Engine
36 - Piston
00 - General
Operation
The groove around the diameter of the upper main top of the pistons. Oil spray also enters the small end
bearing shells allows oil transfer to an oil jet located bearing bushes via a feed hole on the top of each
in the crankcase bearing saddle. Jets are installed at connecting rod.
the main bearing positions.
Note: On turbocharged engines additional J-jets are
The jets spray oil directly to the under side of the installed. Oilways connect the J-shaped jets fixed to
pistons effectively transferring heat away from the the crankcase at the underside of each cylinder bore.
Figure 181.
1 1
6
2
5
1 Groove 2 Oil jet

3 Pistons 4 Bearing bushes
5 Crankshaft 6 J shaped jets
15 - 138 9813/7400-1 15 - 138

15 - Engine
36 - Piston
00 - General
Check (Condition)
1. Check the piston for signs of damage and
excessive wear. Measure the piston skirt
diameter, piston pin bore and the clearance in
the piston ring grooves to confirm they are within
service limits. Refer to Piston, Technical Data
(PIL 15-36).
2. Check the piston pin for signs of damage and
excessive wear. Measure the pin diameter to
confirm it is within service limits. Refer to Piston,
Technical Data (PIL 15-36).
The connecting rod small end bearing bush is not

renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a
complete assembly.
15 - 139 9813/7400-1 15 - 139

15 - Engine
36 - Piston
00 - General
Remove and Install
Before Removal 3. Get access to the engine.
The following procedure is for one piston and 4. Disconnect and remove the fuel pipes from the
connecting rod assembly. Note that each assembly injectors. Refer to (PIL 18-96).
must be replaced in the same cylinder bore. Label 5. Remove the rocker cover. Refer to (PIL 15-42).
each piston and connecting rod assembly to make
sure it is installed in the correct position on assembly. 6. Remove the fuel injectors. Refer to (PIL 18-18).
1. This procedure requires service parts. Make sure 7. Remove the cylinder head assembly. Refer to
that you have obtained the correct service parts (PIL 15-06).
the engine has been running, let it cool before 9. Remove the big end bearing caps. Refer to (PIL
you start the service work. 15-33-06).
15 - 140 9813/7400-1 15 - 140

15 - Engine
36 - Piston
00 - General
Figure 182.
X
1
1 Piston 2 Piston ring

3 Connecting rod X Longest side of connecting rod
15 - 141 9813/7400-1 15 - 141

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

the carbon deposits from around the top of the
cylinder bore. Take care not to scratch or damage
the cylinder bore.
2. Use a hammer and a short length of wood to
tap the piston from the connecting rod side. Take
care not to scratch or damage the cylinder bore
or the connecting rod bearing surface.
Install
steps.
3. If the upper big end bearing shell has been
removed replace it. Refer to (PIL 15-33-06).
4. Lubricate the cylinder bore with clean engine oil.
5. Use a suitable compressor tool to compress the
piston rings.
6. Insert the piston and connecting rod assembly
into the cylinder bore, make sure that the longest
side of the connecting rod is on the exhaust side
of the crankcase. Take care not to damage the
cooling jets when you guide the connecting rod
down the cylinder bore and over the crank pin
diameter.
After Installation
1. Install the big end bearing caps. Refer to (PIL
15-33-06).
2. Carry out the procedures listed under Before
removal in reverse order.
15 - 142 9813/7400-1 15 - 142

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

To avoid damage or distortion to the rings, use a
1. Clamp the connecting rod in a vice. Take care not suitable piston ring expander tool. Note that the
to damage the connecting rod. oil control ring is installed with a spiral wire. Pull
the wire apart and remove it.
2. It is recommended that the piston rings are
renewed. If they are to be reused, label the 3. Remove the circlips and push out the piston pin.
rings to ensure they are installed in the correct
positions and the correct way up on assembly. 4. Use a suitable cleaning agent, clean the carbon
deposits from the piston.
15 - 143 9813/7400-1 15 - 143

15 - Engine
36 - Piston
00 - General
Figure 183.
A TOP
2 X
B 3
TOP
C
4a
TOP
1
4
6
7
0°
12
12
0°
120°
1 Piston 2 Piston ring - compression No.1

3 Piston ring - compression No.2 4 Piston ring - oil control ring
4a Spiral wire - oil control ring 5 Connecting rod
6 Piston pin 7 Retaining circlip (x2)
X Connecting rod - longest side Y Cast boss - piston
Inspect
1. Inspect the pistons for signs of wear or damage.
Refer to Check (Condition) (PIL 15-36-00).
15 - 144 9813/7400-1 15 - 144

15 - Engine
36 - Piston
00 - General
Assemble
1. The assembly procedure is the opposite of
the disassemble procedure. Additionally do the
following steps.
3. Lubricate the piston pin with clean engine oil.
Assemble the connecting rod to the piston and
insert the piston pin. Make sure that the long side
of the connecting rod is on the same side as the
internal cast boss in the piston.
4. Install new circlips. Make sure that they are
installed correctly in the groove in the piston.
5. Lubricate the piston with clean engine oil. Install
the piston rings to the piston in sequence as
follows:
5.1. Install the spiral wire for the oil control ring
in the bottom groove and locate the locking
wire inside both ends of the spiral as shown.
Using a piston ring expander tool to install
the oil control ring in the bottom groove and
locate the locking wire inside both ends of
the spiral as shown. Ensure that the ring
gap is positioned 180° to the locking wire.
Note: The correct ring orientation can also
be determined from the profile shape of the
ring as shown at C.
5.2. Install the No.2 compression ring into
the middle groove. Note that new rings
have a reference number etched on one
face. Make sure that this face is installed
uppermost in the piston groove. Note:
The correct ring orientation can also be
determined from the profile shape of the
ring as shown at B.
5.3. Install the No.1 compression ring into the
top groove. Note that new rings have a
reference number etched on one face.
Make sure that this face is installed
uppermost in the piston groove. Note:
The correct ring orientation can also be
determined from the profile shape of the
ring as shown at A.
6. Rotate the piston rings so that the ring gaps are
120° apart as shown.
15 - 145 9813/7400-1 15 - 145

15 - Engine
39 - Manifold
39 - Manifold
Contents Page No.
15-39-00 General ......................................................................................................................... 15-147
15 - 146 9813/7400-1 15 - 146

15 - Engine
39 - Manifold
00 - General
00 - General
Introduction
The engine manifold is split into two sections, refer to

inlet manifold (PIL 18-24-03) and exhaust manifold
(PIL 18-24-04).
15 - 147 9813/7400-1 15 - 147

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

15-42-06 Rocker Cover ............................................................................................................... 15-158
15-42-09 Push Rod ..................................................................................................................... 15-160
15-42-21 Tappet ........................................................................................................................... 15-162
15-42-24 Tappet Cover ................................................................................................................ 15-164
15 - 148 9813/7400-1 15 - 148

15 - Engine
00 - General
Introduction .................................................. 15-149 The rocker assembly is an indirect valve actuating
Technical Data ............................................. 15-150 system consisting of rocker arms and a shaft.
Component Identification ............................. 15-151
Operation ..................................................... 15-152 The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
Check (Condition) ........................................ 15-153 movement at the poppet valve to open it. One end is
Remove and Install ..................................... 15-154 raised and lowered by a rotating lobe of the camshaft
Disassemble and Assemble ........................ 15-156 via a tappet and push rod while the other end acts
on the bridge piece which is connected to the valve
stem.
15 - 149 9813/7400-1 15 - 149

15 - Engine
00 - General
Technical Data
Table 61. Rocker Levers, Rocker Shafts and Tappets Data

Valve clearances measured at the valve bridge piece
tip of the rockers (measured cold):
- Inlet 0.19–0.27mm
Rocker clearances measured at the adjusting screw
tip of the rockers (measured cold):
- Inlet 0.15–0.2mm
Rocker lever bore diameter
- min 26.058mm
- max 26.092mm
Rocker shaft diameter
- min 26.003mm
- max 26.021mm
Tappets stem diameter
- min 19.975mm
- max 19.985mm
Tappet bore diameter
- min 20mm
- max 20.021mm
Tappet height (maximum) 55.25mm
15 - 150 9813/7400-1 15 - 150

15 - Engine
00 - General
Figure 184.
2
4
6
2 1
4
3
5
7
2
4
2
4
2
4
2
4
2
4
743830
1 Rocker shaft assembly 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Bridge pieces (x8)
7 Push rods (x8)
15 - 151 9813/7400-1 15 - 151

15 - Engine
00 - General
Operation
When the camshaft lobe raises the outside of the rocker arm is permitted to return due to the camshafts
rocker arm, the inside presses down on the valve rotation, the inside rises to allow the valve spring to
stem to open the valve. When the outside of the close the valve.
Figure 185.
1 Oil feed from main gallery 2 Small transfer gallery

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

where it flows by gravity along a groove to the rocker
Oil is fed from the main gallery via a drilling which tip.
passes up through the crankcase and the cylinder
head to a small transfer gallery under the rocker
shaft pedestal. The oversize rocker shaft fixing bolt
hole allows oil to pass into a drilling in the centre of
the rocker shaft. Further cross drillings transfer oil
to each of the rocker pivot bushes. A cross drilling
15 - 152 9813/7400-1 15 - 152

15 - Engine
00 - General
Check (Condition)
1. Check the rocker shaft and rocker bushings for
signs of damage and excessive wear. Measure
the rocker shaft diameter and rocker bearing
bushes to confirm they are within service limits.
Refer to Technical Data (PIL 15-42). Note: The
rocker bearing bushes are not renewable. If
a rocker bearing bush is damaged or worn
the rocker must be renewed as a complete
assembly.
2. Make sure that all oil-ways and cross drillings in
the rocker shaft, rocker arms and pedestals are
clear and free from debris. Use an air line to blow
through cross drillings.
15 - 153 9813/7400-1 15 - 153

15 - Engine
00 - General
Remove and Install
1. Make sure that the engine is safe to work on. If 3. Disconnect and remove the fuel pipes from the
the engine has been running, let it cool before fuel injectors, refer to Fuel pipes (PIL 18-96).
Figure 186.
2
4
6
2 1
4
3
5
7
2
4
2
4
2
4
2
4
2
4
743830
1 Rocker shaft assembly 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Bridge pieces (x8)
7 Push rods (x8)
15 - 154 9813/7400-1 15 - 154

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

Item Nm
2 24
3 24
15 - 155 9813/7400-1 15 - 155

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

15-42).
Figure 187.
2
2
3
1
2
2
4
4
4
5
4
5
6
7
4
1 Rocker shaft 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - Oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Rockers - inlet (x4)
7 Rockers - exhaust (x4) 8 Wave washers (x8)
15 - 156 9813/7400-1 15 - 156

15 - Engine
00 - General
Disassemble
1. Lift out the rocker shaft fixing bolts, then slide
the pedestals, rockers and wave washers off the
rocker shaft as shown. Label the pedestals and
rockers to make sure that they are installed in the
correct positions on assembly.
2. Check the rocker shaft and rocker bushings for
signs of damage and excessive wear. Refer to
Check (Condition) (PIL 15-42).
Assemble
1. The assembly procedure is the opposite of
the disassemble procedure. Additionally do the
following steps.
2. Lubricate the rocker shaft and rocker bearing
bushes with clean engine oil.
3. Make sure that the rockers and pedestals are
installed in their original positions along the
rocker shaft. Note the position of the oil feed
pedestal.
4. Insert the rocker shaft fixing bolts to hold the
rockers and pedestals loosely in position before
fitting the assembly into the cylinder head. Note
the position of the longer bolt.
After Assembly
1. Install the rocker assembly. Refer to (PIL 15-42).
2. Install the rocker cover. Refer to (PIL 15-42).
15 - 157 9813/7400-1 15 - 157

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

15-00).
Figure 188.
A Rocker cover B Bolts

C Gasket D Injector seals
15 - 158 9813/7400-1 15 - 158

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

Item Nm
B 24
15 - 159 9813/7400-1 15 - 159

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

Introduction .................................................. 15-160 Push rods are used in a reciprocating engine to open
Remove and Install ..................................... 15-161 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 - 160 9813/7400-1 15 - 160

15 - Engine
09 - Push Rod
Remove and Install
Refer to Rocker and Fittings (PIL 15-42).
15 - 161 9813/7400-1 15 - 161

15 - Engine
21 - Tappet
21 - Tappet Figure 190.
Remove and Install

B
Before Removal
1. Drain the oil from the engine.
injectors. Refer to (PIL 18-96). C
B Timing pin - crankshaft
3. Remove the rocker cover. Refer to (PIL 15-42). C Blanking plug
4. Remove the fuel injection pump. Refer to (PIL 12. Remove the fuel injection pump drive gear. Refer
18-18). to (PIL 15-51).
5. Remove the rocker assembly and push rods.
Refer to (PIL 15-42). Removal
6. Remove the starter motor. Refer to (PIL 15-75). The engine must be inverted. DO NOT attempt
to remove the camshaft and its drive gears with
7. Remove the oil sump. Refer to (PIL 15-45). the engine upright. The tappets and push rods will
8. Remove the flywheel. Refer to (PIL 15-54). fall into the engine and further dismantling will be
required to retrieve them.
9. Remove the flywheel housing. Refer to (PIL
15-54). 1. Remove the camshaft timing pin.
10. Rotate the crankshaft until the camshaft timing 2. Carefully withdraw the camshaft and gear
pin can be inserted through the gear and into the assembly from the crankcase. Make sure you
aligning hole in the rear gear case. fully support the camshaft to prevent the lobes
contacting the bearing surfaces in the crankcase.
Figure 189. The bearing surfaces can easily be damaged by
the sharp hard edges on the cam lobes.
Figure 191.
A Timing pin - camshaft

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

D Camshaft and drive gear
15 - 162 9813/7400-1 15 - 162

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

the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a 1. Lubricate the tappets and tappet bores inside the
suitable magnetic probe. Label the tappets to crankcase with clean engine oil.
ensure replacement in their original positions.
2. Insert the tappets in their original positions in the
Figure 192. crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
F the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
E preventing the lobes contacting the bearing
surfaces in the crankcase. Before meshing the
E camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
aligns with the dowel hole in the gear casing.
Insert the timing pin to lock the camshaft in this
position.
After Installation
1. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
injection pump replacement procedure. Refer to
(PIL 18-18).
2. Do the procedures in Before Removal in reverse
order.
E Tappet (8 off)
F Magnetic probe
Inspection
1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting.
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the
dimensions are within service limits.
4. Inspect the cam bearing surfaces inside the
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within
service limits.
5. Inspect the bearing surfaces of the tappets for
the dimensions are within service limits.
6. Inspect the tappet bores inside the crankcase for
the dimensions are within service limits.
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries
in the crankcase and camshaft may be blocked.
Make sure all oil ways are clear and free from
debris.
15 - 163 9813/7400-1 15 - 163

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 64. 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 193.
B B D B B
B A
E C
A Screws
B Tappet covers
C Slot
D Rocker cover
E Tappet cover seals
15 - 164 9813/7400-1 15 - 164

15 - Engine
45 - Oil Sump
45 - Oil Sump
Contents Page No.
15-45-00 General ......................................................................................................................... 15-167
15 - 165 9813/7400-1 15 - 165

Notes:
15 - 166 9813/7400-1 15 - 166

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

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

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

bearings it reverts to sump pressure and splash
lubricates the internal components such as rocker
tips, cam lobes and timing gear teeth. Gravity
drains the oil via drains into the cylinder head and
crankcase, back into the oil sump. A drain slot allows
the oil to drain from the timing case back to the oil
sump.
15 - 167 9813/7400-1 15 - 167

15 - Engine
45 - Oil Sump
00 - General
Figure 194.
1 Oil sump 2 Suction strainer

3 Oil pump 4 Oil cooler
5 Filter 6 Camshaft - high pressure oil feed
7 Crankshaft main bearings - high pressure oil 8 Rocker assembly - high pressure oil feed
feed
9 PTO (Power Take-Off) idler gear bearing/ 10 External high pressure oil feed connection
timing case - high pressure oil feed (crankcase) - Turbocharger (if installed)
11 Main high pressure oil feed gallery 12 Oil pressure switch
(crankcase)
Green- Oil at sump pressure Red- Oil at high pressure
Pink- Oil at lower pressure but higher than
sump pressure
15 - 168 9813/7400-1 15 - 168

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

Template for Sealant 892/01149 1 Removal
Oil Sump - Pressed
1. Remove the fixing bolts and remove the oil sump
Oil Sump Location 892/01150 2
from the engine. The oil sump may be difficult to
Dowel
remove due to adhesion of sealing compound.
Template for Sealant 892/12354 1 If necessary, carefully lever the mating flanges
Oil Sump (Cast) apart. Do not use excessive force, the oil sump
could be damaged. Be sure to retrieve the oil pick
Consumables up seal.
Clear Silicone Sealant 4102/0901 0.31L 2. Use a gasket removal compound, carefully
remove all traces of sealing compound from the
oil sump and engine mating faces. Do not allow
Before Removal the sealing compound to enter the engine.
1. Make sure that the engine is safe to work on. 3. Use a suitable degreasing agent to thoroughly
If the engine has been running, make sure the clean the oil sump.
engine has cooled sufficiently before you start.
Figure 195.
1 Oil sump 1a Integral suction tube

1b Integral baffle plates 2 Oil sump fixing bolts (x20)
3 Oil pick up seal
15 - 169 9813/7400-1 15 - 169

15 - Engine
45 - Oil Sump
00 - General
Installation Figure 197.
1. Lightly smear the new oil pick up seal with oil and X
install into the bedplate as shown.
Figure 196.
3 Oil pick up seal

2. Install the two guide pins at the oil sump screw
holes in the engine.
Special Tool: Oil Sump Location Dowel (Qty.: 2)
S Hole
3. Use the fixing bolts to locate the template to T Hole
the oil sump mating face. Make sure that the T2 Guide pins
template is the correct way round (note that holes X 4mm Bead of sealant
are on different centres).
8. Position the oil sump with the suction tube outlet
Special Tool: Template for Sealant Oil Sump aligned with the oil pump inlet port on the engine.
(Cast) (Qty.: 1) Take care not to damage the oil pick up seal when
Special Tool: Template for Sealant Oil Sump - you install the oil sump. Damage to the seal could
Pressed (Qty.: 1) cause a drop in oil pressure and subsequently
damage to the engine.
4. Apply a bead of sealing compound around the
oil sump flange using the inside edge of the 9. Locate the oil sump on the guide pins on the
template as a guide as shown. Note the beads engine. Avoid smudging the sealant beads. DO
around holes. NOT remove the guide pins until sufficient bolts
Length/Dimension/Distance: 4mm have been installed to secure the oil sump.
Consumable: Clear Silicone Sealant 10. Install the bolts and tighten the bolts to the correct
5. Carefully remove the template without smudging torque value. Note that the bolts are not installed
the sealant beads. at 6 positions.
6. Apply a bead of sealant so as to join the sealant Figure 198.

beads around holes with the bead around the oil
sump flange.
7. After applying the sealing compound, the oil
sump must be installed and the bolts torque
tightened within
Duration: 5min
2 Bolts
Y No bolts to be installed at this position (x6)
15 - 170 9813/7400-1 15 - 170

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

Item Nm
2 24
15 - 171 9813/7400-1 15 - 171

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

15-51-03 Crankshaft Gear ........................................................................................................... 15-178
15-51-06 Camshaft Gear ............................................................................................................. 15-181
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-182
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-185
15-51-22 Rear Case .................................................................................................................... 15-188
15 - 172 9813/7400-1 15 - 172

15 - Engine
51 - Timing Gear
00 - General
Introduction .................................................. 15-173 The timing gears are located inside a case at the
Component Identification ............................. 15-174 flywheel end of the engine.
Operation ..................................................... 15-175
Check (Condition) ........................................ 15-177 The engine must be timed so that the camshaft
operates the valves at the correct times relative to
the crankshaft position.
Valve timing is achieved by ensuring that the

camshaft drive gear is meshed to the crankshaft gear
at their correct angular positions, refer to Engine-
General, Operation, The Four Stroke Cycle (PIL
15-00) for more information about valve timing.
15 - 173 9813/7400-1 15 - 173

15 - Engine
51 - Timing Gear
00 - General
Figure 199.
B E
A Crankshaft gear B Camshaft gear

C High pressure fuel pump gear D Oil pump gear
E Heavy duty PTO device gear (if installed) F Heavy duty PTO device gear (if installed)
G Low duty PTO device gear (if installed)
15 - 174 9813/7400-1 15 - 174

15 - Engine
51 - Timing Gear
00 - General
Operation
All the gears are driven via the crankshaft gear as • Oil pump gear-The lubrication oil pump is driven
follows: directly by the crankshaft gear.
• Power Take-Off (PTO)-driven by the crankshaft
• Camshaft gear-The camshaft is driven at half gear via idler gear.
crankshaft speed. • Low Duty Power Take-Off (PTO) Gear (if
• High pressure fuel pump gear-The high installed)-driven by the camshaft gear.
pressure fuel pump is driven via the camshaft
gear installed to the camshaft.
Figure 200.
B E
A Crankshaft gear B Camshaft gear

C High pressure fuel pump gear D Oil pump gear
E Heavy duty PTO device gear (if installed) F Heavy duty PTO device gear (if installed)
15 - 175 9813/7400-1 15 - 175

15 - Engine
51 - Timing Gear
00 - General
G Low duty PTO device gear (if installed)
15 - 176 9813/7400-1 15 - 176

15 - Engine
51 - Timing Gear
00 - General
Check (Condition)
1. Inspect the gears for wear or damage. If one or
more of the gears are worn or damaged, replace
them.
15 - 177 9813/7400-1 15 - 177

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

Crankshaft / 892/01148 2 15-54).
Camshaft Timing Pin
(444/448/672 Engine) 4. Rotate the crankshaft until the camshaft locking
pin can be inserted through the gear and into the
Note: The illustrations show the engine inverted. If aligning hole in the rear gear case. Note: The
the drive gear components are being removed prior camshaft and crankshaft locking pins must be
to crankshaft or camshaft removal the engine must in position to lock the crankshaft and camshaft
be inverted. If the gear components only are being before removing the crankshaft gear.
removed (for inspection/renewal) then the engine
need not be inverted. Special Tool: Crankshaft / Camshaft Timing Pin
(444/448/672 Engine) (Qty.: 2)
Before Removal 5. Remove the taper blanking plug and insert the
crankshaft locking pin.
1. Remove the starter motor. Refer to (PIL 15-75).
15 - 178 9813/7400-1 15 - 178

15 - Engine
51 - Timing Gear
Figure 201.
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 - 179 9813/7400-1 15 - 179

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 - 180 9813/7400-1 15 - 180

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 - 181 9813/7400-1 15 - 181

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 - 182 9813/7400-1 15 - 182

15 - Engine
51 - Timing Gear
Figure 202.
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 - 183 9813/7400-1 15 - 183

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

15 - 184 9813/7400-1 15 - 184

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 - 185 9813/7400-1 15 - 185

15 - Engine
51 - Timing Gear
Figure 203.
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 - 186 9813/7400-1 15 - 186

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

to confirm it is within service limits, refer to
Technical Data.
Install
steps.
3. Make sure the oil way in the idler gear hub is
through the oil feed drilling.
4. When you install the idler gear hub, make sure
the Idler gear hub location dowel locates into the
hole in the crankcase.
5. Lubricate the idler gear bearing bush with clean
engine oil.
6. Install the flywheel hub to the crankshaft gear,
locate on the dowel. Tighten the bolt to the
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 - 187 9813/7400-1 15 - 187

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 - 188 9813/7400-1 15 - 188

15 - Engine
51 - Timing Gear
22 - Rear Case
Figure 204.
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 - 189 9813/7400-1 15 - 189

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 68. 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 - 190 9813/7400-1 15 - 190

15 - Engine
54 - Flywheel
54 - Flywheel
Contents Page No.
15-54-00 General ......................................................................................................................... 15-193

15-54-03 Housing ........................................................................................................................ 15-196
15-54-09 Gear Ring ..................................................................................................................... 15-199
15-54-12 Drive Plate .................................................................................................................... 15-200
15 - 191 9813/7400-1 15 - 191

Notes:
15 - 192 9813/7400-1 15 - 192

15 - Engine
54 - Flywheel
00 - General
Introduction .................................................. 15-193 Flywheels are used to provide continuous energy in
Remove and Install ..................................... 15-194 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 - 193 9813/7400-1 15 - 193

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

before you start. The flywheel is installed with a 1. Remove the bolts and withdraw the flywheel from
crankshaft position sensor target disc. DO NOT the crankshaft hub. The bolts MUST NOT be
remove the target disc. If the disc is defective the reused. Discard the bolts.
flywheel must be replaced.
Figure 205.
3 1 2
1
T3
1 Flywheel 2 Flywheel fixing bolts (x8)

3 Flywheel location dowel Y Angle tightening mark
15 - 194 9813/7400-1 15 - 194

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

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

Item Torque Value Angle (de-
(Nm) grees)
2 (Ist Stage) 40
2 (2nd Stage) 120
2 (Final Stage) +120
15 - 195 9813/7400-1 15 - 195

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

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

before you start.
15 - 196 9813/7400-1 15 - 196

15 - Engine
54 - Flywheel
03 - Housing
Figure 206.
4 Z
3
Y Y
2
6
2 X
T4 Y
1 Flywheel housing 2 Dowel - 12 mm

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

inside of the flywheel housing.
1. Carefully remove all traces of the old sealant
compound from the flywheel housing mating 3. Carefully inspect all gears, bearings and shafts
faces. for signs of excessive wear or damage. If wear
or damage is evident, the components must be
renewed.
15 - 197 9813/7400-1 15 - 197

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

Anaerobic sealant will not start to cure whilst it 1. Install a new crankshaft rear oil seal.
is open to the atmosphere, however when air is
excluded (for instance when the two parts are 2. Install the flywheel.
put together) it will immediately start to harden. 3. Install the starter motor.
Make sure that all the necessary tools, bolts
etc. are readily available prior to assembling the Table 70. Torque Values
components. The parts must be installed and torque
tightened within5min with a maximum permissible Item Nm
time of 15min 4 47
5 24
removal procedure. Additionally do the following 7 24
steps.
3. Make sure that the dowels are installed to the
mating face of the flywheel housing.
4. Install the sealant template T4 on the housing.
Locate the holes in the template, use the dowel
and three fixing bolts in the fixing points.
Special Tool: Template for Sealant Flywheel
Housing to Gear Case (4 Cyl Elec ) (Qty.: 1)
5. Use the template T4 as a guide, apply a
continuous bead of sealant around the flywheel
housing mating face
5.1. Some engines feature a flywheel housing
with a different fixing hole pattern. Use the
template to apply the sealant but apply
sealant manually in the position shown at Z.
6. Remove the three fixing bolts at positions.
Remove the template T4, make sure not to
smudge the sealant. Discard the template.
7. Locate the flywheel housing on the alignment
pins T3 on the crankcase and install the fixing
bolts. Progressively tighten the bolts to the
7.1. Remove the alignment pins to install the last
two M10 fixing bolts.
7.2. The parts must be separated, thoroughly
cleaned and fresh sealant applied if the
parts have not been torque tightened within
the maximum time period.
Duration: 15min
8. Install the access cover and use the bolts to
secure. Tighten the bolts to the correct torque
value. Refer to Table 70.
15 - 198 9813/7400-1 15 - 198

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 207.
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 - 199 9813/7400-1 15 - 199

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

Introduction .................................................. 15-200 This is a gear type coupling comprising a drive plate
Remove and Install ..................................... 15-201 bolted to the engine flywheel and a coupling clamped
to the input shaft of the wheel drive pump. Both are
contained within the engine bell housing and rear
support frame to which the wheel drive pump is fixed.
Figure 208.
B
A Drive plate
B Coupling (PIL 2731)
15 - 200 9813/7400-1 15 - 200

15 - Engine
54 - Flywheel
12 - Drive Plate
Remove and Install Table 71. Torque Values

Item Nm
Consumables
Description Part No. Size C 23
JCB Threadlocker 4101/0250 0.01L
and Sealer (Medium 4101/0251 0.05L
Strength)
Remove
1. Make the machine safe with the lift arm and cab
raised. Refer to (PIL 01-03).
2. Remove the Wheel drive pump and coupling,
3. Remove the bolts, remove the drive plate from
the flywheel.
Install
removal procedure. additionally do the following
steps.
2. Make sure that the drive plate is installed with
the flat face against the flywheel and the boss is
facing outwards.
3. Coat the threads of the bolts with JCB
Threadlocker and Sealer and tighten to the
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
Figure 209.
A Drive plate
C Bolts
E Boss
15 - 201 9813/7400-1 15 - 201

15 - Engine
60 - Oil Pump
60 - Oil Pump
Contents Page No.
15-60-00 General ......................................................................................................................... 15-203
15 - 202 9813/7400-1 15 - 202

15 - Engine
60 - Oil Pump
00 - General
Introduction .................................................. 15-203 The oil pump is a rotor type pump located inside the
Component Identification ............................. 15-204 timing gear case. The pump is driven by gears via
Check (Condition) ........................................ 15-206 the crankshaft.
The pump consists of two rotors, one running inside
the other. The outer rotor has one more lobe than the
inner rotor and turns on a different axis.
When rotated the gap between the inner and outer

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

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

pump body. As oil pressure increases it acts on a
spool to overcome the pressure of the spring. As the
spool moves it uncovers a port allowing pressurised
oil directly back to the inlet port. In practice the
spool is continually opening and closing to maintain
the correct oil pressure value. The valve is not
adjustable.
15 - 203 9813/7400-1 15 - 203

15 - Engine
60 - Oil Pump
00 - General
Figure 210.
5
1
1 3 2 4
1 5
8 8a
7 7a
9 4
6
1 Oil pump 2 Outer rotor

3 Inner rotor 4 Inlet port
5 Outlet port 6 Relief valve assembly
7 Relief valve spring 7a Relief valve port (return to inlet port 4)
8 Relief valve spool 8a Relief valve pressure port (connected to port 5)
9 Oil pump connecting ports (engine bed plate)
15 - 204 9813/7400-1 15 - 204

15 - Engine
60 - Oil Pump
00 - General
Figure 211.
10
10 CCV Anti drain back valve
15 - 205 9813/7400-1 15 - 205

15 - Engine
60 - Oil Pump
00 - General
Check (Condition)
1. Check the oil pump internal parts for signs of
2. Use feeler gauges to measure the inner and
outer rotor clearance, and the rotor end float to
confirm they are within service limits, refer to
15 - 206 9813/7400-1 15 - 206

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

Torque Wrench 993/70111 1 1. Make sure that the engine is safe to work on. If
(10-100Nm) the engine has been running, let it cool before
The illustrations show the engine inverted. If the 2. Drain the oil from the engine, refer to (PIL 15-21).
oil pump is being removed prior to crankshaft or
camshaft removal, the engine must be inverted. If 3. Remove the starter motor, refer to (PIL 15-75).
the oil pump only is being removed (for inspection or
renewal) then the engine need not be inverted. 4. Remove the flywheel, refer to (PIL 15-54).
This procedure requires service parts. Make sure 5. Remove the flywheel housing, refer to (PIL
you have obtained the correct service parts before 15-54).
you start, refer to Parts Catalogue.
Figure 212.
4 3 X
1 Oil pump 2 Oil pump fixing bolts (x4)

3 Flywheel hub 4 Flywheel hub fixing bolt
X Crankshaft gear Y Oil pump location dowel
15 - 207 9813/7400-1 15 - 207

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

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

Item Nm
2 24
4 47
15 - 208 9813/7400-1 15 - 208

15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ......................................................................................................................... 15-211
15 - 209 9813/7400-1 15 - 209

Notes:
15 - 210 9813/7400-1 15 - 210

15 - Engine
63 - Mount
00 - General
Introduction .................................................. 15-211 Engine mounts support the engine and in some
Remove and Install ..................................... 15-212 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 - 211 9813/7400-1 15 - 211

15 - Engine
63 - Mount
00 - General
Remove and Install
Before Removal
2. Position the machine on firm level ground. Make
the machine safe, refer to (PIL 01-03).
Remove
1. Remove the engine. Refer to (PIL 15-00).
2. Remove the engine mounts.
Install
removal procedure.
15 - 212 9813/7400-1 15 - 212

15 - Engine
69 - Oil Cooler
69 - Oil Cooler
Contents Page No.
15-69-00 General ......................................................................................................................... 15-215
15 - 213 9813/7400-1 15 - 213

Notes:
15 - 214 9813/7400-1 15 - 214

15 - Engine
69 - Oil Cooler
00 - General
Introduction .................................................. 15-215
Component Identification ............................. 15-216
Oil Cooler Assembly
Operation ..................................................... 15-216 The oil cooler and filter are incorporated in a housing
Check (Condition) ........................................ 15-217 that is bolted to the side of the crankcase. The
Remove and Install ..................................... 15-217 housing allows transfer of lubricating oil from the
crankcase to the oil cooler and filter head.
Disassemble and Assemble ........................ 15-219
Some installations have a remote oil filter head. The
oil cooler housing incorporates feed and return ports
for hose connections to the filter head. A remote
oil filter head is used when access to the engine is
restricted.
Oil Cooler Matrix

The oil cooler matrix is a non-serviceable part and
must not be removed from the housing. The housing/
cooler assembly is leak tested during manufacture to
minimise the risk of cross contamination of coolant
and lubricating oil.
15 - 215 9813/7400-1 15 - 215

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

Figure 213. The oil cooler housing allows transfer of lubricating
oil from the crankcase to the oil cooler and filter head.
The coolant also transfers to the housing and passes
1 over the oil cooler matrix causing heat to exchange
from the oil to the coolant.
The cooled and filtered oil then passes back into the
main oil gallery into the crankcase.
An engine oil filler point is also included via cap and

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

Figure 214.
1 3
2 4
8 5
7 6
1
1 Oil cooler housing

2 Oil cooler matrix
3 Sealing gasket (housing to crankcase)
4 Coolant gallery
5 Oil gallery (from cooler to filter head)
6 Oil fill port
7 Oil gallery (from filter head to main oil gallery)
8 Oil gallery (from pump to cooler)
15 - 216 9813/7400-1 15 - 216

15 - Engine
69 - Oil Cooler
00 - General

1. Inspect the sealing faces on the oil cooler matrix,
oil cooler housing and the crankcase. Make sure
Before Removal
that the faces are clean and free from scale or 1. Make sure that the engine is safe to work on. If
damage. the engine has been running, let it cool before
2. Inspect the sealing gasket and o-rings for signs
of damage. If in doubt, renew the gasket or O- 2. Drain the coolant, refer to (PIL 21-00).
rings.
3. Remove the oil filter, refer to (PIL 15-21).
Figure 215.
A B
C D
E
A Oil cooler housing (integral oil filter head)
B Oil cooler housing fixing bolts (x10)
C Oil filter head
D Oil cooler housing (remote oil filter head)
E Remote oil filter head hose ports
Remove
2. If applicable, disconnect the electrical connectors
at the oil pressure switch and the oil temperature
sensor.
3. If applicable, label and disconnect the electrical
connectors at the ECM (Engine Control Module).
Do not touch the electrical pins on the ECM.
Cap the connectors on the harnesses and the
15 - 217 9813/7400-1 15 - 217

15 - Engine
69 - Oil Cooler
00 - General
ECM to prevent ingress of oil and coolant. Tie the Table 73. Torque Values
harnesses away from the oil cooler housing.
Item Description Nm
4. If applicable disconnect the remote oil filter head B Bolts 24
hoses from the ports on the oil cooler.
5. Remove the bolts and lift the oil cooler housing
away from the crankcase. DO NOT attempt to
remove the oil cooler matrix from the oil cooler
housing.
If there is cross contamination of coolant and

lubricating oil, the oil cooler matrix may be faulty. If a
faulty matrix is suspected renew the matrix and the
seals.
Figure 216.
A
B C
A Oil cooler housing

B Oil cooler matrix
C Sealing gasket
Install
steps.
2. Make sure that sealing gasket is undamaged and
correctly located in its groove. A faulty gasket will
cause cross contamination of the lubricating oil
and coolant. If in doubt install a new gasket.
After Installation
1. If applicable, install the oil filter, refer to (PIL
15-21).
2. Refill the cooling system with the recommended
coolant mixture, refer to (PIL 21-00).
3. If applicable, make sure that the harness
connectors are connected to the correct
connectors on the ECM.
4. Start the engine and check for oil and coolant
leaks.
15 - 218 9813/7400-1 15 - 218

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

1. Locate the new O-rings. Install the oil cooler
Dismantling of the oil cooler and oil filter head matrix. Tighten the bolts to the correct torque
assembly is not necessary unless the oil cooler value.
matrix or the seals are faulty.
2. Install the sealing gasket to the oil cooler
Disassemble housing.
1. Remove the four fixing bolts and lift off the oil Table 74. Torque Values
cooler matrix. Item Nm
2. Remove and discard the two sealing O-rings. A 23
3. Remove the sealing gasket.

Figure 217.
D
C
A
B C
A
A
A
A Fixing bolts
B Oil cooler matrix
C O-rings
D Sealing gasket
E Oil cooler housing
Inspect
1. Refer to Oil Cooler - Check Condition.
15 - 219 9813/7400-1 15 - 219

15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ......................................................................................................................... 15-221

15-72-03 Pulley ............................................................................................................................ 15-227
15-72-06 Voltage Regulator ......................................................................................................... 15-229
15 - 220 9813/7400-1 15 - 220

15 - Engine
72 - Alternator
00 - General
Introduction .................................................. 15-221 The alternator is a three phase generator having a
Health and Safety ........................................ 15-222 rotating field winding and static power windings.
Technical Data ............................................. 15-222
Component Identification ............................. 15-223 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Check (Condition) ........................................ 15-223 warning light to the field winding. This creates
Remove and Install ..................................... 15-225 a magnetic field which supplements the residual
Disassemble and Assemble ........................ 15-226 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 - 221 9813/7400-1 15 - 221

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

• Ensure that the battery negative terminal is Technical data may differ between machine variants
connected to the earthing cable. and installations. For full data relating to the
• Never make or break connections to the battery alternator refer to the applicable parts information.
or alternator, or any part of the charging circuit
whilst the engine is running. Disregarding this
instruction will result in damage to the regulator
or rectifying diodes.
• Main output cables are 'live' even when the
engine is not running. Take care not to earth
connectors in the moulded plug if it is removed
from the alternator.
• During arc welding on the machine, protect the
alternator by removing the moulded plug (or if
separate output cables installed, remove the
cables).
• If slave starting is necessary, connect the
second battery in parallel without disconnecting
the vehicle battery from the charging circuit.
The slave battery may then be safely removed
after a start has been obtained. Take care to
connect batteries positive to positive, negative
to negative.
15 - 222 9813/7400-1 15 - 222

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

Figure 218.
Charging Circuit Test
1. Make sure that all the battery and alternator
D connections are in place, secure and making
good metal - to - metal contact, especially the
earth connections to chassis and engine.
2. Adjust the alternator drive belt tension if
necessary and make sure that the battery is well
charged.
3. Turn the ignition switch to the ON position. Oil
pressure and ''No Charge'' warning lights should
glow. If any light fails, re-check the connections.
4. Start the engine; all warning lights should
extinguish rapidly. If the ''No Charge'' warning
light remains ON, re-check the alternator drive
belt tension and that the battery is charged. If
the oil pressure warning remains on stop the
engine Immediately and investigate the engine
A Alternator lubrication system.
B Regulator and brush assembly
C Drive pulley Check 1
D Tie bolts
With the ignition switch ON, check that the heater
motor and screen wiper will operate.
If they operate normally, check the warning light bulb

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

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

withdraw the triple plug from the back of the
alternator. Make a temporary connection between
the small terminal in the plug and earth as shown
below. If the 'No Charge' warning bulb still fails to
light, check the cable for continuity. If the bulb now
lights, check the alternator for a defective regulator.
Figure 219.
Check 2
The following checks should be made using an
analogue (moving pointer) type Multimeter.
15 - 223 9813/7400-1 15 - 223

15 - Engine
72 - Alternator
00 - General
1. Stop the engine and turn the ignition switch to 4. Alternatively, operate the starter for a few
OFF. moments with the ESOS (Engine Shut-Off
Solenoid) fuse removed.
2. Withdraw the alternator plug and connect the
Multimeter between the large terminals and 5. Install an open type shunt between the battery
earth. With the Multimeter set to measure, positive lead and the battery positive terminal.
Voltage: 12V Current: 100A
Figure 220. 6. Connect a Multimeter positive lead to machine
side of the shunt and negative lead to battery side
of the shunt.
7. Connect the leads to the Multimeter and set the
Multimeter to the relevant range as follows.
8. AVO 2002
8.1. Red lead to volts (middle) socket on
Multimeter.
8.2. Black lead to negative on Multimeter.
2.1. The Multimeter should show battery 8.3. Right side slider to DC (Direct Current)
voltage. voltage.
2.2. If the reading is zero, check the cables 8.4. Left side slider,Refer to Figure 221.
for continuity, particularly at the starter
9. AVO 2003
terminals.
9.1. Red lead to amps socket (A) on the
3. If the voltage is correct, check the alternator.
Multimeter.
Alternator Charging Test 9.2. Black lead to negative on Multimeter.
Figure 221. 9.3. Right side slider to DC voltage

9.4. Left side slider to 200 Shunt
10. FLUKE 85
10.1. Red lead to volts socket (V ) on Multimeter.
10.2. Black lead to COM socket on Multimeter.
10.3. Set dial to mV.
11. Start the engine and run at maximum speed
(see Technical Data). Multimeter should show
maximum alternator output in Amps (see
Technical Data). The Multimeter reading should
be taken as soon as possible after starting the
engine, as the charging current will fall rapidly.
12. A zero reading indicates failure of the alternator
and may be caused by one of the following
1. Make sure that all battery and alternator conditions. These are listed in the order of
connections are in place, secure and making probability.
good metal to metal contact, especially the earth
connections to chassis and engine. 12.1. Defective suppression capacitor.
2. Make sure that the alternator drive belt tension is 12.2. Dirty slip rings or worn brushes.
correctly adjusted. 12.3. Defective regulator.
3. If the battery is in a fully charged condition, before 12.4. Defective rectifier.
commencing the test switch on the working lights
for 12.5. Open or short circuited field (rotor)
windings.
Duration: 3min
15 - 224 9813/7400-1 15 - 224

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

windings.
13. To check for a fault, disconnect the capacitor and Figure 222. Alternator location
repeat the charging test. Renew the capacitor if
necessary.
14. To check for faults with the slip rings, bushes or
regulator, remove the regulator and brush box
assembly. Check the condition of the brushes
and, if necessary, clean the slip rings using extra-
fine glass paper. The regulator may only be
renewed.
15. Faults with the rectifier, rotor and stator may be
checked only by removing and dismantling the
alternator for further testing. Remove
1. Disconnect the negative (-) lead followed by the
positive (+) lead from the battery terminals.
2. Remove the alternator (accessory) drive belt.
3. Disconnect the electrical leads from the
alternator terminals. Label the leads to make
sure that they are installed in the correct positions
on assembly.
4. Undo the alternator securing bolts and lift the
alternator away from the cylinder block mounting.
Figure 223.
A
A Alternator
B Securing bolts
Inspect
1. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 225 9813/7400-1 15 - 225

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

removal procedure. Additionally do the following Voltage Regulator and Brushes
steps.
1. The voltage regulator and brush set is a
2. It is not necessary to adjust the position of the combined assembly. Refer to (PIL 15-72-06).
alternator in order to tension the drive belt, as
the accessory drive belt arrangement is self-
tensioning. Drive Pulley
3. Tighten the alternator securing bolts to the 1. Refer to (PIL 15-72-03).
4. Make sure you reconnect the electrical leads to
the alternator in the correct positions and tighten
to the correct torque.
Table 75. Alternator securing bolt torque

Item Torque Value
A 47N·m
B 47N·m
Figure 224.
Table 76. Alternator electrical connection torque

Item Torque Value
B+ 9–13N·m
L 2.7–3.8N·m
W 2.7–3.8N·m
15 - 226 9813/7400-1 15 - 226

15 - Engine
72 - Alternator
03 - Pulley
03 - Pulley
Remove and Install
Remove 5. Install a new drive pulley onto shaft, locate the

key.
the engine has been running, let it cool before Install
2. Get access to the engine. removal procedure. Additionally do the following
steps.
3. Remove the drive belt, refer to (PIL 15-18).
2. Install a new drive pulley on to the shaft, locating
4. Remove nut and washer. Use a suitable puller to
the woodruff key.
withdraw the pulley from the shaft. Take care to
retain the woodruff key.
Figure 225.
15 - 227 9813/7400-1 15 - 227

15 - Engine
72 - Alternator
03 - Pulley
A Cover-brushes B Regulator and brush assembly

C Drive pulley D Nut-drive pulley
E Washer-drive pulley F Woodruff key-drive pulley
G Tie bolts
15 - 228 9813/7400-1 15 - 228

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 a non-serviceable part if it fails, replace

the complete alternator (PIL15-72).
15 - 229 9813/7400-1 15 - 229

15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ......................................................................................................................... 15-231

15-75-03 Solenoid ....................................................................................................................... 15-239
15-75-06 Brush Gear ................................................................................................................... 15-240
15 - 230 9813/7400-1 15 - 230

15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................. 15-231 The electric starter motor is either a permanent-
Health and Safety ........................................ 15-232 magnet or a series-parallel wound direct current
Technical Data ............................................. 15-232 electric motor with a starter solenoid mounted on to
Component Identification ............................. 15-233 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Check (Condition) ........................................ 15-233 the solenoid engages a lever that pushes out the
Remove and Install ..................................... 15-235 drive pinion on the starter driveshaft and meshes the
Disassemble and Assemble ........................ 15-237 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 - 231 9813/7400-1 15 - 231

15 - Engine
75 - Starter Motor
00 - General

WARNING Make the machine safe before
working on it. Park the machine on level ground Refer to Electrical System- General, Technical Data
and lower the loader arm. Stop the engine and (PIL 33-00).
remove the ignition key. Make sure the park brake
is engaged. Disconnect the battery to prevent the
engine being started. Block all four wheels.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to
protect the circuits and components. The battery
must still be disconnected even if a battery
isolator is installed.
Notice: Do not isolate the machine electrics
when the engine is running, this may cause
damage to the machine electrics.
15 - 232 9813/7400-1 15 - 232

15 - Engine
75 - Starter Motor
00 - General

Figure 226. 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 227.
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 - 233 9813/7400-1 15 - 233

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 229. 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 231.
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 - 234 9813/7400-1 15 - 234

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

permissible voltage, a high resistance in the
earth lead or connections is indicated.
Figure 234.
6. Connect the voltmeter between battery positive
and the starter main terminal. With the starter A
switch off, the voltmeter should indicate battery E
voltage, but it should fall to practically zero when
the switch is turned to the on position, maximum
permissible reading B
Voltage: 0.25V
Figure 232.
D
C
A Electrical lead (Terminal 30)
B Security cover
C Starter motor
D Bolt (x3)
E Electrical lead (Terminal 50)
A Starter main terminal Remove

7. If the reading is above the maximum permissible 1. Make sure the engine is safe to work on. If the
voltage, a high resistance is present in the engine has been running, make sure that the
insulated lead or in the solenoid. Connect the engine has cooled sufficiently before you start
multimeter between the battery positive and work.
solenoid connection. If the multimeter now reads
zero with the switch closed, the fault is in the 2. Remove the security nut and bolt, remove the
solenoid. security cover (if installed).
Figure 233. 3. Disconnect the battery negative lead followed by

the positive lead from the battery terminals.
4. Disconnect the electrical leads from the starter
motor terminals. Label the leads to make sure
they are installed in the correct positions on
assembly.
5. Undo the bolts (x3) and withdraw the starter
motor from the flywheel housing.
Inspection
1. Check the drive pinion splines for damage and
H Battery positive and solenoid connection excessive wear.
8. Finally install the engine stop fuse. 2. Check the brushes for wear. Renew the brushes
if the length is less than
Install
steps.
15 - 235 9813/7400-1 15 - 235

15 - Engine
75 - Starter Motor
00 - General
2. Make sure that the flywheel housing and starter

motor mating faces are clean.
4. Make sure you reconnect the electrical leads to
the starter motor in the correct positions.
5. Install the security cover (if installed).

Item Nm
A 15
D 43–47
E 3.6
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15 - Engine
75 - Starter Motor
00 - General
These parts are non-serviceable if any part fails, sure the wave washer is installed inside the
replace the complete starter motor (PIL15-75). For cover.
cleaning and checking purposes only, dismantle the
1.6. Carefully install the commutator end cover,
motor as follows:
then tighten the tie bolts.
Brush Gear Starter Solenoid
1. Check the brush gear as follows:
1. Check the starter solenoid as follows:
1.1. Remove the tie bolts and carefully separate
1.1. Disconnect the starter motor cable from the
the commutator end cover.
solenoid connector post.
1.2. Remove the screws. Remove the brush
1.2. Remove the screws and carefully withdraw
holder and brushes.
the solenoid assembly.
1.3. Check the brushes for wear. Install or
1.3. Make sure that the sealing ring is
renew the brush set as required. Renew the
undamaged and correctly installed.
brushes if they are less than
Length/Dimension/Distance: 8mm 1.4. Before you install the solenoid make sure
you engage the pinion lever arm through
1.4. Clean the commutator. the hole in the solenoid actuator rod, then
tighten the screws.
1.5. Before installing the commutator end
cover, make sure that the sealing ring is 1.5. Reconnect the starter motor cable to the
undamaged and correctly installed. Make solenoid connector post.
15 - 237 9813/7400-1 15 - 237

15 - Engine
75 - Starter Motor
00 - General
Figure 235.
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
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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.

the complete starter motor (PIL15-75).
15 - 239 9813/7400-1 15 - 239

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.

the complete starter motor (PIL15-75).
15 - 240 9813/7400-1 15 - 240

15 - Engine
84 - Sensor
84 - Sensor
Contents Page No.
15-84-00 General ......................................................................................................................... 15-243

15-84-03 Crankshaft Position ...................................................................................................... 15-253
15-84-06 Camshaft Position ........................................................................................................ 15-257
15-84-09 Knock ........................................................................................................................... 15-261
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-264
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-267
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-270
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-273
15-84-19 Exhaust Temperature ................................................................................................... 15-276
15-84-21 Engine Oil Pressure ..................................................................................................... 15-279
15-84-24 Fuel Temperature ......................................................................................................... 15-282
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-285
15-84-33 Coolant Temperature .................................................................................................... 15-287
15-84-42 Engine Oil Temperature ............................................................................................... 15-290
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-293
15-84-51 Nitrogen Oxide (NOx) .................................................................................................. 15-296
15 - 241 9813/7400-1 15 - 241

Notes:
15 - 242 9813/7400-1 15 - 242

15 - Engine
84 - Sensor
00 - General
Introduction .................................................. 15-243 The engine sensors continually send signals to the
Technical Data ............................................. 15-244 ECM (Engine Control Module) to help the ECM to
Component Identification ............................. 15-246 control the smooth running of the engine and related
Fault-Finding ................................................ 15-248 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 - 243 9813/7400-1 15 - 243

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

Sensor (TMAP)
Atmospheric Output voltage +/- V
pressure bar V
Table 78.
(psi)
Crankshaft Position Sensor 0.98 -0.025/ 1.84 0.05
Type Hall effect. +0.025
(14.2 -0.4/+0.4)
Table 79. Table 82.

Camshaft Position Sensor Knock Sensor
Type Hall effect. Type Piezo crystal.
Fixing screw tightening 24N·m
torque
Table 80.
Fixing screw thread di- M8
Coolant Temperature Sensor ameter
Type Temperature dependant resis-
tance. Table 83.
Tightening 22N·m max
Throttle Position Sensor (TPS)
(1)
torque
Thread diame- M12 x 1.5. Type Two channel ratio metric
ter voltage output sensor.
Temperature v Resistance Table Supply voltage 5V
Temperature °C Resistance Ω +/- % Rotational range 75°
(°F) Output range Linear output voltage
25 (77.0) 2,062 5.7 over the rotational
range.
50 (121.9) 833 4.3
(1) The throttle position sensor is not supplied as part
100 (211.9) 187 2
of the engine assembly. The technical data given is
110 (229.8) 144 2.4 compatible with the specification required.
Table 84.
Table 81.
Rail Pressure Sensor
Inlet Manifold Air Pressure and Temperature
Sensor (TMAP) Type The rail pressure sensor
is integral with the com-
Fixing screw 22N·m max mon rail.
tightening
torque
Table 85.
Fixing screw M6
thread diameter High Pressure Rail Fuel Valve
Supply voltage 5V Type The HPV (High Pressure
Temperature Sensor Valve) is integral with
the common rail.
Type Temperature dependant resistor.
Temperature v Resistance Table Table 86.
Temperature °C Resistance Ω +/- %
Fuel Temperature Sensor
(°F)
Type The fuel temperature
5 (41.0) 4,707 4.66
sensor is integral with
10 (50.0) 3,791 4.55 the high pressure fuel
15 (59.0) 3,075 4.44 pump.
20 (68.0) 2,510 4.33
25 (77.0) 2,062 4.22 Table 87.
30 (86.0) 1,715 4.12 Oil Pressure Switch
Pressure Sensor Set pressure 0.6bar (8.7psi) falling.
Type Piezo-resistive Switch mode Normally open.
Atmospheric Pressure v Voltage Max pressure 27.5bar (398.5psi)
15 - 244 9813/7400-1 15 - 244

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

Max working pressure 13.8bar (200.0psi)
Tightening torque 23N·m max.
Thread diameter M12 x 1.5.
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15 - Engine
84 - Sensor
00 - General
Engine Sensors and Actuators
Figure 236.
B
P
F
G
H
J
K
A Coolant temperature sensor (PIL 15-84) B Turbocharger actuator (not installed on 55Kw
engines) (PIL 18-36)
D TMAP (Temperature Manifold Air Pressure) (PIL E Fuel temperature sensor (PIL 15-84)
15-84)
F Fuel inlet metering valve (PIL 18-18) G Camshaft position sensor (PIL 15-84)
H Crankshaft position sensor (PIL 15-84) J Oil temperature sensor (PIL 15-84)
K Oil pressure switch (PIL 15-84) P Inter cooler outlet temperature sensor (PIL
15-84)
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15 - Engine
84 - Sensor
00 - General
Figure 237.
M
C
C Exhaust manifold pressure sensor (PIL 15-84) L Fuel pressure relief valve (HPV) (PIL 15-84)
M EGR (Exhaust Gas Recirculation) actuator (PIL N Exhaust manifold temperature sensor (PIL
18-27) 15-84)
O Oil level switch (optional) (PIL 15-84)
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15 - Engine
84 - Sensor
00 - General
Fault-Finding
Fault
General Sensor Fault Table 88. Page 15-248
Water in Fuel Sensor Fault Table 89. Page 15-248
Knock Sensors Table 90. Page 15-249
TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure) Table 91. Page 15-250
Crankshaft Position Sensor Table 92. Page 15-250
Camshaft Position Sensor Table 93. Page 15-251
TMAF (Temperature and Mass Air Flow) Sensor Table 94. Page 15-252
Table 88. General Sensor Fault

Cause Remedy
Sensor supply voltage fault Disconnect the sensor, check sensor voltage supply
at the harness connector (see relevant sensor help
file for pin numbers or refer to engine electrical
schematic). If voltage supply is faulty, disconnect all
other sensors in turn until voltage supply returns.
If sensor supply voltage is OK, proceed to 'Sensor
connection faulty'.
Sensor connection faulty Check the condition of sensor to harness connection,
make sure the seals are in place, check for signs
of corrosion or contamination. Repair/replace as
necessary.
If no fault is found, proceed to 'Sensor failure'.
Sensor failure Check the sensor resistance (see relevant help file
page). If sensor is out of specification replace.
If no faults is found, proceed to ECM (Engine Control
Module) connection fault'.
ECM connection fault Disconnect the harness from engine ECM and
inspect. Check seals are in place, check for signs of
corrosion or contamination.
If ECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing an ECM.
If harness is damaged, repair or replace as
necessary.
If no fault is found proceed to 'Wiring fault'.
Wiring fault Check the harness continuity. Check the machine
and engine earth contacts. Repair/ replace as
necessary.
If no fault is found, raise Techweb Helpdesk call.
Table 89. Water in Fuel Sensor Fault

Cause Remedy
Sensor supply voltage fault Check the presence of electrical supply on water
sensor.
connection faulty'.
necessary.
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15 - Engine
84 - Sensor
00 - General
Cause Remedy
If no faults is found, proceed to ECM connection
fault'.
necessary.
Wiring fault Check the harness continuity and machine and
engine earth contacts. Repair/ replace as necessary.
Table 90. Knock Sensors

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Knock sensors – Water temperature
sensor – Air temperature sensor – Fuel temperature
sensor – Barometric pressure sensor (built inside the
ECM).
Check the knock sensors connection and screw
torque (Check particularly the ground shield
connection). Repair as necessary and re-enter all
injector calibration codes (read then write) in correct
position to reset learned parameters.
If no fault is found proceed to 'Knock sensors ground
fault'.
Knock sensors ground fault Check the grounding of knock sensors, repair as
necessary.
If no fault is found proceed to ECM connection fault'.
ECM connection fault Disconnect ECM and inspect. Check seals are in
place, check for signs of corrosion or contamination.
necessary.
Wiring fault Check the harness continuity and electrical
installation, repair/replace as necessary.
If no fault is found proceed to 'Injector calibration
codes fault'.
Injector calibration codes fault Check the injector calibration codes recorded in
ECM, if found fault re-enter all injector calibration
codes (read then write) in correct position to reset
learned parameters.
If the injector calibration codes are OK, test the
vehicle on road and check the DTC (Diagnostic
Trouble Code) again with the diagnostic tool. If the
problem is still present, replace the knock sensors.
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15 - Engine
84 - Sensor
00 - General
Table 91. TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure)
Cause Remedy
Sensor supply voltage or calibration fault Disconnect the sensor, check sensor voltage supply
schematic). If voltage supply is faulty, disconnect
all other sensor in turn until voltage supply returns.
Replace the faulty sensor. If no sensor is faulty
replace the ECM.
If sensor supply voltage is OK, proceed to 'Air inlet
circuit fault'.
Air inlet circuit fault Check the consistency of barometric pressure
reading. Verify the conformity of air inlet circuit:– VGT
(Variable Geometry Turbocharger) / Turbo – Leakage
before VGT / Turbo – Air filter – Valve position using
ServiceMaster – Vane state.
Check all the hose connections for air leaks, repair
as necessary.
necessary.
fault'.
If ECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing an ECM
necessary.
If no fault found, raise Techweb Helpdesk call.
Table 92. Crankshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to ECM connection fault'.
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15 - Engine
84 - Sensor
00 - General
Cause Remedy
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the crankshaft position sensor target wheel if
damaged, replace with a new crankshaft.
If no fault is found raise Techweb Helpdesk call.
Table 93. Camshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to Step 4.
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the Cam target wheel if damaged, replace
with new camshaft.
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15 - Engine
84 - Sensor
00 - General
Table 94. TMAF (Temperature and Mass Air Flow) Sensor

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

Introduction .................................................. 15-253 The crankshaft position sensor is a device used
Operation ..................................................... 15-254 to monitor the position or rotational speed of the
Check (Operation) ....................................... 15-255 crankshaft. This information is used by the ECM
Remove and Install ..................................... 15-255 (Engine Control Module) to control the ignition
system timing and other engine parameters.
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15 - Engine
84 - Sensor
Operation
A signal is generated by the crankshaft mounted processed by the ECM (Engine Control Module) to
target wheel and crankshaft position sensor. It is determine the timing of fuel injection.
Figure 238.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM 2 Camshaft position sensor

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

1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
Before Removal
2. Inspect the sealing O-ring. If it is defective,
replace the sensor. The O-ring is integral to the
sensor and cannot be replaced.
2. Clean the sensor and the adjacent area of the
flywheel housing.
Figure 239.
A
D
C
A Crankshaft position sensor

B Electrical connector
C Bolt
D Guard
15 - 255 9813/7400-1 15 - 255

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

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

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

Introduction .................................................. 15-257 The camshaft position sensor is a device that detects
Operation ..................................................... 15-258 the passing of a gap on a camshaft target wheel. It
Check (Operation) ....................................... 15-259 sends a signal to the ECM (Engine Control Module)
Remove and Install ..................................... 15-259 which stroke number piston is on so that the ECM
knows which cylinder to inject the fuel into.
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15 - Engine
84 - Sensor
Operation
A signal is generated by the camshaft mounted target The ECM will select the correct cylinder for fuel
wheel and camshaft position sensor. This information injection.
is used by the ECM (Engine Control Module) to
process the signal to determine the engine phase
(which cylinder is firing).
Figure 240.
TDC 2 3
5
4
C1 C2
D1 D2 6

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

1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
Before Removal
crankcase.
Figure 241.
A
B
A Camshaft position sensor

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

item. If the sensor is defective it must be replaced.
15 - 259 9813/7400-1 15 - 259

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

Item Nm
C 8
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15 - Engine
84 - Sensor
09 - Knock
09 - Knock Introduction
Introduction .................................................. 15-261 There are two knock sensors fixed to the side of the
Operation ..................................................... 15-262 crankcase with a centre mounted bolt. One sensor is
Check (Operation) ....................................... 15-262 situated between cylinders 1 and 2, and the second
Remove and Install ..................................... 15-263 is situated between cylinders 3 and 4.
A knock sensor is a device that measures engine

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

the knock sensor detects pinging. At that point the
ECM retards the ignition timing just enough for the
pinging to stop. The knock sensor ensures that you
are getting as much power and fuel economy as
possible from your engine.
Figure 242. Knock sensor locations
A
B
A Knock sensor - cylinders 1 and 2

B Knock sensor - cylinders 3 and 4
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15 - Engine
84 - Sensor
09 - Knock
Operation Check (Operation)
The knock sensors detect pre-ignition (knock) by 1. For the full inspection and testing procedure,
means of sensing engine vibration. The vibration refer to the help files in ServiceMaster.
signal is sent to the engine ECM (Engine Control
Module)where the ECM will adjust the fuel timing to
give optimum performance, economy and driveability
and prevent engine damage. The voltage signal is
proportional to engine vibration/acceleration.
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15 - Engine
84 - Sensor
09 - Knock
Remove and Install 3. Tighten the bolt to the correct torque value.
Torque: 22–26N·m
The following procedure is for one knock sensor. The
procedure for both sensors is identical.
Before Removal
Remove
2. Disconnect the electrical connector at the knock
sensor.
3. Remove the bolt and remove the knock sensor
from the crankcase.
The knock sensor is a non-serviceable item. If the

sensor is defective it must be replaced.
Figure 243.
B C
A Knock sensor
C Bolt
Install
steps.
2. Make sure that the sensor mates fully with the
adjacent face on the crankcase.
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15 - Engine
84 - Sensor
14 - Exhaust Manifold Temperature
14 - Exhaust Manifold Temperature Introduction

Introduction .................................................. 15-264 The exhaust manifold temperature sensor is screwed
Operation ..................................................... 15-265 directly into the top of the exhaust manifold between
Check (Operation) ....................................... 15-265 cylinder 3 and 4 exhaust outlet ports.
Figure 244. Exhaust manifold
temperature sensor location
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15 - Engine
84 - Sensor
The exhaust manifold temperature sensor measures For the full inspection and testing procedure, refer to
the exhaust gas temperature from the engine, before the help files in ServiceMaster.
it reaches the turbocharger. The analogue voltage
signal is 1–4.5V.
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15 - Engine
84 - Sensor
Remove and Install

Special Tools
Deep Socket 892/12351 1
Before Removal
Figure 245.
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 - 266 9813/7400-1 15 - 266

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

Introduction .................................................. 15-267 The exhaust manifold pressure sensor also known
Operation ..................................................... 15-268 as the manifold absolute pressure sensor is a device
Check (Operation) ....................................... 15-268 that is used to calibrate the fuel delivery on an ECM
Remove and Install ..................................... 15-269 (Engine Control Module) Controlled engine.
The sensor is mounted in the rear section of the

rocker cover.
Figure 246.
C Exhaust manifold pressure sensor
15 - 267 9813/7400-1 15 - 267

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 - 268 9813/7400-1 15 - 268

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 247.
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 - 269 9813/7400-1 15 - 269

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 .................................................. 15-270 sensor is mounted in a port on top of the inlet
Operation ..................................................... 15-271 manifold. It measures the inlet manifold boost air
Check (Operation) ....................................... 15-271 pressure and temperature. The sensor incorporates
a piezo-resistive element and resistor.
Figure 248.
D TMAPsensor
15 - 270 9813/7400-1 15 - 270

15 - Engine
84 - Sensor
The TMAP (Temperature Manifold Air Pressure) 1. Remove oil and sludge contamination from the
sensor measures the inlet manifold boost air sensor.
pressure and temperature. The sensor produces an
analogue signal voltage proportional to air pressure. 2. Carefully inspect the sensor. If it is defective,
replace it.
15 - 271 9813/7400-1 15 - 271

15 - Engine
84 - Sensor
Remove and Install 3. Carefully push the sensor into its location bore in
the inlet manifold. Do not use excessive force.
Before Removal
1. Make sure that the engine is safe to work on. If Table 99. Torque Values
the engine has been running, let it cool before Item Nm
you start the service work. C 3.3
inlet manifold.
Figure 249.
A
C B
D
A TMAP (Temperature Manifold Air Pressure)
C Bolt
D O-ring seal
Remove
3. Remove the bolt.
4. Remove the sensor from the inlet manifold
together with O-ring.
The TMAP sensor is a non-serviceable item. If the

sensor is defective, it must be replaced.
Install
steps.
2. Make sure that the sealing O-ring is correctly
installed.
15 - 272 9813/7400-1 15 - 272

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 .................................................. 15-273 measures the amount of air coming in to the engine
Operation ..................................................... 15-274 and the air temperature. It is mounted between the
Check (Operation) ....................................... 15-274 air filter and turbo charger.
Remove and Install ..................................... 15-275 Figure 250.
15 - 273 9813/7400-1 15 - 273

15 - Engine
84 - Sensor
The TMAF (Temperature and Mass Air Flow) sensor Faults relating to the TMAF (Temperature and Mass
produces a digital signal measuring air flow, and an Air Flow) will normally be reported by the fault codes.
analogue signal measuring inlet air temperature.
1. Remove contamination from the sensor. Do not
touch the air flow sensor area or temperature
sensor area.
2. Carefully inspect the sensor. If it is defective,
replace it.
replace it.
Figure 251.
1 Air flow sensor area

2 Temperature sensor area
15 - 274 9813/7400-1 15 - 274

15 - Engine
84 - Sensor
Remove and Install Install

Do not install a TMAF sensor which has been
Before Removal dropped or damaged. Replace it with a new one.
1. Make sure that the engine is safe to work on. If 1. The installation procedure is the opposite of the
the engine has been running, let it cool before removal procedure. Additionally do the following
you start the service work. step.
2. Get access to the TMAF (Temperature and Mass 2. Tighten the screws to the correct torque value.
Air Flow) sensor
3. Clean the area around the sensor to prevent
Item Nm
contamination entering the engine.
2 5
Remove
Figure 252.
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 253.
1 Air flow temperature sensor area

2 Temperature sensor area
15 - 275 9813/7400-1 15 - 275

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

Introduction .................................................. 15-276 The exhaust temperature sensor is located in the
Operation ..................................................... 15-277 exhaust system just before the SCR (Selective
Check (Operation) ....................................... 15-277 Catalytic Reduction) catalyst.
15 - 276 9813/7400-1 15 - 276

15 - Engine
84 - Sensor

Special Tools
The exhaust temperature sensor measures the Description Part No. Qty.
exhaust gas temperature just before it reaches the Digital Multimeter 892/00298 1
SCR (Selective Catalytic Reduction) catalyst. The
analogue voltage signal is 0 - 5V 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.
The resistance values specified are correct at 20°C

(68.0°F).
1. Disconnect the electrical connector from the

exhaust temperature sensor.
2. Switch the ignition on.
3. Connect the multimeter across the harness pins.
Special Tool: Digital Multimeter (Qty.: 1)
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 - 277 9813/7400-1 15 - 277

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 254.
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 - 278 9813/7400-1 15 - 278

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

Introduction .................................................. 15-279 The oil pressure switch is mounted in a port on the
Technical Data .......................................... 15- oil cooler housing.
Operation ..................................................... 15-280
Check (Operation) ....................................... 15-280 Figure 255.
A
A Engine oil pressure switch
15 - 279 9813/7400-1 15 - 279

15 - Engine
84 - Sensor
The oil pressure switch contacts open when the 1. For the full inspection and testing procedure,
engine oil pressure is below 0.6bar. refer to the help files in ServiceMaster.
15 - 280 9813/7400-1 15 - 280

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

item. If the switch is faulty or damaged it must be
renewed.
Install
steps.
2. Replace the sealing washer.
3. Tighten the engine oil pressure switch to the
Torque: 16N·m
15 - 281 9813/7400-1 15 - 281

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

Introduction .................................................. 15-282 The fuel temperature sensor is an integral part of
Operation ..................................................... 15-283 the fuel injection high pressure pump, refer to (PIL
Check (Operation) ....................................... 15-283 18-18).
Figure 256.
E Fuel temperature sensor
15 - 282 9813/7400-1 15 - 282

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 - 283 9813/7400-1 15 - 283

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 - 284 9813/7400-1 15 - 284

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

Introduction .................................................. 15-285 The fuel rail pressure sensor measures the fuel
Operation ..................................................... 15-286 pressure in the common rail.
Figure 257.
A Fuel rail pressure sensor
15 - 285 9813/7400-1 15 - 285

15 - Engine
84 - Sensor
27 - Fuel Rail Pressure
Operation Remove and Install
The fuel rail pressure sensor measures the fuel This part is a non-serviceable component, if it
pressure in the fuel rail. This allows the ECM (Engine is defective, replace the complete common rail
Control Module) to control the IMV (Inlet Metering assembly. (Refer to PIL 18-18).
Valve) to deliver the correct amount of fuel to the high
pressure fuel pump. This keeps the fuel pressure in
the fuel rail constant at all engine RPM (Revolutions
Per Minute).
15 - 286 9813/7400-1 15 - 286

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

Introduction .................................................. 15-287 The coolant temperature sensor is located on the
Operation ..................................................... 15-288 cylinder head at the drive belt end.
Check (Operation) ....................................... 15-288
A
A Coolant temperature sensor
15 - 287 9813/7400-1 15 - 287

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

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

injection the ECM (Engine Control Module)
processes the signal to determine the engine
operating temperature. The ECM adjusts the
injection timing and the amount of fuel injected, this
can facilitate cold starting.
15 - 288 9813/7400-1 15 - 288

15 - Engine
84 - Sensor

Item Nm
1 16
Before Removal
2. Drain the coolant, refer to (PIL 21-00).
Figure 259.
1
P1
1 Coolant temperature sensor

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

serviceable item. If the switch is faulty or damaged it
must be renewed.
Install
steps.
3. Tighten the coolant temperature sensor to the
4. Refill the cooling system with the recommended
coolant mixture, refer to Technical Data (PIL
21-00).
5. Start the engine and check for coolant leaks.
15 - 289 9813/7400-1 15 - 289

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

Introduction .................................................. 15-290 The engine oil temperature sensor is mounted in a
Operation ..................................................... 15-291 port on the oil cooler housing adjacent to the engine
Check (Operation) ....................................... 15-291 oil dipstick.
Figure 260. Engine oil tem-
perature sensor location
A Engine oil temperature sensor
15 - 290 9813/7400-1 15 - 290

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 - 291 9813/7400-1 15 - 291

15 - Engine
84 - Sensor

Item Nm
Special Tools
Description Part No. Qty. 1 21
Before Removal
Figure 261.
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 - 292 9813/7400-1 15 - 292

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

Introduction .................................................. 15-293 The intercooler outlet sensor is located in the air
Operation ..................................................... 15-294 intake on the inlet manifold.
Check (Operation) ....................................... 15-294
P Intercooler outlet sensor
15 - 293 9813/7400-1 15 - 293

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 - 294 9813/7400-1 15 - 294

15 - Engine
84 - Sensor
Remove and Install
Before Removal
Figure 263.
A Intercooler outlet temperature sensor
Remove
3. Remove the sensor from the air intake.
4. Cap the open port with a blanking cap to prevent
dirt ingress.
Install
step.
2. Tighten the sensor to the correct torque value.

Item Nm
A 8.5
15 - 295 9813/7400-1 15 - 295

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

Introduction .................................................. 15-296
Operation ..................................................... 15-297
Introduction
Remove and Install ..................................... 15-298 Reaction of nitrogen and oxygen gases in the air
during combustion, especially at high temperatures
causes the NOx (Nitrogen Oxide) emission from the
exhaust system.
To monitor the NOx emission, two NOx sensors are

installed on the exhaust system. One is the upstream
NOx sensor and another is downstream NOx sensor.
The Upstream NOx sensor is installed before the
SCR (Selective Catalytic Reduction) catalyst and it
measures NOx level in the exhaust gases before
the after-treatment system. The downstream NOx
sensor is installed after the SCR catalyst and it
measures NOx level in the exhaust outlet.
Figure 264.
P
B
C
A D
P
F
K E L M N
G H J
A DEF (Diesel Exhaust Fluid) system control unit-
ECM (Engine Control Module) or a separate
ECU (Electronic Control Unit)
B Supply module (SM)- pump, filter and valves
C DEF tank- tank, tank level sensor and heating
device (with or without DEF quality sensor)
D Engine coolant connections – used to defrost
DEF
E Dosing module– DEF injector nozzle
F Engine coolant connections – for nozzle cooling
G Diesel Oxidation Catalyst (DOC) – Not installed
on all systems
H Mixer
J SCR
K NOx sensor - Upstream
L Upstream catalyst temperature sensor
M Downstream catalyst temperature sensor
N NOx sensor - Downstream
P DEF lines (inlet, pressure and return) – usually
heated by electric elements or engine coolant
15 - 296 9813/7400-1 15 - 296

15 - Engine
84 - Sensor
Operation
NOx (Nitrogen Oxide) sensors are similar to The NOx sensors will not work unless they are at
wideband oxygen sensors, but typically have their the correct temperature, so they have an integrated
own control module that communicates with the heater that is also module controlled. The power
SCR (Selective Catalytic Reduction)ECU (Electronic supply to the NOx sensor control module is critical
Control Unit) over a CAN (Controller Area Network) for proper sensor operation.
bus.
During a cold start, moisture in the exhaust system
Two NOx sensors are used: can interfere with the NOx sensor operation. In
this scenario, the ECU will not turn on the NOx
• Upstream sensor at the Turbocharger exhaust sensor heaters until the exhaust temperatures reach
outlet. a certain threshold and condensed moisture is
• Downstream sensor from the SCR catalyst. evaporated. This can result in a delay of up to 5min
before both NOx sensors are fully operational.
These two signals are then compared to determine
the conversion efficiency of the catalyst.
Figure 265.
G E
C H
J
F C
K
A O2 B NOx
C O and O2 D N
E NOx sensor body F First chamber
G Nerst cell 1 H Second chamber
J Catalytic element K Nerst cell 2
Diesel NOx sensors are of dual-purpose. They are catalytic element, which breaks them into nitrogen
used to measure both the oxygen level in the and oxygen gases.
exhaust as well as NOx (NO and NO2) content.
The measurements take place in two separate A second Nerst cell is then used to pump the newly
chambers in the sensor, and the exhaust gases flow generated oxygen out of the chamber, and this
sequentially through one and then into the other. electric current is used to calculate the NOx levels in
the exhaust. The residual nitrogen gases then flow
Gases flow from the exhaust stream through a out an exit port in the second measurement chamber.
diffusion barrier to reach the first chamber, which
pumps the free oxygen out using a Nerst cell (simple When two NOx sensors are in a urea SCR system,
oxygen sensor). The electric current for operating the upstream sensor is used to estimate what
this first Nerst cell is used to measure the exhaust amount of DEF (Diesel Exhaust Fluid) needs to be
oxygen content. injected ahead of the SCR catalyst to achieve optimal
NOx conversion. The downstream (post-catalyst)
With the free oxygen removed, the NOx is then sensor is then used to check the results.
left to pass through another diffusion barrier and
into the second measurement chamber. At this
point, the NOx molecules come into contact with a
15 - 297 9813/7400-1 15 - 297

15 - Engine
84 - Sensor
Remove and Install
Consumables not attempt to disconnect the harness as damage will

Description Part No. Size be caused.
Graphite/Calcium 4004/7545 -
Fluoride Based Metal Before Removal
Free Anti-Seize
Compound 1. Make sure that the engine is safe to work on. If
NOx (Nitrogen Oxide) sensors are extremely you start the service work.
delicate. Care must be taken to avoid knocks and
2. Get access to the NOx sensor.
impacts which can damage the sensor. Do not
touch the tip of the sensor, doing so can prevent it 3. Ensure that the area around the NOx sensor
from functioning correctly. The NOx sensor and the is clean to prevent contamination of the SCR
sensor control unit are permanently connected, do (Selective Catalytic Reduction) system.
Remove
Figure 266.
1 NOx sensor 2 Harness support bracket

3 NOx sensor retaining nut 4 Cable tie
15 - 298 9813/7400-1 15 - 298

15 - Engine
84 - Sensor
Figure 267.
7
5 Electrical connector 6 Sensor control unit

7 Bolts
1. Disconnect the electrical connector from the 4. Carefully insert the NOx sensor into the exhaust
Sensor control unit. system. Make sure that it is seated correctly.
Tighten the retaining nut to the correct torque
2. Remove the cable ties from the harness support value.
brackets.
5. Install the harness support bracket around the
3. Remove the bolts (x2) that secure the Sensor NOx sensor.
control unit to the machine.
6. Install the Sensor control unit.
4. Remove the harness support bracket.
6.1. Install the bolts (x2) finger tight to minimise
5. Remove the NOx sensor retaining nut. the strain on the harness.
6. Remove any additional supports or clips. 6.2. Tighten the bolts to the correct torque value.
7. Remove the NOx sensor and the Sensor control 6.3. Connect the electrical connector.
unit from the machine.
7. Install the new cable ties around the harness
support brackets.
Install
8. Install any additional supports and clips.
1. Inspect the sensor for signs of damage. Pay
particular attention to the mating faces of the Table 105. Torque Values
sensor and exhaust system. Clean off any oil
or corrosion. Make sure that the faces are flat, Item Nm
smooth and free from damage. 3 70
7 10
2. Replace the NOx sensor sealing washer.
3. Apply anti-seize compound to the threads of the
retaining nut. Make sure the correct anti-seize
compound is used to prevent damage to the SCR
system.
Consumable: Graphite/Calcium Fluoride Based
Metal Free Anti-Seize Compound
15 - 299 9813/7400-1 15 - 299

15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ......................................................................................................................... 15-301
15 - 300 9813/7400-1 15 - 300

15 - Engine
90 - Air Intake
00 - General
00 - General Component Identification

Component Identification ............................. 15-301 Refer to Fuel System- Exhaust, General, Component
Check (Condition) ........................................ 15-302 Identification (PIL 18-24).
15 - 301 9813/7400-1 15 - 301

15 - Engine
90 - Air Intake
00 - General
Check (Condition)
Refer to: General (Page 15-105).
15 - 302 9813/7400-1 15 - 302

Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-00-30 Throttle Control System ................................................................................................. 18-15
18-03 Tank
18-03-00 General ........................................................................................................................... 18-19
18-09 Filter
18-09-00 General ........................................................................................................................... 18-21
18-09-09 Pre-Filter Element .......................................................................................................... 18-24
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-27
18-18 Injection
18-18-00 General ........................................................................................................................... 18-31
18-18-03 Injector ............................................................................................................................ 18-46
18-18-07 Injector Seal ................................................................................................................... 18-51
18-18-12 Rail ................................................................................................................................. 18-53
18-18-15 Pump .............................................................................................................................. 18-55
18-21 Fuel Pump
18-21-00 General ........................................................................................................................... 18-63
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-69
18-24-03 Inlet Manifold .................................................................................................................. 18-71
18-24-04 Outlet Manifold ............................................................................................................... 18-75
18-24-27 Spark Arrestor ................................................................................................................ 18-79
18-27 Exhaust Gas Recirculation (EGR)
18-27-00 General ........................................................................................................................... 18-81
18-27-03 Actuator .......................................................................................................................... 18-88
18-35 Turbocharger
18-35-00 General ........................................................................................................................... 18-91
18-36 Variable Geometry Turbocharger (VGT)
18-36-00 General ........................................................................................................................... 18-99
18-36-03 Actuator ........................................................................................................................ 18-106
18-96 Fuel Pipe
18-96-00 General ......................................................................................................................... 18-109
18-96-03 High Pressure Pipe ...................................................................................................... 18-112
18-96-06 Low Pressure Pipe ....................................................................................................... 18-115
9813/7400-1
2017-03-31
Acronyms Glossary

DTI Dial Test Indicator
HPV High Pressure Valve
IMV Inlet Metering Valve
NOx Nitrogen Oxide
TMAP Temperature Manifold Air Pressure
VGT Variable Geometry Turbocharger
WIF Water in Fuel
9813/7400-1
2017-03-31
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3

18-00-30 Throttle Control System ................................................................................................. 18-15
18 - 1 9813/7400-1 18 - 1
Notes:
18 - 2 9813/7400-1 18 - 2
00 - General
Introduction ...................................................... 18-3 USE THE CORRECT FUEL. The potential for engine
Health and Safety ........................................... 18-4 damage due to the use of incorrect or contaminated
Technical Data ................................................. 18-4 fuel is much greater with common rail injection
Component Identification ................................. 18-5 technology than with mechanical injection systems.
For information about fuel types and cleanliness
Operation ......................................................... 18-6 requirements, refer to Consumable Products (PIL
Fault-Finding .................................................... 18-9 75-00), Technical Data, Fuel, Acceptable and
Discharge and Pressurise ............................. 18-11 Unacceptable Fuels and Cleanliness Requirements.
Clean ............................................................. 18-11
For information about the fuel injection system, refer
Check (Pressure) .......................................... 18-13 to (PIL 18-18).
Common Rail Fuel Injection

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

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

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

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

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

more important than with mechanical direct injection
systems. To combat fuel contamination, a water
separator and pre-filter is installed in addition to the
main filter.
18 - 3 9813/7400-1 18 - 3
00 - General

Fuel Table 106. Fuel System Data
High pressure pump Delphi DFP 4.2
fuel system. Stop the engine immediately if a fuel
type
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the Direction of rotation from Anti-clockwise
engine running. Completely wipe off any spilt fuel drive end
which could cause a fire. There could be a fire and Fuel lift pump type Electrically operated
injury if you do not follow these precautions. Fuel filter micron rating
Fluid Under Pressure Pre-filter 5 micron
Fine jets of fluid at high pressure can penetrate the Main filter 2 micron
skin. Keep face and hands well clear of fluid under Fuel filter restriction - 0.65bar (9.4psi)
pressure and wear personal protective equipment. maximum pressure drop
Hold a piece of cardboard close to suspected Fuel return restriction - 0.22bar (3.2psi)
leaks and then examine the cardboard for signs of maximum
fluid. If fluid penetrates your skin, get medical help Injector information Electronically controlled
immediately. solenoid actuated in-
WARNING! Do not open the high pressure fuel jectors. Each injector is
system with the engine running. Engine operation marked with a unique
causes high fuel pressure. High pressure fuel spray calibration code.
can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow these
instructions will lead to dirt entering the fuel system.
Dirt in the fuel system will seriously damage the fuel
injection equipment and could be expensive to repair.
Notice: The high pressure fuel system is extremely
susceptible to damage if it is contaminated. Always
clean the engine using the correct procedures before
carrying out maintenance. Contamination of the fuel
system can cause catastrophic failure of the engine.
Notice: Running the engine with air in the system
could damage the fuel injection pump. After
maintenance, the system must be bled to remove
any air.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
accordance with local regulations. Use authorised
18 - 4 9813/7400-1 18 - 4
00 - General
Figure 268.
3
2
15
A
6 6 6 6
14
13
1 16
1 ECM (Engine Control Module)(refer to PIL 2 High pressure fuel injection pump (refer to PIL
33-45) 18-18)
3 Common fuel rail (refer to PIL 18-18) 6 Fuel injectors (refer to PIL 18-18)
13 Fuel filter (2 micron) (refer to PIL 18-09) 14 Fuel pre-filter and water separator (5 micron)
(refer to PIL 18-12)
15 Electric feed pump (refer to PIL 18-21) A Electrical sensors (refer to PIL 15-84)
B Fuel tank (refer to PIL 18-03)
18 - 5 9813/7400-1 18 - 5
00 - General
Operation
The fuel system is central to the performance and Some fuel flows through the pump at all times to
efficiency of the engine, distributing an accurate provide internal lubrication and cooling. This fuel
amount of fuel to each cylinder at exactly the right bleeds back to tank via the bleed-off fuel lines.
time.
Pressurised fuel from the high pressure pump
Fuel is drawn from the fuel tank by the electric passes into the common fuel rail. The high pressure
lift pump integral via the 5 micron pre-filter/water pump is capable of pressurising the fuel in the rail
separator. (The fuel lift pump is integral with the pre- up to 2000 bar. The ECM controlled IMV is used to
filter/water separator assembly.) control the amount, and therefore pressure of the fuel
in the common rail.
Fuel is pressurised at low pressure by the electric
lift pump and passes through an engine mounted 2 In some operating conditions the inlet metering valve
micron fuel filter on its way to the inlet on the high is not able to reduce the rail pressure quickly enough
pressure pump. (if the operator goes from full throttle to no throttle
suddenly for example). In these circumstances the
Important: Use of the correct fuel grade, together rail pressure is dumped to the bleed off line using the
with effective filtration and decontamination of the ECM controlled electric HPV (High Pressure Valve).
fuel is essential. The high pressure pump, injectors
and engine can be damaged beyond repair by High pressure fuel pipes connect the injectors to
contaminated fuel or use of incorrect fuel. the common fuel rail. The injectors are electrically
controlled and incorporate a small solenoid valve.
The high pressure fuel injection pump is a rotary type
and is gear driven by the engine. The pump consists Injection timing is determined by the ECM. Electrical
of two sections, the transfer pump and high pressure data from several sensors is continually monitored
pump. Fuel is first pressurised to about 6 bar by the and processed by the ECM to determine when, how
transfer pump. A constant pressure is maintained much and to which cylinder fuel must be injected.
regardless of engine speed by the regulating valve.
The injectors inject fuel in response to a supply
Fuel is transferred to the high pressure pump via of electrical current from the ECM. So precise is
the IMV (Inlet Metering Valve). The metering valve the control that several injections of fuel occur
controls the amount of fuel transferred depending on during each firing stroke for maximum efficiency and
the engine operating parameters (throttle position, minimum emissions. During fuel injection some fuel
coolant temperature etc.). The metering valve is bleeds off the injectors and back to tank via bleed off
controlled by the ECM (Engine Control Module). lines.
18 - 6 9813/7400-1 18 - 6
00 - General
Figure 269.
2b
2e 2
2c 2d
3b
3
5 4
15
6 6 6 6
14
16
13
1 ECM 2 Fuel high pressure pump

2b IMV 2c Fuel high pressure pump (transfer section)
18 - 7 9813/7400-1 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 107. Colour code key

Colour Component
Green Tank pressure
Blue Transfer pressure
Red Injection rail pressure
Yellow Electrical connections
-ECM - injectors
Light Green Pump internal pressure,
injector bleed-off
18 - 8 9813/7400-1 18 - 8
00 - General
Fault-Finding
Fault
Fuel Consumption Excessive Table 108. Page 18-9
Fuel/Oil- Leaking from Exhaust Manifold Table 109. Page 18-9
General Fuel System Faults Table 110. Page 18-10
Exhaust Gas Recirculation Table 111. Page 18-10
Table 108. Fuel Consumption Excessive

Cause Remedy
Additional load on engine. Check/repair accessories and vehicle components.
Refer to the equipment manufacturer's procedures.
Operator technique. Review operation for correct gear shifts, deceleration
and idling.
Fuel leaks. Check for external leaks at the fuel tank, fuel lines,
filters and lift pump WARNING: Do not repair
defective fuel lines. If there is a fuel leak remove and
discard the necessary components and install new
ones.
Air intake or exhaust leaks.
ECM (Engine Control Module)or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
One or more engine injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
clearances.
Table 109. Fuel/Oil- Leaking from Exhaust Manifold

Cause Remedy
Operating for extended periods under light or no load Review operation for correct gear shifts, deceleration
conditions. and idling.
Air intake or exhaust leaks.
Turbocharger lubricating oil drain line obstructed. Check/clean line.
Exhaust leak at the Manifold or Turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Check for a cracked manifold.
Valve guide seals are leaking. Replace valve guide stem seals as required.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
18 - 9 9813/7400-1 18 - 9
00 - General
Table 110. General Fuel System Faults

Cause Remedy
Fuel supply fault Check the low pressure circuit connections are
secure.
Check the fuel pressure in low circuit/tank level.
Check the fuel type (EN590 Specification).
Check for the external diesel fuel leaks.
Check the filter is not blocked
Check the fuel lift pump operation (Refer to
ServiceMaster help files).
Replace/repair as necessary.
If no faults are found, proceed to "Engine does not
start," or "Engine starts," depending on symptoms
Engine does not start Complete the ‘Static Injector Leak Test’.
If the injector back leak is above the limit, replace
injector(s) as necessary.
If the injector back leak is OK check the rail pressure
is above 300 bar, if not, replace the high pressure
pump.
If the rail pressure is OK and back leak is within
limits, raise Techweb Helpdesk Call.
Engine starts Complete the ‘Dynamic IMV (Inlet Metering Valve)
Test’.
If the IMV is faulty replace the high pressure pump.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
injector(s).
If the back leak is OK complete the ‘Dynamic HPV
(High Pressure Valve) test’
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 111. Exhaust Gas Recirculation

Cause Remedy
Air inlet circuit fault Check the air inlet circuit: – Valve position using
ServiceMaster – Check the EGR (Exhaust Gas
Recirculation) linkage – Vane state
If no fault is found proceed to 'EGR valve connection
fault'.
EGR valve connection fault Check the EGR valve connection. Check that the
supply voltage is correct. Repair as necessary.
Check that the EGR valve position can reach MIN
(0%) to MAX position (100%). Use ServiceMaster to
launch the learning procedure of the EGR position.
18 - 10 9813/7400-1 18 - 10
00 - General
Discharge and Pressurise Clean

Notice: Running the engine with air in the
system could damage the fuel injection pump. Cleanliness Requirements
After maintenance, the system must be bled to
remove any air. Important: Additional cleaning must be carried out
prior to working on the high pressure fuel system.
Obey all fuel system health and safety information. It is extremely important the high pressure fuel
Refer to (PIL 18-00). components and the adjacent parts of the engine
are meticulously cleaned before any components are
The entry of air into the fuel system can cause removed. Refer to:-Effects of Contamination.
problems such as difficult engine starting and
unstable engine running. Air can enter the system if Before starting work on the high pressure fuel
the following occurs: system, make sure that the working environment
is suitable. Refer to:-Maintenance Environment,
• A fuel system component has been Common Rail Fuel Injection.
disconnected. For example, a fuel filter renewal.
• A leak in the low pressure side of the fuel 1. Refer to: Fuel - Health and Safety (PIL 18-00).
system during engine operation, or the low
pressure pipes have been disconnected. Refer 2. Clean the machine, prior to completing any
to Fuel System - General (PIL 18-00) for a more maintenance work.
detailed description of the fuel circuit. 3. Clean the engine, refer to: Engine - Clean (PIL
• The fuel tank is allowed to drain fully during 15-00).
normal operation.
4. Remove the hoses, electrical harnesses and
The engine installation features an electrically ancillaries to improve access and expose any
operated fuel lift pump. The system is designed to remaining trapped dirt close to the relevant high
bleed automatically when the lift pump is operated. pressure components.
Make sure that as much air is removed from the fuel
as possible before you start the engine. Bleed the 5. Wash away any remaining dirt or debris and then
system as follows: dry the area using a compressed air jet. When
the area is dry use a soft clean brush to remove
Important: DO NOT attempt to bleed the high sand or grit particles that remain.
pressure fuel system by loosening the high pressure
pipe connections even when the engine is not Effects of Contamination
running. To bleed the fuel system follow the correct
procedure. Whist the requirement for a good level of cleanliness
is well known and common practice, the introduction
1. Turn on the machine ignition switch to start the of high pressure common rail fuel injection
fuel lift pump. DO NOT start the engine. Allow the necessitates working to new levels of cleanliness.
pump to run for 30 seconds.
Once inside the system, fuel circuit contaminants
2. Turn off the machine ignition switch to stop the
greatly affect the performance and life of the fuel
fuel lift pump. Wait 10 seconds and then turn the
injection equipment. For example, contaminants in
ignition switch to start the pump. DO NOT start
the fuel pump will develop internal wear to cause
the engine. Allow the pump to run for 30 seconds.
internal leakage and hence lower discharges. Use
3. Repeat step 2 twice more before you start the of poor quality fuels and poor maintenance could
engine. also lead to contaminants entering the fuel injectors.
There is a possibility of catastrophic equipment
4. Start the engine and make sure it runs smoothly. 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.
• Gases - Air, sulphur dioxide etc. which can
create corrosive compounds if dissolved in the
fluid.
18 - 11 9813/7400-1 18 - 11
00 - General
These contaminants can appear during dedicated workshop equipped with a suitable clean
manufacture, assembly, operation and maintenance. room, but in practice this is not always possible.
The main filter is rated at 2 micron = 0.002 mm Maintenance procedures requiring removal or
(0.0007874 in). The pre-filter is rated at 5 micron. replacement of fuel system components, particularly
Listed are a few typical comparisons of micron size: high pressure components, require special
precautions to make the working environment
Figure 270. 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
working in different environments:
Worksite - Open to weather

C
B
This repair site is not an acceptable location. Only
in extreme circumstances should a machine be
repaired on an open site. Use the guidelines below:
A
• Clean the engine, refer to (PIL 15-00). If the
machine is on hard standing, clean away the
A 8 Microns material washed from the engine.
B 70 Microns • Place suitable clean boards on the ground
C 100 Microns around the machine.
• Erect clean plastic sheeting to shelter the
• Red Blood Cell = 8 microns (0.008 mm, engine from wind and rain.
0.000315 in). • Wear a new disposable environmental type suit
• Human Hair = 70 microns (0.07 mm, 0.00275 when working on the fuel system. If the suit
in). becomes contaminated with mud, move away
• Grain of Salt = 100 microns (0.1 mm, 0.00394 from the engine and change into a new suit.
in). • Use clean latex gloves (non-powdered).
• The smallest particle visible to the naked eye is • Before you start work make sure that all the
40 microns (0.00157in) approximately. required replacement parts and tools are on
site. Make sure that the replacement parts are
The main filter and pre-filter must be changed in still sealed inside their packaging.
accordance with the applicable service schedule • Cap all exposed ports and orifices immediately.
and procedures. The water in fuel sensor must be Do not leave them open.
maintained to ensure correct operation at all times. • High pressure fuel pipes MUST BE RENEWED
if any pipe joint is loosened or disconnected. DO
The potential for engine damage due to fuel NOT re-use the original pipe.
contamination is much greater when using common
rail injection technology than with mechanical
injection systems. This is because common rail
Worksite - Closed to weather from above
requires components with smaller manufacturing This repair site is the least acceptable condition,
tolerances, especially the fuel injectors. In addition, if possible move the machine to a more suitable
common rail operates at much higher fuel pressures, environment. Use the guidelines below:
over five times that of mechanical systems.
• Clean the engine, refer to (PIL 15-00). Clean the
Similar pressures are used by commercial water floor of all material washed from the engine.
jet cutting machines to cut metal. Fortunately clean • Place suitable clean boards on the ground
diesel fuel has lubricating qualities that prevents around the machine.
erosion of components but it is obvious that • Erect clean plastic sheeting to shelter the
contaminated fuel will cause serious damage at such engine from the wind and the possibility of
high pressures. debris such as dirt and dust falling from above.
• Wear a new disposable environmental type suit
Maintenance Environment, Common when working on the fuel system. If it becomes
Rail Fuel Injection contaminated with mud, move away from the
engine and change into a new suit.
Depending on circumstances engine maintenance • Use clean latex gloves (non-powdered).
may be required in various working environments. • Before you start work make sure that all the
Obviously procedures are best carried out in a required replacement parts and tools are on
18 - 12 9813/7400-1 18 - 12
00 - General
site. Make sure that the replacement parts are Check (Pressure)
still sealed inside their packaging.
• Cap all exposed ports and orifices immediately.
Do not leave them open. When it is necessary to check the fuel rail pressure
• High pressure fuel pipes MUST BE RENEWED function on a faulty vehicle, it is often difficult to
if any pipe joint is loosened or disconnected. DO decide which component of the system has failed.
NOT re-use the original pipe. It is essential to keep in mind the principles of the
function of the Common Rail Fuel system:
Vehicle Maintenance Workshop
Table 112.
Unless the workshop has a dedicated `sealable Principle Function
clean room' work bay, precautions must still be taken.
Pressure production The pump compresses
• Clean the engine, refer to (PIL 15-00). Clean the the fuel at high pressure
engine in the dedicated area and then move it Pressure regulation The pressure thus pro-
to the workshop. duced is accumulated in
• Clean the floor area around the machine. a rail and measured and
• Erect clean plastic sheeting to shelter the regulated (the rail pres-
engine from any wind and the possibility of sure sensor, the ECU
debris such as dirt and dust falling from above. (Electronic Control Unit)
• Ensure that workshop doors to the outside are and the IMV (Inlet Me-
kept closed. A gust of wind through an open tering Valve) function in
door will easily blow sand particles into the air. a closed loop, excess
pressure is drained to
• Make sure your work wear is clean, non-flocking tank by the HPV (High
and lint free. If in doubt wear a new disposable Pressure Valve)
environmental type suit.
Pressure consumption This pressure is finally
• Use clean latex gloves (non-powdered). consumed by the injec-
• Before you start work make sure that all the tors (injection into the
required replacement parts and tools are on engine cylinders and in-
site. Make sure that the replacement parts are jector management)
still sealed inside their packaging
This means that a pressure fault may come from
• Cap all exposed ports and orifices immediately. the producer, the regulator or the consumers. Simply
Do not leave them open. studying the physical parameters of the rail pressure
• High pressure fuel pipes MUST BE RENEWED does not allow the disassociation of the producer and
if any pipe joint is loosened or disconnected. DO the consumer.
NOT re-use the original pipe.
Symptoms
• The engine won’t start or is difficult to start.
• The engine stalls while running.
• 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 - 13 9813/7400-1 18 - 13
00 - General
Examples: • Excessive negative pressure at the pump inlet

(<- 300m Bar, fuel filter blocked).
• Heavy contamination of the fuel wear and tear
• Mechanical wear in the pump.
on the pump leads to the production of metallic
• Excessive pump inlet temperature.
particles that will seriously disturb the injector
function. Figure 272. 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 271. Increased Back Leak Flow
C
F
C
100 100
E D
0 0
B A
A Production
B Consumption
C Reduction in HP pump capacity
D Pressure deficit
E Pump capacity
E F Injected flow
G Back Leak flow
0 0
B A
A Production
B Consumption
C Increased back leak flow
D Pressure deficit
E Pump capacity
F Injected flow
Example
• Presence of air in the low pressure circuit.
18 - 14 9813/7400-1 18 - 14
30 - Throttle Control System
30 - Throttle Control System Introduction

Introduction .................................................... 18-15 The electronic throttle control system consists of:
Operation ....................................................... 18-16
Diagram ......................................................... 18-17 • Speed sensor (magnetic pick up)
• Engine ECU
• Chassis ECU
• Engine Map Sensor-The manifold absolute
pressure sensor provides instantaneous
manifold pressure information to the engine
ECU. The data is used to calculate air density
and determine the engine air mass flow rate,
which in turn determines the required fuel
metering for optimum combustion.
• Throttle Solenoid
• Hand Throttle Control
• Foot Throttle Control pedal
18 - 15 9813/7400-1 18 - 15
Operation
With the ignition on 12V is supplied to the engine

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.
18 - 16 9813/7400-1 18 - 16
Diagram
Figure 273.
A B
C
44
A Engine ECU B ECU J1 connector

C ECU J2 connector D Hand throttle
E Foot throttle
18 - 17 9813/7400-1 18 - 17
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-19
18 - 18 9813/7400-1 18 - 18
03 - Tank
00 - General
00 - General
Introduction
The fuel tank is a safe container for storing flammable

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 - 19 9813/7400-1 18 - 19
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-21

18-09-09 Pre-Filter Element .......................................................................................................... 18-24
18 - 20 9813/7400-1 18 - 20
09 - Filter
00 - General
Introduction .................................................... 18-21 The fuel filter consists of a paper element folded in
Component Identification ............................... 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 ................................................. 18-23 in accordance with the machine maintenance
schedule. Use only the correct specification filters.
18 - 21 9813/7400-1 18 - 21
09 - Filter
00 - General
Figure 274.
1e 1
1f
1d
2a
2b 1a
2c 1b 1c
1 Fuel pre-filter/ water separator 1a Water bowl

1b Drain screw 1c Water level probe
1d Fuel filter element 1e Electric lift pump
1f Air bleed to tank 2 Fuel filter
2a Paper element 2b Sediment bowl
2c Drain screw
18 - 22 9813/7400-1 18 - 22
09 - Filter
00 - General
Operation Drain and Fill
Fuel is pumped into the filter and passes through 1. Make the machine safe. Refer to (PIL 01-03).
the paper element where any dirt particles or water
droplets are retained. An integral sediment bowl at 2. Drain off any water in the filter element by turning
the bottom of the filter enables water to be drained the drain tap. Any fuel and water mix drained
off by means of a drain screw. must be disposed of in accordance with local
regulations. Do not reuse the drained fuel.
Refer to fuel and exhaust system, filter, component
3. Drain off any water in the water separator bowl.
identification, (PIL 18-09).
Any fuel and water mix drained must be disposed
of in accordance with local regulations. Do not
reuse the drained fuel.
18 - 23 9813/7400-1 18 - 23
09 - Filter
09 - Pre-Filter Element
09 - Pre-Filter Element Introduction

Introduction .................................................... 18-24 The fuel pre-filter with water separator is installed on
Remove and Install ....................................... 18-25 to the fuel lift pump. The fuel lift pump is a sealed
integral electrical unit.
18 - 24 9813/7400-1 18 - 24
09 - Filter
09 - Pre-Filter Element

Remove removal procedure. Additionally do the following
steps.
1. Make the machine safe.
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 275.
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 - 25 9813/7400-1 18 - 25
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-27
18 - 26 9813/7400-1 18 - 26
00 - General
Introduction .................................................... 18-27 The water separator with fuel pre-filter and the fuel
Drain and Fill ................................................. 18-28 lift pump is a sealed integral electrical unit. The
assembly is a non-serviceable component. If any
part is defective, replace the complete pump, filter
and separator assembly.
Figure 276.
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 - 27 9813/7400-1 18 - 27
00 - General
Drain and Fill

1. Obey all fuel system health and safety
information. Refer to (PIL 18-00).
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 277. Typical Engine
A
A Fuel filter
B Drain tap
18 - 28 9813/7400-1 18 - 28
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-31

18-18-03 Injector ............................................................................................................................ 18-46
18-18-07 Injector Seal ................................................................................................................... 18-51
18-18-12 Rail ................................................................................................................................. 18-53
18-18-15 Pump .............................................................................................................................. 18-55
18 - 29 9813/7400-1 18 - 29
Notes:
18 - 30 9813/7400-1 18 - 30
18 - Injection
00 - General
Introduction .................................................... 18-31 Fuel at rail pressure is continuously supplied to the
Component Identification ............................... 18-32 injectors via high pressure fuel pipes.
Operation ....................................................... 18-33
Fault-Finding .................................................. 18-36 The high pressure fuel injector fuel pipes consist
of thick walled, seamless steel tubing. The ends of
Check (Operation) ......................................... 18-43 the tubes are formed with conical nipples for sealing
Calibrate ........................................................ 18-45 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 - 31 9813/7400-1 18 - 31
18 - Injection
00 - General
Figure 278.
N
H
G
D F
M
E
C
J
A Multi-point injector nozzle

B Needle
C Spacer
D Nut
E Valve
F Solenoid coil
G Valve spring
H Calibration dowel
J Injector spring
L Electrical connector
M Return port (bleed off)
N High pressure port and filter element
18 - 32 9813/7400-1 18 - 32
18 - Injection
00 - General
Operation
Fuel Injection Cycle
Figure 279.
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 - 33 9813/7400-1 18 - 33
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 281.
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 280. 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 - 34 9813/7400-1 18 - 34
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 - 35 9813/7400-1 18 - 35
18 - Injection
00 - General
Fault-Finding
Fault
Injector Calibration Table 113. Page 18-36
Injector Trim Codes Table 114. Page 18-36
Open Circuit Injector Table 115. Page 18-37
Injection Bank Table 116. Page 18-37
Short Circuit Injector Table 117. Page 18-38
Engine Low on Power Table 118. Page 18-38
Injector Calibration Table 119. Page 18-39
Open Circuit Injector Table 120. Page 18-39
High Pressure Injection Diagnostics Table 121. Page 18-40
Fuel Rail Pressure Calibration Table 122. Page 18-40
IMV Table 123. Page 18-41
HPV Table 124. Page 18-41
Table 113. Injector Calibration

Cause Remedy
Old/incorrect software version Check if the software is up to date or new software
that will solve this problem is available. Upgrade as
necessary. Re-flash the injector calibration codes,
respecting power down and up delay and taking care
of injector position; erase all the faults.
If no fault is found proceed to 'Injector cylinder
position and value fault'
Injector cylinder position and value fault Check that ‘individual injector corrections’ are
correctly entered in ECM (Engine Control Module).
Check the cylinder position and value.
If no faults is found, proceed to 'Injector program
fault'.
Injector program fault Re-flash the injector calibration codes, respecting
power down and up delay and taking care of injector
position; erase all the faults.
Electrical connection faulty Check the knock sensor connection and screw
torque, repair as necessary. Note: Check the ground
shield connection of knock sensor.
If no knock sensor is installed, raise Techweb
Helpdesk call.
Table 114. Injector Trim Codes

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Knock sensors – Water temperature
sensor – Air temperature sensor – Fuel temperature
sensor – Barometric pressure sensor (built inside the
ECM.
Check the knock sensors connection and screwing
torque (Check particularly the ground shield
connection). Repair as necessary and re-enter all
injector calibration codes (read then write) in correct
position to reset learned parameters.
If no fault is found proceed to 'Knock sensors ground
fault'.
Knock sensors ground fault Check the grounding of knock sensors, repair as
necessary.
If no fault is found proceed to ECM connection fault'.
18 - 36 9813/7400-1 18 - 36
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
If ECMpins are damaged, replace ECM and re-flash
necessary.
insulation, repair/replace as necessary.
If no fault is found proceed to 'Injector calibration
codes faulty'.
Injector calibration codes faulty Check the injector calibration codes recorded inECM,
if found fault re-enter all injector calibration codes
(read then write) in correct position to reset learned
parameters.
If the injector calibration codes are OK, test the
vehicle on road and check the Defect Trouble Code
(DTC) again with the diagnostic tool. If the problem is
still present change the knock sensor.
Table 115. Open Circuit Injector

Cause Remedy
Fuel injector fault Perform the injector buzz test, if the injector is faulty
it will not produce a buzzing sound. In such instances
raise Techweb Helpdesk call.
If no fault is found proceed to 'Injector connection
fault'.
Injector connection fault Check the resistance of injector – For solenoid, it
should be less than 1 ohm.
If the resistance is incorrect, change the injector and
calibrate it.
If no fault is found proceed to 'Electrical/ECM
connection fault'.
ElectricalECM connection fault Disconnect the harness from engine ECM and
necessary.
Table 116. Injection Bank

Cause Remedy
Injector connection fault Check the injector connections corresponding to
faulty bank, repair as necessary.
If no fault is found proceed to 'Injector faulty'.
Injector faulty Check all the injectors individually. Replace the
injector and re-calibrate the ECM with the trim file of
the new injector.
If no fault is found proceed to
'Electrical/ECMconnection fault'.
18 - 37 9813/7400-1 18 - 37
18 - Injection
00 - General
Cause Remedy
Electrical/ECM connection fault Disconnect the harness from engineECM and
If ECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing anECM).
necessary.
Table 117. Short Circuit Injector

Cause Remedy
it not will produce a buzzing sound. In such instances
fault'.
Injector connection fault Disconnect the injector (one by one) to see if the fault
disappeared. Repair/ replace as necessary.
Disconnect the engine harness inter connect plug
it to see if the fault disappears. Repair/replace as
necessary.
connection fault'.
ElectricalECM connection fault Disconnect the harness from engine ECM and
IfECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing an ECM).
Table 118. Engine Low on Power

Cause Remedy
Injector fault - electrical If an electrical injector fault is present raise Techweb
Helpdesk call.
fault'.
Injector connection fault Check the Individual Injector Corrections and injector
connections. If the problem with C3I or injector
connection is evident,replace/repair as necessary.
If no fault is found proceed to 'Fuel rail pressure'.
Fuel rail pressure Check the fuel rail pressure.
If no fault is found proceed to 'Engine Cylinder
compression fault'.
Engine Cylinder compression fault Run the compression test (automatic or manual),
if any of the engine cylinder pressure is not in the
limits, repair/replace as necessary.
If no fault is found proceed to 'Blocked inlet tubes'.
18 - 38 9813/7400-1 18 - 38
18 - Injection
00 - General
Cause Remedy
Blocked inlet tubes Check the fuel lines for any blockage and
contamination. Clean the fuel lines as necessary.
If no fault is found proceed to 'Injector faulty'.
Injector faulty Swap the injectors with another. Re-write the trim
codes. Replace/repair as necessary and re-flash the
injector calibration codes.
Table 119. Injector Calibration

Cause Remedy
Injector calibration fault Re-write the injector calibration codes allowing the
power down and up delay and taking care of injector
position, erase the faults.
If no fault is found proceed to 'Power relay operation
fault'.
Power relay operation fault Check the power relay operation, repair the relay or
wiring as necessary.
If no fault is found proceed to 'ECM connection fault'.
Check the harness continuity and electrical
necessary.
Table 120. Open Circuit Injector

Cause Remedy
it will not produce a buzzing sound. In such instances
fault'.
Injector connection fault Check the resistance of injector. – For solenoid, it
should be less than 1 Ohm.
If the resistance is incorrect, change the injector and
calibrate it.
connection fault'.
ElectricalECM connection fault Disconnect the harness from engineECM and
IfECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing anECM).
necessary.
18 - 39 9813/7400-1 18 - 39
18 - Injection
00 - General
Table 121. High Pressure Injection Diagnostics

Cause Remedy
Pressure diagnostics fault Check the fault of type IMV (Inlet Metering Valve)
or HPV (High Pressure Valve) (if applicable) or rail
pressure sensor, repair the corresponding fault.
If no fault is found proceed to 'High pressure system
fault'.
High pressure system fault Read the Diagnostic Trouble Code (DTC).
Connect the battery booster.
If the DTC links to high pressure control: – Check
the fuel feed circuit is in good condition – Check the
diesel fuel is present in the system – Check there is
no air bubbles or emulsion in the pipes – Check there
is enough fuel pressure in the inlet pump – Check
there are no high pressure circuit leaks – Check the
quality and type of the diesel fuel.
If the low pressure circuit is faulty, repair the low
pressure circuit.
If no faults are found, proceed to 'Engine does not
start' or 'Engine starts' depending on symptoms,
replace the corresponding injectors.
Engine does not start Perform the ‘Dynamic IMV Test’.
If the IMV is faulty replace the IMV.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
corresponding injector(s).
If the back leak is OK complete the ‘Pump Pressure
Build Capacity Test’
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 122. Fuel Rail Pressure Calibration

Cause Remedy
repair/replace as necessary.
If no fault is found, proceed to 'ECM connection fault'.
necessary.
If no fault is found proceed to 'Sensor failure'.
page). If sensor is out of specification replace, the
sensor.
fault'.
18 - 40 9813/7400-1 18 - 40
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from engine ECU (Electronic
Control Unit) and inspect. Check seals are in place,
check for signs of corrosion or contamination.
necessary.
If no fault is found proceed to 'Rail pressure sensor
and rail fault'.
Rail pressure sensor and rail fault Replace the rail pressure sensor and rail.
If the problem still not solved, raise Techweb
Helpdesk call.
Table 123. IMV

Cause Remedy
IMV (Inlet Metering Valve) connection fault Check the connection to IMV
If the IMV connection is faulty, replace the high
Pressure fuel injection pump.
If no fault is found proceed to 'ECM connection fault'.
ECMconnection fault Disconnect the harness from engine ECM and
If ECM pins are damaged, replace ECMand re-flash
necessary.
If no fault is found proceed to 'Electrical resistance
fault'.
Electrical resistance fault Measure the IMV electrical resistance around 5.3
ohms at 20 degrees C.
replace the high Pressure fuel injection pump if the
resistance fault occurs.
If no fault is found proceed to IMV buzz fault'.
IMV buzz fault Perform the IMV buzz test. If the IMV is not buzzing
replace the high Pressure fuel injection pump.
If the IMV buzzes, raise Techweb Helpdesk call.
Table 124. HPV

Cause Remedy
HPV (High Pressure Fuel Valve) connection fault Check the connection of HPV
If the HPV connection is faulty, repair or replace as
necessary.
If no fault is found proceed to ECMconnection fault'.
ECM connection fault Disconnect the harness from engineECM and
IfECM pins are damaged, replace ECM and re-flash
necessary.
18 - 41 9813/7400-1 18 - 41
18 - Injection
00 - General
Cause Remedy
If no fault is found proceed to 'Electrical resistance
fault'.
Electrical resistance fault Measure the HPVelectrical resistance, it should be
around 2.2 ohms at 25 degrees C.
If the electrical resistance is OK, replace the rail and
HPV.
If no fault is found proceed to 'HPV buzzing fault'.
HPV buzzing fault Perform the HPV buzz test. If theHPV is not buzzing
replace the rail and HPV.
If the HPV buzzes, raise Techweb Helpdesk call.
18 - 42 9813/7400-1 18 - 42
18 - Injection
00 - General
Check (Operation) Figure 284. Injector leak off test kit
Special Tools
Servicemaster 721/10855 1
Electronic Test Cable
Servicemaster 892/01033 1*
Electronic Test Kit 892/01174
Data Link Adaptor
(DLA) Kit
Injector Leak-off Test 892/12350 1
Kit (Tier 4)
Injector Cap Kit 892/12359 1
*Unless otherwise stated, you can use any of the
tools shown.
To test the fuel injection system, there are two test

options available. Actuator tests, which supply a
voltage signal to the actuators and diagnostic tests Fuel System Diagnostic Test (Cranking only)
which require the engine to be cranked or started.
This test can be found in the fuel system diagnostic
Static Actuator Tests test (cranking) tab in the EcoMax engine test section
on the engine diagnostic tool within Servicemaster.
The IMV (Inlet Metering Valve), HPV (High Pressure This test closes the injectors, opens the IMV and
Valve) and the injectors can each be tested using the controls the rail pressure using the HPV.
engine diagnostic tool within Servicemaster.
1. Connect the fuel leak off test kit, ensure all open
The IMV test can be found under the fuel system tab fuel pipes are capped.
in EcoMax actuators section. The test sends a signal
to theIMV, normally the IMV can be heard operating Special Tool: Injector Leak-off Test Kit (Tier 4)
and the test results will be displayed. (Qty.: 1)
Special Tool: Injector Cap Kit (Qty.: 1)
The HPV test can be found under the fuel system
2. Use Servicemaster to control the tests and follow
tab in EcoMax actuators section. The test sends a
the on screen instructions in Servicemaster.
signal to the HPV, normally the HPV can be heard
operating. Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
The injector test can be found under the injector test Special Tool: Servicemaster Electronic Test
tab in EcoMax actuators section. The test sends a Cable (Qty.: 1)
signal to each individual injector, normally the injector
can be heard operating. 3. Measure the quantity of diesel fuel obtained in
the leak off kit.
Diagnostic Tests 4. Replace the injectors whose back leak exceeds
the value given in the Servicemaster reference
To diagnose fuel system faults the return flow from table.
the fuel system must be measured using the fuel
Injector leak off test kit. Refer to Injector-Check 5. Replace the fuel rail if the HPV return volume
Operation (PIL 18-18). exceeds the value given in the Servicemaster
help file. Note: The HPV is a non-serviceable
There are two sets of dynamic tests, one for when part.
the engine does not start (Cranking only) and one for
when the engine does start (Engine running). 6. After each replacement confirm the results by re-
testing.
7. If the leak off volumes are within limits and the
maximum rail pressure during the test is below
500 bar this indicates the high pressure pump
capacity may be low.
18 - 43 9813/7400-1 18 - 43
18 - Injection
00 - General
Fuel System Diagnostic Tests (Engine 1. Warm the engine to over 60°C (depending on
Running) the application) and the fuel temperature to over
20°C to be able to start the cycle.
These tests can be found in the fuel system
diagnostic test (engine running) tab in the ecomax 2. Connect the HPV leak off bottle, make sure all
engine test section on the engine diagnostic tool open fuel pipes are capped.
within Servicemaster. 3. Use Servicemaster to control the tests and follow
IMV Dynamic test
4. Measure the quantity of diesel fuel obtained in
1. Warm the engine to over 60°C (depending on
the HPV leak off bottle.
the application) and the fuel temperature to over
20°C to be able to start the cycle. 5. Replace the fuel rail if the HPV return volume
exceeds the value given in the Servicemaster
part.
3. Check status. If test OK, it should report
6. After each replacement confirm the results by re-
Diagnosis finished and no problem detected.
testing.
If the test indicates it is not OK (status
report Diagnosis finished and problem detected).
Replace the High pressure pump. Note: The IMV
is a non-serviceable part.
High Pressure IMV Diagnostic test
This test is designed to check the fuel system by

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

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

by opening the IMV fully and controlling the rail
pressure using the HPV. Leak off flow from the HPV
indicates the high pressure pump capacity.
18 - 44 9813/7400-1 18 - 44
18 - Injection
00 - General
Calibrate
Since the injector operating components are by recorded in code form and attached to the injector
necessity very small, even the most advanced body.
manufacturing techniques do not ensure consistent
injection cycle characteristics between injectors. The codes for each injector installed to the engine are
programmed into the ECM (Engine Control Module).
For example, small variations in the metering orifice The operating software in the ECM uses the data
sizes will alter the time durations for the start and to adjust the control of the injector solenoid coil
stop of fuel injection. The small dimensions involved accordingly. The injector is therefore effectively re-
mean that only a tiny variation will alter the orifice calibrated by the ECM.
area by a relatively large percentage.
It follows that if injectors are removed they must
For this reason it is necessary to individually test and always be installed in their original positions. If
record the operating characteristics of each injector new injectors are installed the ECM must be
assembly at the factory. The results of the test are reprogrammed with the new injector codes.
Figure 285.
18 - 45 9813/7400-1 18 - 45
18 - Injection
03 - Injector
03 - Injector Introduction
Introduction .................................................... 18-46 The fuel Injectors are electronically controlled and
Check (Operation) ......................................... 18-47 incorporate a small solenoid valve. The injectors are
Remove and Install ....................................... 18-48 supplied with pressurised fuel by the high pressure
fuel injection pump and when energised, the injector
atomizes the fuel into a fine mist so that it can burn
easily by the vehicle’s engine.
The fuel injectors are mounted in the inlet manifold

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

chambers, so effective cooling is essential. A special
thin walled sleeve is screwed into the cylinder head
which allows a coolant jacket close to the injector.
The coolant jacket is sealed at the bottom by sealant
on the sleeve thread and at the top by O-ring.
Figure 286.
52 5 1 4
1 Injector
2 Sleeve
3 Cylinder head
4 Coolant jacket
5 Sleeve thread
6 O-ring
18 - 46 9813/7400-1 18 - 46
18 - Injection
03 - Injector
Check (Operation) Figure 287.

B
Special Tools
A
Injector Leak-off Test 892/12350 1
Kit (Tier 4)
Injector Cap Kit 892/12359 1
A
The injectors can be tested using Servicemaster
diagnostics and by means of a leak off test. To test
for a defective injector first use Servicemaster to
diagnose the problems with the high pressure fuel
injection equipment, specifically when the engine A
does not start.
Leak Off Test

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

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

Only).
7.2. Fuel System Diagnostic Tests (Engine
Running).
8. Examine the fuel levels in the test bottles. If the
difference between any of the levels is more than
10 ml. this indicates that there are one or more
defective injectors.
9. Remove the test equipment and replace the
bleed off pipes. Refer to (PIL 18-96).
18 - 47 9813/7400-1 18 - 47
18 - Injection
03 - Injector
4 X 1
The following procedure is for one injector, the
procedures are identical for all injectors.
Note: The original injector calibration codes are

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

replaced. 1 Injector
2 Injector clamp
Remove 3 Retaining bolt
4 Injector sleeve
1. Remove the injector clamp retaining bolt and lift X Injector bleed-off port
the clamp away.
2. Remove and discard the sealing washer. Label
the injector to make sure it is installed in its
original cylinder. Put a clean protective cap over
the nozzle of the injector.
3. Remove and discard the O-ring.
18 - 48 9813/7400-1 18 - 48
18 - Injection
03 - Injector
5 A
D
C
A Correction factor (20 characters)

B Manufacturers reference
C JCB part number
D Injector serial number
steps.
2. Clean off any sludge or oil from the inner bore
of the injector sleeve. Make sure you do not
damage the surface of the bore. Any damage
6 or surface contamination will cause the injector
sealing O-ring to fail.
3. Install a new O-ring.
4. Install a new sealing washer.
7
5. Make sure that the injector is installed in the
correct orientation, with the bleed-off port facing
the right hand side (exhaust manifold) of the
5 Protective cap engine. Make sure the injector is pushed fully into
6 Protective cap the cylinder head.
7 Sealing washer 6. Tighten the injector clamp bolt to the correct
torque value.
Install
After Installation
Important: The fuel injectors are not interchangeable
between cylinders or other engines. Make sure you 1. Replace the rocker cover, refer to (PIL 15-42).
install the injectors in the same positions. If a new
or different injector is installed, the engine electronic 2. Renew the high pressure fuel pipes, Refer to Fuel
control unit (ECU) must be re-programmed. Refer to Pipes (PIL 18-96).
(PIL 33-45), Engine Electronic Control Unit, Vehicle
Set Up Data. 3. Replace the low pressure fuel pipes, Refer to
When new or different injectors are installed, record
the calibration code. Record which cylinder the 4. Start the engine and check for fuel leaks.
injector is installed into. Refer to (PIL 33-45), Engine
Electronic Control Unit, Vehicle Set Up Data.
18 - 49 9813/7400-1 18 - 49
18 - Injection
03 - Injector

Item Nm
3 28
4 39
18 - 50 9813/7400-1 18 - 50
18 - Injection
07 - Injector Seal
07 - Injector Seal
Remove and Install
Special Tools Before Removal

Injector Seal 892/12346 1 1. Make sure that the engine is safe to work on. If
Installation Tool the engine has been running, let it cool before
(Electronic Engine) you start the service work.
Injector Sleeve 892/12348 1 2. Clean the engine. Refer to Engine- Clean (PIL
Installation/Removal 15-00).
Tool
Figure 291.
A Rocker cover B Bolts

C Gasket D Injector seals
18 - 51 9813/7400-1 18 - 51
18 - Injection
07 - Injector Seal
Remove Figure 293.
1. Get access to the engine. E

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

4. Put wooden supports under the rocker cover and
tap out the injector seals using the special tool.
Discard the seals. G
Special Tool: Injector Seal Installation Tool E Injector seal installation tool
(Electronic Engine) (Qty.: 1) F Injector seals
G Wooden supports
Figure 292.
4. Renew the rocker cover gasket.
F E
5. Prevent damage to the seals. Put sleeves/covers
on the injectors. Apply a rubber lubricant to the
seals.
Special Tool: Injector Sleeve Installation/
Removal Tool (Qty.: 1)
6. Install the rocker cover. Refer to (PIL 15-42).
G
After Installation
E Injector seal installation tool
F Injector seals 1. The high pressure fuel pipes must be replaced
G Wooden supports with new parts. Refer to Fuel Pipes (PIL 18-96).
Install 2. Start the engine and check for oil and fuel leaks.

steps.
2. Remove all oil and sludge contamination from
inside the valve chamber.
3. Renew the injector seals. Put supports under the
rocker cover and tap in the new seals using the
special tool.
Special Tool: Injector Seal Installation Tool
(Electronic Engine) (Qty.: 1)
18 - 52 9813/7400-1 18 - 52
18 - Injection
12 - Rail
12 - Rail Introduction
Introduction .................................................... 18-53 The fuel rail also known as a common rail, is a
Remove and Install ....................................... 18-54 pipe resembling a rail that is used to deliver fuel
to individual fuel injectors on internal combustion
engines. It is designed to have an outlet for each
injector, an inlet for a fuel supply and an outlet for a
fuel bleed off.
The fuel rail also incorporates an attached fuel

pressure sensor and a fuel valve. DO NOT
remove the high pressure fuel valve or the fuel
pressure sensor from the rail. If these components
are defective replace the complete common rail
assembly.
Figure 294.
A B
F
E
D
A Fuel pressure sensor

B Outlet
C Bleed off
D High pressure fuel valve
E Inlet
F Rail assembly
18 - 53 9813/7400-1 18 - 53
18 - Injection
12 - Rail

A B
Before Removal
C
1. Obey all fuel system health and safety
E F
2. Make sure that the engine is safe to work on. The
engine must cool and pressure in the fuel system
must decay before you start work. If the engine E
has been running, wait at least one hour before D
you start work.
A Fuel pressure sensor
3. Clean the engine. Refer to Engine-Clean (PIL B High pressure fuel pipe
15-00). C Fuel bleed off pipe
4. Remove the high pressure fuel pipes. Refer to D High pressure fuel valve
Fuel Pipes (high pressure) - Remove and Install E Bolts
(PIL 18-96). F Rail assembly
5. Remove the fuel bleed off pipe at the rail. Refer to Table 126. Torque Values
Fuel Pipes (low pressure) - Remove and Install Item Nm
(PIL 18-96). C 24
Remove
1. Disconnect the electrical connector at the high
pressure fuel valve.
2. Disconnect the electrical connector at the fuel
pressure sensor.
3. Remove the bolts and lift off the common rail
assembly.
Seal the common rail assembly inside a clean plastic

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

replace all of the high pressure fuel pipes. Refer to
(PIL 18-96).
18 - 54 9813/7400-1 18 - 54
18 - Injection
15 - Pump
15 - Pump Introduction
Introduction .................................................... 18-55 The high pressure fuel injection pump is a rotary
Component Identification ............................... 18-56 type device that pumps fuel into the cylinders of
Operation ....................................................... 18-56 the engine. The pump is driven indirectly from the
Remove and Install ....................................... 18-58 crankshaft by gears refer to (PIL 15-51).
18 - 55 9813/7400-1 18 - 55
18 - Injection
15 - Pump

Figure 296. The high pressure fuel injection pump is driven via a
7 8 2 10 gear on the engine and rotates at half engine speed.
The pump comprises of two sections, the transfer
pump and the high pressure pump.
1
9 Although the pump does not control fuel injection
timing, it is still timed in relation to engine phasing.
12 3 By timing the pump pressure pulses, the load on the
engine timing gears is reduced together with reduced
mechanical noise.
Transfer Pump Operation

The integral transfer pump is a vane type. An
engine driven rotor houses four vanes in slots.
13 The rotor rotates inside an eccentric liner. The
6 vanes are held in contact with the liner by springs.
5 Fuel is drawn into the pump chamber at port X,
pressurised by the decreasing volume inside the
chamber and expelled at port Y. Fuel pressure
4 2 11 generated by the transfer pump is limited to a
1 Fuel injection pump specified pressure by an integral pressure regulating
2 Pump fixing nuts (x3) valve. This pressure is maintained regardless of
3 Injection pump gear cover engine speed.6bar (87.0psi)
4 Inlet metering valve electrical connector
5 Fuel temperature sensor electrical connector Figure 297.
6 Fuel pipe connector (inlet)
7 Fuel bleed-off connector
8 Fuel bleed-off connector, injector bleed off
9 Drive shaft nut E
10 Drive gear A
11 Injection pump O-ring oil seal
12 High pressure fuel outlet port B
13 Gear cover O-ring oil seal
D
X Y
A Rotor
B Vanes (x4)
C Eccentric liner
D Springs
E Regulating valve
X Port X
Y Port Y
High Pressure Pump Operation

Fuel passes to the high pressure pump via the IMV
(Inlet Metering Valve). The ECM (Engine Control
18 - 56 9813/7400-1 18 - 56
18 - Injection
15 - Pump
Module) controlled IMV determines the amount of Fuel pressure in the chamber rises and forces the
fuel transferred to the high pressure pump. The inlet valve on to its seat. As the plunger is pushed
plunger actuator block is located on the engine driven further up its chamber the fuel pressure exceeds that
eccentric shaft. When the shaft rotates the actuator of the rail pressure and the delivery valve is forced off
block operates the two plungers. As one plunger is its seat. Fuel is forced into the rail at high pressure.
pushed up its chamber the other is pushed down by
its spring. Figure 299.
State 1 - Charging E
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries. D
When the eccentric shaft is in the position shown
force from spring moves the plunger down its C
chamber. Pressure in the chamber falls below the
rail pressure and the delivery valve closes. Transfer
pressure is now sufficient to force inlet valve off its
seat and allow the fuel to fill the chamber.
Figure 298.
E B
D
A Eccentric shaft
C B Actuator block
C Plunger
D Inlet valve
E Delivery valve
F
A Eccentric shaft
B Actuator block
C Plunger
D Inlet valve
E Delivery valve
F Spring
State 2 - Pumping
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries.
When the eccentric shaft is in the position shown the

actuator block moves the plunger up its chamber.
18 - 57 9813/7400-1 18 - 57
18 - Injection
15 - Pump

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

debris may become exposed or dislodged. Stop the
removal procedures and clean away the exposed
deposits. Refer to Engine- Clean (PIL 15-00).
18 - 58 9813/7400-1 18 - 58
18 - Injection
15 - Pump
11
3
B
A
1
F G
1 Bedplate plug H
A Crankshaft / Camshaft timing pin
C Crankshaft turning tool
4. Use the crankshaft turning tool to turn the E
crankshaft until the timing pin engages in the
crankshaft timing hole.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax 3 Gear cover
(Qty.: 1) 11 Drive shaft nut
Special Tool: Crankshaft / Camshaft Timing Pin B Gear removal tool
(444/448/672 Engine) (Qty.: 1) E Pump gear removal tool, comprises:
F Pump gear removal tool (Reaction cap)
5. Use the gear removal tool and a suitable ratchet G Pump gear removal tool (Body)
drive to remove the fuel injection pump gear H Pump gear removal tool (Bolt)
cover.
Special Tool: Pump Gear Removal Tool (Qty.: 1) 7. Remove the nuts. Use the special C shaped
ring spanner to remove the nut closest to the
6. Remove the drive shaft nut. crankcase. Make sure you remove all nuts (X3).
8. Install the reaction cap over the pump shaft.
Screw the body to the housing. Use a suitable
ratchet drive and socket to screw the bolt in until
you feel a slight resistance.
Special Tool: C-Shaped Ring Spanner (Qty.: 1)
Special Tool: Pump Gear Removal Tool (Qty.: 1)
18 - 59 9813/7400-1 18 - 59
18 - Injection
15 - Pump

2 10
2 10
9
F
G
2 12
2 Fixing nuts
9 Gear pump nut
2 Fixing nuts
10 Drive gear
10 Injection pump drive gear
12 Drive shaft
F Pump gear removal tool (Reaction cap)
G Pump gear removal tool (Body) 2. Make sure that the oil seal is correctly located on
H Pump gear removal tool (Bolt) the pump mounting face.
9. The injection pump drive gear is located on a Figure 305.
taper on the pump drive shaft. To remove the
pump the taper lock must be broken. Support
the fuel pump. Tap the end of the bolt H with a
soft faced hammer. When the taper breaks there
will be an audible sound. Note: The pump drive 16
gear connects to the injection pump drive shaft by
means of taper lock alone, there is no mechanical
locking key.
10. Remove the service tools. Withdraw the pump
from the flywheel housing.
Install
1. Make sure that the taper surfaces on the injection 16 Oil seal
pump drive shaft and gear are clean and free 3. Locate the pump on to the mounting studs.
from oil and damage. Locate the drive gear over the pump drive shaft.
4. Install the fixing nuts and tighten to the correct
torque value.
5. Install the gear pump nut and tighten to the
correct torque value. Note: If a washer is supplied
with a replacement pump, Do not install the
washer. Secure the gear with the gear pump nut
only.
6. Use the tamperproof cover removal tool to install
the gear cover. Make sure its sealing O-ring is
correctly installed. Tighten the gear cover to the
1)
Special Tool: Tamperproof Cover Removal Tool
(Qty.: 1)
18 - 60 9813/7400-1 18 - 60
18 - Injection
15 - Pump
7 8
12
3
B
6
3 Gear cover 5
B Tamperproof cover removal tool
4
After Installation 4 IMV electrical connector
1. Remove the crankshaft turning tool. 5 Fuel temperature sensor electrical connector
2. Remove the crankshaft timing pin and install the 7 Fuel pump bleed-off connection
bedplate plug. 8 Fuel pump bleed-off connection
12 High pressure fuel outlet port
3. Reconnect the fuel pipe couplings at the inlet
connection, reconnect the bleed-off connections Table 127. Torque Values
on the pump.
Item Nm
4. Install a new high pressure fuel pipe, remove 2 24
the protective caps from the ports, refer to Fuel 3 70
Pipes- Remove and Install, refer to (PIL 18-96). 9 65
5. Connect the electrical connectors at the IMV and
the fuel temperature sensor.
6. Replace the fuel filter, refer to (PIL 18-09).
7. Start the engine and check for fuel leaks.
18 - 61 9813/7400-1 18 - 61
21 - Fuel Pump
21 - Fuel Pump
Contents Page No.
18-21-00 General ........................................................................................................................... 18-63
18 - 62 9813/7400-1 18 - 62
21 - Fuel Pump
00 - General
Introduction .................................................... 18-63 The fuel lift pump is a sealed electrical unit integral
Technical Data ............................................... 18-65 with the fuel pre-filter and water separator.
Operation ....................................................... 18-66
Check (Operation) ......................................... 18-66 The assembly is a non-serviceable component. If
any part is defective, replace the complete pump,
Remove and Install ....................................... 18-67 filter and separator assembly.
Figure 308.
A Fuel lift pump

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

from a 24V supply by means of an in-line voltage
reducer.
18 - 63 9813/7400-1 18 - 63
21 - Fuel Pump
00 - General
Figure 309.
A
A Lift pump motor

B Voltage reducer
C In-line electrical connector
D Harness electrical connector
18 - 64 9813/7400-1 18 - 64
21 - Fuel Pump
00 - General
Technical Data
Table 128.
Component Value
Operating pressure 0.8bar (11.6psi)
Expected minimum free 2.5L/min
flow delivery
Table 129. Expected electrical values

Machine Minimum Maximum Minimum Maximum Minimum Maximum
Voltage V Voltage V Voltage V Resistance Resistance Current Draw Current Draw
Ohms Ohms A A
12 8 16 0.8 1.5 4 8
24 20 30 4.9 5.7 4 5.5
18 - 65 9813/7400-1 18 - 65
21 - Fuel Pump
00 - General
The pump draws fuel from the tank, through the water If the fuel lift pump is suspect, measure the delivery
separator, pumping it through the fuel filter and into flow rate.
the fuel injection pump. The pump has a built in
protection against running dry and will shut down Flow Test
after 2min if no fuel is present.
1. Make the machine safe, refer to (PIL 01-03).
2. Disconnect the fuel hose from the outlet of the
pump/ filter assembly.
3. Connect a length of fuel hose from the pump
outlet to a suitable fuel container.
Volume: 5L
4. Activate the fuel pump. Do not attempt to start
the engine.
5. Run the pump. The fuel flow must be equal to or
greater than the value shown.
Duration: 1min
Flowrate: 2.5L/min
Machines with Electronic Control Fuel

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

within Servicemaster to energise the fuel pump (fuel
lift pump test). After a 5s delay the pump runs for a
period of 24s.
18 - 66 9813/7400-1 18 - 66
21 - Fuel Pump
00 - General
Remove and Install
Remove 4. Disconnect the WIF (Water in Fuel) sensor

harness connector.
Refer to Figure 310.
5. Make sure to mark label on the fuel pipes to aid
The fuel lift pump is installed on the loader tower. in the installation.
This procedure is also similar for the machines with
6. Disconnect the fuel pipes at the fuel lift pump by
lift pumps installed on the side of the fuel tank.
means of the quick release connectors.
1. Make the machine safe. Refer to (PIL 01-03). 7. Disconnect the drain hose at drain tube.
2. Disconnect the battery. 8. Support the fuel lift pump and remove the bolts.
3. Disconnect the fuel lift pump harness connector. 9. Remove the fuel lift pump together with its pre-
filter/separator from the machine.
Figure 310.
D
C
A B E
H
F
A WIF sensor harness connector B Fuel pipe

C Fuel lift pump harness connector D Fuel lift pump
E Fuel pipe F Bolt
G Drain tube H Pre-filter/Seperator
J Fuel pipe
Install
removal procedure.
Table 130. Colour code

Fuel pipe Colour
E Blue
J Red
18 - 67 9813/7400-1 18 - 67
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-69

18-24-03 Inlet Manifold .................................................................................................................. 18-71
18-24-04 Outlet Manifold ............................................................................................................... 18-75
18-24-27 Spark Arrestor ................................................................................................................ 18-79
18 - 68 9813/7400-1 18 - 68
24 - Exhaust
00 - General
Introduction .................................................... 18-69 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-70 away from the controlled combustion inside the
Check (Condition) .......................................... 18-70 engine by means of an exhaust pipe. Depending
on the machine design, the exhaust gas may flow
through the following components:
• Cylinder head and exhaust manifold.

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

away from the users of the machine. Note machines
or generators that work indoors can quickly fill an
enclosed space with carbon monoxide or other
poisonous exhaust gases if they are not properly
vented to the outdoors.
18 - 69 9813/7400-1 18 - 69
24 - Exhaust
00 - General

Exhaust Gases Excessive smoke from the exhaust stack combined
Machine exhaust gases can harm and possibly kill with a complaint of low power could be as a result of:
you or bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure • Dirt or dust (unfiltered air) ingested directly into
there is good ventilation. If possible, install an the engine, resulting in damage to the cylinder
exhaust extractor. If you begin to feel drowsy, stop bores, there will also be a possible increase in
the machine at once and get into fresh air. oil consumption.
• Air leaks from the air hose connections.
Sparks • Exhaust manifold leaks.
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
Hot Components
Touching hot surfaces can burn skin. The engine and
been running. Allow the engine and components to
cool before servicing the unit.
Switch off the engine before working in the engine
engine cover open.
18 - 70 9813/7400-1 18 - 70
24 - Exhaust
03 - Inlet Manifold
03 - Inlet Manifold Introduction

Introduction .................................................... 18-71 The inlet manifold (or intake manifold) supplies
Check (Condition) .......................................... 18-72 combustion air to the cylinders in compression
Remove and Install ....................................... 18-73 ignition engines or the air/fuel mixture for spark
ignition engines (except most direct injection spark
ignition engines). Even distribution of the air or
air/fuel is important to optimize the efficiency and
performance of the engine.
The manifold is required to be air tight under pressure

and vacuum conditions and can be required to
provide mounting points for sensors, grid heaters,
throttle bodies and other components depending on
the engine type and specification.
18 - 71 9813/7400-1 18 - 71
24 - Exhaust
03 - Inlet Manifold
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.
18 - 72 9813/7400-1 18 - 72
24 - Exhaust
03 - Inlet Manifold
Remove and Install
Before Removal 2. Make sure that the engine is safe to work on. If
1. This procedure requires service parts. Make you start the service work.
before you start, refer to Parts Catalogue. 3. Get access to the engine.
4. Remove the fuel rail assembly. Refer to (PIL
18-18).
Figure 311.
6
12 11 10
8
13
9
3
4
5
1 Inlet manifold 2 Manifold gasket

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

ingress of dirt.
1. Disconnect the TMAP (Temperature Manifold Air
Pressure) sensor electrical connector. 5. Inspect the manifold, refer to Check Condition
(PIL 18-24).
2. Disconnect the air inlet hose.
3. Remove the bolts 3 and lift the inlet manifold from
the cylinder head. Discard the gasket.
18 - 73 9813/7400-1 18 - 73
24 - Exhaust
03 - Inlet Manifold
Install
steps.
2. Renew the manifold gasket.
3. Loosely assemble the manifold, together with the
new inlet gasket to the cylinder head, use the two
bolts (one at each end).
4. With the manifold and gasket in position, install
the remaining six bolts.

Item Nm
3 43
18 - 74 9813/7400-1 18 - 74
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction

Introduction .................................................... 18-75 Figure 312.
Component Identification ............................... 18-76 A B
Check (Condition) .......................................... 18-76
A Exhaust manifold
B Manifold gasket and heat shield
18 - 75 9813/7400-1 18 - 75
24 - Exhaust

Figure 313. 1. Check the manifold mating faces for signs of
A B damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
4. Visually inspect for leaks at the exhaust manifold.
Make sure all gaskets are in good condition,
replace as required.
A Exhaust manifold
B Manifold gasket and heat shield
18 - 76 9813/7400-1 18 - 76
24 - Exhaust
Remove and Install
Before Removal 2. Make sure that the engine is safe to work on. If
1. This procedure requires service parts. Make you start the service work.
before you start, refer to Parts Catalogue. 3. Get access to the engine.
4. Disconnect the oil pipes to the turbocharger, refer
to (PIL 18-36).
Figure 314.
1 Exhaust manifold 2 Fixing bolts M10 x 57mm (x8)

3 Manifold gasket
Remove 2. Renew the manifold gasket.
1. Remove the upper four bolts. 3. Install the lower four bolts, together with the new
exhaust gasket to the cylinder head (screw in the
2. Loosen the lower four bolts and lift the exhaust bolts approximately to a length of 8 mm).
manifold from the cylinder head. Remove the
bolts and discard the gasket. 4. Rest the manifold in position on the row of
lower bolts by locating the slots, then install the
3. Cap the exhaust ports to prevent ingress of dirt. remaining four upper bolts.
4. Inspect the manifold, refer to Check Condition 5. Tighten the bolts to the correct torque value.
(PIL 18-24). Refer to Torque and Angle Tightening procedure
(PIL 72-00 ).
Install
After Installation
removal procedure. Additionally do the following 1. Reconnect the oil pipes to the turbocharger (if
steps. installed).
18 - 77 9813/7400-1 18 - 77
24 - Exhaust
2. Install the exhaust pipe and the silencer box.

3. Start the engine and check for exhaust leaks.

Item Torque Value Torque Angle
(Nm) (Degrees)
2 (First Stage) 25
2 (Final Stage) +90
18 - 78 9813/7400-1 18 - 78
24 - Exhaust
27 - Spark Arrestor
27 - Spark Arrestor
Clean
Important: Wear a dust mask when cleaning the

spark arrester. Make sure the exhaust is cool before
the service work is performed.
1. Make the machine safe with the lift arm lowered,

3. Place a suitable container under the drain plug.
4. Remove the drain plug from the exhaust.
5. Gravity will allow trapped particles to escape
from the hole. When carbon particles have
stopped draining, gently tap the exhaust or use
a fine wire to remove any additional trapped
carbon.
6. Install the drain plug into the exhaust, tighten by
hand, then turn 1/8th of a turn to secure.
Figure 315.
A Drain plug
18 - 79 9813/7400-1 18 - 79
27 - Exhaust Gas Recirculation (EGR)
Contents Page No.
18-27-00 General ........................................................................................................................... 18-81

18-27-03 Actuator .......................................................................................................................... 18-88
18 - 80 9813/7400-1 18 - 80
00 - General
Introduction .................................................... 18-81 The EGR (Exhaust Gas Recirculation) system is
Component Identification ............................... 18-82 a technique that re-circulates a portion of the
Operation ....................................................... 18-83 exhaust gases back into the combustion chamber.
Check (Condition) .......................................... 18-84 The system cools and controls the quantity of re-
circulated exhaust gas.
The EGR valve is controlled by the CAN (Controller
Area Network)bus system (PIL 33-45), the valve
opens and closes to allow the exhaust gases to
flow back into the intake system via the EGR cooler.
This has the effect of lowering the combustion
temperature and reducing the formation of NOx
(Nitrogen Oxide).
In order to ensure full power is always available when

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

a feedback position sensor, linkage and a valve
mechanism. The valve actuator, which is controlled
by the CANbus system, position sensor and linkage,
drives the valve to the demanded position.
18 - 81 9813/7400-1 18 - 81
00 - General
Figure 316.
B
C
D
A E
F
G
A VGT (Variable Geometry Turbocharger) actuator B VGT

C EGR (Exhaust Gas Recirculation) valve D EGR actuator
E EGR intermediate cooler F Main plate cooler
G Mixer tube
Table 133. Colour Code Key

Colour System
Blue Coolant Flow 1
Red Recirculated Gas Flow
Green Air Flow
Yellow Coolant flow 2
18 - 82 9813/7400-1 18 - 82
00 - General
Operation Figure 319.
1. Exhaust gases enter the exhaust manifold.

Figure 317.
4. Exhaust gases enter the mixer tube.

Figure 320.
2. The exhaust gases travel through the
intermediate EGR (Exhaust Gas Recirculation)
cooler.
Figure 318.
5. The exhaust gases are mixed with new air and

re-enter the engine.
Figure 321.
3. The exhaust gases enter the main cooler which
reduces the heat.
18 - 83 9813/7400-1 18 - 83
00 - General
Check (Condition)
1. Check that the EGR (Exhaust Gas Recirculation)
for excessive carbon build up. Visually inspect for
leaks at the EGR. Make sure all gaskets are in
good condition, replace as required.
18 - 84 9813/7400-1 18 - 84
00 - General
Remove and Install

Figure 322.
C
B D
E
A
F
G

C EGR (Exhaust Gas Recirculation) actuator D EGR valve
E EGR Intermediate Cooler F Main Plate Cooler
G Mixer Tube
18 - 85 9813/7400-1 18 - 85
00 - General
Remove 8. Remove the four bolts that retain the heat-shield

to the EGR control module.
1. Remove the EGR cooler hose (LHS viewed from
the rear of the engine). 9. Remove the bolt from the cooler pipe.
2. Remove the two EGR cooler bracket assembly 10. Remove the cooler connections (four banjo
bolts. fittings and copper washers) from the EGR
control module and electrical harness connector.
3. Carefully remove the main EGR cooler.
11. Remove the three small bolts that fix the control
4. Remove the EGR cooler hose (RHS viewed from module to the EGR valve.
the rear of the engine).
12. Remove the two bolts that fix the EGR bracket to
5. Remove the four nuts fixing the EGR tube in tube the W-clip that clamp the cooler pipes together
cooler pipe assembly to the EGR valve. (captive nuts).
6. Remove the EGR actuator control rod pivot pin 13. Remove the EGR valve body from the mounting
fixing clips and the EGR control rod. studs fixed to the manifold with a steel gasket
both sides.
7. Remove the bolt fixing the EGR tube in tube
cooler to the rear of the cylinder head.
Figure 323.
19
22
41
42 41
45
5 41 35
25 20
17 41
10
29
38
32
19 41
3 20
22 15
7
37
4 13
20 20 6
42
12
27 8 40
1
26 39
20 42
42 14
43
23 16
9 21
34
2 28
23
24 31
1 Main EGR cooler 2 Intermediate EGR cooler

3 EGR valve 5 Pipe (Coolant return to header)
6 Pipe (Under actuator to coolant return) 7 Pipe (EGR actuator feed)
18 - 86 9813/7400-1 18 - 86
00 - General
8 Pipe (EGR cooler out) 9 Pipe (rear of head feed)

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

Network) driven device and can only be
1. The installation procedure is the opposite of the evaluated with the use of Servicemaster. Refer
removal procedure. Additionally do the following to EGR Actuator (PIL 18-27).
steps.
4. All conditions of the EGR are reported by the fault
2. Renew all O-rings, sealing washers and gaskets. codes. Test the turbocharger boost pressure,
refer to Check Operation (PIL 18-36).
3. Tighten the fixings to the correct torque value.
Note: Tighten the EGR cross over tube bolts in Table 134. Torque Values
the correct order, 1 to 4 as shown in 2 stages.
Item Nm
Figure 324. 31 50
32 27
2
33 16
39 24
40 24
4
41 10.5
42 24
43 24
44 24
3
1
After Installation
1. Complete the actuator learn procedure, Refer to
Servicemaster, JCB Engine > Diagnostic Tool >
Ecomax Actuators > Actuator Learn > EGR Valve
Position Learn.
2. Start the engine and check for exhaust leaks and
coolant leaks.
18 - 87 9813/7400-1 18 - 87
03 - Actuator
03 - Actuator Introduction
Introduction .................................................... 18-88 The EGR (Exhaust Gas Recirculation) actuator is a
Remove and Install ....................................... 18-89 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 - 88 9813/7400-1 18 - 88
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 - 89 9813/7400-1 18 - 89
35 - Turbocharger
35 - Turbocharger
Contents Page No.
18-35-00 General ........................................................................................................................... 18-91
18 - 90 9813/7400-1 18 - 90
35 - Turbocharger
00 - General
Introduction .................................................... 18-91 The turbocharger (turbo) is a turbine driven forced
Component Identification ............................... 18-92 induction device that makes an engine more efficient
Check (Condition) .......................................... 18-93 and helps to produce more power for its size.
Check (Operation) ......................................... 18-94
Engine exhaust gasses drive a turbine, which in turn
Remove and Install ....................................... 18-95 drives a compressor via a common shaft. The shaft
bearings are lubricated by a feed from the engine
lubrication system.
A turbocharged engine is more powerful and efficient

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

flap type valve is housed in the turbocharger body.
The valve is actuated by a diaphragm type actuator
via an actuator rod. When the pressure generated
by the turbocharger compressor reaches a pre-set
value the actuator opens the valve, some exhaust
gas is diverted back to the exhaust manifold and
the turbocharger turbine speed reduces. In this way
the pre-set maximum boost pressure from the turbo
charger is not exceeded, regardless of engine speed.
18 - 91 9813/7400-1 18 - 91
35 - Turbocharger
00 - General
Figure 325.
7.5
7 7.4 7.3,4 1 9
12
7.2
8
11
7.3,13
3
6
8.8 5
1 Turbocharger 2 Exhaust manifold

3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
18 - 92 9813/7400-1 18 - 92
35 - Turbocharger
00 - General
Check (Condition) Figure 327.
1. Visually inspect for leaks at the turbocharger.

Make sure all gaskets are in good condition,
replace as required.
2. Check the turbine and compressor blades inside
the turbocharger rotate freely and smoothly by
hand. If the blades are stiff to turn, or damaged
the turbocharger must be replaced.
3. Make sure that the oil feed pipe and oil drain pipe
are clear and free from debris and sludge.
4. Check the turbine shaft running clearance.
4.1. Place the stylus of a DTI (Dial Test Indicator)
against the shaft.
4.2. Move the shaft sideways. 5.2. Move the shaft axially.
Figure 326. 5.3. Make sure that the shaft end float is within
the specified limits. Refer to Turbocharger,
4.3. Make sure that the turbine shaft running

clearance is within the specified limits.
Refer to Turbocharger, Technical Data (PIL
18-35).
5. Check the shaft end float.
5.1. Place the stylus of the DTI against the end
of the shaft.
18 - 93 9813/7400-1 18 - 93
35 - Turbocharger
00 - General
Check (Operation)
To maximise the duration of the turbocharger follow

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

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

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 94 9813/7400-1 18 - 94
35 - Turbocharger
00 - General
Remove and Install
Figure 328.
7.5
7 7.4 7.3,4 1 9
12
7.2
8
11
7.3,13
3
6
8.8 5
1 Turbocharger 2 Exhaust manifold

3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
1. This procedure requires service parts. Make sure 5. Drain the cooling system.
start, refer to Parts Catalogue. Remove
2. Make sure that the engine is safe to work on. 1. Disconnect the air induction hose at the inlet
If the engine has been running, make sure the manifold and turbocharger. Remove the hose.
engine has cooled sufficiently before you start.
2. Remove the pipe clip. Undo fixing bolts and
3. Remove the ignition key. remove the oil drain pipe. Note that the pipe pulls
18 - 95 9813/7400-1 18 - 95
35 - Turbocharger
00 - General
off the pipe adaptor, leaving the adaptor in place.

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

Item Nm
4 21
6 24
8 24
13 36
18 - 96 9813/7400-1 18 - 96
36 - Variable Geometry Turbocharger (VGT)
Contents Page No.
18-36-00 General ........................................................................................................................... 18-99

18-36-03 Actuator ........................................................................................................................ 18-106
18 - 97 9813/7400-1 18 - 97
Notes:
18 - 98 9813/7400-1 18 - 98
00 - General
Introduction .................................................... 18-99 The VGT (Variable Geometry Turbocharger) is
Component Identification ............................. 18-101 the next generation in turbocharger technology.
Operation ..................................................... 18-102 The turbocharger uses variable vanes to control
Check (Condition) ........................................ 18-103 exhaust flow and to introduce EGR (Exhaust Gas
Recirculation) to reduce emission in diesel engines.
Check (Operation) ....................................... 18-103 The turbocharger is bolted to the outlet port of the
Remove and Install ..................................... 18-104 exhaust manifold.
The turbo uses heat and energy from the waste

exhaust gases to drive a turbine which in turn drives
the compressor to pull new air at high pressure
into the cylinders. The extra volume of air allows
more fuel to be injected increasing the engine power
output.
This has the effect of lowering the combustion

temperature and reduces formation of NOx gases.
The air is compressed to a minimum pressure of

1 bar (14.5 lb/in2) depending upon engine speed
and load. The turbocharger spins at up to 100,000
rpm and reaches temperatures approaching 700 ºC
(1292 ºF); it is essential, therefore, that a good supply
of oil reaches it at all times. The oil not only lubricates
the turbocharger but also carries away excess heat.
External oil feed pipe connected to a port on the
crankcase supplies oil to the turbocharger bearing.
Oil returns to the engine oil sump via an external
drain pipe. Integral oil seals prevent oil escaping to
the compressor and turbine ends of the turbocharger.
18 - 99 9813/7400-1 18 - 99
00 - General
Figure 329.
B
A VGT
B VGT actuator
18 - 100 9813/7400-1 18 - 100

00 - General
Figure 330.
B
C
D
A E
F
G

C EGR (Exhaust Gas Recirculation) valve D EGR actuator
E EGR intermediate cooler F Main plate cooler
G Mixer tube
18 - 101 9813/7400-1 18 - 101

00 - General
1. Exhaust gases move through the scroll volume

spread across a slot and over the louvres turning
the turbine and out of the outlet.
Figure 331.
4. The angle of the airflow can be adjusted as it

strikes the adjustable louvres to change the turbo
performance.
Figure 334.
2. The louvre ring sits inside the turbine housing

with the turbine spinning in the centre.
Figure 332.
3. The outer ring is adjusted by the actuator.
18 - 102 9813/7400-1 18 - 102

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

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

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 103 9813/7400-1 18 - 103

00 - General
Remove and Install
Before Removal 3. Remove the ignition key.
1. This procedure requires service parts. Make sure 4. Get access to the engine.
start, refer to Parts Catalogue. 5. Drain the cooling system. Refer to (PIL 21-00).
2. Make sure that the engine is safe to work on. If 6. Remove the EGR (Exhaust Gas Recirculation)
the engine has been running, let it cool before valve. Refer to (PIL 18-27).
Figure 335.
10
7
6
2
8
9 9
3
4
14
17
16 19 11
20
15 12
18
13
1 Turbocharger 2 Gasket
3 Studs M8 4 Lock nut
18 - 104 9813/7400-1 18 - 104

00 - General
5 Studs M10 6 Pipe adaptor (oil drain connection)

7 Gasket drain pipe 8 O-Ring
9 Bolt M6 10 Clip
11 Oil drain pipe 12 Gasket drain pipe
13 Bolts M8 14 Oil feed pipe
15 Pipe clip 16 Banjo bolts M12
17 Copper Washer 18 W Clip
19 Banjo bolts M16 20 Copper Washer M16
Remove 2. Test the VGT (Variable Geometry Turbocharger)

boost pressure.
1. Disconnect the air induction hose at the inlet
manifold and turbocharger. Remove the hose. Table 136. Torque Values
2. Undo the bolts and remove the oil drain pipe. Item Nm
Note that the pipe pulls off the pipe adaptor, 4 24
leaving the adaptor in place. Cap the open ports 9 10
to prevent ingress of dirt. Discard the O-ring and 13 24
the gasket.
16 36
3. Remove the pipe clips. Undo the banjo bolts at 19 21
each end of the oil feed pipe, remove the pipe.
Cap the open ports to prevent ingress of dirt.
Discard the sealing washers.
4. Remove the exhaust manifold from the cylinder
head complete with the turbocharger still
installed, refer to Exhaust Manifold- Removal
and Replacement. Discard the exhaust manifold
gasket.
5. With the exhaust manifold removed from the
engine, undo the nuts and separate the
turbocharger from the manifold. Discard the
gasket
6. If the turbocharger is to be replaced remove the
bolts and pipe adaptor. Discard gasket.
Install
steps.
2. Check the condition of the turbocharger. Refer to
(PIL 18-35).
3. Prime the top of the turbo with 200ml of fresh
clean engine oil. It is Important: not to run the new
turbo dry.
4. Renew all O-rings, sealing washers and gaskets.
5. Note that the exhaust manifold gasket also
functions as a heat-shield.
6. Tighten the nuts, bolts and banjo bolts to the
After Installation
1. Start the engine and check for exhaust leaks.
18 - 105 9813/7400-1 18 - 105

03 - Actuator
03 - Actuator Install
steps.
Special Tools
Description Part No. Qty. 2. Perform the VGT (Variable Geometry
Data Link Adaptor 892/01174 1 Turbocharger) position learn routine using
(DLA) Kit Servicemaster. Refer to the engine Helpfiles.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
Before Removal 1)
1. Make the machine safe. Refer to (PIL 01-03). Table 137. Torque Values
2. Make sure that the engine is safe to work on. If Item Nm
the engine has been running, let it cool before B 10
you start the service work. C 13
Remove
Figure 336.
D A
A Actuator
B Actuator linkage
C Nuts (x4)
D Electrical connector
2. Disconnect the actuator linkage from the
actuator.
3. Disconnect the coolant hoses. Plug all the open
ports and hoses to prevent contamination. Make
sure that any spills or residual coolant is cleaned
up immediately.
4. Remove the nuts (x4) and remove the actuator
from the turbocharger housing.
18 - 106 9813/7400-1 18 - 106

96 - Fuel Pipe
96 - Fuel Pipe
Contents Page No.
18-96-00 General ......................................................................................................................... 18-109

18-96-03 High Pressure Pipe ...................................................................................................... 18-112
18-96-06 Low Pressure Pipe ....................................................................................................... 18-115
18 - 107 9813/7400-1 18 - 107

Notes:
18 - 108 9813/7400-1 18 - 108

96 - Fuel Pipe
00 - General
Introduction .................................................. 18-109 Fuel at rail pressure is continuously supplied to
Health and Safety ........................................ 18-110 the injectors via high pressure fuel pipes. The high
Component Identification ............................. 18-110 pressure fuel injector pipes consist of thick walled,
Preparation .................................................. 18-111 seamless steel tubing. The ends of the tubes are
formed with conical nipples for sealing in the sealing
cones on the common rail and on the injector at port.
It is essential that the pipes are maintained and

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

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

removed for any reason they must be renewed.
Installing the original fuel pipes will cause fuel leaks
at the pipe connections.
18 - 109 9813/7400-1 18 - 109

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 Figure 337.
causes high fuel pressure. High pressure fuel A
spray can cause serious injury or death. A A A
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system, B
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and H
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously C
damage the fuel injection equipment and could be
expensive to repair. G
E
D
A Pipe assembly high pressure - fuel rail to

injector (x4)
B Injector
C Pipe assembly high pressure - injection pump to
fuel rail
D Pipe low pressure - return to tank
E Injection pump
F Pipe assembly low pressure - Fuel injectors to
tank
G Pipe assembly low pressure - fuel rail to tank
H Fuel rail
18 - 110 9813/7400-1 18 - 110

96 - Fuel Pipe
00 - General
Preparation
Important: Before you disconnect or remove fuel must decay before you start work. If the engine
pipes make sure that you have the correct new parts. has been running, wait at least one hour before
The high pressure fuel pipes MUST BE REPLACED you start work.
with new ones. The new fuel pipes must remain
sealed inside their bags before use. If a bag is open 2. Clean the engine. Refer to Engine-Clean (PIL
DO NOT USE the fuel pipe, get a new one. 15-00).
Obey all fuel system health and safety information. 3. Remove the protective cover. Push out the four
Refer to (PIL 18-00). plastic segments. Remove the screws and lift off
the cover.
4. Remove any dirt or debris that is exposed. Refer
to Engine-Clean (PIL 15-00).
Figure 338.
A Protective cover B Plastic segments (x4)

C Screws
18 - 111 9813/7400-1 18 - 111

96 - Fuel Pipe
03 - High Pressure Pipe
03 - High Pressure Pipe 5.3. Remove any dirt or debris that is exposed.
Refer to Engine, Clean (PIL 15-00-00).
Remove and Install 6. Always use a spanner at the top of the fuel pipe
nut (this will prevent damage to the nut).
Special Tools
Description Part No. Qty. Figure 340.
Socket 17MM Offset - 331/27987 1
(HP Fuel pipes)
(10-100Nm)
Important. Before disconnecting or removing fuel

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

1.1. The high pressure fuel pipes MUST BE
REPLACED with new ones.
1.2. The new fuel pipes must remain sealed
inside their bags before use. If a bag is open
DO NOT USE the fuel pipe, get a new one.
2. Obey all fuel system health and safety Injector Fuel Pipes
Remove
3. Make sure that the engine is safe to work on.
The procedure describes how to remove one fuel
3.1. The engine must cool and pressure in the pipe.
fuel system must decay before you start
work. Figure 341.
3.2. If the engine has been running, wait at least B
one hour before you start work.
A
4. Clean the engine. Refer to Engine, Clean (PIL C
15-00-00).
5. Remove the protective cover as follows.
E
Figure 339.
B
A Fuel pipe
A B Nut 1
C Fuel injector
D Fuel rail
E Nut 2
C
1. Remove the fuel pipes one at a time as follows.
A Screw
B Plastic segment 1.1. Loosen the nut 2 at the fuel rail. Do not
C Protective cover remove the nut at this step.
1.2. Use the 17mm deep socket special tool at
5.1. Push out the plastic segments. the top of nut. This will prevent damage to
5.2. Remove the screws and lift off the cover. the nut.
18 - 112 9813/7400-1 18 - 112

96 - Fuel Pipe
Special Tool: Socket 17MM Offset - (HP Injection Pump to Rail Fuel Pipe
Fuel pipes) (Qty.: 1)
Special Tool: Torque Wrench (10-100Nm) Remove
(Qty.: 1)
Figure 342.
1.3. Push the fuel pipe against the injector cone
and at the same time remove the nut 1. A
B
1.4. Push the fuel pipe against the fuel rail cone
and at the same time remove the nut 2.
1.5. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
1.6. Remove the fuel pipe.
1.7. Seal all the open ports, use the correct parts
from the service kit.
2. Repeat step 1 to remove the other fuel pipes.
3. Discard the old fuel pipes.
Install
Important: The high pressure fuel pipes must be E
replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a bag
is open do not use the fuel pipe, get a new one. Do
not open the bag until you are ready to assemble the D
fuel pipe.
1. Make sure that the bleed-off adaptors are C

assembled on the injectors before you install the A Nut 1
high pressure pipes. B Fuel rail
C Injection pump
2. Assemble the fuel pipes one at a time. The D Nut 2
procedure describes how to assemble one fuel E Fuel pipe
pipe.
1. Remove the fuel pipe as follows.
2.1. Put the correct end of the fuel pipe against
the correct injector cone. 1.1. Loosen the nut 2. Do not remove the nut at
this step.
2.2. Tighten the nut 1 with your hand.
1.2. Use the 17mm deep socket special tool at
2.3. Put the other end of the fuel pipe against the
the top of nut. This will prevent damage to
correct fuel rail cone.
the nut.
2.4. Tighten the nut 2 with your hand. Special Tool: Socket 17MM Offset - (HP
2.5. Nuts must be tightened in the correct Fuel pipes) (Qty.: 1)
sequence. Tighten nut 1 and then nut 2. Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
2.6. Use the special tool at the top of nut 1 and
tighten it to the correct torque value. 1.3. Push the fuel pipe against the injector cone
and at the same time remove the nut 1.
Torque: 27N·m
Special Tool: Socket 17MM Offset - (HP 1.4. Push the fuel pipe against the rail cone and
Fuel pipes) (Qty.: 1) at the same time remove the nut 2.
2.7. Put the spanner at the top of nut 2 and 1.5. Make sure that there is no dirt or debris on
tighten it to the correct torque value. the fuel pipe or the connectors.
Torque: 27N·m 1.6. Remove the fuel pipe.
1.7. Seal all the open ports, use the correct parts
from the service kit.
2. Discard the old fuel pipe.
18 - 113 9813/7400-1 18 - 113

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

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

1.1. Put the correct end of the fuel pipe against
the correct pump cone at the injection
pump.
1.3. Put the other end of the fuel pipe against the
correct fuel rail cone.
1.5. Nuts must be tightened in the correct
sequence. Tighten nut 2 and then nut 1.
1.6. Use the special tool at the top of nut 2 and
tighten it to the correct torque value.
Torque: 27N·m
Special Tool: Socket 17MM Offset - (HP
Fuel pipes) (Qty.: 1)
1.7. Put the spanner at the top of nut 1 and
tighten it to the correct torque value.
Torque: 27N·m
After Installation
1. Ensure that all pipes are correctly installed
and located in retaining clips as applicable. If
retaining clips are missing or damaged they must
be replaced or renewed
18 - 114 9813/7400-1 18 - 114

96 - Fuel Pipe
06 - Low Pressure Pipe
06 - Low Pressure Pipe Figure 343.

B
Remove and Install
A
Before Removal A
Obey all fuel system health and safety information.
Refer to Fuel System, Health and Safety (PIL 18-00). C
Low Pressure Fuel Pipes

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

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

Before Removal
Obey all fuel system health and safety information.

must decay before you start work. If the engine
has been running, wait at least one hour before
you start work.
2. Clean the engine. Refer to Engine, Clean (PIL
15-00).
3. Remove the protective cover as follows.
18 - 115 9813/7400-1 18 - 115

96 - Fuel Pipe
06 - Low Pressure Pipe
3.1. Push out the plastic segments. Figure 345.

3.2. Remove the screws and lift off the cover.
Figure 344.
D
C
B
A B
C
A Screw A Location tabs
B Plastic segment B Bleed pipe connector
C Protective cover C Bleed pipe clip
D High pressure fuel pipe
3.3. Remove any dirt or debris that is exposed.
Refer to Engine, Clean (PIL 15-00). After Assembly
4. To remove the bleed pipe clips, remove the high 1. Make sure that all pipes are correctly installed
pressure fuel pipes first. Refer to (PIL 18-96-03). and located in retaining clips as applicable. If the
retaining clips are missing or damaged they must
5. DO NOT try to repair fuel pipes or connectors. be replaced or renewed.
Defective fuel pipe assemblies must be replaced.
Remove
3. Install the protective cover. Refer to Figure 344.
The following details the removal and replacement
of one bleed-off connector. The procedure for the
remaining connectors is identical.
1. Gently spring the location tabs apart and pull out

the bleed pipe connector. DO NOT use excessive
force on the tabs.
2. Remove and discard the O-ring.
3. If it is necessary to remove the bleed off pipe
assembly, remove the nylon fitting at the high
pressure pump.
4. Cap all open ports to prevent ingress of dirt and
debris.
Install
1. Install a new O-ring.
2. Push in the bleed pipe connector until the
location tabs snap over the connector.
3. If applicable, replace the high pressure fuel pipes
with new ones. DO NOT use a high pressure fuel
pipe that was removed. Refer to (PIL 18-96-03)
18 - 116 9813/7400-1 18 - 116

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

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ............................................................................................................................. 21-9
21-05 Fan Motor
21-05-00 General ........................................................................................................................... 21-11
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-17
21-09 Pump
21-09-00 General ........................................................................................................................... 21-21
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-27
21-93 Hose
21-93-00 General ........................................................................................................................... 21-33
9813/7400-1
2017-01-10
Acronyms Glossary
CAC Charge Air Cooler

RPM Revolutions Per Minute
9813/7400-1
2017-01-10
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9813/7400-1 21 - 1
Notes:
21 - 2 9813/7400-1 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
Operation ......................................................... 21-4 kept at its normal operating temperature to achieve
Fault-Finding .................................................... 21-5 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Drain and Fill ................................................... 21-7 quickly and then maintain it.
Check (Level) .................................................. 21-7
21 - 3 9813/7400-1 21 - 3
21 - Cooling System
00 - Cooling System
00 - General
Health and Safety Operation

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the The coolant pump is driven via a pulley and front end
cap, hot coolant can spray out and burn you. accessory drive belt, the pump draws coolant from
Make sure that the engine is cool before you work the pump cavity.
on the cooling system.
The coolant is pumped through the outlet gallery
CAUTION Antifreeze can be harmful. Obey the to the oil cooler cavity in the left-hand side of the
manufacturer's instructions when handling full crankcase. As the coolant flows past the oil cooler
strength or diluted antifreeze. matrix, heat is exchanged from the oil to the coolant.
This enables the oil to function as a coolant as well
as a lubricant. Refer to Oil Cooler (PIL 15-69) and Oil
Filter (PIL 15-21).
The coolant leaves the oil cooler cavity and passes

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

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

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

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

enables coolant to circulate through a heater matrix
when the thermostat is open or closed, ensuring fast
heater warm up.
21 - 4 9813/7400-1 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Fault-Finding
Fault
Coolant - Loss. Table 138. Page 21-5
Coolant - Over Temperature. Table 139. Page 21-5
Coolant - Under Temperature. Table 140. Page 21-6
Coolant - Contaminated. Table 141. Page 21-6
Table 138. Coolant - Loss.

Cause Remedy
Incorrect coolant level. Check the level.
DEF (Diesel Exhaust Fluid) tank heater circuit The coolant to DEF tank heater circuit has not bled
bleeding. correctly after work has been carried out. When this
(1)
circuit bleeds, the coolant level will drop until the

circuit has bled fully. Check the level until it stabilises.
Coolant leaking from engine radiator or cab heater. Visually inspect the radiator heater, hoses and
connection to locate the leak. If oil is present in the
coolant, check for a transmission or engine oil cooler
leak.
External engine coolant leak. Visually inspect the engine and components for
seal, gasket hose connection leaks. Make sure all
hose clips are in good condition and torqued to the
recommended figure. Make sure all spring band
clamps are in good condition and apply sufficient
pressure to the hoses.
Overheating or compression gases leaking, resulting See Also: Table 139. Coolant - Over Temperature.
in loss through the radiator overflow.
If installed, transmission cooler leak. Check/replace the transmission cooler. Check for
coolant in the inlet manifold and in the oil.
Lubricating oil cooler leak. Check/replace the oil cooler. Check for coolant in the
oil.
EGR (Exhaust Gas Recirculation) cooler leak. Check/replace the EGR cooler. Check for signs of
(1)
coolant leaking into combustion chamber.

SCR (Selective Catalytic Reduction) system leak. Check for signs of engine coolant in the DEF and
(1)
DEF in the engine coolant. Check the dosing

metering module and the head unit for leaks.
Cylinder head gasket leak. Check/replace the head gasket.
Cylinder head cracked or porous. Check/replace the cylinder head.
Crankcase coolant passages leaking. Check/replace the crankcase.
(1) If installed
Table 139. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 138. Coolant - Loss.
External radiator matrix blocked with dirt or chaff. Clean exterior or radiator matrix.
Air flow to the radiator inadequate or restricted. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Coolant pump or fan drive belts loose. Check/correct belt tension.
Radiator hose collapsed, restricted or leaking. Check/replace hose.
Oil level over filled. Check oil level.
Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system.
Over concentration of antifreeze. Remove part of the coolant from cooling system and
replace with water.
21 - 5 9813/7400-1 21 - 5
21 - Cooling System
00 - Cooling System
00 - General
Cause Remedy
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, incorrect or missing. Check/replace the thermostat.
Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the
correct vented thermostat is installed. If aeration
continued, check for a compression leak through the
head gasket.
Coolant pump faulty. Check/replace the coolant pump.
Vent line from engine and/or radiator blocked or Check routing and operation or vent line.
incorrectly routed (sudden overheating).
Leak between the top tank and the auxiliary tank Check for coolant leakage between radiator auxiliary
(sudden overheating). tank and radiator top tank.
Cooling passages in radiator, cylinder head, head Flush the system and fill with clean coolant.
gasket or block blocked.
ECM (Engine Control Module) (if installed) or Check the electronic fault codes. Check the electrical
electrical sensor fault. connections at the ECM and sensors.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
Table 140. 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 141. 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 138. Coolant - Loss.
gasket, cylinder head and crankcase.
SCR system leak.
(2)
See Also: Table 138. Coolant - Loss.
(2) If installed
21 - 6 9813/7400-1 21 - 6
21 - Cooling System
00 - Cooling System
00 - General
Drain and Fill Check (Level)

Consumables
Description Part No. Size 1. Make the machine safe. Refer to (PIL 01-03).
Antifreeze HP/ 4006/1101 5L 2. Open the access cover to get access to the
Coolant ASTM D6210 4006/1120 20L engine.
Concentrate 4006/1103 200L
3. Check the level of coolant in the coolant
expansion tank. If necessary remove the filler
The graphic shows a typical engine cooling system,
cap and top up to the level indicated.
the system you are working on may look slightly
different. 4. Install the filler cap and make sure it is tight.
1. Make the machine safe. Refer to (PIL 01-03). 5. Run the engine for a while to raise the coolant to
working temperature and pressure.
6. Stop the engine and check for leaks.
4. Carefully loosen the cap just enough to let any
pressure escape. Remove the cap when all
pressure is released.
5. Disconnect the bottom radiator hose and allow
the coolant to drain into a suitable container.
6. Flush the system by pouring clean water into the
filler port.
7. Connect the bottom radiator hose.
8. Fill the expansion tank, using the necessary anti-
freeze solution, to the level indicated.
Consumable: Antifreeze HP/Coolant ASTM
D6210 Concentrate
9. Run the engine for a while to raise the coolant
to working temperature and pressure. Stop the
engine and check for leaks. Check the level in
the expansion tank and top up if necessary.
Figure 346.
A
B
A Cap
B Bottom radiator hose
C Expansion tank
21 - 7 9813/7400-1 21 - 7
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ............................................................................................................................. 21-9
21 - 8 9813/7400-1 21 - 8
21 - Cooling System
03 - Cooling Pack
00 - General
00 - General
Introduction
The cooling pack contains the following major

components:
• Radiator.
• Cooling fan.
• CAC (Charge Air Cooler).
• Condenser for air-conditioning (if installed).
• Oil cooler (if installed).
21 - 9 9813/7400-1 21 - 9
21 - Cooling System
05 - Fan Motor
05 - Fan Motor
Contents Page No.
21-05-00 General ........................................................................................................................... 21-11
21 - 10 9813/7400-1 21 - 10
21 - Cooling System
05 - Fan Motor
00 - General
Introduction .................................................... 21-11 The cleanliness of this component is critical and must
Technical Data ............................................... 21-12 conform to JCB standard 9993/0003.
21 - 11 9813/7400-1 21 - 11
21 - Cooling System
05 - Fan Motor
00 - General
Technical Data
Table 142.
Description Data
Displacement 11 ccm/rev
Maximum continuous 110bar (1,594.2psi)
pressure
Rotational speed 500 to 3500 RPM (Rev-
olutions Per Minute)
Operating temperature 0–80°C (32.0–175.9°F)
(Continuous)
Operating temperature -20°C (68.0°F)
(Cold start)
Operating temperature 100°C (211.9°F)
(Maximum intermittent)
Shaft seal type Single Viton
Maximum shaft seal 10bar (144.9psi)
pressure (Continuous)
Maximum shaft seal 17bar (246.4psi)
pressure (Intermittent)
Rotation Counter clockwise
21 - 12 9813/7400-1 21 - 12
21 - Cooling System
05 - Fan Motor
00 - General
Remove and Install
Hydraulic Pressure 3. Discharge the hydraulic pressure from the

system. Refer to (PIL 30-00).
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose, 4. Mark all hoses to help installation.
hose line must be vented. Make sure the hose 5. Remove the hoses and cap the ends with
service line has been vented before connecting or blanking caps to prevent loss of fluid and ingress
removing hoses. Make sure the engine cannot be of dirt.
started while the hoses are open.
6. Support the hydraulic fan motor and remove the
Remove bolts.
1. Make the machine safe with the lift arm lowered. 7. Remove the hydraulic fan motor from the
Refer to (PIL 01-03). machine.
2. Raise the operator station. Refer to (PIL 09-00). 8. Make sure that you do not miss the woodruff key
from the fan motor drive shaft.
21 - 13 9813/7400-1 21 - 13
21 - Cooling System
05 - Fan Motor
00 - General
Figure 347.
E
D
F
F A
A Hydraulic fan motor B Adaptor 1

C Adaptor 2 D Bolt
E Washer F Locknut
G Adaptor 3
21 - 14 9813/7400-1 21 - 14
21 - Cooling System
05 - Fan Motor
00 - General
Install
steps.
2. Make sure that all the hoses and the ports are
clean and free from dirt.
21 - 15 9813/7400-1 21 - 15
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-17
21 - 16 9813/7400-1 21 - 16
21 - Cooling System
06 - Expansion Tank
00 - General
Introduction .................................................... 21-17 The expansion tank retains coolant that has been
Remove and Install ....................................... 21-18 forced out of the machines radiator under pressure.
As the machine runs, the temperature of the coolant

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

tank returns to the radiator naturally when the engine
is cold.
21 - 17 9813/7400-1 21 - 17
21 - Cooling System
06 - Expansion Tank
00 - General
Remove and Install
Remove
to the ground. Refer to (PIL 01-03).
2. Unlock the rear cover (if lock is installed).
3. Open the rear cover and install the lynch pin.
4. Drain the tank. Refer to Cooling System - Drain
and Fill (PIL 21-00).
5. Disconnect the cooling hoses.
6. Support the tank and remove the bolts (x4).
7. Remove the expansion tank from the rear cover.
Figure 348.
A
C
A
B B
A Cooling expansion tank

B Bolts (x4)
C Cooling hoses
Install
step.
2. Fill the cooling system with the recommended
coolant. Refer to (PIL 75-09).
21 - 18 9813/7400-1 21 - 18
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-21
21 - 19 9813/7400-1 21 - 19
Notes:
21 - 20 9813/7400-1 21 - 20
21 - Cooling System
09 - Pump
00 - General
Introduction .................................................... 21-21 The coolant pump is a centrifugal type located in the
Component Identification ............................... 21-22 front of the crankcase, driven by the engine drive belt.
Operation ....................................................... 21-22
Remove and Install ....................................... 21-23 The impeller rotates to circulate the coolant through
the cooling system. The pump shaft bearing and seal
are not renewable.
21 - 21 9813/7400-1 21 - 21
21 - Cooling System
09 - Pump
00 - General

Figure 349. The coolant pump is driven via a pulley and front end
1 accessory drive belt, the pump draws coolant from
2 the pump cavity. The coolant is pumped through the
outlet gallery to the oil cooler cavity in the left-hand
side of the crankcase. As the coolant flows past the
oil cooler matrix, heat is exchanged from the oil to the
coolant. This enables the oil to function as a coolant
as well as a lubricant.
For cooling system operation. Refer to (PIL 21-00).
1 Coolant pump
2 Drive pulley
3 Impeller
21 - 22 9813/7400-1 21 - 22
21 - Cooling System
09 - Pump
00 - General
Before Removal
1. Make sure that the machine is safe. If the engine
has been running, let it cool before you start the
service work. Refer to (PIL 01-03).
3. Drain the coolant.
4. Remove the coolant pump drive belt.
Remove
2
1. Remove the fixing screws. 1
2. Remove the coolant pump assembly.
3. Remove and discard the sealing O-ring.
1 Coolant pump assembly

2 Fixing screws
The pump is a non-serviceable item. If the pump is

faulty or damaged it must be renewed.
Install
steps.
2. Make sure that the mating face on the crankcase
is clean and free from damage.
3. Install a new sealing O-ring.
4. Tighten the screws to the correct torque value.
21 - 23 9813/7400-1 21 - 23
21 - Cooling System
09 - Pump
00 - General
Figure 351.
P1
P1 Sealing O-ring
After Installation
1. Install the coolant pump drive belt.
2. Refill the engine with the recommended coolant
mixture.
3. Start the engine and check for coolant leaks.

Item Nm
2 24
21 - 24 9813/7400-1 21 - 24
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-27
21 - 25 9813/7400-1 21 - 25
Notes:
21 - 26 9813/7400-1 21 - 26
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-27 The thermostat is located between the engine and
Component Identification ............................... 21-28 the radiator. The function of the thermostat is to block
Operation ....................................................... 21-28 the flow of coolant to the radiator until the engine has
Check (Condition) .......................................... 21-29 warmed up to a sufficient temperature.
Check (Operation) ......................................... 21-30 When the engine is cold, no coolant flows through
the engine. Once the engine reaches its operating
temperature, generally about 95°C (203°F), the
thermostat opens. By letting the engine warm up as
quickly as possible, the thermostat reduces engine
wear, deposits and emissions.
21 - 27 9813/7400-1 21 - 27
21 - Cooling System
12 - Thermostat
00 - General

Figure 352. The thermostat is a wax element type and is
configured for by-pass blanking. The thermostat
functions as follows:
State A - Closed (Engine Cold)

When the engine is cold the wax pellet has
contracted into its housing. This allows the spring to
act against the thermostat body and move the valve
A plate up against its seat, closing the outlet port to the
radiator. Since the bottom valve plate is connected
to the top valve plate it also moves up, opening the
bypass port. The coolant flows from the thermostat
housing inlet port into the bypass gallery.
Figure 353.
7 3
8 11
6
10
5
A Thermostat
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1mm diameter orifice
State B - Open (Engine Hot)

When the engine is hot, the wax pellet melts,
as it does so it expands and pushes against
the diaphragm. The diaphragm reacts against
the actuating rod and both the top and bottom
valve plates move down into the thermostat body,
compressing spring. The outlet port to the radiator
is now open and the bypass port is closed. A 1mm
21 - 28 9813/7400-1 21 - 28
21 - Cooling System
12 - Thermostat
00 - General
diameter orifice allows trapped air to be expelled Check (Condition)

from the system.
Figure 354. 1. If the thermostat is suspected of being faulty,

7 3 perform a thermostat test, refer to Thermostat
- Check Operation (PIL 21-12) to confirm its
serviceability. Note that the thermostat is a non-
8 11 serviceable item. If the thermostat is faulty or
damaged it must be renewed.
2. Inspect the seal for damage or splits. If necessary
renew the seal. Make sure that the seal is
correctly located.
9
6
10
5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1mm diameter orifice
21 - 29 9813/7400-1 21 - 29
21 - Cooling System
12 - Thermostat
00 - General
Check (Operation)
A period of 3–5min before the thermostat valve starts

to operate is normal because of the time required to
heat soak the thermostat.

2. Remove the thermostat housing and the
thermostat. Refer to (PIL 21-12).
3. Suspend the thermostat in a suitable container
of coolant. Use an external heat source to
gradually increase the temperature of the
coolant. Note: When working with boiling water,
all the necessary safety precautions must be
taken. Refer to Figure 355.
Figure 355.
4. Use a thermometer to measure the temperature

of the coolant.
5. When the coolant reaches the operating range of
the thermostat the valve should start to open, the
movement of the valve plate should be evident.
6. Record the start to open temperature, the fully
open temperature and the amount of valve lift
travel when fully open. Compare this with the
data in Technical Data (PIL 21-00).
21 - 30 9813/7400-1 21 - 30
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-33
21 - 31 9813/7400-1 21 - 31
Notes:
21 - 32 9813/7400-1 21 - 32
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-33 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-34 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-34 between the engine and the radiator/cooling pack.
21 - 33 9813/7400-1 21 - 33
21 - Cooling System
93 - Hose
00 - General

when the coolant is hot. When you remove the 1. Visually inspect the engine and related cooling
cap, hot coolant can spray out and burn you. components for:
Make sure that the engine is cool before you work
on the cooling system. 1.1. Leaks.
1.2. Cracked, burnt or perished hoses.
1.3. Hose clips are in good condition and
tightened to the correct torque value.
21 - 34 9813/7400-1 21 - 34
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-18 Park Brake
24-18-00 General ............................................................................................................................. 24-5
9813/7400-1
2015-01-09
Notes:
9813/7400-1
2015-01-09
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9813/7400-1 24 - 1
Notes:
24 - 2 9813/7400-1 24 - 2
24 - Brake System
00 - Brake System
00 - General
00 - General
Introduction
Refer to Park Brake-Introduction (PIL 24-18).
24 - 3 9813/7400-1 24 - 3
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ............................................................................................................................. 24-5
24 - 4 9813/7400-1 24 - 4
24 - Brake System
18 - Park Brake
00 - General
Introduction ...................................................... 24-5 The park brake assembly is mounted on to the rear
Technical Data ................................................. 24-6 wheel motor case (refer to PIL 27-32) and connects
Operation ......................................................... 24-6 via the brake shaft.
Check (Operation) ........................................... 24-7
A brake disc pack, with alternate discs splined to the
Remove and Install ......................................... 24-7 brake shaft and brake housing, is compressed by
Disassemble and Assemble ............................ 24-8 the force of a disc spring that acts through a piston.
The friction between the discs generates a holding
torque.
Figure 356.
Z
9
2
12
15
14
16
10
11
13
Z Brake port
2 Rear wheel motor case
9 Annular area
10 Brake disc spring
11 Brake disc pack
12 Brake piston
13 Cover screws
16 Brake shaft
24 - 5 9813/7400-1 24 - 5
24 - Brake System
18 - Park Brake
00 - General
Technical Data Operation
Table 144. When fluid is fed via the brake port into the annular
area, the pressure on the underside of the piston
Description Wheeled Ma- Tracked Ma-
rises, opposing the spring force. If sufficient pressure
chine chine
is applied, the piston moves to the right, removing
Motor Type MCR5 MCR10 the compression on the disc pack and allowing the
Pack Height X 36.45 -0.05/ 41 -0.1/+0.1mm motor to turn freely. When the pressure is removed,
+0.05mm the spring forces the piston back to the left and once
No of item 10 16 19 again compresses the disc pack. Thus, the brake is
No of item 11 14 17 fail-safe.
No of item 4 24 24 If no plug is fitted, the brake may be manually
No of item 9 8 8 released by loosening the end cover screws.
Item 4 Torque 35–39N·m 70–77N·m
Figure 357.
Item 9 Torque 70–77N·m 117–122N·m
Z
9
2
12
15
14
16
10
11
13
Z Brake port
2 Rear wheel motor case
9 Annular area
10 Brake disc spring
11 Brake disc pack
12 Brake piston
13 Cover screws
16 Brake shaft
24 - 6 9813/7400-1 24 - 6
24 - Brake System
18 - Park Brake
00 - General
Increase the pressure to the brake port until the The cleanliness of this component is critical and must
motor shaft just begins to move by hand. This conform to JCB standard 9993/0003.
pressure should not exceed 15bar (217.4psi).
Remove
With 250bar (3,623.2psi) differential pressure
applied to the motor and zero brake pressure, the 1. Make the machine safe with the lift arm and cab
brake should hold the motor torque. raised. Refer to (PIL 01-03).
Figure 358. 2. Remove the drive chains. Refer to (PIL 27-63).
3. Remove the wheel drive motor. Refer to (PIL
Z 27-32).
9
2 4. Remove the mounting capscrews, remove the
park brake assembly off the brake shaft and the
rear case of the motor.
12 Install
procedure.
15
Figure 359.
12 10/ 11
14
16
17
10 6
13 14
11
13 15
Z Brake port
16 Motor shaft 1 7
16 5
4
3 2 9 8
1 Drain plug
2 Brake housing
3 Rear case
4 Capscrews
5 Cover plate and gasket
6 Disc spring
7 Piston
8 Piston seal
9 Capscrews
10 Brake disc
11 Brake disc
12 Shims
13 Brake shaft
14 Brake housing seal
24 - 7 9813/7400-1 24 - 7
24 - Brake System
18 - Park Brake
00 - General
15 Bush Disassemble and Assemble

16 Distributor
17 Cylinder block Consumables
Extreme Performance 4003/1327 0.4kg
Moly Grease 4003/1326 12.5kg
JCB High Strength 4102/0551 0.05L
Threadlocker
The disassembly and assembly instructions are

intended for cleaning purposes and for the
replacement of seals.
If on inspection the motor components are found to

be worn it is recommended that the motor unit is
replaced with a new one.
Disassemble
1. Remove the drain plug to drain the oil from the
motor.
2. Mark the position of the brake housing relative to
the rear case.
3. Remove all the capscrews alternately, one turn
at a time.
4. Remove the cover plate and gasket. Lift out the
disc spring.
5. Remove the piston using a tapped hole. Remove
the piston seal from the piston.
6. Remove all the capscrews and washers.
7. The brake pack can now be removed (brake
housing, brake discs, shims and brake shaft).
8. Remove the seal from the brake housing.
9. The bush need not be removed unless it is
damaged in which case it must be replaced.
24 - 8 9813/7400-1 24 - 8
24 - Brake System
18 - Park Brake
00 - General
Figure 360. at the end of the pack closest to the rear case
(On wheeled machines a washer is installed
12 10/ 11 against the rear case before the shims). Refer to
Technical Data (PIL 24-18)
17
6 Figure 361.
X
13 14
15
1 7
16 5
4
3 2 9 8
1 Drain plug
2 Brake housing
3 Rear case
4 Capscrews
5 Cover plate and gasket
6 Disc spring
7 Piston X Brake pack height
8 Piston seal 6. Install the brake housing to the rear case
9 Capscrews assembly. Align the marks made during
10 Brake disc disassembly.
11 Brake disc
12 Shims 7. Apply JCB Locking Fluid to the capscrews. Install
13 Brake shaft the capscrews, with washers to the rear case.
14 Brake housing seal Tighten the screws in a diagonal sequence, to
15 Bush maintain squareness, to the correct torque value.
16 Distributor
17 Crankcase Consumable: JCB High Strength Threadlocker
8. Install the brake pack to the brake shaft.
Assemble
9. Install a new seal to the brake housing, make
1. Check all components are clean and free from sure of the correct orientation of the seal to
debris. groove. A tool may be required for assembly.
2. If the bush has been removed, press a new bush 10. Install a new seal to the piston. Lubricate the seal
into the shaft. Make sure that the bush is pressed with oil and then install the piston into the brake
fully home. assembly, make sure that no damage occurs to
the seal.
3. Insert the brake shaft through the distributor to
engage with the splines of the cylinder block. 11. Install the disc spring. Make sure that the contact
surfaces are coated with S1 grease.
4. Assemble the brake discs into a pack and clamp
in a vice. Make sure the inner discs alternate with Consumable: Extreme Performance Moly
the outer discs and an outer disc is placed at Grease
each end of the pack.
12. Place the cover plate and a new gasket on to the
5. Check the brake pack height X adding shims brake housing.
as required to obtain a pack height, an extra
13. Insert the capscrews into the brake housing,
outer plate is preferred to reduce the number
tighten by hand.
of required shims. The shims should be placed
24 - 9 9813/7400-1 24 - 9
24 - Brake System
18 - Park Brake
00 - General
14. Tighten the capscrews to the correct torque

value. Tighten the screws gradually on opposite
sides to maintain squareness. Refer to Technical
Data (PIL 24-18)
15. Refill the motor housing with the correct hydraulic
oil through the plug then install the plug.
24 - 10 9813/7400-1 24 - 10
27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-27 Hub
27-27-00 General ........................................................................................................................... 27-31
27-29 Wheel
27-29-00 General ........................................................................................................................... 27-39
27-31 Wheel Drive Pump
27-31-00 General ........................................................................................................................... 27-45
27-31-03 Coupling ......................................................................................................................... 27-58
27-32 Wheel Drive Motor
27-32-00 General ........................................................................................................................... 27-61
27-32-60 Adaptor ........................................................................................................................... 27-74
27-33 Tyre
27-33-00 General ........................................................................................................................... 27-77
27-36 Track
27-36-00 General ........................................................................................................................... 27-79
27-36-06 Rubber Track ................................................................................................................. 27-90
27-36-12 Gearbox Sprocket .......................................................................................................... 27-95
27-36-15 Frame ............................................................................................................................. 27-97
27-36-18 Idler Wheel ..................................................................................................................... 27-99
27-36-24 Bottom Roller ............................................................................................................... 27-101
27-36-27 Tensioner/Recoil unit .................................................................................................... 27-103
27-37 Track Drive Pump
27-37-00 General ......................................................................................................................... 27-109
27-37-03 Coupling ....................................................................................................................... 27-123
27-38 Track Drive Motor
27-38-00 General ......................................................................................................................... 27-127
27-63 Drive Chain
27-63-00 General ......................................................................................................................... 27-141
9813/7400-1
2017-02-09
Acronyms Glossary

PWM Pulse Width Modulation
9813/7400-1
2017-02-09
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9813/7400-1 27 - 1
Notes:
27 - 2 9813/7400-1 27 - 2
27 - Driveline
00 - Driveline
00 - General
Introduction ...................................................... 27-3 For: Wheeled .............................. Page 27-3
Operation ......................................................... 27-5 For: Tracked ................................ Page 27-3
Diagram ........................................................... 27-7
Fault-Finding .................................................. 27-28
(For: Wheeled)
The transmission circuit consists of two pump units
which drive the left and right drive motors. The pump
units are mounted in tandem on a common drive
shaft which is driven by the engine.
P1 drives the drive motor on the left side of the

machine.
P2 drives the drive motor on the right side of the

machine.
Figure 362. Wheeled Machine
M1 Motor 1 M2 Motor 2
P1 Pump 1 P2 Pump 2
X Manifold
(For: Tracked) P1 drives the drive motor on the left side of the
machine.
The transmission circuit consists of two pump units
which drive the left and right drive motors. The pump P2 drives the drive motor on the right side of the
units are mounted in tandem on a common drive machine.
shaft which is driven by the engine.
27 - 3 9813/7400-1 27 - 3
27 - Driveline
00 - Driveline
00 - General
Figure 363. Tracked Machine
P1 Pump 1 P2 Pump 2
X Manifold
27 - 4 9813/7400-1 27 - 4
27 - Driveline
00 - Driveline
00 - General
Operation
For: Wheeled .............................. Page 27-5 into the motor output shaft which extend into the
For: Tracked ................................ Page 27-5 chain case. Each motor transmits the drive by means
of two chains to sprockets mounted on short drive
shafts within the wheel hub assemblies.
(For: Wheeled)
Lubrication of the hub assemblies occurs due to oil
Wheeled Machines picked up by the chains and sprockets which runs
along the driveshafts and into the bearings.
The hydraulic motors are bolted to the inner side of
the drive chain cases. A double sprocket is splined
Figure 364.
E
C
D B
A Hydraulic motor B Chain

C Chain D Wheel hub assembly
E Wheel hub assembly
(For: Tracked) Sprockets mounted on the output flanges of the

motors transmit drive directly to the tracks. Refer to
Tracked Machines (PIL 27-36).
The drivetrain consists of left and right hand hydraulic

motors, each mounted directly on to the track frame.
27 - 5 9813/7400-1 27 - 5
27 - Driveline
00 - Driveline
00 - General
Figure 365.
A Hydraulic motor B Sprocket

C Track frame
27 - 6 9813/7400-1 27 - 6
27 - Driveline
00 - Driveline
00 - General
Diagram
No Drive Selected pumps P1 and P2. The machine remains stationary.

The park brake switch is left on by the operator, the
With the engine running but no drive selected, oil cut out solenoid X is not energized and the brakes
from charge pump P4 is fed through the fan and are left on.
through the filter F1 to transmission pumps P1 and
P2. As the pump swash plates are spring loaded to the
neutral position there is no delivery from either pump
When the transmission joystick is not operated, no and the machine remains stationary.
PWM (Pulse Width Modulation) signal is applied the
solenoids C1 and C2 to operate the swash plates of The machine is prevented from moving by oil locked
up in the pump/motor circuit.
27 - 7 9813/7400-1 27 - 7
Notes:
27 - 8 9813/7400-1 27 - 8
27 - Driveline
00 - Driveline
00 - General
Page 27-10 Figure 366. Page 27-11
F1
C1 C2 C1 C2 P4
P1 P2
27 - 9 9813/7400-1 27 - 9
27 - Driveline
00 - Driveline
00 - General
Figure 366. (Part 1 of 2) Page Page
27-10 27-11
F1
C1 C2
Page 27-11
P1
27 - 10 9813/7400-1 27 - 10
27 - Driveline
00 - Driveline
00 - General
27-10 27-11
F1
C1 C2 P4
Page 27-10
P2
27 - 11 9813/7400-1 27 - 11
27 - Driveline
00 - Driveline
00 - General
C1 Solenoid 1 C2 Solenoid 2
F1 Filter P1 Pump 1
P2 Pump 2 P4 Pump 4
X Cut-out solenoid
Forwards Drive Selected P2 to pass to the motors M1 and M2 and the machine
moves forward.
When the park brake switch is depressed if the ECU
(Electronic Control Unit) reads charge pressure and Flow from P1 and P2 is also fed to the motor flushing
the lap bar and left hand pod are lowered then the valves M1b and M2b causing them to move down.
cut out solenoid X is energized and the brakes are This enables hot oil in the drive circuits to be replaced
released. with cooler oil.
When the joystick is moved to select forward, a PWM Return oil from the motors flows back into the
signal is sent to solenoids C1 on pumps P1 and P2. transmission pumps. Any excess oil from the pump
The swash plates are tilted causing flow from P1 and casing is fed back to tank T.
27 - 12 9813/7400-1 27 - 12
27 - Driveline
00 - Driveline
00 - General
F1
C1 C2 C1 C2 P4
P1 P2
27 - 13 9813/7400-1 27 - 13
27 - Driveline
00 - Driveline
00 - General
27-14 27-15
F1
C1 C2
Page 27-15
P1
27 - 14 9813/7400-1 27 - 14
27 - Driveline
00 - Driveline
00 - General
27-14 27-15
F1
C1 C2 P4
Page 27-14
P2
27 - 15 9813/7400-1 27 - 15
27 - Driveline
00 - Driveline
00 - General
C1 Solenoid 1 M1 Motor 1
M2 Motor 2 M1b Motor flushing valve 1
M2b Motor flushing valve 2 P1 Pump 1
P2 Pump 2 T Tank
X Cut-out solenoid
Reverse Drive Selected P2 to pass to the motors M1 and M2 and the machine
moves backwards.
When the park brake switch is depressed if the
ECU reads charge pressure and the lap bar and left Flow from P1 and P2 is also fed to the motor flushing
hand pod are lowered then the cut out solenoid X is valves M1b and M2b causing them to move up. This
energized and the brakes are released. enables hot oil in the drive circuits to be replaced with
cooler oil.
When the joystick is moved to select reverse, a PWM
signal is sent to solenoids C2 on pumps P1 and P2. Return oil from the motors flows back into the
The swash plates are tilted causing flow from P1 and transmission pumps. Any excess oil from the pump
casing is fed back to tank T.
27 - 16 9813/7400-1 27 - 16
27 - Driveline
00 - Driveline
00 - General
F1
C1 C2 P4
C1 C2
P1 P2
27 - 17 9813/7400-1 27 - 17
27 - Driveline
00 - Driveline
00 - General
27-18 27-19
F1
C1 C2
Page 27-19
P1
27 - 18 9813/7400-1 27 - 18
27 - Driveline
00 - Driveline
00 - General
27-18 27-19
F1
C1 C2 P4
Page 27-18
P2
27 - 19 9813/7400-1 27 - 19
27 - Driveline
00 - Driveline
00 - General
C2 Solenoid 2 M1 Motor 1
M2 Motor 2 M1b Motor flushing valve 1
M2b Motor flushing valve 2 P1 Pump 1
P2 Pump 2 T Tank
X Cut-out solenoid
27 - 20 9813/7400-1 27 - 20
27 - Driveline
00 - Driveline
00 - General
Left Spin Turn Selected to turn forwards and right hand motor M2 to turn
backwards. Thus the machine spins turns right.
When the park brake switch is depressed if the
ECU reads charge pressure and the lap bar and left Flow from P1 and P2 is also fed to the motor flushing
hand pod are lowered then the cut out solenoid X is valves M1b and M2b causing them to move up (M2b)
energized and the brakes are released. or down (M1b). This enables hot oil in the drive
circuits to be replaced with cooler oil.
When the joystick is moved to select spin turn, a
PWM signal is sent to solenoid C1 on pump P1 Return oil from the motors flows back into the
and C2 on pump P2. The swash plates are tilted transmission pumps. Any excess oil from the pump
in opposite directions causing left hand motor M1 casing is fed back to tank T.
27 - 21 9813/7400-1 27 - 21
Notes:
27 - 22 9813/7400-1 27 - 22
27 - Driveline
00 - Driveline
00 - General
F1
C1 C2 C1 C2 P4
P1 P2
27 - 23 9813/7400-1 27 - 23
27 - Driveline
00 - Driveline
00 - General
27-24 27-25
F1
C1 C2
Page 27-25
P1
27 - 24 9813/7400-1 27 - 24
27 - Driveline
00 - Driveline
00 - General
27-24 27-25
F1
C1 C2 P4
Page 27-24
P2
27 - 25 9813/7400-1 27 - 25
27 - Driveline
00 - Driveline
00 - General
C1 Solenoid 1 C2 Solenoid 2
M1b Motor flushing valve 1 M2b Motor flushing valve 2
P1 Pump 1 P2 Pump 2
T Tank X Cut-out solenoid
27 - 26 9813/7400-1 27 - 26
27 - Driveline
00 - Driveline
00 - General
High Speed Selected

When two speed is selected the PWM signal to the
solenoids C1 and C2 is increased.
27 - 27 9813/7400-1 27 - 27
27 - Driveline
00 - Driveline
00 - General
Fault-Finding
Fault
Hydrostatic Transmission Faults Table 145. Page 27-28
Table 145. Hydrostatic Transmission Faults

Cause Remedy
No oil in hydrostatic system Check supply of oil to pump.
Isolator bar or arm rest not in correct position Ensure isolator bar and arm rest are in operating
position, check electrical wiring and switch as
required.
Tyres worn or pressure incorrect Check tyre pressures and condition.
Charge pressure incorrect Charge pressure is controlled by the Charge
Pressure Relief Valve, Carry out flow check.
No or low pump output Check pump - Carry out wheel speed check. If one
pump suspect, swap the motor feed hoses and
notice if problem changes sides - if ‘yes’, pump
related fault; if ‘no’, motor related fault.
A high pressure ‘loop’ relief valve/tow valve open/set Replace relief valve and re-check.
incorrectly
Pump neutral position set incorrectly Adjust servo neutral position.
Pump servos incorrectly set Adjust servos.
Feed hose failure Check motor feed hoses.
Brake hose failure Inspect brake hoses.
Brake release pressure incorrect Check charge/brake pressure.
Electrical failure (brake valve circuit) Check brake valve electrical circuit.
Brake valve inoperative Check valve (sticking spool, etc.).
Brakes not released Inspect motor brakes for seal damage. Repair as
required.
Mechanical brake failure Check brake components (worn plates, spring
damage, etc.).
Motor leakage Check motor case drain for confirmation of internal
leakage (compare one motor with the other). Pulsing
leakage indicates piston ring damage; continuous
leakage, possibly more in one direction than the
other, indicates distributor seal damage. On wheeled
machines, check for shaft seal leakage by checking
chain case oil level - increase in oil level indicates
possible leakage.
Joystick inoperative Check joystick (plunger movement, leaking seals,
etc.)
Chain tension Check chain tension.
Motor failure Inspect motor for damage. Check the screen for sign
of damage. Repair as required.
Chain/sprocket damage Inspect chain and sprocket. Repair as required.
Pump/engine drive coupling failure Check coupling.
Internal damage Noise once per revolution indicates piston damage.
Noise eight times per revolution indicates cam
damage. Repair as required.
Timing incorrect or stop pin damaged Inspect motor for damage or incorrect timing. Check
charge pressure. Repair as required.
27 - 28 9813/7400-1 27 - 28
27 - Driveline
00 - Driveline
00 - General
Cause Remedy
Dirt or fault in motor flushing circuit Inspect motor for dirt or damage. Repair as required.
No Drive in any direction Transmission cut off valve sticking or the electrical
system.
Machine veers to one side when travelling- Refer to Servicemaster, Set-up Tools, Calibration
procedure.
27 - 29 9813/7400-1 27 - 29
27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ........................................................................................................................... 27-31
27 - 30 9813/7400-1 27 - 30
27 - Driveline
27 - Hub
00 - General
Introduction .................................................... 27-31 The hub is the part of the axle where the wheel
Technical Data ............................................... 27-32 is mounted and where the axle shaft (if installed)
Check (Condition) .......................................... 27-32 passes through.
Some hubs are not driven and rotate due to motion
Disassemble and Assemble .......................... 27-35 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 - 31 9813/7400-1 27 - 31
27 - Driveline
27 - Hub
00 - General
Technical Data Check (Condition)
Table 146. Pre-load Washer Thickness Thoroughly clean and dry all components. Examine
the bearings, axle shaft and casing for wear or
Washer part number Thickness
damage. Renew as necessary.
242/00096 0.025–0.045mm
823/10303 0.05–0.11mm
823/10304 0.115–0.175mm
823/10254 0.18–0.24mm
823/10255 0.245–0.305mm
823/10256 0.31–0.37mm
823/10257 0.375–0.435mm
823/10258 0.44–0.5mm
823/10259 0.505–0.565mm
823/10317 0.57–0.63mm
27 - 32 9813/7400-1 27 - 32
27 - Driveline
27 - Hub
00 - General
Remove and Install
It is the same procedure to remove the hub on both 6. Support the hub assembly and remove the 8
sides of the machine. bolts that secure the hub. Note: If the rear hub is
to be removed, both hubs on that side must be
Remove rotated to slacken both chains.
1. Make the machine safe with the lift arm and cab 7. Remove the chain case cover plate. Lift off the
raised, refer to (PIL 01-03). appropriate chain from the motor drive sprocket.
Note: The rear hub is driven by the inner chain,
2. Drain the oil from the drive chain case, refer to therefore the front chain will need to be lifted off
(PIL 27-63). first.
3. Raise and support the machine on the side to be 8. Lift the hub assembly clear of the aperture.
worked on.
9. Remove the chain from the sprocket then move
4. Remove the front and rear wheels refer to (PIL the hub away from the machine.
27-30).
10. Remove and discard the O-ring seal.
5. Remove the chain case access cover.
Figure 370.
A Bolts B Axle shaft

C Hub case
27 - 33 9813/7400-1 27 - 33
27 - Driveline
27 - Hub
00 - General
Install
procedure.
2. A new O-ring must be installed. Apply a smear
of petroleum jelly to the groove before you install
the O-ring, this will retain the ring in the groove.
Smear the hub mounting face and O-ring with
petroleum jelly.
3. Position the hub assembly close to the mounting
aperture and install the chain over the sprocket.
4. Mount the hub on to the machine. Tighten the
bolts to the correct torque value.
5. Install the cover plate, install a new gasket.
6. Refill the chain case with the correct oil.
27 - 34 9813/7400-1 27 - 34
27 - Driveline
27 - Hub
00 - General
Special Tools 2. Remove the drive sprocket.

3. Support the hub case assembly on the outer
Oil Seal Assembly Tool 825/10002 1 flange with the wheel hub facing downwards,
Oil Seal Installation 825/10003 1 press out the axle shaft. The inner bearing 6
Tool will remain in the hub case and can be removed
separately if necessary. The outer race of the
Consumables bearing 7 will also be left in the casing and can
Description Part No. Size be removed if necessary.
Special HP Grease 4003/2017 0.4kg
4. Remove the shaft seal and discard.
4003/2006 12.5kg
4003/2005 50kg 5. If installed and if necessary, remove the bolts 9
with washers and remove the twine cutter.
Disassemble
1. Remove the bolt 1, plain washer and the pre-load
washer.
Figure 371.
27 - 35 9813/7400-1 27 - 35
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27 - Hub
00 - General
1 Bolt 2 Plain washer

3 Pre-load washer 4 Drive sprocket
5 Axle shaft 6 Inner bearing
7 Outer bearing 8 Shaft seal
9 Bolts 10 Washers
11 Twine cutter 12 Bolts
13 Hub case
Assemble Figure 372.
1. Assemble the twine cutter, if previously removed,

tighten the bolts 9 to the correct torque value.
2. Lubricate the outer bearing 7 and seal with
Special HP Grease before assembly. The inner
bearing 6 should be assembled without grease.
Consumable: Special HP Grease
3. Press the outer bearing 7 into the hub case,
make sure that the outer bearing is pressed fully
home.
4. Assemble the outer race of the bearing 6 into the
hub case. Make sure it is pressed fully home.
5. Install the two halves of the oil seal installation
tool A around the axle shaft and position a new
shaft seal 8, with the seal lip facing inwards,
against the installation tool. Feed the axle shaft
into the hub case.
Special Tool: Oil Seal Installation Tool (Qty.: 1)
4 Drive sprocket
6. Assemble the inner race of the bearing 6 on to the 5 Axle shaft
axle shaft and drive sprocket on to the splines of 6 Inner bearing
the axle shaft. Note: The front sprocket should be
assembled with its boss towards the hub case. 7. Screw the threaded stud of the oil seal assembly
The rear sprocket should be assembled with its tool B fully into the end of the axle shaft as shown
boss away from the hub case. then continue turning the stud to pull the axle
shaft into the hub case so that the oil seal is
fully installed. Release the assembly tool and
remove the oil seal installer. Note that it may be
necessary to gently tap the end of the shaft to
release the installer.
Special Tool: Oil Seal Assembly Tool (Qty.: 1)
8. Reassemble the tool B and continue to pull the
axle shaft into position by tightening the stud C
to pre-load the bearings. Rotate the shaft during
this process to seat the bearings correctly.
27 - 36 9813/7400-1 27 - 36
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27 - Hub
00 - General
Figure 373. 12. Assemble the pre-load washer on to the

axle shaft with the stepped face towards the
shaft (part number face away from the shaft).
Install the washer and bolt. Tighten the bolt 1
A B progressively to achieve the correct torque value
while you rotate the shaft to seat the bearings
C correctly.
13. Check that the hub rotates freely by hand.

Item Nm
C 80
D 244
A 1 220
9 28
A Oil seal installation tool

B Oil seal assembly tool
C Stud
9. Tighten the stud C to the correct torque value.
Rotate the axle shaft one full revolution to
make sure that the bearings are fully seated
then recheck and, if necessary, tighten the stud
C further to achieve the correct torque value
(torque setting whilst checking pre-load).
10. Position a dial gauge against the flat face of the
sprocket as shown at D and zero the gauge.
Reposition the dial gauge on to the end of the
axle shaft as shown at E and note the reading.
Remove the gauge and the assembly tool.
Figure 374.
D C
C Stud
D Flat face of sprocket
E End of axle shaft
11. The pre-load washer 3 is available in various
thicknesses to allow for the correct pre-load of
the bearings 6 and 7, refer to Technical Data.
Select the pre-load washer which gives the
closest match to the dial gauge reading.
27 - 37 9813/7400-1 27 - 37
27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ........................................................................................................................... 27-39
27 - 38 9813/7400-1 27 - 38
27 - Driveline
29 - Wheel
00 - General
Introduction .................................................... 27-39 On new machines, and whenever a wheel has been
Health and Safety .......................................... 27-40 removed, check the wheel nut torques every two
Technical Data ............................................... 27-41 hours until they stay correct. Every day, before
Remove and Install ....................................... 27-42 starting work, check that the wheel nuts are tight.
Tighten the wheel nuts (in a diagonal sequence) to
the correct torque value, refer to Technical Data.
27 - 39 9813/7400-1 27 - 39
27 - Driveline
29 - Wheel
00 - General
Health and Safety

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
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.
27 - 40 9813/7400-1 27 - 40
27 - Driveline
29 - Wheel
00 - General
Technical Data
Table 148.
Size (in) width x di- Ply Make Name Pressure
ameter
12 x 16.5 10 Solideal SKS Extra 4.1bar (59psi)
14 x 17.5 12 Solideal SKS Extra 4.1bar (59psi)
12 x 16.5 10 Hauler Lifemaster 4.1bar (59psi)
8 x16 10 Solideal Resilient 4.1bar (59psi)
15.5 x 16.5 14 Hauler SKS Hauler 4.9bar (71psi)
33 x 6 x 11 Brawler S Flex
33 x 6 x11 Brawler S Flex
27 - 41 9813/7400-1 27 - 41
27 - Driveline
29 - Wheel
00 - General
Remove and Install
Use the same procedure for all four wheels.
Remove
2. Loosen the nuts.
Figure 375.
A
A Nut
3. Raise and support the ends of the machine on
blocks.
Figure 376.
B
B Block
4. Remove the road wheel.
Install
step.
2. Tighten the nuts to the correct torque value.

Item Nm
A 244
27 - 42 9813/7400-1 27 - 42
27 - Driveline
31 - Wheel Drive Pump
Contents Page No.
27-31-00 General ........................................................................................................................... 27-45

27-31-03 Coupling ......................................................................................................................... 27-58
27 - 43 9813/7400-1 27 - 43
Notes:
27 - 44 9813/7400-1 27 - 44
27 - Driveline
00 - General
Introduction .................................................... 27-45 The transmission pump consists of two pump units,
Technical Data ............................................... 27-47 one for each drive motor, mounted in tandem on a
Component Identification ............................... 27-47 common drive shaft which is driven by the engine.
Operation ....................................................... 27-48 Each unit consists of a series of parallel axial pistons
mounted in a barrel which is rotated by the engine
Diagram ......................................................... 27-49 driven shaft. The pistons are operated by a tiltable
Check (Pressure) .......................................... 27-50 swashplate. The stroke of the pistons and therefore
Adjust ............................................................ 27-54 the displacement of the pump is varied by increasing
Disassemble and Assemble .......................... 27-54 or decreasing the angle of the swashplate. Also by
reversing the angle of the swashplate the flow of
oil from the pump is reversed which reverses the
rotation of the appropriate drive motor.
Slipper pads are fitted to the ball ends of the pistons

and these slide on the surface of the swashplate,
adjusting to the angle of the surface. The end face of
the cylinder barrel runs against a valve plate which
directs the oil flow into and out of the bores as the
barrel rotates.
The angle of the swashplate is varied by means

of a hydraulic servo cylinder which is operated by
the machine’s control joystick. Thus the pumps’
displacement is varied from full displacement in
one direction to full displacement in the opposite
direction.
The components of the pump are contained within

the pump casing and are fully submerged in oil
which is supplied by the charge circuit. Charge flow
is required to make up internal leakage, maintain
positive pressure in the main circuit, provide flow for
cooling and for operation of the pump control system.
• Charge Pressure - The charge pressure (and

hence the drive system servo pressure) is
controlled by the charge pump P4 which is set
to a predetermined limit. Refer to Gear Pumps
(PIL 30-11).
• High Pressure Relief Valves - There are four of
these valves, one for each of the output ports of
the pump. They provide protection against high
transient pressures in the motor circuits.
27 - 45 9813/7400-1 27 - 45
27 - Driveline
00 - General
Figure 377.
27 - 46 9813/7400-1 27 - 46
27 - Driveline
00 - General
Table 150. Pumps P1 and P2 Figure 378.

Pump Blue Pump Yellow Pump
R
Type Tandem axi- Tandem axi-
al piston Type al piston Type P
A20VGS40, A20VGS40,
Electro propor- Electro propor-
R
tional or electro tional or electro
direct control direct control
Main Relief 425bar 385bar
Pressure (6,160psi) (5,580psi)
Charge Pres- 17–18bar (245– 17–18bar (245–
sure (at engine 260psi)(1) 260psi)
(1)
idle) MB
sure (at maxi- 375psi) 375psi) BR
mum revs) AR
Maximum Dis- 0.46m³ 0.46m³
placement
(1) Oil temperature at 50° C) variable with engine AF BF
MB
speed
Figure 379.
P
R
27 - 47 9813/7400-1 27 - 47
27 - Driveline
00 - General
Figure 380. Operation

MA
Speed Related Pilot Pressure Supply -
EH Control Valve
This pilot pressure is directed to the stroke cylinder
of the pump by operation of the drive joysticks.
MG The pump displacement can be steplessly varied in
each flow direction and is influenced by both the
T speed of the pump drive and the system pressure.
The flow direction (i. e. machine moving forwards
or backwards) is determined by either joystick being
activated.
G
Increasing the system pressure (i. e. machine load)
will have the effect of swivelling the pump back
to a smaller displacement. An overload protection
circuit for the engine (against stalling) is achieved
AF Drive motor port - Forwards by combining this pressure dependent reduction in
AR Drive motor port - Reverse pump stroke with a reduction in pilot pressure as the
BF Drive motor port - Forwards engine speed drops.
BR Drive motor port - Reverse
Any additional power requirement, e. g. hydraulic
G Hydraulic oil inlet port
functions from the loader or attachments, could
MA Charge pressure test port
cause the speed of the engine to drop further. This
MB Charge pressure test port
will cause a further reduction in pilot pressure and
MG Pilot pressure test port
thus of the pump displacement. Automatic power
P Park brake port
distribution and full exploitation of the available
R Air bleed port
power are achieved in this way, both for the travel
T Drain port
drive and for the loader hydraulics, with priority given
to the loader hydraulics.
27 - 48 9813/7400-1 27 - 48
27 - Driveline
00 - General
Diagram
Refer to Hydraulic System - General - Schematic

Circuit (PIL 30-00-50).
27 - 49 9813/7400-1 27 - 49
27 - Driveline
00 - General
Check (Pressure)

Pressure Gauge (0-400 892/00279 4
Bar)
Pressure Gauge (0-70 892/00346 1
Bar)
Low Pressure Valve (Charge Pressure)

Pressure testing must only be carried out when the
hydraulic oil is at normal operating temperature.50°C
(121.9°F).
G1
1. Connect a pressure gauge to port G1.
Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
Figure 381.
G1
Y
X Shim
Y Valve assembly
4.1. Remove the low pressure valve.
4.2. Add or remove shims as appropriate.
2. Apply pressure to port G. 5. Tighten the valve assembly to the correct torque
value.
Figure 382.
High Pressure (HP) Valves
G
(121.9°F).
1. Connect the pressure gauges to the blanked off

motor feed ports.
Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
4)
G Port
3. Check the pressure, the maximum pressure
reading should be as stated in Technical Data.
4. Adjust the pressure.
27 - 50 9813/7400-1 27 - 50
27 - Driveline
00 - General

E
D
A A
A C
XXX
A Valve Cap
2. Operate the valves for a short time only to avoid
overheating. P
3. If necessary, adjust the valve.

C Factory pressure setting
3.1. Remove the cap then lift out the valve D Cartridge
cartridge. E Allen screw
Figure 385. 3.4. While still holding the cartridge, turn the
valve stem clockwise to increase the
setting. One turn increases the pressure by
A the amount shown.
Pressure: 44bar (637.7psi)
3.5. Tighten the lock screw.
3.6. Tighten the valve cap to the correct torque
value. Install the valve assembly to the
pump and re-check the setting. The factory
pressure setting is stamped on the top face
of the cartridge.
Charge Pressure Relief Valve

Adjustment
B
1. Make sure that the pressure gauge is connected
to port G. Refer to Figure 387.
A Valve cap
B Cartridge
3.2. Hold the top of the cartridge with a suitable
pair of pliers.
3.3. Loosen the lock screw using an Allen key.
27 - 51 9813/7400-1 27 - 51
27 - Driveline
00 - General
Figure 387. 3. Check the pressure. If necessary, adjust the

pressure as follows:
J 3.1. If the pressure is low, remove the relief valve
and add shim(s).
3.2. If the pressure is high, remove the relief
valve and remove shim(s).
L
The 1mm change in shim thickness varies the
pressure by 3.9bar (56.5psi). The shims are
available in 0.3mm, 0.5mm and 1mm sizes.
Mechanical centering of pump

The control piston has strong centering springs
to make sure that once the pump is adjusted for
the neutral position it will always return to neutral
position. If an adjustment is necessary, do the
K
following steps:
1. Connect the port X1 and X2 with the hose

or tubing of internal diameter more than the
specified. This is to make sure that there is
an equal pressure on both sides of the control
module during centering operation.
J Pump Dimension: 6.35mm
K Shim
L Port G 2. Install the pressure gauges at port MA and port
MB. Refer to Figure 388.
2. Operate the pump at the normal operating speed
and temperature.
Figure 388.
J
M
R
N
P
S
Q
J Pump M Port X1
N Port X2 P Jam nut
Q Mechanical centering adjusting screw R Port MA
S Port MB
3. Block the port A and port B or stall the motor. 5. Turn the mechanical centering adjusting screw
until one of the gauges on port MA and port MB
4. Operate the motor and loosen the jam nut. reads the specified pressure value.
Pressure: 68.95bar (999.3psi)
27 - 52 9813/7400-1 27 - 52
27 - Driveline
00 - General
6. Turn the mechanical centering adjusting screw

in opposite direction until other gauge shows the
specified pressure value.
back at middle of the position got in the step 5
and step 6. This is the neutral position.
8. Make sure that the pressure on both gauges is
equal.
9. Tighten the jam nut.
10. Stop the pump and remove the hose or tubing
from the port X1 and port X2.

Item Description Nm
A Valve cap 250
Y Port 70
27 - 53 9813/7400-1 27 - 53
27 - Driveline
00 - General
Adjust Disassemble and Assemble

Consumables
The only adjustment possible with this pump is Description Part No. Size
adjusting the pressure, refer to Check (Pressure) and Special HP Grease 4003/2017 0.4kg
4003/2006 12.5kg
4003/2005 50kg
Following a complete rebuild of the pump, it is

necessary for it to be set up on a dynamic test rig.
Due to this fact we recommend that no dismantling
work is carried out beyond the components covered
in this section.
When dismantling this assembly, check the

components for wear and renew if necessary.
Drive Shaft Seal

1. Remove the track drive pump from the machine.
2. Remove the retaining ring.
Figure 389.
A Retaining ring
3. Remove the seal.
27 - 54 9813/7400-1 27 - 54
27 - Driveline
00 - General

B
B Self-tapping Screws
C Seal
3.1. Screw self-tapping screws into the holes in 2. Hold the adjustment screw, then use an Allen key
the seal. to loosen and remove the locknut.
3.2. Pull out the seal using pliers.
Figure 393.
4. During installation lightly grease the dust seal,
dust lips and shaft sealing surface.
5. Press the seal fully into the pump housing using
a suitable pressing tool.
Figure 391.
D
D Locknut
3. Mark the position of the cover then remove the
cover fixing screws.
Control Piston Cover Seal

1. Make a note of dimension X.
27 - 55 9813/7400-1 27 - 55
27 - Driveline
00 - General
E Cover
F Fixing screw
4. Lift off the cover while you turn the setting screw.
Figure 395.
G O-Ring
6. Replace the cover, align the marks previously
made, and secure with screws. Refer to Figure
394.
7. Install the locknut and tighten until dimension X
is achieved. Refer to Figure 392.
Low Pressure Valve Seals

E Cover
1. Unscrew the low pressure valve and withdraw
5. Replace the O-rings in the groove of the the assembly.
adjustment screw and in the groove in the cover.
Figure 397.
H Low pressure valve

2. Replace the seal and back-up ring.
27 - 56 9813/7400-1 27 - 56
27 - Driveline
00 - General
J
K
N
N
M
M
J Seal
K Back-up ring
P
3. Replace the valve assembly and tighten to the
correct torque value. Refer to Figure 397.
High Pressure Valve Seals

1. Unscrew the appropriate high pressure valve and
withdraw the assembly. M Seal
N Back-up ring
Figure 399. P Sleeve

L
Item Description Nm
H High pressure valve 70
L Low pressure valve 250
L High pressure valve

2. Replace the seal and back-up ring, use a sleeve
as shown.
27 - 57 9813/7400-1 27 - 57
27 - Driveline
03 - Coupling
03 - Coupling Introduction
Introduction .................................................... 27-58 This is a gear type coupling comprising a drive plate
Remove and Install ....................................... 27-59 bolted to the engine flywheel and a coupling clamped
Figure 401.
B
A Drive plate (PIL 15-54)
B Coupling
27 - 58 9813/7400-1 27 - 58
27 - Driveline
03 - Coupling
Remove and Install

Consumables
JCB Threadlocker and 4101/0550 0.01L
Sealer (High Strength) 4101/0552 0.2L
Remove
2. Remove the wheel drive pump, refer to (PIL
27-31).
3. Remove the capscrew, remove the coupling off
the pump input shaft.
Figure 402.
B
F
B Coupling
D Capscrew (hidden)
F Circlip
Install
procedure.
2. Before you install the coupling to the pump input
shaft, make sure that the circlip is installed to the
groove in the bore.
3. Coat the threads of the capscrew with JCB
Threadlocker and tighten to the correct torque
value.
(High Strength)

Item Nm
D 49
27 - 59 9813/7400-1 27 - 59
27 - Driveline
32 - Wheel Drive Motor
Contents Page No.
27-32-00 General ........................................................................................................................... 27-61

27-32-60 Adaptor ........................................................................................................................... 27-74
27 - 60 9813/7400-1 27 - 60
27 - Driveline
00 - General
Introduction .................................................... 27-61 The radial piston motor consists of a two part
Operation ....................................................... 27-63 housing, rotary piston group, cam, output shaft and
Diagram ......................................................... 27-64 a flow distributor.
The motor converts hydrostatic energy into
Disassemble and Assemble .......................... 27-69 mechanical energy.
Hydraulic fluid is directed from the motor inlet port

in the rear case via the flow distributor through
galleries to the cylinder block. The radially arranged
pistons in the cylinder bores face a pressure increase
and perform via rollers a stroke movement against
the cam ring. The reaction force at the cam ring
generates a torque, which is transferred to the output
shaft via splines in the cylinder block.
When the torque exceeds the shaft load, the cylinder

block turns which causes the pistons to stroke
(working stroke). Once the end of a stroke is reached
the piston is returned to its bore by the reaction force
at the cam (return stroke) and the fluid is fed to the
motor outlet port in the rear case.
The output speed depends on the displacement

and is proportional to the inward flow. The number
of working and return strokes corresponds to the
number of lobes on the cam multiplied by the number
of pistons.
Figure 403.
6 5
Z 4
A B
L
1
2 7
1 Front case housing 2 Rear case housing

3 Pistons 4 Cylinder block
5 Cam, Cam ring 6 Output shaft
27 - 61 9813/7400-1 27 - 61
27 - Driveline
00 - General
7 Flow distributor
Two Speed Option

The motor can be switched to a low-torque and
high-speed mode. This is achieved by operating an
integrated valve which directs hydraulic fluid to only
one half of the motor while continuously re-circulating
the fluid in the other half.
This reduced displacement mode reduces the flow

required for a given speed and gives the potential
for cost and efficiency improvements. The motor
maximum speed remains unchanged.
27 - 62 9813/7400-1 27 - 62
27 - Driveline
00 - General
Operation When there is no drive and no pressure difference

in the loop the shuttle spool Ma is held in the central
position by its springs. The diagram shows the high
Single Speed pressure in one side of the loop causing the shuttle
spool to move to down. Oil from the port B is fed from
The basic components of the transmission motor are the opposite end of the shuttle to the relief valve.
the cylinder block containing eight radially positioned
pistons with attached rollers working inside a circular When the return pressure exceeds the pressure
cam, the distributor, shuttle valve and flushing valve. within the motor casing the relief valve Md opens
The pistons and rollers are located in bores in allowing the oil to flow into the casing to cool the
the cylinder block. The rollers bear against the motor before returning to tank. When the oil flow is
convoluted inside face of the cam so that as oil is reversed in the motor the shuttle spool moves in the
fed under pressure to each piston in turn the cylinder opposite direction.
block is forced to turn.
Figure 405.
Oil from the pump is fed into the appropriate cylinder
bores by means of the distributor plate. As the
cylinder block rotates the distributor delivers oil to the
appropriate cylinders to continue the rotating force.
The drive from the cylinder block is transferred to the

output sprocket by means of a splined drive shaft.
Z Md
Figure 404.
T
Mc
A Ma
Ma Shuttle spool
Mc Hydrostatic brake
Md Relief valve
B T Return to tank
Z Motor flush
Two Speed
BR The motor can be switched to a low-torque and
A Main port integrated valve which directs hydraulic fluid to only
B Main port one half of the motor while continuously re-circulating
T Return to tank the fluid in the other half.
BRBrake release
When high speed is selected the two speed spool Mb
Loop Flushing is pressurised and moves up to close off two galleries
in the distributor. This results in oil being supplied to
The purpose of the loop flushing system allows oil only half the number of cylinders, the others remain
from the closed loop circuit to be fed into the motor idle.
casing at Z during operation for cooling of the motor
components. As the flow of oil through the motor is the same as
before the operating cylinders and pistons work twice
27 - 63 9813/7400-1 27 - 63
27 - Driveline
00 - General
as fast and therefore the output shaft turns at a faster Diagram

speed.
Figure 406. Figure 407. Single Speed Machines
T
A
Z Z Md
Mc
Ma
Mb
Ma Shuttle spool BR
Mb Two Speed spool
Mc Hydrostatic brake A Main port
Md Relief valve B Main port
T Return to tank T Tank Port
BR Brake release BRBrake Release
SP Two Speed feed
Z Motor flush
27 - 64 9813/7400-1 27 - 64
27 - Driveline
00 - General
Figure 408. 2 Speed Machines
T
A
FWD
B
REV
SP BR
A Main port
B Main port
T Tank Port
BR Brake Release
SP 2 Speed port
27 - 65 9813/7400-1 27 - 65
27 - Driveline
00 - General
Remove and Install
Consumables 2. Remove the drive chains. Refer to (PIL 27-63).

3. Mark all hoses to make sure of correct
JCB Threadlocker 4101/0250 0.01L installation.
Strength) 4. Remove the hoses, cap the ends with blanking
caps to prevent loss of fluid and ingress of dirt.
The cleanliness of this component is critical and must
conform to JCB standard 9993/0003. 5. Support the motor and remove the bolts.
6. Remove the motor, cap the ports with blanking
Remove caps to prevent loss of fluid and ingress of dirt.
27 - 66 9813/7400-1 27 - 66
27 - Driveline
00 - General
Figure 409. Single Speed Motor
B A
C
A Motor B Bolts
C Drive chain
27 - 67 9813/7400-1 27 - 67
27 - Driveline
00 - General
Figure 410. 2 Speed Motor
C B A
A Motor B Bolts
C Drive chain
Install Consumable: JCB Threadlocker and Sealer

(Medium Strength)
procedure. Table 154. Torque Values
2. Make sure all hoses and ports are clean and free Item Nm
from dirt. Tighten the bolts to the correct torque B 184
value.
3. Apply JCB Threadlocker and Sealer to the motor
mounting bolts before installation.
27 - 68 9813/7400-1 27 - 68
27 - Driveline
00 - General
Consumables Motor- Disassemble

JCB High Strength 4102/0551 0.05L The illustration shows a single speed motor. The
Threadlocker procedure also applies to the two speed motor.
Special HP Grease 4003/2017 0.4kg 1. Remove the drain plug and drain the oil from the
4003/2006 12.5kg motor.
4003/2005 50kg
2. Mark the relative positions of the front case, rear
The following disassembly and assembly case and rotational assembly.
instructions are intended for cleaning purposes and
3. Remove all the capscrews.
for the replacement of seals.
4. Separate the front and rear case assemblies
If on inspection the motor components are found to from the rotational assembly. Take care to keep
be worn it is recommended that the motor unit is the rotational assembly items together as a unit.
replaced with a new one.
Park Brake
Figure 411.
4
3
2
1 Drain plug 2 Front case assembly

3 Rear case assembly 4 Rotational assembly
5 Capscrews
27 - 69 9813/7400-1 27 - 69
27 - Driveline
00 - General
Motor- Assemble Figure 412.
1. Check all the components are clean and free

from debris. 1
6
2. Install a new O-ring to the mating face of the front
case assembly.
2
3. Install the rotational assembly to the front case
assembly, take care not to damage the shaft
splines. Position the cam of the rotational
assembly to align the reference marks made
during disassembly.
4. Install a new O-ring to the mating face of the
rear case assembly and position the rear case
assembly on to the rotational assembly, align the 3
reference marks. 4 8 7
5
5. Coat the capscrews with JCB Threadlocker and
install to the assembly. Tighten the capscrews 1 O-ring
diagonally to the correct torque value. 2 Split ring
Consumable: JCB High Strength Threadlocker 3 Washer
4 Motor shaft
6. Check that the drive shaft rotates freely. 5 Bearing cup
6 Seal
7 Seal
Table 155. Torque Table 8 Bearing cup
Description Torque Value
Capscrews (Item 5) 117–122N·m Front Case- Assemble
Front Case- Disassemble from debris.
1. Remove the O-ring. 2. Use a suitable tool to insert the bearing cup 5 into
the front case.
2. Remove the split ring, use a soft steel drift to
separate, then remove the washer. 3. Use a suitable tool to insert a new seal into the
front case. Lubricate the lip of the seal with G3
3. Support the front case on blocks and press the
grease.
motor shaft out of the bearings.
4. Use a mechanical puller to remove the bearing
cup from the front case. 4. Use a suitable tool to insert the rear bearing cup
into the front case.
5. Carefully remove the seals from the front case.
5. Install the new seal into the groove in the front
6. Use a mechanical puller or soft steel drift to case. Lubricate the lip of the seal with G3 grease.
remove the bearing cup from the front case.
7. Use a mechanical puller to remove the bearing
cones from the shaft. 6. Place the motor shaft vertically on to a press.
7. Warm the front bearing cone, then use a bench
press and a suitable tool to press on to the motor
shaft.
8. Pack the front bearing cone with G3 grease.
9. Cover the shaft spline with tape to protect the lip
seal.
10. Install the front case assembly to the motor shaft
assembly.
27 - 70 9813/7400-1 27 - 70
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00 - General
11. Remove the tape from the spline. Figure 413.

12. Warm the rear bearing cone, then use a bench
press and a suitable tool to a load of 4 tonnes to 2
press on to the motor shaft. Rotate the front case 3
5 times during this process.
13. Install the split ring on to the motor shaft.
1
14. With the pre-load still applied, use a set of
slip gauges to measure the gap between the
bearing and the split ring. This step should be
completed less than 10 minutes after you remove
the bearing from the heater.
15. Remove the pre-load.
16. Remove the split ring and install the washer with
a thickness of 0.1 to 0.2 mm (0.004 to 0.008 in)
greater than the measured gap, then install the
split ring.
17. Check that the motor shaft rotates freely in the
front case assembly.
Rotational Assembly
The components of the rotational assembly should
be kept together. Pistons must be installed in the
same bores from which they were removed.
1 Pistons
If there are signs of wear on the pistons, rollers or 2 Rollers
cam, the complete motor must be replaced. 3 Cam
Rear Case- Disassemble

1. Remove the park brake, refer to (PIL 24-18).
2. Remove and discard the O-rings (if installed).
3. Drop the rear case assembly from approximately
80 mm (3 in) on to a wooden or plastic
surface (timing face down). This will release the
distributor from the assembly. At all times take
care not to damage the timing face.
4. Remove the stop pin from the rear case.
5. Check the timing face of the distributor. If
necessary lap the timing face.
6. Remove and discard all of the sealing rings.
27 - 71 9813/7400-1 27 - 71
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00 - General
Figure 414. Two Speed Machine Rear Case- Assemble

4 1. Check that all components are clean and free
2 from debris.
3
2. Place the springs into the recesses in the
distributor and use a small amount of grease to
hold them in position.
12
5 3. Insert new distributor seals (as appropriate) into
6 the correct grooves in the rear case with a
minimum distortion of the seals.
1 4. Insert the stop pin into the distributor stop pin

hole.
7 8 9 10 5. Use a suitable tool to install and align the
distributor into the rear case in line with the stop
pin hole in the rear case.
1 O-ring
6. Install new O-rings.
2 O-ring
3 O-ring
4 Rear case assembly Two Speed Spool- Disassemble
5 Distributor
6 Stop pin 1. Remove the spool with the washer.
7 Sealing ring 2. Remove the internal spool and spring 4 from the
8 Sealing ring spool assembly.
9 Sealing ring
10 Sealing ring 3. Remove the spring 5.
11 Sealing ring
12 Springs 4. Remove the washer and the circlip from the
spool.
Figure 415. Single Speed Machine
5. Remove the seal ring and the seal 8 from the rear
4 case. Remove the seal 9 from the brake housing.
2 6. Inspect the spool for damage, replace if
1 necessary.
12
5
6
7 8 9
1 O-ring
2 O-ring
4 Rear case assembly
5 Distributor
6 Stop pin
7 Sealing ring
8 Sealing ring
9 Sealing ring
12 Springs
27 - 72 9813/7400-1 27 - 72
27 - Driveline
00 - General
Figure 416.
4
5
7 9
8
3
2
6 10
1 Spool
2 Washer
3 Internal spool
4 Spring
5 Spring
6 Circlip
7 Seal ring
8 Seal
9 Seal
10 Brake housing
Two Speed Spool- Assemble

1. Install the circlip and the washer on to the spool.
2. Insert the spring 5 into the rear case.
3. Insert the spring 4 and poppet into the bore of the
spool.
4. Insert new O-rings into the seal ring and install
the seal ring into the brake housing.
5. Lubricate the spool with oil and install the
assembly into the rear case. Check that the
assembly moves freely.
27 - 73 9813/7400-1 27 - 73
27 - Driveline
60 - Adaptor
60 - Adaptor Introduction
Introduction .................................................... 27-74 The drive motor drain line is installed with a screen
Remove and Install ....................................... 27-75 filter adaptor. The filter adaptor must be replaced in
line with the maintenance schedules.
Figure 417.
A Drain line filter adaptor
27 - 74 9813/7400-1 27 - 74
27 - Driveline
60 - Adaptor
Remove and Install
Remove
2. Get access to the drive motor. Refer to (PIL
27-32).
3. Remove the drain line filter adaptor.
Figure 418.
A Drain line filter adaptor
Install
procedure.
2. Tighten the adaptor to the correct torque value.
27 - 75 9813/7400-1 27 - 75
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33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ........................................................................................................................... 27-77
27 - 76 9813/7400-1 27 - 76
27 - Driveline
33 - Tyre
00 - General
00 - General
Health and Safety

DANGER Make sure that all tyres are inflated
to the correct pressure. Refer to the machine
operator manual.
WARNING An exploding tyre can kill. Inflated
tyres can explode if over-heated or over-inflated.
Follow the instructions given when inflating the
tyres. Do not cut or weld the rims. Use a tyre/
wheel specialist for all repair work.
WARNING Wheels and tyres are heavy. Take
care when lifting or moving them. Store with care
to ensure that they cannot fall and cause injury.
WARNING Do not use the machine with
damaged, incorrectly installed, incorrectly inflated
or excessively worn tyres. Recognise the speed
limitation of the tyres installed and do not operate
at more than their recommended maximum
speed.
WARNING Running tyres outside recommended
guidelines may result in failure of the tyres which
at high speeds may endanger life.
WARNING Deflate the tyre you wish to change
before removing the wheel from the machine.
Air pressure in the tyres can cause the tyre and
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner
and outer wheel halves together when there is air
pressure in the tyre. Always wear safety glasses.
WARNING Do not install pneumatic tyres on a
wheel made for a solid tyre. Do not install a solid
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for
your machine, contact your local JCB dealer or a
trained specialist.
WARNING When ordering tyres, you must
specify not only the tyre size but also the speed
designation. The correct tyres for the machine are
shown in the Operator's Manual. On no account
should you use tyres of other designations
without first gaining approval from the machine
manufacturer.
WARNING Remove the valve core to make sure
the tyre is fully deflated. If the tyre is not fully
deflated, unseen damage to the wheel and / or
tyre could cause the assembly to explode.
27 - 77 9813/7400-1 27 - 77
27 - Driveline
36 - Track
36 - Track
Contents Page No.
27-36-00 General ........................................................................................................................... 27-79

27-36-06 Rubber Track ................................................................................................................. 27-90
27-36-12 Gearbox Sprocket .......................................................................................................... 27-95
27-36-15 Frame ............................................................................................................................. 27-97
27-36-18 Idler Wheel ..................................................................................................................... 27-99
27-36-24 Bottom Roller ............................................................................................................... 27-101
27-36-27 Tensioner/Recoil unit .................................................................................................... 27-103
27 - 78 9813/7400-1 27 - 78
27 - Driveline
36 - Track
00 - General
Introduction .................................................... 27-79 The track assemblies are mounted on each side of
Health and Safety .......................................... 27-80 the machine chassis in place of the wheel hubs.
Fault-Finding .................................................. 27-83 The machine sits on rollers which run inside the
rubber track. A front idler wheel slides in grooves
Check (Condition) .......................................... 27-87 in the track frame and locates against the spring
loaded tensioner which protects the track against
shock loadings. A grease filled hydraulic cylinder
inside the recoil unit provides a facility for the correct
tensioning of the track. The rear idler wheel gives an
additional secure location for the track.
The track is rotated by a hydraulic motor mounted on

the track frame. The sprocket on the output shaft of
the motor locates in holes in the track.
27 - 79 9813/7400-1 27 - 79
27 - Driveline
36 - Track
00 - General
Health and Safety

Raised Machine
Never position yourself or any part of your body
under a raised machine which is not correctly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
CAUTION! The following operations must only be
undertaken by persons familiar with track changing
operations and who are qualified to perform the
operations. All persons must keep clear of the
machine driven sprocket.
CAUTION! Ensure that all persons are clear of the
track and especially of the driven sprocket during the
following operations.
Notice: When converting a machine from steel
tracks to rubber tracks, the track guides must be
removed. When converting from rubber tracks to
steel tracks the track guides must be installed.
Damage to the tracks may result if this is not carried
out.
WARNING! Recoil unit servicing must only be carried
out by JCB dealers. You could be killed or injured if
you tamper with it.
CAUTION! The recoil unit spring can cause serious
injury if suddenly released. Take great care when
removing and replacing the spring retaining nut.
Scrap recoil units must be dismantled before transfer
from the workshop. Do not use flame cutting
equipment unless precautions are taken to release
the spring pressure slowly.
27 - 80 9813/7400-1 27 - 80
27 - Driveline
36 - Track
00 - General
Figure 419. F Hydraulic motor

B H G Sprocket
H Track frame
C
D
G F
A
E
A Rollers
B Rubber Track
C Front idler wheel
D Grease Tensioner (Spring loader recoil unit)
E Rear idler wheel
27 - 81 9813/7400-1 27 - 81
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36 - Track
00 - General
Figure 420.
C
D
A
E
A Rollers C Front idler wheel

D Grease Tensioner (Spring loader recoil unit) E Rear idler wheel
F Hydraulic motor G Sprocket
H Track frame
27 - 82 9813/7400-1 27 - 82
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36 - Track
00 - General
Fault-Finding
Fault
Core Bar (Separation) Table 156. Page 27-83
Core Bars (Breaking in the middle) Table 157. Page 27-83
Core Bars (Breaking on the wings) Table 158. Page 27-83
Core Bars (Fast Abrasion) Table 159. Page 27-84
Core Bars (Oxidation (Rusting) Table 160. Page 27-84
Steel Cord (Breaking) Table 161. Page 27-84
Steel Cord (Separation) Table 162. Page 27-84
Steel Cord (Exposure) Table 163. Page 27-85
Steel Cord (Sticking Out) Table 164. Page 27-85
Outer Track Rubber - Tearing/Cuts Table 165. Page 27-85
Outer Track Rubber (Fast Abrasion) Table 166. Page 27-85
Outer Track Rubber (Cracks) Table 167. Page 27-85
Outer Track Rubber (Longitudinal Cracks) Table 168. Page 27-86
Inner Track Rubber (Tearing/Cuts) Table 169. Page 27-86
Inner Track Rubber (Cracks) Table 170. Page 27-86
Miscellaneous (Not Engaging Correctly) Table 171. Page 27-86
Miscellaneous (Detracking) Table 172. Page 27-86
Table 156. Core Bar (Separation)

Cause Remedy
Low track tension, the core bars are likely to hit the Check the track tension regularly (as recommended
running gear components and lead to separation in service schedules)
from the track
Hard material (stone, metal) stuck between the top of Clean the tracks regularly as recommended,
the two core bars particularly after operation in clay soil
Sprocket teeth badly worn (hook-shaped) When installing a track on a machine, always make
sure that the sprocket is in good condition. If the
sprocket is damaged it must be changed
Oxidation (rusting) of the core bars Regularly clean and grease the components
If one or more core bars are separated from the track Replace the track
Table 157. Core Bars (Breaking in the middle)

Cause Remedy
Excessive track tension together with a shock load, Check the track tension regularly (as recommended
for example, climbing pavement edges in service schedules)
Hard material (stone, metal) stuck between the Clean the tracks regularly as recommended,
sprocket and the core bar with excessive track particularly after operation in clay soil
tension
Abrasion of the teeth The track is not appropriate for the sprocket. Make
sure that the sprocket is not excessively worn and is
in good condition
Idler spring ineffective Clean the spring if it is clogged (with clay, for
instance) and make sure that it is in working order
Table 158. Core Bars (Breaking on the wings)

Cause Remedy
Only one side of the track is in contact with the Always operate the machine on both tracks. Use a
ground, for instance, sitting astride a trench, or ramp to mount and dismount from pavement edges
passing over pavement edges at an angle.
If one or more core bars are broken Replace the track
If the core bars break on the wings The track can still be used but note that eventually
long term damage will occur unless the track is
replaced
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36 - Track
00 - General
Table 159. Core Bars (Fast Abrasion)

Cause Remedy
The sprocket is not correct for the track Make sure that the sprocket is genuine JCB. Make
sure the sprocket is in good condition
The teeth of the sprocket are worn (hook shaped) Replace the sprocket. When new tracks are installed,
the sprockets should always be checked (and
renewed if necessary).
Operating environment is extremely abrasive Clean the tracks with fresh water
Core bars are worn out The track must be replaced (The track does not
have to be replaced if the core bar abrasion is below
approximately 20%)
Table 160. Core Bars (Oxidation (Rusting)

Cause Remedy
Operating in an environment which increases Clean the tracks with fresh water after operation.
likelihood of oxidation (rusting), for example newly Make sure that the visible metallic components of the
spread compost ground could increase acidic or track are greased
alkali values
Prolonged exposure to detergents, paint, solvents or Clean the tracks with fresh water after operation in
fuel areas where chemicals can attack the tracks
If the core bars are slightly rusted The track can be used. However, the propagation of
rust under the rubber should be monitored, otherwise
it is possible that the core bar will separate from the
rubber
Table 161. Steel Cord (Breaking)

Cause Remedy
The sprocket is not appropriate for the track (the Make sure that the sprocket is genuine JCB. Make
pitch does not fit). sure the sprocket is in good condition.
Hard material (stone, metal) stuck between the track Check the tension regularly. Clean the tracks
and the sprocket with excessive track tension regularly as recommended, particularly after
operation in clay soil
The steel cord has been exposed and rusted As soon as you see small cracks on the lug side,
clean with water and repair immediately
The steel cord is broken The track must be replaced. As a preventive
measure always check the tension
Table 162. Steel Cord (Separation)

Cause Remedy
Excessive tension of the track (during installation, Check the tension regularly
excessive tension plus a foreign body, shearing
sharp bend on hard surface)
The sprocket is not appropriate for the track Make sure that the sprocket is genuine JCB. Make
27 - 84 9813/7400-1 27 - 84
27 - Driveline
36 - Track
00 - General
Table 163. Steel Cord (Exposure)

Cause Remedy
Stones and sharp material can tear the rubber and The life expectancy of a track is greatly reduced by
expose the steel cord working on a site where sharp and pointed materials
are numerous. Operate the machine with attention to
the ground surface in rough terrain, e.g. demolition
sites, rocky ground etc.
Individual strands of steel cord sticking out of the Individual strands can be cut off (the number of steel
track does not necessarily mean the track needs to cord strands is always over specified), however
be replaced exposed strands should be repaired immediately
(see recommended repair procedures)
Table 164. Steel Cord (Sticking Out)

Cause Remedy
Strands of the steel cord may sometimes stick out Individual strands of steel cord sticking out of the
of the rubber track. This is caused by the friction of track does not necessarily mean the track needs
the sprocket against the edges of the track sprocket to be replaced. Individual strands can be cut off
holes (the number of steel cord strands is always over
specified), however exposed strands should be
repaired immediately (see recommended repair
procedures
Table 165. Outer Track Rubber - Tearing/Cuts

Cause Remedy
Cuts on the lug are often due to particularly sharp The life expectancy of a track is greatly reduced by
materials such as stones, the problem is particularlyworking on a site where sharp and pointed materials
evident if using sharp driving techniques on are numerous. Operate the machine with attention to
demolition type ground (e.g. stones, debris etc.) the ground's surface in rough terrain, e.g. demolition
The life expectancy of a track is greatly reduced by Operate the machine with attention to the ground's
working on a site where sharp and pointed materials surface in rough terrain, e.g. demolition sites, rocky
are numerous ground etc.
Table 166. Outer Track Rubber (Fast Abrasion)

Cause Remedy
Sharp driving on hard and abrasive surfaces, for Operate the machine with care, avoid making quick
example concrete, asphalt etc. and repeated turns
Operation on surfaces where the temperature is Do not stay too long on very hot surfaces. On the
unusually high, for instance, travelling over freshly other hand, the track is safe if you just go across this
laid asphalt area.
A track can still be used if the lug is higher than 5mm If less than 5mm, the track must be replaced. Refer
also to warranty pro-rata use scale
Table 167. Outer Track Rubber (Cracks)

Cause Remedy
Bending fatigue of the rubber after excessive use Make sure cracks do not reach the metallic
components of the track
Long storage (a few months) outside in the sunlight Tracks must be stored indoors or under cover away
from direct sunlight and bad weather
The track can be used as long as the cracks do not When the cracks expose the steel cords, the track
reach the metallic components of the track must be replaced or repaired
27 - 85 9813/7400-1 27 - 85
27 - Driveline
36 - Track
00 - General
Table 168. Outer Track Rubber (Longitudinal Cracks)

Cause Remedy
The edges of the rubber track are often deformed Operate the machine with care, avoid concrete
largely due to a bumpy ground surface, stones pavements and big rocks
and other objects, which cause intensive stress on
the edges resulting in damage. Especially when a
machine drives over concrete pavements, this type of
damage easily occurs
Table 169. Inner Track Rubber (Tearing/Cuts)

Cause Remedy
Stones and sharp material can tear the rubber at the The life expectancy of a track is greatly reduced by
edges of the track working on a site where sharp and pointed materials
are numerous. Operate the machine with attention to
the ground's surface in rough terrain, e.g. demolition
Driving close to pavement edges and ridges - Drive the machine carefully, avoid driving over
causing the edges to be forcefully bent against the projections, prevent the track edges from contacting
track frame ridges etc.
The track can be used as long as the cuts do not When the cracks expose the steel cords, the track
reach the metallic components must be replaced or repaired
Table 170. Inner Track Rubber (Cracks)

Cause Remedy
Excessive tension of the rubber Check the tension regularly
Excessive vibration whilst the machine remains Do not let the machine sit too long in the same
stationary, for example using an auxiliary attachment position when operating in these conditions. Move
such as a hammer the machine from time to time so that the pressure of
the vibrations is not always felt on the same place of
the track
The track can be used as long as the cuts do not When the cracks expose the steel cords, the track
reach the metallic components must be replaced or repaired
Table 171. Miscellaneous (Not Engaging Correctly)

Cause Remedy
Excessive abrasion of the sprocket teeth Make sure that the sprocket is genuine JCB. Make
Excessive tension of the track leading to incorrect Check the track tension regularly (as recommended
track pitch in service schedules)
Table 172. Miscellaneous (Detracking)

Cause Remedy
Low track tension Check the tension regularly
The rollers are worn out and the track is not correctly Check the rollers and running gear components in
guided accordance with the recommended service intervals
Sharp bends (shearing stress) Drive carefully on hard surfaces like concrete,
asphalt etc.
Machine working following a hillside which weathers Make sure that the ground is firm when working
or is soft along a hillside and drive carefully
27 - 86 9813/7400-1 27 - 86
27 - Driveline
36 - Track
00 - General
Check (Condition) Figure 423. Core Bars (Fast Abrasion)
Rubber tracks are used in numerous operating

environments / applications, it is therefore possible
that damage may occur to the track. The damage
may be superficial and the track can continue to be
used or repaired, but sometimes it may be necessary
to replace the track to avoid damage to the track
running gear.
Below are some examples of typical failures, refer

to the fault finding tables for possible causes, Figure 424. Core Bars (Oxidation)
prevention and corrective actions.
Figure 421. Core Bars (Separation)
Figure 425. Steel Cord (Breaking)
Figure 422. Core Bars (Breaking)
Figure 426. Steel Cord (Separation)
27 - 87 9813/7400-1 27 - 87
27 - Driveline
36 - Track
00 - General
Figure 427. Steel Cord (Exposure) Figure 429. Outer Track Rubber (Tearing/Cuts)
Figure 430. Outer Track Rubber (Fast Abrasion)
Figure 428. Steel Cord (Sticking Out)
Figure 431. Outer Track Rubber (Cracks)
27 - 88 9813/7400-1 27 - 88
27 - Driveline
36 - Track
00 - General
Figure 432. Outer Track Rub- Figure 434. Inner Track Rubber (Cracks)
ber (Longitudinal Cracks)
Figure 433. Inner Track Rubber (Tearing/Cuts)
B
A
A Cut
B Tear
27 - 89 9813/7400-1 27 - 89
27 - Driveline
36 - Track
06 - Rubber Track
06 - Rubber Track Introduction

Introduction .................................................... 27-90
Fault-Finding .................................................. 27-91
Track Construction
Repair ............................................................ 27-92 The structure of the rubber track consists of core bar
Remove and Install ....................................... 27-93 and steel cord encased in the rubber track. The core
bar and steel cord give the track its internal strength
and ensure engagement of the sprocket whilst the
rubber provides flexibility.
Compared to steel tracks, the characteristics of the

materials used for the rubber tracks bring about
significant improvements. They do not damage
paved and fragile surfaces, they offer more comfort
to the user and are quieter than steel tracks.
Figure 435.
N
M
L Rubber track
M Core bar
N Steel cord
Serial Number Location and Production

Date
The track is embossed with the production date and
serial number.
27 - 90 9813/7400-1 27 - 90
27 - Driveline
36 - Track
06 - Rubber Track
Figure 436. Fault-Finding

Refer to Track-Fault Finding (PIL 27-36).
27 - 91 9813/7400-1 27 - 91
27 - Driveline
36 - Track
06 - Rubber Track
Repair Figure 438.
Minor cuts which occur between the lugs can be

repaired with a suitable repair kit. Cuts no longer
than 30mm and no deeper than 10mm do not
need to be repaired. Cuts beyond these dimensions
should be repaired as detailed. Note, if steel is
evident (irrespective of cut size), then a repair should
be completed to prevent oxidation (rusting) and
subsequent long term damage.
Specialist rubber compounds for cold vulcanisation

can be purchased from various outlets. The
procedures below describe typical good practice
repair procedures. Always check the manufacturer's
instructions.
3. Apply the adhesive.
1. Use a brush or compressed air to clean the cut
thoroughly to make sure of the correct adhesion Figure 439.
of the bonding agents. If oil is evident, a cleaning
solution should be used to make sure the area
is dry.
Figure 437.
4. Mix the rubber compound. Note, the repair

rubber is usually supplied as two separate
compounds which are mixed together in
equal quantities. Follow the manufacturers
instructions.
2. Use sandpaper or a clean wire brush to roughen Figure 440.
the area in and around the cut to make sure of
good bonding adhesion. Make sure that the area
is roughened approximately 30 to 40 mm wider
than the cut. Clean the area using a suitable air
compressor.
5. Make sure that the adhesive applied in 3

has completely dried and then apply another
27 - 92 9813/7400-1 27 - 92
27 - Driveline
36 - Track
06 - Rubber Track
adhesive layer. When the second adhesive layer Remove and Install
is almost dry (sticky to the touch) the rubber
compound should be firmly applied to the cut.
Lifting Equipment
The compound should be higher than the original
rubber track by You can be injured if you use incorrect or faulty lifting
6. Allow to harden. Approximate curing times: enough and suitable for the job. Make sure that lifting
Table 173. local regulations.
Curing Time (Hours) Temperature
Remove
24 30°C (86.0°F)
48 40°C (103.9°F) - 45 1. Position the machine on a firm, level surface.
(112.9)
2. Raise the machine on the side to be worked on
72 50°C (121.9°F) - 60
as follows:
(139.9)
2.1. Place a block of wood under one end of
If the cut is on the track edge, this is more difficult to the shovel and fully lower and tilt the shovel
repair. In some instance, it is possible to repair with onto the block so as to raise the front of the
a strong bonding adhesive. machine.
2.2. Position blocks under the front and rear of
the chassis then raise the shovel to lower
the machine so that the chassis sits on the
blocks. Alternatively use a suitable jack to
raise the machine, take care not to damage
the chassis.
3. Remove the access cover and unscrew the
grease adjuster to release the track tension.
Collect and discard the grease. Use a lever to
push the front idler wheel fully in.
Figure 441.
A Access cover
B Grease adjuster
4. Thread a sling through holes in the track between
the rear idler and the sprocket. Insert a suitable
round section steel bar between the sling and the
track. Use a hoist to raise the bar so as to rotate
the track slightly until the bar is positioned at the
top of the sprocket.
27 - 93 9813/7400-1 27 - 93
27 - Driveline
36 - Track
06 - Rubber Track
Figure 442. motor to rotate the sprocket as necessary to

locate its teeth into the grooves of the track.
C 4. Lower the track onto the sprocket and remove
D the hoist and bar.
5. Pump grease into the adjuster to extend the front
idler wheel ensuring that the track is correctly
located on the idler wheels and guide rollers.
6. Lower the machine to the ground and adjust the
track tension.
7. Replace the access cover.
C Sling Recheck the track adjustment after the machine has

D Steel bar been driven for a while.
5. Use the hoist to lift the track clear of the sprocket. Table 174. Torque Values
6. Unscrew the sprocket retaining bolts and remove Item Description Nm
the sprocket. F Sprocket 300
Figure 443.
E Bolt
F Sprocket
7. Position a support under the track to take up the
sag at the bottom.
8. Manoeuvre the track off the rear idler and away
from the machine.
Install
1. Position the track so that it locates under the
bottom rollers and around the front and rear idler
wheels. Position a support under the track to take
up the sag at the bottom.
2. Place a steel bar under the track adjacent to the
sprocket and support the weight of the track.
3. Assemble the sprocket to the motor flange and
tighten the securing bolts. Operate the track
27 - 94 9813/7400-1 27 - 94
27 - Driveline
36 - Track
12 - Gearbox Sprocket
12 - Gearbox Sprocket Technical Data

Technical Data ............................................... 27-95 Table 175.
Component Weight
Gearbox sprocket 6.5kg
27 - 95 9813/7400-1 27 - 95
27 - Driveline
36 - Track
12 - Gearbox Sprocket
Remove and Install 4. Pump grease into the grease tensioner to extend
the front idler wheel to make sure that the track
Special Tools is correctly located on the idler wheels and guide
Description Part No. Qty. rollers.
Grease Gun 892/00913 1 Special Tool: Grease Gun (Qty.: 1)
Attachment Special Tool: Grease Gun Attachment (Qty.: 1)
Grease Gun 992/11300 1 Consumable: Special HP Grease
Consumables 5. Lower the machine to the ground and adjust the

track tension.
Special HP Grease 4003/2017 0.4kg Recheck the track adjustment after the machine has
4003/2006 12.5kg been driven.
4003/2005 50kg
Removal Item Nm
E 300
1. Position the machine on a firm, level surface.
2. Remove the track (PIL 27-36-06).
Refer to: Remove and Install (Page 27-93).
3. Remove the sprocket retaining bolts and remove
the sprocket.
Figure 444.
E Retaining bolts
F Sprocket
Install
procedure. Note the following:
2. Assemble the sprocket to the motor flange and
tighten the retaining bolts. Operate the track
motor to rotate the sprocket as necessary to
locate its teeth into the grooves of the track.
3. Install the track (PIL 27-36-06)
27 - 96 9813/7400-1 27 - 96
27 - Driveline
36 - Track
15 - Frame
15 - Frame Figure 445.
Remove and Install

Lifting Equipment
local regulations.
Notice: Do not pull the frame too far away otherwise
the hoses will rip off.
Remove
as follows:
2.1. Place a block of wood under one end of the 6. Remove the bolts from the front mounting.
shovel and fully lower and tilt the shovel on
to the block so as to raise the front of the Figure 446.
machine.
B
the machine so that the chassis sits on
the blocks. Alternatively use a suitable jack A
to raise the machine, taking care not to
damage the chassis.
3. Remove the track, refer to (PIL 27-36).
4. Mark the hoses to aid installation, disconnect the
motor feed and return hoses.
5. Sling the track frame and support the weight
using a suitable hoist. A Front mounting bolts
B Rear mounting bolts
7. Remove the bolts from the rear mounting. It
will be necessary to release the top two bolts
gradually whilst easing the frame away from the
machine.
8. Once access has been gained, disconnect the
motor drain and brake hoses, mark the hoses to
aid installation.
9. Manoeuvre the track frame away from the
machine.
Install
procedure.
27 - 97 9813/7400-1 27 - 97
27 - Driveline
36 - Track
15 - Frame

Item Nm
A 220
B 220
27 - 98 9813/7400-1 27 - 98
27 - Driveline
36 - Track
18 - Idler Wheel
18 - Idler Wheel Remove and Install

Remove
This component can be removed without removing
the track frame from the machine.
Figure 447.
A Rear idler wheel

1. Make the machine safe, refer to (PIL 01-03).
3. Remove the bolts that secure the rear idler wheel
4. Remove the rear idler wheel.
Install
Installation is a reversal of the removal procedure.
27 - 99 9813/7400-1 27 - 99
27 - Driveline
36 - Track
18 - Idler Wheel

Figure 448.
1
5 2
6 3
1 Rim 2 Seal
3 Bracket 4 Bearing
5 Plug 6 Shaft
7 O-ring 8 Bracket
27 - 100 9813/7400-1 27 - 100

27 - Driveline
36 - Track
24 - Bottom Roller
24 - Bottom Roller Remove and Install

Remove
These components can be removed without
removing the track frame from the machine.
Figure 449.
B
A Roller
1. Make the machine safe. refer to (PIL 01-03).
2. Remove the track. (refer to (PIL 27-36).
3. Remove the bolts that secure the roller.
4. Remove the roller assembly.
Install
procedure.
27 - 101 9813/7400-1 27 - 101

27 - Driveline
36 - Track
24 - Bottom Roller

Figure 450.
7 6 5
1
2
3
1 Bracket
2 Seal
3 Plug
4 Circlip
5 Shaft
6 Centre bracket
7 Bracket
27 - 102 9813/7400-1 27 - 102

27 - Driveline
36 - Track
27 - Tensioner/Recoil unit
27 - Tensioner/Recoil unit Health and Safety

WARNING Recoil unit servicing must only be
Health and Safety ........................................ 27-103 carried out by JCB dealers. You could be killed or
Technical Data ............................................. 27-104 injured if you tamper with it.
Remove and Install ..................................... 27-104 CAUTION The recoil unit spring can cause
Disassemble and Assemble ........................ 27-105 serious injury if suddenly released. Take great
care when removing and replacing the spring
retaining nut. Scrap recoil units must be
dismantled before transfer from the workshop.
Do not use flame cutting equipment unless
precautions are taken to release the spring
pressure slowly.
27 - 103 9813/7400-1 27 - 103

27 - Driveline
36 - Track
Technical Data Remove and Install

Table 178. be removed or handled using a suitable lifting
Component Weight method and device.
Front idler wheel and re- 60.5kg
coil unit Remove
Rear idler wheel 32.2kg
Guide roller 27.8kg These components can be removed without
removing the track frame from the machine.
Figure 451.
A
A Idler wheel
B Grease tensioner
as follows:
2.1. Place a block of wood under one end of
the shovel and fully lower and tilt the shovel
onto the block so as to raise the front of the
machine.
the machine so that the chassis sits on
the blocks. Alternatively use a suitable jack
to raise the machine, taking care not to
damage the chassis.
4. Remove the Idler wheel and grease tensioner
assembly.
27 - 104 9813/7400-1 27 - 104

27 - Driveline
36 - Track
Install Disassemble and Assemble

Replacement is a reversal of the removal procedure. CAUTION The recoil unit spring can cause
serious injury if suddenly released. Take great
care when removing and replacing the spring
retaining nut. Scrap recoil units must be
dismantled before transfer from the workshop.
Do not use flame cutting equipment unless
precautions are taken to release the spring
pressure slowly.
The Illustration shows the complete recoil unit/Idler

wheel assembly. We recommend that the recoil unit
is not disassembled, replace this assembly.
Figure 452.
A Idler wheel
B Recoil unit
C Spring retaining nut
When dismantling the Idler wheel assembly, check

the components for wear and renew if necessary.
27 - 105 9813/7400-1 27 - 105

27 - Driveline
36 - Track
Figure 453.
8
2
7
9
1 Idler wheel
2 Bracket left
3 Plug
4 Circlip
5 Shaft
6 Bearing
7 Seal
8 Bracket right
9 O-ring
27 - 106 9813/7400-1 27 - 106

27 - Driveline
37 - Track Drive Pump
Contents Page No.
27-37-00 General ......................................................................................................................... 27-109

27-37-03 Coupling ....................................................................................................................... 27-123
27 - 107 9813/7400-1 27 - 107

Notes:
27 - 108 9813/7400-1 27 - 108

27 - Driveline
00 - General
Introduction .................................................. 27-109 The transmission pump consists of two pump units,
Technical Data ............................................. 27-111 one for each drive motor, mounted in tandem on a
Component Identification ............................. 27-111 common drive shaft which is driven by the engine.
Operation ..................................................... 27-112 Each unit consists of a series of parallel axial pistons
mounted in a barrel which is rotated by the engine
Diagram ....................................................... 27-113 driven shaft. The pistons are operated by a tiltable
Check (Pressure) ........................................ 27-114 swashplate. The stroke of the pistons and therefore
Adjust .......................................................... 27-118 the displacement of the pump is varied by increasing
Remove and Install ..................................... 27-118 or decreasing the angle of the swashplate. Also by
reversing the angle of the swashplate the flow of
oil from the pump is reversed which reverses the
rotation of the appropriate drive motor.
Slipper pads are fitted to the ball ends of the pistons

and these slide on the surface of the swashplate,
adjusting to the angle of the surface. The end face of
the cylinder barrel runs against a valve plate which
directs the oil flow into and out of the bores as the
barrel rotates.
The angle of the swashplate is varied by means

of a hydraulic servo cylinder which is operated by
the machine’s control joystick. Thus the pumps’
displacement is varied from full displacement in
one direction to full displacement in the opposite
direction.
The components of the pump are contained within

the pump casing and are fully submerged in oil
which is supplied by the charge circuit. Charge flow
is required to make up internal leakage, maintain
positive pressure in the main circuit, provide flow for
cooling and for operation of the pump control system.
• Charge Pressure - The charge pressure (and

hence the drive system servo pressure) is
controlled by the charge pump P4 which is set
to a predetermined limit. Refer to Gear Pumps
(PIL 30-11).
• High Pressure Relief Valves - There are four of
these valves, one for each of the output ports of
the pump. They provide protection against high
transient pressures in the motor circuits.
27 - 109 9813/7400-1 27 - 109

27 - Driveline
00 - General
Figure 454.
27 - 110 9813/7400-1 27 - 110

27 - Driveline
00 - General
Table 179. Pumps P1 and P2 Figure 455.

Pump Blue Pump Yellow Pump
R
Type Tandem axi- Tandem axi-
al piston Type al piston Type P
A20VGS40, A20VGS40,
Electro propor- Electro propor-
R
tional or electro tional or electro
direct control direct control
Main Relief 425bar 385bar
Pressure (6,160psi) (5,580psi)
sure (at engine 260psi)(1) 260psi)
(1)
idle) MB
sure (at maxi- 375psi) 375psi) BR
mum revs) AR
Maximum Dis- 0.46m³ 0.46m³
placement
(1) Oil temperature at 50° C) variable with engine AF BF
MB
speed
Figure 456.
P
R
27 - 111 9813/7400-1 27 - 111

27 - Driveline
00 - General
Figure 457. Operation

MA
Speed Related Pilot Pressure Supply -
EH Control Valve
This pilot pressure is directed to the stroke cylinder
of the pump by operation of the drive joysticks.
MG The pump displacement can be steplessly varied in
each flow direction and is influenced by both the
T speed of the pump drive and the system pressure.
The flow direction (i. e. machine moving forwards
or backwards) is determined by either joystick being
activated.
G
Increasing the system pressure (i. e. machine load)
will have the effect of swivelling the pump back
to a smaller displacement. An overload protection
circuit for the engine (against stalling) is achieved
AF Drive motor port - Forwards by combining this pressure dependent reduction in
AR Drive motor port - Reverse pump stroke with a reduction in pilot pressure as the
BF Drive motor port - Forwards engine speed drops.
BR Drive motor port - Reverse
Any additional power requirement, e. g. hydraulic
G Hydraulic oil inlet port
functions from the loader or attachments, could
MA Charge pressure test port
cause the speed of the engine to drop further. This
MB Charge pressure test port
will cause a further reduction in pilot pressure and
MG Pilot pressure test port
thus of the pump displacement. Automatic power
P Park brake port
distribution and full exploitation of the available
R Air bleed port
power are achieved in this way, both for the travel
T Drain port
drive and for the loader hydraulics, with priority given
to the loader hydraulics.
27 - 112 9813/7400-1 27 - 112

27 - Driveline
00 - General
Diagram
Refer to Hydraulic System - General - Schematic

Circuit (PIL 30-00-50).
27 - 113 9813/7400-1 27 - 113

27 - Driveline
00 - General
Check (Pressure)

Pressure Gauge (0-400 892/00279 4
Bar)
Pressure Gauge (0-70 892/00346 1
Bar)
Low Pressure Valve (Charge Pressure)

(121.9°F).
G1
1. Connect a pressure gauge to port G1.
Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
Figure 458.
G1
Y
X Shim
Y Valve assembly
4.1. Remove the low pressure valve.
4.2. Add or remove shims as appropriate.
2. Apply pressure to port G. 5. Tighten the valve assembly to the correct torque
value.
Figure 459.
High Pressure (HP) Valves
G
(121.9°F).
1. Connect the pressure gauges to the blanked off

motor feed ports.
Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
4)
G Port
3. Check the pressure, the maximum pressure
reading should be as stated in Technical Data.
4. Adjust the pressure.
27 - 114 9813/7400-1 27 - 114

27 - Driveline
00 - General

E
D
A A
A C
XXX
A Valve Cap
2. Operate the valves for a short time only to avoid
overheating. P
3. If necessary, adjust the valve.

C Factory pressure setting
3.1. Remove the cap then lift out the valve D Cartridge
cartridge. E Allen screw
Figure 462. 3.4. While still holding the cartridge, turn the
valve stem clockwise to increase the
setting. One turn increases the pressure by
A the amount shown.
Pressure: 44bar (637.7psi)
3.5. Tighten the lock screw.
3.6. Tighten the valve cap to the correct torque
value. Install the valve assembly to the
pump and re-check the setting. The factory
pressure setting is stamped on the top face
of the cartridge.
Charge Pressure Relief Valve

Adjustment
B
1. Make sure that the pressure gauge is connected
to port G. Refer to Figure 464.
A Valve cap
B Cartridge
3.2. Hold the top of the cartridge with a suitable
pair of pliers.
3.3. Loosen the lock screw using an Allen key.
27 - 115 9813/7400-1 27 - 115

27 - Driveline
00 - General
Figure 464. 3. Check the pressure. If necessary, adjust the

pressure as follows:
J 3.1. If the pressure is low, remove the relief valve
and add shim(s).
3.2. If the pressure is high, remove the relief
valve and remove shim(s).
L
The 1mm change in shim thickness varies the
pressure by 3.9bar (56.5psi). The shims are
available in 0.3mm, 0.5mm and 1mm sizes.
Mechanical centering of pump

The control piston has strong centering springs
to make sure that once the pump is adjusted for
the neutral position it will always return to neutral
position. If an adjustment is necessary, do the
K
following steps:
1. Connect the port X1 and X2 with the hose

or tubing of internal diameter more than the
specified. This is to make sure that there is
an equal pressure on both sides of the control
module during centering operation.
J Pump Dimension: 6.35mm
K Shim
L Port G 2. Install the pressure gauges at port MA and port
MB. Refer to Figure 465.
2. Operate the pump at the normal operating speed
and temperature.
Figure 465.
J
M
R
N
P
S
Q
J Pump M Port X1
N Port X2 P Jam nut
Q Mechanical centering adjusting screw R Port MA
S Port MB
3. Block the port A and port B or stall the motor. 5. Turn the mechanical centering adjusting screw
until one of the gauges on port MA and port MB
4. Operate the motor and loosen the jam nut. reads the specified pressure value.
27 - 116 9813/7400-1 27 - 116

27 - Driveline
00 - General

in opposite direction until other gauge shows the
specified pressure value.
back at middle of the position got in the step 5
and step 6. This is the neutral position.
8. Make sure that the pressure on both gauges is
equal.
9. Tighten the jam nut.
10. Stop the pump and remove the hose or tubing
from the port X1 and port X2.

Item Description Nm
A Valve cap 250
Y Port 70
27 - 117 9813/7400-1 27 - 117

27 - Driveline
00 - General

Consumables
The only adjustment possible with this pump is Description Part No. Size
adjusting the pressure, refer to Check (Pressure) and JCB Threadlocker 4101/0250 0.01L
Technical Data (PIL 27-31). and Sealer (Medium 4101/0251 0.05L
Strength)
Lifting Equipment
local regulations.
Remove
2. Drain the hydraulic tank. Refer to (PIL 30-03).
3. Label all the hose connections to enable correct
installation. Disconnect the hoses and plug the
exposed hydraulic connections.
4. Sling the complete pump unit using suitable lifting
equipment.
5. Remove the bolts and ease the unit away
from the engine. Once the pump coupling has
separated from the engine, the unit can be lifted
clear.
6. The loader pump can now be separated from the
transmission pump.
Install
1. Using suitable lifting equipment, ease the
pump unit into position, make sure that the
pump/engine coupling engages smoothly and
completely.
2. Coat the threads of the flange bolts with JCB
Threadlocker and Sealer, install and tighten to
the correct torque value.
(Medium Strength)
3. Install the hydraulic connections and tighten to
the correct torque value. Note: Refill the pumps
with filtered, clean oil via the pump outlets before
you finally tighten the outlet connections.
4. Refill the hydraulic tank. Refer to (PIL 30-03).
5. Prime the system. Refer to Store and
Recommission. Refer to (PIL 27-31).
27 - 118 9813/7400-1 27 - 118

27 - Driveline
00 - General
Figure 466. Disassemble and Assemble

Consumables
4003/2006 12.5kg
4003/2005 50kg
Following a complete rebuild of the pump, it is

A necessary for it to be set up on a dynamic test rig.
Due to this fact we recommend that no dismantling
work is carried out beyond the components covered
in this section.

Drive Shaft Seal

A
1. Remove the track drive pump from the machine.
A Bolts Refer to (PIL 27-37).
2. Remove the retaining ring.
Figure 467.
A Retaining ring
3. Remove the seal.
27 - 119 9813/7400-1 27 - 119

27 - Driveline
00 - General

B
B Self-tapping Screws
C Seal
3.1. Screw self-tapping screws into the holes in 2. Hold the adjustment screw, then use an Allen key
the seal. to loosen and remove the locknut.
3.2. Pull out the seal using pliers.
Figure 471.
4. During installation lightly grease the dust seal,
dust lips and shaft sealing surface.
5. Press the seal fully into the pump housing using
a suitable pressing tool.
Figure 469.
D
D Locknut
3. Mark the position of the cover then remove the
cover fixing screws.
Control Piston Cover Seal

1. Make a note of dimension X.
27 - 120 9813/7400-1 27 - 120

27 - Driveline
00 - General
E Cover
F Fixing screw
4. Lift off the cover while you turn the setting screw.
Figure 473.
G O-Ring
6. Replace the cover, align the marks previously
made, and secure with screws. Refer to Figure
472.
7. Install the locknut and tighten until dimension X
is achieved. Refer to Figure 470.
Low Pressure Valve Seals

E Cover
1. Unscrew the low pressure valve and withdraw
5. Replace the O-rings in the groove of the the assembly.
adjustment screw and in the groove in the cover.
Figure 475.
H Low pressure valve

2. Replace the seal and back-up ring.
27 - 121 9813/7400-1 27 - 121

27 - Driveline
00 - General
J
K
N
N
M
M
J Seal
K Back-up ring
P
High Pressure Valve Seals

1. Unscrew the appropriate high pressure valve and
withdraw the assembly. M Seal
N Back-up ring
Figure 477. P Sleeve

L
Item Description Nm
H High pressure valve 70
L Low pressure valve 250
L High pressure valve

2. Replace the seal and back-up ring, use a sleeve
as shown.
27 - 122 9813/7400-1 27 - 122

27 - Driveline
03 - Coupling
03 - Coupling Introduction
Introduction .................................................. 27-123 This is a gear type coupling comprising a drive plate
Remove and Install ..................................... 27-124 bolted to the engine flywheel and a coupling clamped
Figure 479.
B
A Drive plate (PIL 15-54)
B Coupling
27 - 123 9813/7400-1 27 - 123

27 - Driveline
03 - Coupling
Remove and Install

Consumables
JCB Threadlocker and 4101/0550 0.01L
Sealer (High Strength) 4101/0552 0.2L
Remove
2. Remove the wheel drive pump, refer to (PIL
27-31).
3. Remove the capscrew, remove the coupling off
the pump input shaft.
Figure 480.
B
F
B Coupling
D Capscrew (hidden)
F Circlip
Install
procedure.
2. Before you install the coupling to the pump input
shaft, make sure that the circlip is installed to the
groove in the bore.
3. Coat the threads of the capscrew with JCB
Threadlocker and tighten to the correct torque
value.
(High Strength)

Item Nm
D 49
27 - 124 9813/7400-1 27 - 124

27 - Driveline
38 - Track Drive Motor
Contents Page No.
27-38-00 General ......................................................................................................................... 27-127
27 - 125 9813/7400-1 27 - 125

Notes:
27 - 126 9813/7400-1 27 - 126

27 - Driveline
00 - General
Introduction .................................................. 27-127 The radial piston motor consists of a two part
Technical Data ............................................. 27-129 housing, rotary piston group, cam, output shaft and
Diagram ....................................................... 27-129 a flow distributor.
The motor converts hydrostatic energy into
Disassemble and Assemble ........................ 27-133 mechanical energy.
Hydraulic fluid is directed from the motor inlet port

in the rear case via the flow distributor through
galleries to the cylinder block. The radially arranged
pistons in the cylinder bores face a pressure increase
and perform via rollers a stroke movement against
the cam ring. The reaction force at the cam ring
generates a torque, which is transferred to the output
shaft via splines in the cylinder block.
When the torque exceeds the shaft load, the cylinder

block turns which causes the pistons to stroke
(working stroke). Once the end of a stroke is reached
the piston is returned to its bore by the reaction force
at the cam (return stroke) and the fluid is fed to the
motor outlet port in the rear case.
The output speed depends on the displacement

and is proportional to the inward flow. The number
of working and return strokes corresponds to the
number of lobes on the cam multiplied by the number
of pistons.
Figure 481.
6 5
Z 4
A B
L
1
2 7
1 Front case housing 2 Rear case housing

3 Pistons 4 Cylinder block
5 Cam, Cam ring 6 Output shaft
27 - 127 9813/7400-1 27 - 127

27 - Driveline
00 - General
7 Flow distributor
Two Speed Option

The motor can be switched to a low-torque and
integrated valve which directs hydraulic fluid to only
one half of the motor while continuously re-circulating
the fluid in the other half.
This reduced displacement mode reduces the flow

required for a given speed and gives the potential
for cost and efficiency improvements. The motor
maximum speed remains unchanged.
27 - 128 9813/7400-1 27 - 128

27 - Driveline
00 - General
Technical Data Diagram
Table 183. Motors M1 and M2 Figure 482. Single Speed Machines

Motor Type Radial Piston Radial Piston
Single Speed Two Speed
Displacement 1.07L 1.07L/0.67L
Maximum 420bar 420bar
Working Pres- (6,086.9psi) (6,086.9psi)
sure
Maximum 150rpm 150rpm
Speed
Minimum Brake 11bar 11bar
Release Pres- (159.4psi) (159.4psi)
sure A Main port
B Main port
Minimum Brake 4,400N·m 4,400N·m Z Drain port
Holding Torque F Filter port
Figure 483. Two Speed Machines
A Main port
B Main port
Z Drain port
F Filter port
X 2 Speed port
27 - 129 9813/7400-1 27 - 129

27 - Driveline
00 - General
Remove and Install
Consumables 2. Remove the sprocket. Refer to (PIL 27-36).

JCB Threadlocker 4101/0250 0.01L installation.
Strength) 4. Remove the hoses, cap the ends with blanking
conform to JCB standard 9993/0003. 5. Support the motor and remove the bolts.
6. Remove the motor, cap the ports with blanking
Remove caps to prevent loss of fluid and ingress of dirt.
1. Make the machine safe with the lift arm and cab 6.1. Single Speed Motor
27 - 130 9813/7400-1 27 - 130

27 - Driveline
00 - General
Figure 484.
D
C
A Motor B Bolts
C Sprocket retaining bolts D Sprocket
6.2. 2 Speed Motor
27 - 131 9813/7400-1 27 - 131

27 - Driveline
00 - General
Figure 485.
D
C
A
A Motor B Bolts
C Sprocket retaining bolts D Sprocket
Install Table 184. Torque Values
1. Replacement is a reversal of the removal Item Nm

procedure. B 184
2. Make sure all hoses and ports are clean and free
from dirt. Tighten the bolts to the correct torque
value.
3. Apply JCB Threadlocker and Sealer to the motor
mounting bolts before installation.
(Medium Strength)
27 - 132 9813/7400-1 27 - 132

27 - Driveline
00 - General
Consumables Park Brake

JCB High Strength 4102/0551 0.05L Refer to (PIL 24-18).
Threadlocker
JCB Threadlocker 4101/0250 0.01L Motor-Disassemble
Strength) The illustration shows a cover 1 on the rear case
instead of the brake assembly used on the JCB
application.
4003/2006 12.5kg
4003/2005 50kg 1. Mark the relative positions of the front case, rear
case and rotational assembly.
The disassemble and assemble instructions are
intended for cleaning purposes and for the 2. Remove all the capscrews.
replacement of seals.
3. Separate the front and rear case assemblies
If on inspection the motor components are found to from the rotational assembly. Take care to keep
be worn it is recommended that the motor unit is the rotational assembly items together as a unit.
replaced with a new unit.
Figure 486.
3 1
2
1 Cover 2 Front case assembly

3 Rear case assembly 4 Rotational assembly
5 Capscrews
27 - 133 9813/7400-1 27 - 133

27 - Driveline
00 - General
Motor-Assemble Figure 487.

from debris. 1
2. Install a new O-ring to the mating face of the front 6 7
case assembly.
3. Install the rotational assembly to the front case
assembly, take care not to damage the shaft 9
splines. Position the cam of the rotational
assembly to align the reference marks made 2
during disassembly.
4. Install a new O-ring to the mating face of the
rear case assembly and position the rear case
assembly on to the rotational assembly, align the
reference marks.
5. Coat the capscrews with JCB Locking Fluid and
install to the assembly. Tighten the capscrews 4
diagonally to the correct torque value.
Consumable: JCB High Strength Threadlocker
3
6. Check that the drive shaft rotates freely.
Table 185. Torque Table 8

Description Torque Value 5
Capscrews (Item 5) 282–300N·m
1 O-ring
Front Case-Disassemble 2 Split ring
1. Remove the O-ring. 3 Washer
4 Motor shaft
2. Remove the split ring, use a soft steel drift to 5 Bearing cup
separate, then remove the washer. 6 Seal
7 Seal
3. Support the front case on blocks and press the 8 Bearing cup
motor shaft out of the bearings. 9 Plug
4. Use a mechanical puller to remove the bearing Front Case-Assemble
cup 5 from the front case.
5. Carefully remove the seals from the front case from debris.
and the motor shaft. Carefully remove the seal 7
from the front case. 2. Use a suitable tool to insert the bearing cup 5 into
the front case.
6. Use a mechanical puller or soft steel drift to
remove the bearing cup 8 from the front case. 3. Use a suitable tool to insert a new seal into the
front case. Lubricate the lip of the seal with G3
7. Use a mechanical puller to remove the bearing grease.
cones from the shaft.
4. Use a suitable tool to insert the rear bearing cup
into the front case.
5. Use a suitable tool to install both halves of the
new seal 6 into the grooves in the front case and
the motor shaft. Lubricate the contact faces of the
seal with hydraulic oil.
6. Place the motor shaft vertically on to a press.
27 - 134 9813/7400-1 27 - 134

27 - Driveline
00 - General
7. Warm the front bearing cone, then use a bench Figure 488.
press and a suitable tool to press on to the motor
shaft.
3 2
8. Pack the front bearing cone with G3 grease.
9. Cover the shaft spline with tape to protect the lip 1
seal.
10. Remove the plug from the hub.
11. Install the front case assembly to the motor shaft
assembly.
12. Remove the tape from the spline.
13. Warm the rear bearing cone, then use a bench
press and a suitable tool to a load of 4 tonnes to
press on to the motor shaft. Rotate the front case
5 times during this process.
14. Install the split ring on to the motor shaft.
15. With the pre-load still applied, use a set of
slip gauges to measure the gap between the
bearing and the split ring. This step should be
completed less than 10 minutes after you remove
the bearing from the heater.
16. Remove the pre-load. 1 Pistons
2 Rollers
17. Remove the split ring and install the washer with
3 Cam
a thickness of 0.2 to 0.3 mm (0.008 to 0.012 in)
greater than the measured gap, then install the
split ring. Rear Case-Disassemble
18. Half fill the seal 6 cavity with hydraulic oil. Coat 1. Remove the park brake, refer to (PIL 24-18).
the threads of the plug with JCB Sealant before 2. Remove and discard the O-rings.
you insert into the plug hole and tighten.
Consumable: JCB Threadlocker and Sealer 3. Drop the rear case assembly from approximately
(Medium Strength) 80 mm (3 in) on to a wooden or plastic
surface (timing face down). This will release the
19. Check that the motor shaft rotates freely in the distributor from the assembly. At all times take
front case assembly. care not to damage the timing face.
Rotational Assembly 4. Remove the stop pin from the rear case.
5. Check the timing face of the distributor. If
The components of the rotational assembly should
necessary lap the timing face.
be kept together. Pistons must be installed in the
same bores from which they were removed. 6. Remove and discard all of the sealing rings.
If there are signs of wear on the pistons, rollers or
cam, the complete motor must be replaced.
27 - 135 9813/7400-1 27 - 135

27 - Driveline
00 - General
Figure 489. Rear Case-Assemble

1. Check that all components are clean and free
4 from debris.
2
2. Place the springs into the recesses in the
distributor and use a small amount of grease to
1 hold them in position.
3. Insert new distributor seals (as appropriate) into
12 the correct grooves in the rear case with a
5 minimum distortion of the seals.
4. Insert the stop pin into the distributor stop pin
hole.
6 5. Use a suitable tool to install and align the
distributor into the rear case in line with the stop
pin hole in the rear case.
6. Install new O-rings.
7
8 9 10 11 Flushing Valve-Disassemble
1. Remove the plug 1 and O-ring 2 from the rear
case.
1 O-ring 2. Remove the spring 3.
2 O-ring
3 O-ring 3. Remove the poppet and shim (if installed).
4 Rear case assembly
4. Remove the plug 5 and O-ring 6 from the rear
5 Distributor
case.
6 Stop pin
7 Sealing ring 5. Remove the spring 7.
8 Sealing ring
9 Sealing ring 6. Remove the flushing spool and washer.
10 Sealing ring
11 Sealing ring 7. Remove the spring 10 from the rear case spool
12 Springs bore.
8. Inspect the spool and the poppet for damage and
debris, if necessary replace the parts.
27 - 136 9813/7400-1 27 - 136

27 - Driveline
00 - General
Figure 490.
B-B
10
8
7
9
6
5
C
3
4
B B 2
1
C-C
C
1 Plug 2 O-ring
3 Spring 4 Poppet
5 Plug 6 O-ring
7 Spring 8 Flushing spool
9 Washer 10 Spring
Flushing Valve-Assemble Table 186. Torque Table
1. Install the spring 10 into the spool bore in the rear Description Torque Value
case. Plug (Item 5) 35–40N·m
Plug (Item 1) 12–15N·m
2. Lubricate the flushing spool with oil and insert
into the spool bore. Make sure that it moves
freely. Two Speed Spool-Disassemble
3. Install the washer and spring 7. 1. Remove the spool with washer.
4. Install the new O-ring 6 to the plug 5, Install into 2. Remove the internal spool and spring 4 from the
the rear case and tighten the plug to the correct spool assembly.
torque value.
3. Remove the spring 5.
5. Assemble the shim (if installed) and the spring 3
4. Remove the washer and the circlip from the
into the poppet. Lubricate the poppet with oil and
spool.
insert into the rear case.
5. Remove the seal ring and the seal 8 from the rear
6. Install a new O-ring 2 to the plug 1, install to
case. Remove the seal 9 from the brake housing.
the rear case and tighten the plug to the correct
torque value. 6. Inspect the spool for damage, replace if
necessary.
27 - 137 9813/7400-1 27 - 137

27 - Driveline
00 - General
Figure 491.
4
5
7 9
8
3
2
6 10
1 Spool
2 Washer
3 Internal spool
4 Spring
5 Spring
6 Circlip
7 Seal ring
8 Seal
9 Seal
10 Brake housing
Two Speed Spool-Assemble

1. Install the circlip and washer on to the spool.
2. Insert the spring 5 into the rear case.
3. Insert the spring 4 and poppet into the bore of the
spool.
4. Insert new O-rings into the seal ring and install
the seal ring into the brake housing.
5. Lubricate the spool with oil and install the
assembly into the rear case. Check that the
assembly moves freely.
27 - 138 9813/7400-1 27 - 138

27 - Driveline
63 - Drive Chain
63 - Drive Chain
Contents Page No.
27-63-00 General ......................................................................................................................... 27-141
27 - 139 9813/7400-1 27 - 139

Notes:
27 - 140 9813/7400-1 27 - 140

27 - Driveline
63 - Drive Chain
00 - General
Introduction .................................................. 27-141 The final drive to the wheels is achieved using four
Remove and Install ..................................... 27-142 chains. A chain casing on each side of the machine
houses two chains, one to the front wheel and one to
the rear wheel. The chain casings contain oil in which
the chains run, the chains are driven by the wheel
drive motors. Refer to (PIL 27-00).
27 - 141 9813/7400-1 27 - 141

27 - Driveline
63 - Drive Chain
00 - General
Remove and Install Figure 493. Right-hand side
Consumables A C
Description Part No. Size B
JCB Chain Lubricant 4004/0237A 0.3L
If you need to remove the rear drive chains, you must

remove the front drive chains first.
Remove D
E
2. Raise and support the machine on the side to be
worked on.
A Drive motor
3. Drain the oil from the chain case, refer to (PIL B Front drive chain
27-63). C Rear drive chain
D Front hub
4. Remove the front and rear wheels, refer to (PIL E Rear hub
27-30).
5. Remove the front hub, refer to (PIL 27-27). Install
6. Remove the drive motor mounting bolts to create 1. Installation is a reverse of the removal procedure.
space between the drive motor sprocket and the
chain case wall.
3. Apply lubricant to the sprocket and chain, check
7. Remove the front drive chain from the motor
for correct operation.
sprocket.
Consumable: JCB Chain Lubricant
8. If necessary, remove the rear hub, refer to (PIL
27-28).
9. Remove the rear drive chain from the motor
sprocket.
Figure 492. Left-hand side
B A
C
D
E
A Drive motor
B Front drive chain
C Rear drive chain
D Front hub
E Rear hub
27 - 142 9813/7400-1 27 - 142

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-49 Schematic Symbols ........................................................................................................ 30-14
30-00-50 Schematic Circuit ........................................................................................................... 30-18
30-03 Tank
30-03-00 General ........................................................................................................................... 30-27
30-03-12 Suction Strainer .............................................................................................................. 30-31
30-03-24 Breather .......................................................................................................................... 30-33
30-04 Filter
30-04-00 General ........................................................................................................................... 30-37
30-04-03 Main ................................................................................................................................ 30-38
30-04-09 Return Line .................................................................................................................... 30-40
30-10 Charge Pump
30-10-00 General ........................................................................................................................... 30-45
30-11 Gear Pump
30-11-00 General ........................................................................................................................... 30-47
30-15 Cylinder Ram
30-15-00 General ........................................................................................................................... 30-53
30-15-06 Lift Arm ........................................................................................................................... 30-60
30-15-07 Lift Extension .................................................................................................................. 30-62
30-15-11 Lift Arm Crowd ............................................................................................................... 30-63
30-15-99 Seal Kit ........................................................................................................................... 30-66
30-18 Accumulator
30-18-00 General ........................................................................................................................... 30-71
30-18-06 Smooth Ride System (SRS) .......................................................................................... 30-75
30-51 Lift Arm Control Valve Block
30-51-00 General ........................................................................................................................... 30-81
30-60 Directional Control Valve
30-60-00 General ........................................................................................................................... 30-89
30-60-15 Joystick ........................................................................................................................... 30-91
30-60-28 Auxiliary Changeover ................................................................................................... 30-101
30-60-40 Lift Arm Self Levelling .................................................................................................. 30-103
30-60-81 Cooling Fan .................................................................................................................. 30-105
30-71 Pilot Changeover Valve
30-71-00 General ......................................................................................................................... 30-109
30-93 Hose
30-93-00 General ......................................................................................................................... 30-113
30-97 Connectors
30-97-00 General ......................................................................................................................... 30-117
30-97-03 Quick Release Coupling .............................................................................................. 30-120
30-97-09 Adaptor ......................................................................................................................... 30-122
9813/7400-1
2017-03-27
30-97-18 O-Ring Face Seal (ORFS) ........................................................................................... 30-124
30-97-24 Push Lock Fitting ......................................................................................................... 30-126
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-127
9813/7400-1
2017-03-27
Acronyms Glossary
ARV Auxiliary Relief Valve

MRV Main Relief Valve
ORFS O-Ring Face Seal
SAE Society of Automotive Engineers
SRS Smooth Ride System
9813/7400-1
2017-03-27
Notes:
9813/7400-1
2017-03-27
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-49 Schematic Symbols ........................................................................................................ 30-14
30-00-50 Schematic Circuit ........................................................................................................... 30-18
30 - 1 9813/7400-1 30 - 1
Notes:
30 - 2 9813/7400-1 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
Technical Data ................................................. 30-5 to specific components in a machine.
Diagram ........................................................... 30-5
To help you trace specific hydraulic problems to
Fault-Finding .................................................... 30-6 a faulty unit (valve, actuator, ram etc.), refer to
Discharge and Pressurise ............................... 30-9 Fault finding (PIL 30-00). Once you have traced the
Drain and Fill ................................................... 30-9 faulty unit, refer to the relevant section for removal,
Clean ............................................................. 30-10 disassembly and checking instructions.
Check (Level) ................................................ 30-11 To help identify circuits, valves, rams etc. mentioned
Check (Pressure) .......................................... 30-12 in the fault finding procedures. Refer to the hydraulic
Bleed ............................................................. 30-12 schematic diagrams (PIL 30-00-50).
• Before you begin fault finding, read the Health

and Safety Information. Refer to (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 (121.9°F).
• Whatever the fault, check the condition of the
hydraulic fluid. Drain and replace if necessary.
Refer to Hydraulic fluid quality in this procedure
and Hydraulic System - Clean (PIL 30-00).
• Make sure you remove ALL contamination and
if possible identify its origin. It may be part of a
component from elsewhere in the circuit.
Hydraulic Fluid Quality

This machine uses a large volume of fluid in the
hydraulic system for power transmission, equipment
lubrication, rust prevention and sealing. According
to a survey conducted by a pump manufacturer,
seventy per cent of the causes of problems in
hydraulic equipment were attributable to inadequate
maintenance of the quality of the hydraulic fluid.
Therefore, it is obvious that control of the quality of
the hydraulic fluid helps prevent hydraulic equipment
problems and greatly improves safety and reliability.
Furthermore from an economic angle it extends the
life of the hydraulic fluid if quality is maintained.
Hydraulic Contamination
Once inside the system, hydraulic circuit
contaminants greatly affect the performance and life
of hydraulic equipment. For example, contaminants
in a hydraulic pump develop internal wear to cause
internal leakage and hence lower discharges. Wear
particles generated will circulate with the hydraulic
fluid to cause further deterioration in the performance
of this and other equipment. Contaminants also
enter principal sliding sections of the equipment
causing temporary malfunction, scuffing, sticking
and leakage and can lead to major problems. The
main contaminants can be classified as follows:
30 - 3 9813/7400-1 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
started while the hoses are open.
manufacture, assembly and operation.
WARNING! Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well clear of
pressurised fluid and wear protective glasses. If fluid
penetrates your skin, get medical help immediately.
WARNING! Take care when disconnecting hydraulic
hoses and fittings as the oil will be hot.
WARNING! Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not use
the machine if a hose or hose fixture is damaged.
Notice: Using incorrect fluid could damage the
system. See Fluids, Capacities and Lubricants for
the correct fluid. The fluid can harm your skin. Wear
rubber gloves. Cover cuts or grazes.
Notice: Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component
has been disconnected, always install protective
caps and plugs to prevent dirt ingress.Failure to
follow these instructions will lead to dirt entering the
system. Dirt in the system will seriously damage
the systems components and could be expensive to
repair.
CAUTION! The temperature of the hydraulic oil will
be high soon after stopping the machine. Wait until it
cools before beginning maintenance.
Notice: Using incorrect fluid could damage the
system. See Fluids, Capacities and Lubricants for
the correct fluid. The fluid can harm your skin. Wear
rubber gloves. Cover cuts or grazes.
30 - 4 9813/7400-1 30 - 4
00 - General
00 - General
Technical Data Diagram
Table 187. Main Valve Block Hydraulic State Colour Codes

Description Data
Nominal flow 90L/min. +35L/min @ Some diagrams in this section use colours to
AUX inlet represent the different hydraulic system states. Refer
to Figure 494.
Nominal working pres- 230bar (3,333.3psi)
sure Figure 494.
MRV (Main Relief Valve) 230bar (3,333.3psi) @
setting 90L/min
Tilt ARV (Auxiliary Relief 280bar (4,058.0psi)
Valve) setting 1 2 3 4 5 6 7
Lift ARV setting 280bar (4,058.0psi)
1 Lock up
2 Cavitation
Table 188. Loader Pump - Standard (P3) 3 Exhaust
Description Data 4 Neutral
Type Tandem gear 5 Servo
6 Pressure
Displacement @ 230bar 38 cc
7 Maximum pressure
(3,333.3psi)
Table 189. Charge Pump (P4)

Description Data
Type Tandem gear
Charge pressure 24bar (347.8psi)
(1,594.2psi)
Table 190. Loader Pump - High-Flow (P5)

Description Data
Type Triple gear
Relief 230bar (3,333.3psi)
(3,333.3psi)
Table 191. Return Line Filter (inc. High Flow)

Description Data
Maximum working pres- 5bar (72.5psi)
sure
Maximum rated flow 125L/min
Filtration level 10 Micron
Table 192. Hydraulic Tank Capacity

Description Data
Total capacity 32L
To sight glass 26L
Table 193. Ram dimensions

Ram lo- Bore Rod Di- Stroke Weight
cation ameter
Lift 90mm 50mm 835mm 56.3kg
Extend 80mm 50mm 1,100mm 46.6kg
Tilt 100mm 45mm 387mm 38.4kg
30 - 5 9813/7400-1 30 - 5
00 - General
00 - General
Fault-Finding
Fault
Lack of power in all loader functions Table 194. Page 30-6
All hydraulic rams slow to operate Table 195. Page 30-6
One hydraulic service fails to operate or is slow to operate Table 196. Page 30-6
Engine tends to stall when hydraulics are under load Table 197. Page 30-7
Valve spool sticking Table 198. Page 30-7
Ram creep Table 199. Page 30-7
Hydraulic oil becomes too hot Table 200. Page 30-7
Boom judders when used while machine is moving Table 201. Page 30-8
Table 194. Lack of power in all loader functions

Cause Remedy
Insufficient hydraulic fluid Check for leaks and top up as required
Hydraulic leaks in system Check hoses, replace as required
Main relief valve (MRV) setting incorrect Check and adjust as required
Low loader pump flow Check pump flow, if necessary service or replace
pump
Charge filter by-pass valve leaking Check condition of hydraulic filter, Check operation of
by-pass valve
Charge pressure incorrect Check relief valve or charge pump
Piston rod bent Replace piston rod, Check pressure setting of MRV,
Check that associated pivot pins are adequately
greased
Manual control linkage bent Disconnect linkage. Repair linkage or renew
Table 195. All hydraulic rams slow to operate

Cause Remedy
Low loader pump flow Check pump flow, if necessary service or replace
pump
Charge pressure incorrect Check relief valve or charge pump
Servo pressure low Carry out charge pressure check, Check for blocked
service feed hose or faulty joystick
Neutral circuit or low pressure lines leaking, Check pipe lines and replace as required
damaged, trapped or kinked
Restriction in neutral circuit lines Check hoses and pipes, replace as necessary
Service pipe lines leaking, damaged, trapped or Check hoses and pipes, replace as required
kinked
Table 196. One hydraulic service fails to operate or is slow to operate

Cause Remedy
kinked
Ram or pipe lines from ram leaking Check and rectify as required
Valve spool not operating Check for leaks, rectify as required. Make sure that
spool lock-out is operating (check for faulty wiring,
solenoid sticking, burr on spool, etc.). Make sure that
associated load hold check valve is operating. On
servo machines, check operation of joystick and feed
hoses. On manual machines, check that control lever
and associated linkage is operating the spool, rectify
as required
30 - 6 9813/7400-1 30 - 6
00 - General
00 - General
Cause Remedy
Valve spool not moving fully from neutral to full Spool movement should be 5.5 mm (0.22 in). On
selection servo machines, check servo (charge) pressure
Valve spool leaking Rectify, check for contamination
Poor engine performance Check engine performance
Table 197. Engine tends to stall when hydraulics are under load
Cause Remedy
Poor engine performance Check engine performance
Manual control linkage bent Disconnect linkage. Repair linkage or renew
Table 198. Valve spool sticking

Cause Remedy
Oil cooler obstructed Remove debris from cooler fins
Hydraulic fluid dirty Clean tank strainer. If strainer badly clogged, drain
and flush hydraulic system then fill with clean
hydraulic fluid
Service pipe connection over tightened Check tightness
Valve housing twisted during installation Loosen retaining bolts and tighten to correct torque
Bent spool Disassemble control valve. Renew spool as
necessary
Spool return spring broken Renew as necessary
Spool return spring or cap out of alignment Remove cap, check that spring is in correct position.
Install cap and tighten bolts to correct torque value
Temperature distribution within control valve not Warm up entire system before using service
uniform
Table 199. Ram creep

Cause Remedy
Valve spool not operating Check for leaks, rectify as required. Make sure that
spool lock-out is operating (check for faulty wiring,
solenoid sticking, burr on spool, etc.). Make sure that
associated load hold check valve is operating. On
servo machines, check operation of joystick and feed
hoses. On manual machines, check that control lever
and associated linkage is operating the spool, rectify
as required
Piston rod bent Replace piston rod. Check pressure setting of MRV,
Check that associated pivot pins are adequately
greased
Table 200. Hydraulic oil becomes too hot

Cause Remedy
Hydraulic filter clogged Change hydraulic filter
Charge filter by-pass valve leaking Check condition of hydraulic filter, Check operation of
by-pass valve
Air in hydraulic system Bleed System
Oil temperature abnormally high Check for correct fluid. Check oil cooler and grille for
blockage
30 - 7 9813/7400-1 30 - 7
00 - General
00 - General
Table 201. Boom judders when used while machine is moving

Cause Remedy
Loader pump flow low Check flow rate
Restriction in neutral circuit lines Check hoses and pipes, replace as necessary
kinked
30 - 8 9813/7400-1 30 - 8
00 - General
00 - General
Discharge and Pressurise Drain and Fill

CAUTION Oil will gush from the hole when the
Release the Auxiliary Hydraulic Pressure drain plug is removed. Keep to one side when you
remove the plug.
Use the procedure below to vent the hydraulics.
You must vent the hydraulics before carrying out
maintenance on the machine.
Drain
1. Make the machine safe with the lift arm lowered,
1. Make the machine safe with the lift arm lowered. refer to (PIL 01-03).
2. Stop the engine and wait until the hydraulic
2. Turn off the engine. system has cooled.
3. Wearing a suitable glove, pull the relief pin ring 3. Tilt the cab. Refer to Make the machine safe with
outwards firmly to relieve pressure on all auxiliary the lift arm raised, refer to (PIL 01-03).
couplers.
Duration: 5s 4. Discharge the hydraulic pressure from the
system, refer to (PIL 30-00).
Figure 495.
5. Locate the hydraulic oil drain plug in the left rear
wheel arch.
6. Place a suitable container beneath the drain plug
to catch the oil.
B
7. Remove the drain plug and catch the hydraulic
oil.
A
Fill
procedure, note the following:
C
2. Install the drain plug with a new O-ring.
3. Fill the system with the correct oil to the correct
level.
4. Tighten the plug to the correct torque value.
A Auxiliary coupler
B Auxiliary coupler
C Relief pin
30 - 9 9813/7400-1 30 - 9
00 - General
00 - General
Figure 497. Clean

B Special Tools
C
E
Hydraulic Flushing Rig 892/01255 1
Cleaning Operation
The purpose of cleaning oil is to remove
contaminants of all types and sludge by filtering
hydraulic fluid through a cleaning unit. Follow the
instructions in the Hydraulic flushing rig instruction
A manual.
Procedure
1. Connect the Hydraulic flushing rig in place of the
hydraulic filter.
Special Tool: Hydraulic Flushing Rig (Qty.: 1)
2. Run the system for sufficient time to pump all the
hydraulic fluid through the unit.
3. Disconnect the cleaning unit and reconnect the
filter.
4. Top up the system with clean hydraulic fluid as
required.
Figure 498.
D
A
A Hydraulic tank
D Drain plug

Item Nm
A 30
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 - 10 9813/7400-1 30 - 10
00 - General
00 - General
• Red Blood Cell = 8 microns (0.008 mm, Check (Level)

0.000315 in)
• Human Hair = 70 microns (0.07 mm, 0.00275
in) 1. Make the machine safe. Refer to (PIL 01-03).
• Grain of Salt = 100 microns (0.1 mm, 0.00394
in) 2. Look at the hydraulic fluid in the sight tube. If
the hydraulic fluid is cloudy, water or air is in the
The smallest particle visible to the naked eye is system. Water or air in the system can damage
40 microns (0.00157) approximately. Standards will the hydraulic pump. Refer to Hydraulic System
often be quoted to ISO (International Standards Clean and Fault Finding (PIL 30-00).
Organisation) for which literature can be obtained. 3. The level of hydraulic fluid should be between the
two marks on the sight tube.
4. If necessary, add the recommended hydraulic
fluid:
4.1. Release the pressure from the hydraulic
tank.
4.2. Get safe access to the hydraulic filler port.
4.3. Use a suitable container to add the
hydraulic fluid through the filler port.
4.4. Check the level of hydraulic fluid.
30 - 11 9813/7400-1 30 - 11
00 - General
00 - General
Check (Pressure) Bleed
Refer to Driveline, Wheel Drive Pump, General (PIL If you replace the hydraulic oil or repair/replace a
27-31-00). hydraulic component or remove any hydraulic pipes,
you must bleed the air from the hydraulic circuit.
1. Loosen both of the suction lines on the pump.

Figure 499.
A
A Pump suction lines
2. Remove the air bleed screws on the transmission
pump.
Figure 500.
R
R Air bleed screws

3. Check the hydraulic oil level and top up as
required. Refer to (PIL 30-00).
4. Once clean oil is present at the suction line
tighten the suction line.
30 - 12 9813/7400-1 30 - 12
00 - General
00 - General
5. Once clean oil is present at the air bleed screw

holes install the bleed screws.
6. Start the engine and use the instrument panel
to monitor the charge pressure. Refer to (PIL
30-24), Operation - Logic Control. If the charge
pressure does not rise stop the engine and
resolve the fault.
7. Once the charge pressure is measured, check
the operation of all the hydraulic services and
check for leaks.
30 - 13 9813/7400-1 30 - 13
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-14 Complex hydraulic components and circuits can
Diagram ......................................................... 30-15 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 - 14 9813/7400-1 30 - 14
00 - General
Diagram Table 206. Control valves

Symbol Description
Used to enclose sever-
Table 203. 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 204. 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 205. 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 - 15 9813/7400-1 30 - 15
00 - General
Table 207. 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 208. 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
Quick release couplings
- connected General control
Quick release couplings
- disconnected Push button operated
Reservoir - return line
above fluid level Lever operated
Reservoir - return line

Pedal operated
below 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 - 16 9813/7400-1 30 - 16
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 seperate pilot
valve
Pressure guage
Pressure switch
30 - 17 9813/7400-1 30 - 17
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-18 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-19 representation of the machines hydraulic circuit. It
shows the components of the circuit as simplified
hydraulic symbols, and the connections between
the different components. The schematic diagram
is used to troubleshoot problems and to make
sure that all the connections have been made and
that everything is present. Detailed schematics for
individual systems are given in the relevant PIL
section.
30 - 18 9813/7400-1 30 - 18
00 - General
Diagram
Hydraulic schematic 333-X3611-1 (sheet 1) Telescopic Lift Arm
30 - 19 9813/7400-1 30 - 19
Notes:
30 - 20 9813/7400-1 30 - 20
00 - General

3
22
M1 1 26
M2
25
28
P4 P5
24
6 2
21
10
15
9 27
8 P1 P2 P1 P2 P3
30 - 21 9813/7400-1 30 - 21
00 - General
30-22 30-23
M1 1
M2
P4 P5
Page 30-23
10
15
9 27
8 P1 P2 P1 P2 P3
30 - 22 9813/7400-1 30 - 22
00 - General
30-22 30-23
22
26
M2
25
28
24
2
21
Page 30-22
10
30 - 23 9813/7400-1 30 - 23
00 - General
1 Charge filter 2 Brake transducer

3 Auxiliary drain manifold 6 Charge transducer
7 Return filter 8 Tank
9 Pressure breather 10 2-Speed valve (optional)
15 Fan motor 21 Primary control valve
22 SRS (Smooth Ride System) valve (optional) 24 Lift arm cylinder
25 Bucket cylinder 26 Extend cylinder
27 Lower valve 28 Extending Lift arm control valve
M1 Left-hand side single speed motor M2 Right-hand side single speed motor
P1 Loader pump P2 Charge pump
P3 High flow pump (optional) P4 Transmission pump
P5 Transmission pump
30 - 24 9813/7400-1 30 - 24
03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ........................................................................................................................... 30-27

30-03-12 Suction Strainer .............................................................................................................. 30-31
30-03-24 Breather .......................................................................................................................... 30-33
30 - 25 9813/7400-1 30 - 25
Notes:
30 - 26 9813/7400-1 30 - 26
03 - Tank
00 - General
Introduction .................................................... 30-27 The hydraulic tank holds excess hydraulic oil to
Technical Data ............................................... 30-28 accommodate volume changes due to the following.
Remove and Install ....................................... 30-30 • 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: General (Page 30-3).
30 - 27 9813/7400-1 30 - 27
03 - Tank
00 - General
Technical Data
Table 209.
32L (Total Capacity)
Capacity
26L (To sight glass)
30 - 28 9813/7400-1 30 - 28
03 - Tank
00 - General
Figure 502.
B
C
E
A Tank B Filler cap / Suction Strainer

C Breather D Drain plug
E Main Filter
30 - 29 9813/7400-1 30 - 29
03 - Tank
00 - General
B
Remove C
E
2. Discharge the hydraulic pressure from the
3. Drain the hydraulic tank. Refer to (PIL 30-00).
4. Remove the battery and battery tray. Refer to
(PIL 33-03).
A
5. Remove the air filter housing and air intake hose.
6. Unplug the hydraulic oil temperature sensor.
7. Mark all the hoses to help installation.
8. Remove the hoses, cap the ends with blanking
9. Support the hydraulic tank and remove the fixing
bolts.
10. Remove the hydraulic tank, cap the ports with
blanking caps to prevent loss of fluid and ingress
of dirt.
Install
procedure.
from dirt.
3. Fill the tank with the correct hydraulic oil to the
correct level. Refer to (PIL 30-00).
4. Make sure all components are tightened to the

Item Nm
D 22
30 - 30 9813/7400-1 30 - 30
03 - Tank
12 - Suction Strainer
12 - Suction Strainer Introduction

Introduction .................................................... 30-31 The suction strainer is a component used for trapping
Remove and Install ....................................... 30-32 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 - 31 9813/7400-1 30 - 31
03 - Tank
12 - Suction Strainer

Remove procedure.

3. Discharge the hydraulic system. Refer to (PIL
30-00).
4. Unscrew the filler cap from the top of the
hydraulic tank.
5. Remove the suction strainer.
Figure 504.
B
C
E
D
A Hydraulic tank
B Filler cap
E Suction strainer (not shown located inside item
B)
30 - 32 9813/7400-1 30 - 32
03 - Tank
24 - Breather
24 - Breather Introduction
Introduction .................................................... 30-33 The hydraulic tank breather allows air in and out of
Remove and Install ....................................... 30-34 the tank. This smooths out the pressure fluctuations
in the hydraulic tank as hydraulic fluid is rapidly
drawn out from, or returned to the tank.
The breather also prevents contaminants like

moisture and particles from entering the tank when
air is drawn in. Contaminates can easily corrode,
wear out or otherwise reduce the fluid performance
of a hydraulic system.
When air is expelled from the tank the breather

prevents hydraulic fluid spillage.
30 - 33 9813/7400-1 30 - 33
03 - Tank
24 - Breather
Remove and Install
Remove
3. Unscrew the breather from top of the hydraulic
tank.
Figure 505.
B
C
E
D
A Hydraulic tank
C Breather
Install
procedure.
30 - 34 9813/7400-1 30 - 34
04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ........................................................................................................................... 30-37

30-04-03 Main ................................................................................................................................ 30-38
30-04-09 Return Line .................................................................................................................... 30-40
30 - 35 9813/7400-1 30 - 35
Notes:
30 - 36 9813/7400-1 30 - 36
04 - Filter
00 - General
00 - General
Introduction
Hydraulic filters are an important part of the

machines hydraulic system. Metal particles are
continually produced by mechanical components
and need to be removed along with other
contaminants.
The hydraulic filter assemblies are designed to filter

all the contamination that is generated through use
to the required level of cleanliness.
Filters are positioned in many different locations.

Refer to the relevant hydraulic filter for the location
and removal procedure.
The filters must be serviced to the requirements

of the machine maintenance schedules. To ensure
optimum performance and reliability it is important
that the machine's hydraulic system is serviced
periodically in accordance with the manufacturers
requirements.
30 - 37 9813/7400-1 30 - 37
04 - Filter
03 - Main
03 - Main Introduction
Introduction .................................................... 30-38 The main hydraulic filter is usually located in the main
Remove and Install ....................................... 30-39 hydraulic return line close to, or inside the hydraulic
tank.
Most filters incorporate a bypass valve. If the

filter becomes blocked, the bypass valve opens
and allows fluid to bypass the filter. This prevents
excessive back pressure which can damage the
hydraulic system. The filter is not effective when the
bypass valve is open.
30 - 38 9813/7400-1 30 - 38
04 - Filter
03 - Main
Remove and Install 3. Tighten the filter to the correct torque value.

The cleanliness of this component is critical and must Item Nm
conform to JCB standard 9993/0003.
E 30
Remove
1. Drain the Hydraulic Oil. Refer to (PIL 30-00).
2. Use a spanner to unscrew the filter canister
from the tank, remove the filter element from the
canister.
Figure 506.
E
E Hydraulic filter
Install
removal procedure.
2. Lubricate the seal on the new filter element with
clean oil and place inside the canister
30 - 39 9813/7400-1 30 - 39
04 - Filter
09 - Return Line
09 - Return Line Introduction

Introduction .................................................... 30-40 The cleanliness of this component is critical and
Technical Data ............................................... 30-41 must conform to JCB standard 9993/0003. Refer to
Remove and Install ....................................... 30-42 Hydraulic System - Introduction (PIL 3000).
30 - 40 9813/7400-1 30 - 40
04 - Filter
09 - Return Line
Technical Data
Table 212. Pressures

Description Pressures
Maximum working pres- 50bar (724.6psi)
sure
Table 213. Flow Rates

Description Flow Rates
Maximum rated flow 100L/min
Table 214. Filtration Level

Description Thickness
Filtration Level 10μm
30 - 41 9813/7400-1 30 - 41
04 - Filter
09 - Return Line
Remove and Install
Remove 3. Mark all hoses to help installation.
1. Make the machine safe. Refer to (PIL 01-03). 4. Remove the hoses, cap the ends with blanking
system. Refer to (PIL 30-00). 5. Remove the bolts and remove the filter assembly.
Figure 507.
A Return line filter
Installation
procedure.
from dirt.
30 - 42 9813/7400-1 30 - 42
10 - Charge Pump
10 - Charge Pump
Contents Page No.
30-10-00 General ........................................................................................................................... 30-45
30 - 43 9813/7400-1 30 - 43
Notes:
30 - 44 9813/7400-1 30 - 44
10 - Charge Pump
00 - General
00 - General
Technical Data

Maximum flow - Tandem 34L/min
Gear
(1)
(1) At 2400 rev/min and 25bar (362.3psi)
30 - 45 9813/7400-1 30 - 45
11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ........................................................................................................................... 30-47
30 - 46 9813/7400-1 30 - 46
11 - Gear Pump
00 - General
Introduction .................................................... 30-47 The standard machine has two gear pumps. The high
Technical Data ............................................... 30-48 flow machine has three gear pumps. The gear pumps
Operation ....................................................... 30-48 are bolted onto the transmission pumps in series.
The pumps are fixed displacement triple gear type
Disassemble and Assemble .......................... 30-50 and are direct driven by the engine. The high flow
pump section has an integrated unloader valve
section.
30 - 47 9813/7400-1 30 - 47
11 - Gear Pump
00 - General
Technical Data Operation
Table 216. Standard Pump (P3) - Flow Rates The loader pump P3 delivers oil flow to the machines
services. The oil flow passes through the main
control valve and joins the flow from high-flow gear
Maximum flow
(1)
90.8L/min pump P5 (if fitted), Oil returns to tank via a filter and
(1) At 2400 rev/min and 230 bar (3335 lbf/in2) cooler.
Table 217. High Flow Pump The charge pump P4 delivers oil flow to the main
(P3 and P5) - Flow Rates pumps P1 and P2 via filter F1 and the hydraulic fan.
Flow is then provided to the loader and transmission
Description Flow Rates servo joysticks.
Maximum flow - Lift Arm 90.8L/min
Section P3
(1)
Note: The pump shown is for illustration purposes
Maximum flow - High 41.6L/min only, the pump can vary depending on the machine
specification.
Flow Section P5
(1)
(1) At 2400 rev/min and 230 bar (3335 lbf/in2) Figure 508.
Table 218. Displacement

Pump Description Volume
P3 Loader Pump 0.038L
P4 Charge Pump 0.014L
P5 High Flow 0.017L
Pump
P5
P4
P3
P3 Loader pump
P4 Charge pump
P5 High flow pump
30 - 48 9813/7400-1 30 - 48
11 - Gear Pump
00 - General
Remove and Install Figure 510. Standard Machines
D
conform to JCB standard 9993/0003.

only, the pump can vary depending on the machine
specification.
Remove
system. Refer to (PIL 30-00). D
3. Mark all hoses and electrical connections to D Bolts
make sure of correct installation.
4. Remove the hoses, cap the ends with blanking Install
5. On high flow machines disconnect the wiring to removal procedure. Additionally do the following
the solenoid. steps.
Figure 509. High Flow Machines 2. Position the loader pump on to the main pump,
take care to engage the splines of the drive
E coupling.
D
3. Install and tighten the bolts to the correct torque
value.
4. Connect the suction hose. Fill the pump body
with clean hydraulic oil through the outlet hose
aperture then connect the hoses.
5. On high flow machines connect the wiring to the
solenoid.
6. Refill the hydraulic tank.
D Bolts (x2)
E Solenoid
6. Support the pump and remove the bolts (x2).
7. Remove the loader pump, cap the ports with
of dirt.
30 - 49 9813/7400-1 30 - 49
11 - Gear Pump
00 - General
Disassemble and Assemble Figure 512.
Gear pumps are manufactured using a process

known as cut-in, during which the gears, motor body,
and bearing blocks are allowed to establish a unique
relationship to each other.
Dismantling a pump and replacing components

is not recommended. Removal or replacement of
some internal components will modify their critical
dimensions, because pumps are cut-in at a specific
pressure to ensure maximum efficiency, removal
or replacement of internal components may be
detrimental to pump efficiency.

only, the pump can vary depending on the machine
specification.
4. Screw two self tapping screws one or two turns
into the seal.
Shaft Seal Replacement
Figure 513.
1. Clean the shaft area of all rust and dirt.
2. Use needle nose pliers or a sharp screwdriver to
remove the dust protector.
Figure 511.
A
5. Use side cutting wire pliers to remove the seal by

A Dust Protector prying out. Take care not to damage the shaft.
B Shaft seal
C Shaft
3. Use a sharp punch or awl to punch two holes
in the shaft seal. Do not drill the holes as this
can produce contamination which could enter the
pump.
30 - 50 9813/7400-1 30 - 50
11 - Gear Pump
00 - General
D C
D Side cutting wire pliers

6. Discard the seal.
Inspect the components

1. Inspect the new seal, the motor housing seal A Dust protector
bore and the sealing area on the shaft for rust, B Shaft seal
wear, and contamination. C Installation sleeve
2. Polish the shaft and clean the housing if

necessary, be careful not to allow contamination
to fall into the pump.
Install the new shaft seal

1. Cover the shaft splines with tape to protect the
shaft and seal during installation.
2. Lubricate the inside of the seal with hydraulic oil.
3. Start the seal into the housing with the cupped
side of the seal facing the pump.
4. Use an installation sleeve to press the seal slowly
into place. Stop when the seal is seated. The
installation sleeve should be 0.5 mm (0.02 in)
smaller than the housing bore.
5. Use the installation sleeve to install the dust
protector until it is flush with the pump housing.
30 - 51 9813/7400-1 30 - 51
15 - Cylinder Ram
15 - Cylinder Ram
Contents Page No.
30-15-00 General ........................................................................................................................... 30-53

30-15-06 Lift Arm ........................................................................................................................... 30-60
30-15-07 Lift Extension .................................................................................................................. 30-62
30-15-11 Lift Arm Crowd ............................................................................................................... 30-63
30-15-99 Seal Kit ........................................................................................................................... 30-66
30 - 52 9813/7400-1 30 - 52
15 - Cylinder Ram
00 - General
Introduction .................................................... 30-53 A hydraulic cylinder ram is a mechanical actuator
Health and Safety .......................................... 30-54 that is used to give a single directional force
Technical Data ............................................... 30-55 through a single action stroke. It is used in many
Component Identification ............................... 30-56 applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
Disassemble and Assemble .......................... 30-57 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 - 53 9813/7400-1 30 - 53
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 - 54 9813/7400-1 30 - 54
15 - Cylinder Ram
00 - General
should be kept to a minimum. If leaving for Technical Data

more than one week, apply a light coating
of suitable grease or petroleum jelly to the .............................................. Page 30-
exposed part of the ram piston rod. .............................................. Page 30-
2. Use genuine JCB parts when replacing parts.
Table 219. Dimensions
2.1. If parts other than genuine JCB parts Ram Descrip- Lift Arm Lift Arm
are used, the desired results may not be tion Crowd
obtained. Use only genuine JCB parts.
Bore 114.3mm 101mm
3. Caution during dismantling and reassembly. Rod diameter 63.5mm 50.8mm
Stroke 710mm 328.9mm
3.1. Dismantling the ram while it is still installed
on the machine can be dangerous as Weight 70.6kg 36.9kg
unexpected movements of the machine can End cap 678N·m 678N·m
occur. Remove the ram from the machine (Torque Value)
and then dismantle. Piston head 405N·m 405N·m
3.2. If reassembled with dirty hands, foreign (Torque Value)
matter can enter the ram causing a shorter
life span and also the other hydraulic
equipment may be damaged. Reassemble Table 220. Drilling Details
in a clean state. for Piston Head Retention
3.3. Follow the instructions in the diagrams Cylinder Ram 50 x 90 60 x 110
regarding torque tightening for screwed Size (mm)
parts. If the torque is too high or too low, it Dowel Size 25 x 8 30 x 12
can cause damage. (mm)
Guide Drill Di- 4mm 6mm
ameter
Guide Drill 19mm 25mm
Depth
Dowel Drill Di- 8-8.1mm 12-12.1mm
ameter (X)
Dowel Drill 27-28mm 32-33mm
Depth (Y)
Table 221. Dimensions

Ram De- Lift Arm Lift Arm Lift Arm
scription Crowd Extend
Bore 90mm 100mm 80mm
Rod diame- 50mm 45mm 50mm
ter
Stroke 833.5– 385.5– 1,098.5–
836.5mm 388.5mm 1,101.5mm
Weight 56.3kg 38.4kg 46.6kg
End cap 678N·m 678N·m 678N·m
(Torque
Value)
Piston head 405N·m 405N·m 405N·m
(Torque
Value)
30 - 55 9813/7400-1 30 - 55
15 - Cylinder Ram
00 - General
Figure 516. Typical Cylinder Ram
1 End cap 2 Seal

3 Seal 4 Seal
5 Locking dowel 6 Piston head
7 Piston rod 8 O-ring
9 Inner rod seal 10 Outer rod seal
11 O-ring 12 Piston eye bush
30 - 56 9813/7400-1 30 - 56
15 - Cylinder Ram
00 - General
Consumables Description Part No. Size

Description Part No. Size JCB Threadlocker 4101/0250 0.01L
Cleaner/Degreaser 4104/1557 0.4L and Sealer (Medium 4101/0251 0.05L
- General purpose Strength)
solvent based parts
cleaner The numerical sequence shown on the illustration is
JCB Activator 4104/0251 0.2L intended as a guide to disassembly.
4104/0253 1L
Figure 517. Typical Cylinder Ram
1 End cap 2 Seal

3 Seal 4 Seal
5 Locking dowel 6 Piston head
7 Piston rod 8 O-ring
30 - 57 9813/7400-1 30 - 57
15 - Cylinder Ram
00 - General
9 Inner rod seal 10 Outer rod seal

11 O-ring 12 Piston eye bush
Disassemble 2. Remove all swarf and contamination. Insert a

dowel into the drilled hole, make sure that the
1. Disassemble the cylinder ram assembly in tapped extractor hole is to the outside.
numerical sequence.
Figure 518.
2. Discard all seals and 'O' rings
Assemble
1. Assembly is a reversal of the disassemble
procedure.
2. Thoroughly clean the threads of piston head,
piston rod, end cap and the cylinder with a wire
brush.
3. Use new seals and O-rings throughout the
assembly. Refer to the cylinder ram sealing
procedure. Make sure that all threads are free
from grease, hydraulic oil and old locking fluids,
use JCB Cleaner/Degreaser. Allow solvent to dry
for 15 minutes before applying JCB Activator. 5 Locking dowel
Consumable: Cleaner/Degreaser - General X Drill diameter
purpose solvent based parts cleaner Y Drill depth
Consumable: JCB Activator
New Piston Head Installed to a Pre-drilled
4. Make sure that all lubricants used during Piston Rod
assembly do not come into contact with the
locking fluids. 1. Use a drill to make a hole through the piston
head and the piston rod at 90° from the existing
5. Apply JCB Activator to the threads of the piston drilled dowel hole in the piston rod. Follow the
head 6. Allow to dry for 15 minutes before procedure, New Rod and Piston Head.
bringing into contact with JCB Threadlocker.
Note: Threadlocker and Activator must not New Piston Head Installed to a Pre-drilled Piston
contact seals, bearing rings or 'O' rings. Head
6. Apply JCB Threadlocker & Sealer (High Use the pre-drilled hole in the piston head. Care
Strength) to all threads of the piston rod. Install must be taken not to elongate the existing hole in the
and tighten the piston head to the correct torque piston head.
value.
Consumable: JCB Threadlocker and Sealer 1. Use a drill of the same diameter as the pre-drilled
(Medium Strength) hole in the piston head to make a centre mark in
the piston rod. Do not drill the piston rod at this
7. Install the locking dowel to the piston head/rod stage.
as follows:
2. Use an undersized diameter drill as a guide and
New Rod and Piston Head drill into the piston rod to the required depth.
Refer to Drilling details for piston head retention,
If both are required, the following procedure should Technical Data (PIL 30-15). Make sure that the
be followed: drill has centred correctly on the centre mark
made in step 1.
1. Use a drill to make a hole through the piston head
into the piston rod. Use an undersized diameter 3. Use the correct size diameter drill to suit the
drill first as a guide and then use the correct dowel and drill to the required depth. Refer
size diameter drill to suit, refer to Drilling head to Drilling details for piston head retention,
retention, Technical Data (PIL 30-15). Technical Data (PIL 30-15).
4. Remove all swarf and contamination. Insert the
dowel into the drilled hole, make sure that the
tapped extractor hole is to the outside.
30 - 58 9813/7400-1 30 - 58
15 - Cylinder Ram
00 - General
5. Take care to retain the end cap at the furthest end

of the piston rod from the cylinder, coat the thread
of the cylinder with JCB Activator. Next apply JCB
Threadlocker to the thread of the end cap. Wait
15 minutes before bringing the two together and
then torque-tighten the end cap into the cylinder.
Consumable: JCB Activator
(Medium Strength)
Note: If hydraulic oil contacts uncured Threadlocker,

a weakening of the bond will result. Cure times
vary according to the ambient temperature. Allow
approximately 1 hour at 20 °C between assembly
and filling the cylinder ram with oil.
When installing cylinder and piston eye bushes,

make sure that the split in the bush is set at 90° to
the longitudinal centreline of the cylinder.
When operating in cold conditions which are

consistently below freezing, it is recommended that
the rams are operated slowly to their full extent
before commencing normal working.
30 - 59 9813/7400-1 30 - 59
15 - Cylinder Ram
06 - Lift Arm
06 - Lift Arm Introduction

A Lift cylinder ram

B Crowd cylinder ram
30 - 60 9813/7400-1 30 - 60
15 - Cylinder Ram
06 - Lift Arm
Remove and Install 8. Remove the locking bolt and withdraw the
cylinder ram end pivot pin using a slide hammer
Special Tools screwed into the tapped hole in the end of the pin.
Description Part No. Qty. Special Tool: Slide Hammer Kit (Qty.: 1)
9. Lift the ram clear of the machine.
Consumables
Description Part No. Size Install
Special HP Grease 4003/2017 0.4kg 1. Replacement is a reversal of the removal
4003/2006 12.5kg procedure.
4003/2005 50kg
2. Grease all pins and locking bolts.
Remove Consumable: Special HP Grease
1. Make the machine safe with the lift arm raised. 3. Make sure all hoses and ports are clean and free
Refer to (PIL 01-03). from dirt. Tighten the bolts to the correct torque
value.
system. Refer to (PIL 30-00). Table 222. Torque Values
3. Support the lift arm using suitable lifting Item Nm

equipment. B 56
4. Remove the locking bolt.

5. Use a slide hammer to drive out the rod end pivot
pin, Refer to (PIL 06-30). Take care to support
the cylinder ram.
Figure 521.
A
B
C
B
C
A Lift ram
B Locking bolt (x2)
C Pivot pins (x2)
6. Lower the ram on to the machine chassis.
30 - 61 9813/7400-1 30 - 61
15 - Cylinder Ram
07 - Lift Extension
07 - Lift Extension Figure 525.
Remove and Install

Special Tools
Remove
2. Remove the inner lift arm. Refer to (PIL
06-12-06).
3. Start the engine and raise the lift arm. Make
sure that you install the safety strut. Refer to PIL
(01-03).
4. Disconnect the hydraulic hoses (x2). C
Figure 524.
B
B Circlip
C Pivot pin
7. Remove the pivot pin.
8. Remove the hydraulic ram from the machine.
A Hydraulic hoses
5. Start the engine and lower the lift arm.
6. Remove the circlip securing the pivot pin.
30 - 62 9813/7400-1 30 - 62
15 - Cylinder Ram
11 - Lift Arm Crowd
11 - Lift Arm Crowd Introduction

A Lift cylinder ram

B Crowd cylinder ram
30 - 63 9813/7400-1 30 - 63
15 - Cylinder Ram
11 - Lift Arm Crowd
Special Tools
Consumables B
C
4003/2006 12.5kg
4003/2005 50kg
This procedure applies to vertical and radial lift

machines.
Remove
2. If possible, tilt the quickhitch fully forward so that A
it lies flat on support blocks.
system. Refer to (PIL 30-00). D

A Locking bolt
B Locking bolt
5. Remove the locking bolts. C Rod end pivot pin
D Cylinder end pivot pin
6. Use a slide hammer to drive out the rod end
pivot pin, Refer to (PIL 06-30). Take care to
support the ram. If the quickhitch cannot be tilted
fully forward, get a second person to support the
quickhitch plate while the pivot pin is driven out.
7. Support or sling the ram.
8. Remove the cylinder end pivot pin.
9. Lift the ram clear of the machine.
Install
steps.
2. Grease all pivot pins and locking bolts.
from dirt.
4. Tighten the locking bolts to the correct torque
value.
30 - 64 9813/7400-1 30 - 64
15 - Cylinder Ram
11 - Lift Arm Crowd

Item Nm
A 56
B 56
30 - 65 9813/7400-1 30 - 65
15 - Cylinder Ram
99 - Seal Kit
99 - Seal Kit Figure 531.
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 532.
(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 533.
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 - 66 9813/7400-1 30 - 66
15 - Cylinder Ram
99 - Seal Kit
Figure 534. 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 536.
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 535.
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 537.
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 - 67 9813/7400-1 30 - 67
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 538.
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 - 68 9813/7400-1 30 - 68
18 - Accumulator
18 - Accumulator
Contents Page No.
30-18-00 General ........................................................................................................................... 30-71

30 - 69 9813/7400-1 30 - 69
Notes:
30 - 70 9813/7400-1 30 - 70
18 - Accumulator
00 - General
Introduction .................................................... 30-71 A hydraulic accumulator is a pressure storage
Health and Safety .......................................... 30-72 reservoir used to store hydraulic fluid, the non-
Technical Data ............................................... 30-72 compressible hydraulic fluid is held under pressure
Component Identification ............................... 30-73 by a compressed nitrogen gas. It is designed to
increase or relieve pressure in the hydraulic system.
Discharge and Pressurise ............................. 30-73
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: General
(Page 30-71).
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 - 71 9813/7400-1 30 - 71
18 - Accumulator
00 - General

DANGER Use only nitrogen gas to charge
accumulators. The use of any other gas can Table 226.
cause the accumulators to explode. Remember Application Type Pressure
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your SRS (Smooth Piston Bladder 30.35bar
workplace. Do not allow excessive quantities of Ride System) (439.9psi)
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
discharge of the accumulator.
WARNING You must vent all the hydraulic
pressure from the accumulators before
disconnecting them from the hydraulic system.
Replacement accumulators will only be supplied in

an uncharged, non pressurised condition to meet
Health and Safety, and Air freight hazardous goods
requirements.
30 - 72 9813/7400-1 30 - 72
18 - Accumulator
00 - General
Component Identification Discharge and Pressurise

Special Tools
Figure 539. Description Part No. Qty.
Accumulator Charging 892/00239 1
Kit (Piston Type)
General
The accumulator charging kit is required to check the
pre-charge pressure of an accumulator and to fill and
C vent the nitrogen. The charging kit is screwed into the
accumulator's gas valve and connected to a nitrogen
source with the hose supplied. If only the pre-charge
pressure is to be checked or reduced the hose is not
A required.
Note: Some accumulators are factory sealed for life

B and cannot be serviced, if they do not have a gas
recharging point, replace the accumulator if faulty.
This procedure only applies to accumulators with a
gas charging point.
Note: The threads on the top of the nitrogen gas

A Diaphragm (sealed for life)-Non Rechargeable bottles can vary widely worldwide, you may need
B Diaphragm (with gas valve)-Rechargeable to source an adaptor locally, for specifications and
C Piston Bladder-Rechargeable further details, refer to www.hydac.com.au.
Pressurise
2. Remove the relevant accumulator from the
machine, refer to Accumulator-Remove and
Install (PIL 30-18).
3. Remove the protective cap from the accumulator
gas valve.
4. Connect the nitrogen charging tool kit and
adaptor to the accumulator gas valve.
Special Tool: Accumulator Charging Kit (Piston
Type) (Qty.: 1)
5. Connect the charging tool flexible hose to a
bottle of compressed nitrogen gas installed with
a pressure regulator valve, set to the minimum
pressure.
6. Screw the spindle three turns anti-clockwise to
open the accumulator gas valve.
7. Open the charging tool bleed valve. Carefully
open the nitrogen gas bottle valve and confirm
that nitrogen gas flows freely. Close the gas
bottle valve and the bleed valve.
8. Carefully open the nitrogen gas bottle valve
and watch the gauge, allow nitrogen to flow by
increasing the pressure regulator setting until the
required pre-charge pressure is achieved. Close
the gas bottle valve.
30 - 73 9813/7400-1 30 - 73
18 - Accumulator
00 - General
9. Let the pressure settle for 10 to 15 minutes. This 4. Either connect the charging tool flexible hose to a
will allow the gas temperature to stabilise. If the bottle of compressed nitrogen gas, or remove the
charge pressure is exceeded, with the gas bottle hose and install a suitable high pressure blanking
closed, adjust the pressure in the accumulator by plug at the charging tool port.
carefully opening and closing the bleed valve.
5. Screw the spindle three turns anti-clockwise to
10. When complete, screw the spindle clockwise open the accumulator gas valve.
to fully close the accumulator gas valve, then
open the changing tool bleed valve to vent the 6. Carefully open the charging tool bleed valve
charging hose. until all the nitrogen gas is vented from the
accumulator.
11. Disconnect the charging tool from the
accumulator. 7. Disconnect the charging tool from the
accumulator.
12. Check the gas-tightness of the gas valve by
applying soapy water around it. Install the
protective cap.
Figure 540.
B
A
D
E
C
A Protective cap
B Accumulator gas valve
C Spindle
D Charging tool bleed valve
E Gas bottle valve
Discharge
1. Remove the relevant accumulator from the
machine, refer to Accumulator - Remove and
Install (PIL 30-18).
2. Remove the protective cap from the accumulator
gas valve.
3. Connect the nitrogen charging tool kit and
adaptor to the accumulator gas valve.
30 - 74 9813/7400-1 30 - 74
18 - Accumulator
06 - Smooth Ride System (SRS)
06 - Smooth Ride System (SRS) Introduction

Introduction .................................................... 30-75 The accumulator is located under the operator
Technical Data ............................................... 30-76 station.
Discharge and Pressurise ............................. 30-77 The piston type accumulator operates as a liquid
spring absorbing displaced fluid from the lift rams. It
Remove and Install ....................................... 30-77 is selectable from a switch in the operator station.
Important: Replacement accumulators will only be

supplied in an uncharged, non-pressurised condition
to meet Health and Safety and Air freight hazardous
goods requirements.
Figure 541.
A Accumulator
30 - 75 9813/7400-1 30 - 75
18 - Accumulator
Table 227. Figure 542.

Description Data
Charging gas Air free dry Nitrogen
Accumulator capacity 0.95L
Accumulator weight 4.1kg
Maximum operating 250bar (3,623.2psi)
pressure
Pre-charge pressure 303bar (4,391.3psi)
A Accumulator
30 - 76 9813/7400-1 30 - 76
18 - Accumulator
Discharge and Pressurise Remove and Install
Discharge and Pressurise the SRS (Smooth Remove

Ride System) Accumulator, refer to Accumulator,
Discharge and Pressurise (PIL 30-18). 1. Make the machine safe with the lift arm and cab
installation.
5. Support the accumulator and remove the bolts.
6. Remove the accumulator, cap the ports with
of dirt.
Figure 543.
B
A Accumulator
B Bolts
Install
procedure.
30 - 77 9813/7400-1 30 - 77
18 - Accumulator
from dirt. Tighten the bolts to the correct torque
value.
30 - 78 9813/7400-1 30 - 78
51 - Lift Arm Control Valve Block
Contents Page No.
30-51-00 General ........................................................................................................................... 30-81
30 - 79 9813/7400-1 30 - 79
Notes:
30 - 80 9813/7400-1 30 - 80
00 - General
Operation ....................................................... 30-83
Diagram ......................................................... 30-86 The valve block consists of two hydraulic servo
operated spools that control the loader arm lift and
Remove and Install ....................................... 30-87 carriage crowd (tilt) functions and a third servo
operated attachments spool which is controlled via
two proportional solenoids on the valve.
A MRV (Main Relief Valve) controls the maximum

pressure generated in the loader circuits.
30 - 81 9813/7400-1 30 - 81
00 - General
Technical Data
Table 228. Fixed Displacement

Valve - Pressure Settings
Description Pressure
Nominal Working Pres- 230bar (3,333.3psi)
sure
MRV (Main Relief Valve) 230bar (3,333.3psi)
(1)
Setting
ARV (Auxiliary Relief 280bar (4,058.0psi)
Valve) Setting (All ports)
Relief Pressure 95% of relief setting at
100cc/min
(1) At 60 litres/minute
Table 229. Fixed Displacement

Valve - Flow Rates
Description Flow Rate
Nominal Flow 130L/min
Table 230. Load Sensing

Valve - Pressure Settings
Nominal Working Pres- 230bar (3,333.3psi)
sure
MRV Setting 260bar (3,768.1psi)
ARV Setting (All ports) 280bar (4,058.0psi)
Table 231. Load Sensing Valve - Flow Rates

MRV Flow 90L/min
ARV Flow 5L/min
30 - 82 9813/7400-1 30 - 82
00 - General
Operation
When no service is selected the oil passes straight An electrically operated servo cut-off valve is
through the neutral gallery of the valve block. When installed in the servo feed circuit. This is operated
a service is selected the neutral gallery is blocked by by the isolator switch to allow spool movement only
the selected spool and oil is directed past the load when the switch is closed, i.e. when the isolator bar
hold check valve and on to the ram to operate the and left hand arm rest is lowered.
service.
A self level valve, installed as an option, diverts a
Return oil from the ram is fed back through the spool small amount of oil to the carriage tilt ram to give
into the valve block exhaust gallery and back to tank. self levelling as the lift arm is raised. The valve is
Note that loader raise and lower return oil is fed back electrically controlled and can be switched on or off
to the neutral gallery. by the operator.
Fixed Displacement
Figure 544.
D
LV
R
NC
PB
MRV P
ARV
L B A T
ARV ARV (Auxiliary Relief Valve) MRV MRV (Main Relief Valve)
LV Load hold check valve A Auxiliary
30 - 83 9813/7400-1 30 - 83
00 - General
B Crowd (Tilt) D Hi-flow inlet (optional)

I Inlet L Loader
P Pilot PB High flow drain (optional)
R Outlet/Return T Return to tank
Figure 545. Cross sectional view
Load Sensing
Figure 546.
30 - 84 9813/7400-1 30 - 84
00 - General
Figure 547.
A B
E
99
D F
A Inlet Port B Outlet Port

C Lift Point D Load Sense Port
E MRV Gauge Port F Work Port
G Pilot Drain H Pilot Supply
30 - 85 9813/7400-1 30 - 85
00 - General
Diagram 2B Tilt ram rod

3A Auxiliary flow A
3B Auxiliary flow B
Fixed Displacement
Figure 548.
1A 1B 2A 2B 3A 3A
280 BAR 280 BAR
P
P
230 BAR
PB
L B A
P D
P
A Auxiliary
B Crowd (Tilt)
D Hi flow inlet (optional)
L Loader
P Pilot
PB High flow drain (optional)
1A Loader ram rod
1B Loader ram head
2A Tilt ram head
2B Tilt ram rod
3A Auxiliary flow A
3B Auxiliary flow B
Load Sensing
Figure 549.
1A 1B 2A 2B 3A 3B
X Y Z
A Auxiliary
B Crowd (Tilt)
X Bucket
Y Loader
Z Auxiliary
1A Loader ram rod
1B Loader ram head
2A Tilt ram head
30 - 86 9813/7400-1 30 - 86
00 - General

Remove procedure.
1. Make the machine safe with the lift arm and cab 2. Make sure all hoses and ports are clean and free
raised. Refer to (PIL 01-03). from dirt.

installation.
4. Remove the hoses and cap the ends with
of dirt.
5. Support the valve block and remove the bolts.
6. Remove the valve block, cap the ports with
of dirt.
Figure 550.
1 Excavator control valve block (load sense)
30 - 87 9813/7400-1 30 - 87
60 - Directional Control Valve
Contents Page No.
30-60-00 General ........................................................................................................................... 30-89

30-60-15 Joystick ........................................................................................................................... 30-91
30-60-28 Auxiliary Changeover ................................................................................................... 30-101
30-60-40 Lift Arm Self Levelling .................................................................................................. 30-103
30-60-81 Cooling Fan .................................................................................................................. 30-105
30 - 88 9813/7400-1 30 - 88
00 - General
00 - General
Introduction
Flow Control Valves Figure 554.
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 551.
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 552. 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 556.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 89 9813/7400-1 30 - 89
00 - General
Figure 557. 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 - 90 9813/7400-1 30 - 90
15 - Joystick
15 - Joystick Introduction
Introduction .................................................... 30-91 The electro/hydraulic joysticks comprise of a control
Component Identification ............................... 30-92 lever and a base that conveys a controlled signal and
Remove and Install ....................................... 30-92 provides the requested hydraulic system function.
30 - 91 9813/7400-1 30 - 91
15 - Joystick
Component Identification Remove and Install

Figure 558. The procedure is for the left hand joystick, the
procedure for the right hand joystick is the same.
Remove
C 2. Disconnect the battery. Refer to (PIL 33-03).
3. Remove the covers from around the joystick
body.
4. Disconnect the electrical connections.
A
5. Remove the screw (x4) and the washer (x4).
B 6. Carefully remove the joystick from the machine.
A Screw
B Washer
C Joystick
D Base
30 - 92 9813/7400-1 30 - 92
15 - Joystick
Figure 559.
A Screw
B Washer
C Joystick
D Base
Install
step.
2. Tighten the screw to the correct torque value.

Item Description Nm
A Screw 9.9
30 - 93 9813/7400-1 30 - 93

Operation ....................................................... 30-96
Diagram ......................................................... 30-98 The SRS (Smooth Ride System) valve is located
under the transmission pump. The ECU (Electronic
Remove and Install ....................................... 30-99 Control Unit) must read from the pressure transducer
0 to 12 bar in the lift circuit before the SRS solenoids
are energized (lift arm must be lowered). When the
SRS switch is activated on the left hand switch panel
the coils C, D and E are activated. Refer to Diagram
(PIL 30-60).
The lift arm can be raised and lowered without

disabling the SRS system.
Float Option
Some machines have a float option incorporated into
the valve. With the bucket on the ground 0 to 12 bar
must be measured in the lift arm raise line. Float can
then be activated, the float coils are then activated.
30 - 94 9813/7400-1 30 - 94
Technical Data
Table 233. Pressures

Maximum Operating 280bar (4,058.0psi)
Pressure
Nominal Pressure 230bar (3,333.3psi)

Input Flow 60L/min
30 - 95 9813/7400-1 30 - 95
Operation
Hydraulic Operation Figure 560. Hydraulic Schematics
When the SRS (Smooth Ride System) switch in H

the operator station is in OFF position, the SRS
accumulator solenoid and the SRS check solenoid
are de-energised. F
The SRS accumulator solenoid vents the

accumulator to tank and the SRS check solenoid
blocks the flow from the head side of the lift ram. B
When the SRS switch in the operator station is in the

ON position, the SRS accumulator solenoid and the
SRS check solenoid are energised. This connects C L
the head side of the lift ram to the accumulator and
to check valve.
G
The check valve opens and connects the rod side of
the lift ram to the tank through a SRS accumulator
solenoid.
J K
B SRS accumulator solenoid

C SRS check solenoid
F Accumulator (30bar (434.8psi), 0.95L)
G Transducer
H To tank
J Head side lift arm
K Rod side lift arm
L Check valve
Electrical Operation
The schematic diagram shows how the electrical
circuit works when different functions are operated.
Before you start fault finding, make sure that you

understand how the electrical circuits work. Most of
the potential faults can be traced using a multimeter
to carry out continuity checks on wires, switches and
solenoids.
30 - 96 9813/7400-1 30 - 96
Figure 561. Electrical Schematics
30 - 97 9813/7400-1 30 - 97
Diagram F Plug
G Lift Cylinder
T Tank
Figure 562. SRS Valve with Float
T F D
E C
G
A Accumulator (30 bar)
B Pressure Transducer
C SRS Coil
D SRS Coil
E Float Coil
F Float Coil
G Lift Cylinder
T Tank
Figure 563. SRS Valve without Float
A
T
D
F
E C
G
A Accumulator (30 bar)
B Pressure Transducer
C SRS Coil
D SRS Coil
E SRS Coil
30 - 98 9813/7400-1 30 - 98
Remove and Install
The removal procedure is the same for machines 5. Support the valve and remove the bolts.
with or without the float option.
6. Remove the valve, cap the ports with blanking
Remove
1. Make the machine safe with the lift arm and cab Install
2. Discharge the hydraulic pressure from the procedure.
3. Mark all hoses and electrical connections to from dirt. Tighten the bolts to the correct torque
make sure of correct installation. value.
Figure 564.
A Bolt B Smooth ride system valve
30 - 99 9813/7400-1 30 - 99

Item Nm
A 56
30 - 100 9813/7400-1 30 - 100

28 - Auxiliary Changeover
28 - Auxiliary Changeover Introduction

Introduction .................................................. 30-101 The auxiliary changeover valve toggles between
Remove and Install ..................................... 30-102 auxiliary and lift arm extension. It is controlled by the
pilot changeover valve. It is located next to the lift
arm.
Figure 565.
A Auxiliary changeover valve
30 - 101 9813/7400-1 30 - 101

28 - Auxiliary Changeover
Remove and Install
Remove
2. Discharge the hydraulic pressure. Refer to (PIL
30-00-00).
3. Disconnect the hydraulic hoses (x4). Put a label
on the hoses to help installation.
Figure 566.
C
B
A
C
A Auxiliary changeover valve
B Hydraulic hoses (x4)
C Bolts (X2)
4. Remove the bolts (x2).
5. Remove the auxiliary changeover valve from the
machine.
Install
step.
required. Refer to (PIL 30-00-00).
30 - 102 9813/7400-1 30 - 102

40 - Lift Arm Self Levelling
40 - Lift Arm Self Levelling Introduction

Introduction .................................................. 30-103 The Electro-Hydraulic Attachment Positioning
Operation ..................................................... 30-104 System (EHAPS) uses the main control valve to
keep attachments level when the lift arm is raised or
lowered.
The system uses a ground level sensor mounted

inside the quickhitch, a lift arm position sensor and a
hydraulic pressure sensor measures the crowd ram
pressure.
30 - 103 9813/7400-1 30 - 103

40 - Lift Arm Self Levelling
Operation
If the Electro-Hydraulic Attachment Positioning

System (EHAPS) is switched on, a snapshot of the
current angle of the quickhitch is captured when the
operator moves the lift arm. As the lift arm moves
up or down, the system will increase or decrease the
amount of crowd or dump to automatically level the
attachment.
If the operator moves the joystick into crowd or

dump positions while lifting or lowering, the system
switches off and gives control to the operator. Once
the joystick returns to purely lifting or lowering a
new angle snapshot is taken and the system again
tries to maintain this new angle. To reduce lag while
lowering, the pressure sensor gives an indication of
the starting point of control.
To restrict unwanted movement if the lift arm hits

the travel end stops, the position sensor shuts off
leveling at the top and bottom of the range of lifting
or lowering.
30 - 104 9813/7400-1 30 - 104

81 - Cooling Fan
81 - Cooling Fan Introduction

Introduction .................................................. 30-105 The cleanliness of this component is critical and must
Component Identification ............................. 30-106 conform to JCB standard 9993/0003.
Diagram ....................................................... 30-106
The cooling fan valve is located behind the operator
station in front of the hydraulic fan motor.
Figure 567.
A Cooling fan valve

B Cooling fan solenoid
30 - 105 9813/7400-1 30 - 105

81 - Cooling Fan
Component Identification Diagram

T M2 M1 M2
P M1
M1 Left hand side single speed motor

M2 Right hand side single speed motor
P Pilot supply port
T Tank supply port
P T
M1 Left hand side single speed motor

M2 Right hand side single speed motor
P Pilot supply
T Tank supply
30 - 106 9813/7400-1 30 - 106

71 - Pilot Changeover Valve
Contents Page No.
30-71-00 General ......................................................................................................................... 30-109
30 - 107 9813/7400-1 30 - 107

Notes:
30 - 108 9813/7400-1 30 - 108

00 - General
Introduction .................................................. 30-109 The pilot changeover valve is a solenoid valve that
Remove and Install ..................................... 30-110 when energised allows pilot pressure to operate the
auxiliary changeover valve. It is energised by default
which allows the lift arm extension to operate. It is
located above the drive pump.
Figure 570.
A Pilot changeover valve
30 - 109 9813/7400-1 30 - 109

00 - General
Remove and Install
Remove
2. Discharge the hydraulic pressure. Refer to (PIL
30-00-00).
3. Raise the operator station. Refer to (PIL
09-00-00).
Figure 571.
D
C
A
B
B
A Pilot changeover valve

B Hydraulic hoses
C Electrical connector
D Bolts (x2)
5. Disconnect the hydraulic hoses.
7. Remove the pilot changeover valve from the
machine.
Install
step.
30 - 110 9813/7400-1 30 - 110

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-113
30 - 111 9813/7400-1 30 - 111

Notes:
30 - 112 9813/7400-1 30 - 112

93 - Hose
00 - General
Introduction .................................................. 30-113 Hydraulic hoses are used to connect different
Disconnect and Connect ............................. 30-114 components in the hydraulic circuit. The hoses
Check (Condition) ........................................ 30-115 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 - 113 9813/7400-1 30 - 113

93 - Hose
00 - General
Disconnect and Connect Figure 574.
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. Refer
to (PIL 30-00).
3. Check the hoses and adaptors for damage.
4. Connect the hoses: 5. Check for leaks:
4.1. Make sure that the hose is not twisted. 5.1. Start the machine.
Pressure applied to a twisted hose can
5.2. Operate the related controls to increase the
cause the hose to fail or the connections to
pressure in the hydraulic system.
loosen.
5.3. Stop the machine then remove the key.
Figure 572.
5.4. Check for indications of leakage at the hose
connections. Correct, as necessary.
Disconnecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure. Refer
to (PIL 30-00).
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 573. 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 - 114 9813/7400-1 30 - 114

93 - Hose
00 - General
Check (Condition)
Hydraulic Hoses
WARNING Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not
use the machine if a hose or hose fixture is
damaged.
WARNING Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well
clear of fluid under pressure and wear personal
protective equipment. Hold a piece of cardboard
close to suspected leaks and then examine the
cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
Examine the hoses for:
• Damaged hose ends

• Worn outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Exposed armouring in the outer covers
• Displaced hose end fittings.
• Worn cover sheathing or hose burst protection
covering
Replace a damaged hose before you use the

machine again.
The replacement hoses must be of the same size,

standard and pressure rating. If necessary, for more
information contact your JCB dealer.
30 - 115 9813/7400-1 30 - 115

97 - Connectors
97 - Connectors
Contents Page No.
30-97-00 General ......................................................................................................................... 30-117

30-97-03 Quick Release Coupling .............................................................................................. 30-120
30-97-09 Adaptor ......................................................................................................................... 30-122
30-97-18 O-Ring Face Seal (ORFS) ........................................................................................... 30-124
30-97-24 Push Lock Fitting ......................................................................................................... 30-126
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-127
30 - 116 9813/7400-1 30 - 116

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 236. 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 238. 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 237. 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 - 117 9813/7400-1 30 - 117

97 - Connectors
00 - General
Hoses installed into Adaptors
Figure 575.
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 Ò' ring

which is compressed into a 45° seat machined into
the face of the adaptor port.
Table 239. 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 240. 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 - 118 9813/7400-1 30 - 118

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 576.
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 Ò' 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 241. 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 - 119 9813/7400-1 30 - 119

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-120 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-121 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 577.
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 - 120 9813/7400-1 30 - 120

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. Refer to (PIL 01-03).
• Do not leave the coupling where it may be run
over by a machine or otherwise crushed, this 2. Discharge the hydraulic pressure. Refer to (PIL
will distort the sleeve and prevent connection 30-00).
and disconnection.
• Never try to turn the sleeve when the coupling is 3. Wipe the two faces of the male and female
disconnected as this will cause the locking ball couplings and make sure they are clean.
to jam under the locking sleeve and damage the
coupling. 4. Make sure that ball in the female coupling is
• Never try to strip the coupling down, there are located in one of its slots.
no user serviceable parts. If the coupling is
5. Connect the male coupling into the female
damaged it must be replaced with a new one.
coupling.
• Never hit the centre poppet of the coupling to
try and release the locked in pressure. This can 6. Where applicable, rotate the sleeve half a turn
cause irreparable damage to the coupling and and make sure that the locking ball does not align
serious injury. with the slot.
• When connecting the couplings, never clamp
on the sleeve of the female or nose of the male,
this will cause distortion and/or damage.
Disconnect
• Never subject the couplings to external forces, 1. Make the machine safe. Refer to (PIL 01-03).
especially side load. This can decrease the life
of the coupling or cause failure. 2. Discharge the hydraulic pressure. Refer to (PIL
• Never allow the torsional forces transmitted 30-00).
from the hoses to unscrew/screw together the
couplings. 3. Where applicable, align the slot with ball.
• Never use a coupling as a plug.
• Do not connect and disconnect with pressure in 4. Pull back the sleeve to release the coupling.
the line unless the coupling type is specifically Figure 578.
designed to do so.
C D E
C Ball
D Slot
E Sleeve
30 - 121 9813/7400-1 30 - 121

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-122 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-123 may utilise Positional Type SAE (Society of
Automotive Engineers) Hydraulic Adaptors. When
you install a Positional Type Hydraulic Adaptor, it is
important to adopt the Remove and Install procedure
(PIL 30-97). If this procedure is not followed correctly,
damage to the O-ring seal can occur which can result
in oil leaks.
Figure 579.
A O-ring seal
B Locknut
C Washer
30 - 122 9813/7400-1 30 - 122

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 580.
Z Adaptor thread
6. Tighten the locknut to the correct torque value.

Item Nm
B 81
A O-ring seal
B Locknut
C Backing washer
4. Screw the adaptor into the port of the hydraulic
component as far as possible, so that all the
threads engage and the O-ring seal is correctly
seated against the sealing face.
5. Set the angular position of the adaptor as
required, then secure by tightening the locknut.
When installed correctly no more than one thread
should be visible at Z as shown.
30 - 123 9813/7400-1 30 - 123

97 - Connectors
18 - O-Ring Face Seal (ORFS)
18 - O-Ring Face Seal (ORFS) Introduction

Introduction .................................................. 30-124 The ORFS (O-Ring Face Seal) type fittings are
Remove and Install ..................................... 30-125 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 - 124 9813/7400-1 30 - 124

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. Refer
to (PIL 30-97-18).
4 Swivel nut - Hand tight
To prevent damage to the ORFS during the assembly 5 Swivel nut - Torque tightened
procedure it is important to use the double-spanner
method to tighten the fittings. Figure 585.
Figure 582.
D
1 Torque spanner
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.
A Nut
Figure 583. B Sleeve
3 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 - 125 9813/7400-1 30 - 125

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 586.
D A
C B
A Tube
B Collet
C O-ring
D Steel support tube
30 - 126 9813/7400-1 30 - 126

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 587.
A B C
E D
A Snap ring
B O-ring and back-up ring
C Tube
D Fitting body
E Hose
30 - 127 9813/7400-1 30 - 127

Notes:
30 - 128 9813/7400-1 30 - 128

Contents Page No.
33-00 Electrical System

33-00-00 General ............................................................................................................................. 33-3
33-00-50 Schematic Circuit ............................................................................................................. 33-5
33-00-90 Earth Point ..................................................................................................................... 33-52
33-03 Battery
33-03-00 General ........................................................................................................................... 33-55
33-03-03 Isolator Switch ................................................................................................................ 33-62
33-06 Battery Cable
33-06-00 General ........................................................................................................................... 33-67
33-09 Power Distribution
33-09-00 General ........................................................................................................................... 33-69
33-09-03 Fuse ............................................................................................................................... 33-71
33-09-06 Relay .............................................................................................................................. 33-73
33-12 Harness
33-12-00 General ........................................................................................................................... 33-75
33-12-04 Chassis ........................................................................................................................... 33-85
33-12-06 Lift Arm ......................................................................................................................... 33-100
33-12-09 Engine .......................................................................................................................... 33-108
33-12-12 Operator Station ........................................................................................................... 33-117
33-12-45 Power Distribution ........................................................................................................ 33-132
33-12-57 Heating, Ventilating and Air-Conditioning (HVAC) ....................................................... 33-133
33-12-58 Heater ........................................................................................................................... 33-134
33-12-59 Compressor .................................................................................................................. 33-135
33-12-61 Throttle ......................................................................................................................... 33-136
33-12-63 Smooth Ride System (SRS) ........................................................................................ 33-137
33-12-69 Reverse Warning Alarm ............................................................................................... 33-139
33-12-76 Window Washer/Wipe .................................................................................................. 33-140
33-12-77 Front Window Washer/Wiper ....................................................................................... 33-141
33-15 Alarm
33-15-03 Reverse Warning .......................................................................................................... 33-143
33-24 Instruments
33-24-00 General ......................................................................................................................... 33-147
33-24-10 Hourmeter .................................................................................................................... 33-157
33-27 Interior Switch
33-27-15 Hand Throttle Control ................................................................................................... 33-161
33-40 Bulb
33-40-00 General ......................................................................................................................... 33-163
33-42 Exterior Light
33-42-00 General ......................................................................................................................... 33-167
33-42-15 Front Work Light .......................................................................................................... 33-168
33-42-18 Rear Road Light ........................................................................................................... 33-169
33-42-30 Rear Work Light ........................................................................................................... 33-170
9813/7400-1
2017-02-22
33-45 Control Module
33-45-00 General ......................................................................................................................... 33-173
33-45-06 Engine .......................................................................................................................... 33-176
33-45-37 Electro Hydraulic (EH) ................................................................................................. 33-177
33-45-49 Chassis ......................................................................................................................... 33-179
33-48 Entertainment
33-48-03 Radio ............................................................................................................................ 33-183
33-54 Window Washer/Wipe
33-54-00 General ......................................................................................................................... 33-187
33-54-03 Tank .............................................................................................................................. 33-190
33-54-09 Front Motor ................................................................................................................... 33-192
33-57 Electronic Diagnostic
33-57-00 General ......................................................................................................................... 33-197
33-57-03 Servicemaster .............................................................................................................. 33-199
33-57-90 Fault Codes .................................................................................................................. 33-232
33-84 Sensor
33-84-07 Hydraulic Pressure ....................................................................................................... 33-269
33-84-41 Lift Arm ......................................................................................................................... 33-271
33-84-85 Platform Down Limit ..................................................................................................... 33-273
33-86 Solenoid
33-86-14 Transmission ................................................................................................................ 33-277
33-86-15 Transmission Pilot ........................................................................................................ 33-279
33-86-41 Lift Arm ......................................................................................................................... 33-283
33-86-50 Implement Pilot ............................................................................................................ 33-286
33-86-78 Hydraulic Hi-Flow ......................................................................................................... 33-288
33-86-92 Cooling Fan .................................................................................................................. 33-290
9813/7400-1
2017-02-22
Acronyms Glossary

DLA Data Link Adaptor
DTC Diagnostic Trouble Code
DVD Digital Versatile Disc
EH Electro-Hydraulic
EMS Electronic Monitoring System
HVAC Heating Ventilation Air Conditioning
LCD Liquid Crystal Display
LED Light Emitting Diode
MIL Malfunction Indicator Lamp
PWM Pulse Width Modulation
SPP Service Parts Pro
SRS Smooth Ride System
USB Universal Serial Bus
9813/7400-1
2017-02-22
Notes:
9813/7400-1
2017-02-22
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-5
33-00-90 Earth Point ..................................................................................................................... 33-52
33 - 1 9813/7400-1 33 - 1
Notes:
33 - 2 9813/7400-1 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
Make sure that all the health and safety warnings
in this section are followed. The machine must be
safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.
33 - 3 9813/7400-1 33 - 3
00 - General

Arc Welding Table 243. General
To prevent the possibility of damage to electronic
Description Data
components, disconnect the battery and the
alternator before arc-welding on the machine or System type 12V, Negative earth
attached implements. Alternator 14V, 80A
If the machine is equipped with sensitive electrical Starter motor 12V, 2kW
equipment, i.e. amplifier drivers, electronic control
units (ECUs), monitor displays, etc., then disconnect Table 244. Transmission Pump
them before welding. Failure to disconnect the Description Data
sensitive electrical equipment could result in Voltage 12V
Coil resistance @ 20°C 3.66Ω
Parts of the machine are made from cast iron, welds (68.0°F)
on cast iron can weaken the structure and break. Do Coil resistance @ 80°C 4.52Ω
not weld cast iron. Do not connect the welder cable (175.9°F)
PWM (Pulse Width Mod- 70–200Hz
Always connect the welder earth (ground) cable to ulation) range
the same component that is being welded to avoid
the welder earth (ground) cable a distance from the
part being welded no more than 0.6m.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION! Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
33 - 4 9813/7400-1 33 - 4
50 - Schematic Circuit Introduction

Introduction ...................................................... 33-5 A schematic wiring diagram is a simplified pictorial
Diagram ........................................................... 33-8 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 - 5 9813/7400-1 33 - 5
Figure 588.
/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
/7.B4
BLACK
FROM
#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 - 6 9813/7400-1 33 - 6
Figure 589. 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 1.00 mm² 601KK
CAN SHLD
FROM
P130:3 /13.D7 FROM 2.00 mm² 601BU

CAN SHLD 0.50 mm² 601P
CAN SHLD P40:10 /9.A3 FROM
P130:4 /13.D7 FROM 2.00 mm² 601AL

CAN SHLD 1.00 mm² Y
CAN SHLD P066:11 /8.B7 FROM
2.00 mm² SCR

SPMC12 /17.C3 FROM
CAN SHLD 0.75 mm² 601BF

CAN SHLD P024:7 /10.C1 FROM
2.00 mm² SCR

SVMC15 /17.D5 FROM
CAN SHLD 1.00 mm² 601DC -SP6 2.00 mm² 601JD

CAN SHLD P023:7 /10.F2 FROM
1.00 mm² 600H

P034:2 /7.C2 FROM
CAN SHLD 1.00 mm² 601AC

P026:7 /13.F3 FROM
CAN SHLD 1.00 mm² 601AY CAN SHLD 1.00 mm² 601BB
P028:7 /13.B2 FROM
P017:7 /25.E3 FROM
B P029:7 /13.E3
CAN SHLD 1.00 mm² 601KA P021:7 /12.F3
CAN SHLD 1.00 mm² 601BH
B
FROM FROM
CAN SHLD 1.00 mm² 601AL CAN SHLD 1.00 mm² 601DX 2.00 mm² 601JF
P061:7 /16.F2 FROM
P022:7 /12.E3 FROM
-SP28
CAN SHLD 1.00 mm² 601BL CAN SHLD 1.00 mm² 601KC
P052:7 /14.B5 FROM
P065:2 /15.B5 FROM
CAN SHLD 1.00 mm² 601N

P027:7 /21.B4 FROM
CAN SHLD 0.75 mm² 601AK

P042-A /28.E2 FROM
CAN SHLD 1.00 mm² 601EN

P018:7 /30.F2 FROM
A
A
1 2 3 4 5 6 7 8
33 - 7 9813/7400-1 33 - 7
Diagram
Telescopic Lift Arm Machines
33 - 8 9813/7400-1 33 - 8
Figure 590. Start Circuit, Primary
Page 33-10 and Secondary Fuses - 333/

X5071 - Issue 3 (Sheet 1 of 11) Page 33-11
33 - 9 9813/7400-1 33 - 9
33-10 33-11
Page 33-11
33 - 10 9813/7400-1 33 - 10
33-10 33-11
Page 33-10
33 - 11 9813/7400-1 33 - 11
33 - 12 9813/7400-1 33 - 12
Figure 591. CAN Network, Right
Page 33-14 Hand And Left Hand Joystick Bases

- 333/X5071 - Issue 3 (Sheet 2 of 11) Page 33-15
33 - 13 9813/7400-1 33 - 13
33-14 33-15
Page 33-15
33 - 14 9813/7400-1 33 - 14
33-14 33-15
Page 33-14
33 - 15 9813/7400-1 33 - 15
33 - 16 9813/7400-1 33 - 16
Page 33-18 Figure 592. Chassis ECU - 333/

33 - 17 9813/7400-1 33 - 17
33-18 33-19
Page 33-19
33 - 18 9813/7400-1 33 - 18
33-18 33-19
Page 33-18
33 - 19 9813/7400-1 33 - 19
33 - 20 9813/7400-1 33 - 20
Page 33-22 Figure 593. Electro-Hydraulic ECU

33 - 21 9813/7400-1 33 - 21
33-22 33-23
Page 33-23
33 - 22 9813/7400-1 33 - 22
33-22 33-23
Page 33-22
33 - 23 9813/7400-1 33 - 23
33 - 24 9813/7400-1 33 - 24
Page 33-26 Figure 594. Cab Electrics - 333/

33 - 25 9813/7400-1 33 - 25
33-26 33-27
Page 33-27
33 - 26 9813/7400-1 33 - 26
33-26 33-27
Page 33-26
33 - 27 9813/7400-1 33 - 27
33 - 28 9813/7400-1 33 - 28
Figure 595. Engine: ECU (White
Page 33-30 Connector) And Grid Heater - 333/

33 - 29 9813/7400-1 33 - 29
33-30 33-31
Page 33-31
33 - 30 9813/7400-1 33 - 30
33-30 33-31
Page 33-30
33 - 31 9813/7400-1 33 - 31
33 - 32 9813/7400-1 33 - 32
Page 33-34 Figure 596. Engine: ECU (Black Connector)

Harness - 333/X5071 - Issue 3 (Sheet 7 of 11) Page 33-35
33 - 33 9813/7400-1 33 - 33
33-34 33-35
Page 33-35
33 - 34 9813/7400-1 33 - 34
33-34 33-35
Page 33-34
33 - 35 9813/7400-1 33 - 35
33 - 36 9813/7400-1 33 - 36
Page 33-38 Figure 597. Options: Road Lights, Wash/Wipe,

Quickhitch - 333/X5071 - Issue 3 (Sheet 8 of 11) Page 33-39
33 - 37 9813/7400-1 33 - 37
33-38 33-39
Page 33-39
33 - 38 9813/7400-1 33 - 38
33-38 33-39
Page 33-38
33 - 39 9813/7400-1 33 - 39
33 - 40 9813/7400-1 33 - 40
Page 33-42 Figure 598. Earths - 333/

33 - 41 9813/7400-1 33 - 41
33-42 33-43
Page 33-43
33 - 42 9813/7400-1 33 - 42
33-42 33-43
Page 33-42
33 - 43 9813/7400-1 33 - 43
33 - 44 9813/7400-1 33 - 44
Page 33-46 Figure 599. Multifunction Attachment

33 - 45 9813/7400-1 33 - 45
33-46 33-47
Page 33-47
33 - 46 9813/7400-1 33 - 46
33-46 33-47
Page 33-46
33 - 47 9813/7400-1 33 - 47
33 - 48 9813/7400-1 33 - 48
Page 33-50 Figure 600. Fusebox Layout Reference

33 - 49 9813/7400-1 33 - 49
33-50 33-51
Page 33-51
33 - 50 9813/7400-1 33 - 50
33-50 33-51
Page 33-50
33 - 51 9813/7400-1 33 - 51
90 - Earth Point
90 - Earth Point Introduction

Introduction .................................................... 33-52 The ground or earth refers to the reference point in an
Component Identification ............................... 33-53 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 - 52 9813/7400-1 33 - 52
90 - Earth Point
Operator Station
Earthing with a bolt into the floor of the operator
station below the right hand arm rest to the rear of
the operator station harness connectors.
Chassis
Earthing with a bolt into the front top plate of the
machine chassis.
Engine
Earthing with stud welded to the floor of the chassis
in front of the left hand rear engine mount.
33 - 53 9813/7400-1 33 - 53
03 - Battery
03 - Battery
Contents Page No.
33-03-00 General ........................................................................................................................... 33-55

33-03-03 Isolator Switch ................................................................................................................ 33-62
33 - 54 9813/7400-1 33 - 54
03 - Battery
00 - General
Introduction .................................................... 33-55 Batteries used in normal temperate climate
Health and Safety .......................................... 33-56 applications should not need topping up. However,
Technical Data ............................................... 33-57 in certain conditions (such as prolonged operation
Fault-Finding .................................................. 33-58 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Disconnect and Connect ............................... 33-58 frequently and topped up as necessary.
Check (Condition) .......................................... 33-59
Charge ........................................................... 33-60 The electrolyte level should be checked in
Remove and Install ....................................... 33-61 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 601.
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 - 55 9813/7400-1 33 - 55
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
33 - 56 9813/7400-1 33 - 56
03 - Battery
00 - General
put in a closed acid proof receptacle and Technical Data

must be disposed of in accordance with local
environmental waste regulations.
Table 245.
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 - 57 9813/7400-1 33 - 57
03 - Battery
00 - General
Fault-Finding Disconnect and Connect

The most obvious sign of a battery problem is a Notice: Before you install a pair of batteries to
machine not being able to start. However, because a machine, make sure you know the machines
the battery is part of a larger electrical system voltage. Some machines require two batteries but
connected to other parts of the machine, a flat battery have a 12 V electrical system. This means the
may indicate another problem. batteries need to be connected in parallel.
If something else is going wrong in the electrical
For 24 V machines, the batteries must be
system, for example, a weak alternator, corrosion or
connected in series. Incorrect voltage may result
loose connections, cold weather starting, electrical
in serious damage to the electrical system.
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 Disconnect
with an electronic battery tester. Refer to Battery-
Check Condition (PIL 33-03). 1. Make the machine safe. Refer to (PIL 01-03).
2. Get access to the battery. Refer to (PIL 06-06).
3. If the machine has a battery isolator, move the
switch to the OFF position, then remove the key.
4. Disconnect the negative battery lead first.
5. Disconnect the positive battery lead and store
away from the battery.
6. Disconnect and remove the battery leads.
Figure 602. 12V Battery Connection (Example)
_ +
A
C B
12 V
A Battery
B Positive lead
C Negative lead
Connect
1. Check the battery as follows:
1.1. If any terminals are dirty, clean them.
1.2. If the terminal is corroded and has white
powder, wash the terminal with hot water.
33 - 58 9813/7400-1 33 - 58
03 - Battery
00 - General
Make sure the water does not enter the Check (Condition)
battery cells.
1.3. If considerable corrosion is found, then
clean with a wire brush or abrasive Battery Test
paper. Make sure you use eye and hand
protection. Refer to Figure 603. This test is to determine the electrical condition of
the battery and to give an indication of the remaining
Figure 603. useful life.
Before you test the battery, make sure that the

battery is at least 75% charged (Specific Gravity of
1.23 to 1.25 for ambient temperature up to 27°C).
Make sure that the battery is completely

disconnected from the vehicle.
Figure 604.
1.4. After cleaning, apply a thin coat of

petroleum jelly to the terminals.
2. Connect the leads.
2.1. Connect the positive lead then the negative
lead.
3. If the machine has a battery isolator, move the
switch to the ON position.
4. Close and lock the access panels.
A Battery voltage switch

B Check load switch
Connect up the battery tester as follows:
1. Set the Check Load switch to OFF.

2. Set the battery voltage switch to 12V.
3. Connect the red flying lead to the battery positive
(+) terminal and the black flying lead to the
battery negative (-) terminal.
4. Set the Check/Load switch to CHECK to read the
battery no-load voltage which should be at least
12.4 volts.
5. Set the Check/Load switch to LOAD and hold
down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
6. If the tests are unsatisfactory, refer to the fault
diagnosis table.
33 - 59 9813/7400-1 33 - 59
03 - Battery
00 - General
Table 246. Fault Diagnosis Charge

Battery Tester Read- Remedy
ings
CHECK: 0 -12.6 Volts: Renew battery Precautions before Charging
LOAD: less than 6 Volts
Follow all the precautions described below, to
CHECK: 6 -12.4 Volts: Recharge and re-test. If prevent damage to the alternator and battery.
LOAD: less than 9 Volts tests are still unsatisfac-
and falls steadily but re- tory renew battery 1. Make the machine safe. Refer to (PIL 01-03).
mains in yellow zone
CHECK: less than 10 Indicates battery has 2. Make sure that the battery negative terminal
Volts: LOAD: less than 3 been over-discharged is connected to the earth cable. Refer to (PIL
Volts and unlikely to recover. 33-03).
Renew battery
3. Do not connect or disconnect the battery
CHECK: more than 11 Charge battery which or alternator connections, or any part of the
Volts: LOAD: 6 - 10 Volts will probably recover charging circuit while the engine is in operation.
steady If you disregard this instruction, the regulator or
rectifying diodes will be damaged.
Specific Gravity Test
4. Main output cables are always in active state
The specific gravity of the electrolyte gives an idea of current flow even when the engine is not in
of the state of charge of the battery. Readings operation. If the alternator connector is removed,
should be taken using a hydrometer, when the do not earth the moulded plug.
electrolyte temperature is 15°C (60°F). If the battery
has recently been on charge, wait approximately one 5. When you do arc welding on the machine,
hour (or slightly discharge the battery) to dissipate remove the moulded plug (or if the separate
the surface charge before testing. output cables are installed, remove the cables)
to protect the alternator.
Readings should be as tabulated and should not vary
between cells by more than 0.04. A greater variation 6. If it is necessary to jump start the battery then do
indicates an internal fault on that particular cell. the steps below.
6.1. Connect the secondary battery in parallel
If the electrolyte temperature is other than 15°C
without disconnecting the vehicle battery
(60°F) a 'correction factor' must be applied to the
from the charging circuit.
reading obtained. Add 0.07 per 10°C (18°F) if the
temperature is higher than 15°C (60°F) and subtract 6.2. After the jump start, safely disconnect and
the same if the temperature is lower. remove the secondary battery.
Table 247. Specific Gravity at 15°C (60°F)) 6.3. Make sure you connect the positive terminal
to the positive terminal and the negative
Ambient Fully Half Dis- Fully Dis- terminal to the negative terminal of both the
Temper- Charged charged charged batteries.
ature de-
grees C
(degrees
F)
Below 27 1.270-1.290 1.190-1.210 1.110-1.130
(80)
Above 27 1.240-1.260 1.170-1.190 1.090-1.110
(80)
33 - 60 9813/7400-1 33 - 60
03 - Battery
00 - General
Remove and Install

method and device.
Remove
1. Open the rear access cover. Refer to (PIL 06-06).
2. Disconnect the battery. Refer to (PIL 33-03).
3. Remove the fusebox off the top of the battery.
4. Unclip the air filter if necessary. Refer to (PIL
15-24).
5. Undo the wing nuts to release the battery clamp.
6. Carefully lift the battery out of the mounting tray.
Figure 605.
A Battery
B Wing nuts
Install
removal procedure.
33 - 61 9813/7400-1 33 - 61
03 - Battery
03 - Isolator Switch
03 - Isolator Switch Introduction

Introduction .................................................... 33-62 The battery isolator switch is used to disconnect the
Disconnect and Connect ............................... 33-63 battery from the machine electrics. The switch must
Remove and Install ....................................... 33-64 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, PIL (33-03-03).
33 - 62 9813/7400-1 33 - 62
03 - Battery
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. Refer to (PIL
33-03).
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 - 63 9813/7400-1 33 - 63
03 - Battery
Remove and Install
Removal 4. Disconnect the isolator harness.
1. Make the machine safe with the lift arm lowered. 5. Remove the fixings and the battery clamp.
6. Remove the battery.
2. Open the engine compartment cover. Refer to
(PIL 06-06). 7. Remove the locknut and the washer.
3. Disconnect the battery leads. 8. Remove the isolator switch.
Figure 606.
B E,F
K
M
D,J
C
A
P,Q
G,H,L N
A Battery tray B Battery

C Isolator switch D Set screw
E Locknut 1 F Washer 1
G Locknut 2 H Washer 2
J Washer 3 K Battery terminal cover
L Bolt M Battery clamp
N Isolator bracket P Clip
Q Grommet
Figure 607. Electrical schematic Install

removal procedure.
33 - 64 9813/7400-1 33 - 64
06 - Battery Cable
06 - Battery Cable
Contents Page No.
33-06-00 General ........................................................................................................................... 33-67
33 - 65 9813/7400-1 33 - 65
Notes:
33 - 66 9813/7400-1 33 - 66
06 - Battery Cable
00 - General
00 - General
Introduction
The cables connect the battery positive and negative

terminals to the machine electrical system.
33 - 67 9813/7400-1 33 - 67
09 - Power Distribution
Contents Page No.
33-09-00 General ........................................................................................................................... 33-69

33-09-03 Fuse ............................................................................................................................... 33-71
33-09-06 Relay .............................................................................................................................. 33-73
33 - 68 9813/7400-1 33 - 68
00 - General
Introduction .................................................... 33-69 The electrical circuits are protected by fuses. If a
Health and Safety .......................................... 33-70 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 - 69 9813/7400-1 33 - 69
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 - 70 9813/7400-1 33 - 70
03 - Fuse
03 - Fuse Table 249.

Fuse Circuits Protected Rating
Technical Data No.
A1 Instruments 10A
A2 Power hold relay (tier 4 only), fu- 15A
Primary Fuses el pump (tier 4 only), water in fu- (tier 4)
el, engine ECU power feeds (tier 10A
Figure 608. 4 only) (tier 3)
A3 Beacon 10A
A4 12V socket, horn 15A
A5 Diagnostic connector 10A
A6 Chassis ECU 20A
A7 Joystick bases 10A
B1 Work lights 30A
Table 248. B2 Radio, interior light 10A
Fuse Circuits Protected Rating B3 Air suspension/heated seat (op- 20A
No. tional)
1 Starter 100A B4 EH ECU 20A
2 Work lights, radio, interior light 60A B5 Right switch panel 15A
3 Joystick, heated seat, beacon, 60A B6 Right switch panel, left switch 10A
horn panel, ignition switch
4 ECU (Electronic Control Unit)s, 60A B7 Hand throttle, engine ECU switch 10A
right hand console, left hand con- on, throttle actuator relay (tier 3
sole only)
C1 Front wash wipe (optional) 15A
Individual Circuit Fuses C2 Spare 10A
Figure 609. C3 Spare 15A
C4 HVAC (Heating Ventilation Air 40A
7 6 5 4 3 2 1 Conditioning)(optional)
Seven Function Joystick Fuses

A Figure 610.
B
5 4 3 2 1
C
Table 250.
No.
1 12V supply to attachment 20A
2 Attachment primary functions - 20A
Seven function joystick relays A,
B
3 Attachment secondary functions - 20A
Seven function joystick relays C,
D
33 - 71 9813/7400-1 33 - 71
03 - Fuse

No.
4 Attachment third functions - 20A
Seven function joystick relays E,
F
5 Attachment fourth functions - 10A
Seven function joystick relay G
33 - 72 9813/7400-1 33 - 72
06 - Relay
06 - Relay Seven Function Joystick Relays

Figure 612.
Technical Data
Figure 611.
A B C
A B C
D E F
D E F
G H J
G H
Table 251.
Item Description
A Ignition 1
B Ignition 2 Table 252.
C Throttle actuator (tier 3)
Relay Description
D Horn
A Attachment relay 1 primary function A
E Front worklight
B Attachment relay 2 primary function B
F Rear worklight
C Attachment relay 3 secondary func-
G Ignition - wash/wipe (optional) tion A
H Ignition - HVAC (Heating Ventilation D Attachment relay 4 secondary func-
Air Conditioning) (optional) tion B
J Not used E Attachment relay 5 third function A
F Attachment relay 6 third function B
G Attachment latching relay 7 fourth
function
H Attachment relay 8 ignition on
switched
33 - 73 9813/7400-1 33 - 73
12 - Harness
12 - Harness
Contents Page No.
33-12-00 General ........................................................................................................................... 33-75

33-12-04 Chassis ........................................................................................................................... 33-85
33-12-06 Lift Arm ......................................................................................................................... 33-100
33-12-09 Engine .......................................................................................................................... 33-108
33-12-12 Operator Station ........................................................................................................... 33-117
33-12-45 Power Distribution ........................................................................................................ 33-132
33-12-57 Heating, Ventilating and Air-Conditioning (HVAC) ....................................................... 33-133
33-12-58 Heater ........................................................................................................................... 33-134
33-12-59 Compressor .................................................................................................................. 33-135
33-12-61 Throttle ......................................................................................................................... 33-136
33-12-69 Reverse Warning Alarm ............................................................................................... 33-139
33-12-76 Window Washer/Wipe .................................................................................................. 33-140
33-12-77 Front Window Washer/Wiper ....................................................................................... 33-141
33 - 74 9813/7400-1 33 - 74
12 - Harness
00 - General
Introduction .................................................... 33-75
Health and Safety .......................................... 33-76
Harness Drawings
Component Identification ............................... 33-77 Drawings are reproduced from production electrical
Repair ............................................................ 33-79 harness drawings. Each harness drawing includes
Check (Condition) .......................................... 33-81 tables showing wire connections and destinations
for all the connectors on the harness. To identify
the correct harness drawing for a particular machine
refer to the relevant Harness Interconnection page
for the machine serial number range.
33 - 75 9813/7400-1 33 - 75
12 - Harness
00 - General
Health and Safety

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.
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.
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 - 76 9813/7400-1 33 - 76
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 613.
The illustration shows a typical connector and wires. Identifica- Description

Each wire has an individual identification number tion Num-
permanently marked on it, at regular intervals along ber
it's length. The number stamped on the wire identifies 819 The wire's unique identification num-
the following: ber. The wire functions and num-
bers allocated to them are consis-
Table 253. Wire and Harness tent through out the JCB range of
Number Identification products. Refer to Wire Numbers and
Identifica- Description Functions.
tion Num- 9/371 If applicable - The part number of
ber the harness that the wire originates
# The # indicates the start of the identi- from. If the harness part number is
fication number. It is always printed to 719/37100, the number printed on the
the left of the identification number. harness wires will be 9/371 (71 and
B If applicable - The colour of the fly- 00 are common numbers and there-
ing lead that the harness wire should fore deleted).
mate with. For instance, if wire 819
from harness 719/37100 mated with Wire Numbers and Functions
a flying lead coloured black (colour
code B) then the number printed on
the wire would be B-819 9/371. Table 254. Wires 000-199, 1000-1999 (These
numbers are reserved for ignition feeds,
heater start circuits and start circuits)
Wire Number Description
Wires 000 - 099 Unfused ignition feeds
Wires 100 - 199 Fused ignition feeds (feeds via
and 1000 -1999 ignition relays are also classed
as ignition feeds). Power sup-
plies output by a control module.
33 - 77 9813/7400-1 33 - 77
12 - Harness
00 - General
Table 255. Wires 200-399, 2000-3999 (These Table 259. Wires In Splices
numbers are reserved for battery feeds)
Wire Number Description Various The main input wire is allocated
Wires 200-299 Unfused battery feeds. Pow- with a wire number and a suit-
and 2000-2999 er supplies output by a control able description, i.e. Wire 640
module. earth splice to earth. The addi-
Wires 300-399 Fused battery feeds. Power sup- tional wires in the splice are al-
and 3000-3999 plies output by a control module. located the same wire number
and a postfix, i.e. 640A, 640B,
etc.
Table 256. Wires 400-599, 4000-5999
Figure 615.
Wires 400-599 These numbers are reserved for
and 1000-5999 instruments, sensors and vari-
able input/output signal wires
used in electronic systems. CAN
wires also use numbers in this
series.
Table 257. Wires 600-799, 6000-7999

Wires 600-799 These numbers are used for
and 6000-7999 earth wires. When the number
is printed on to a wire it is pre-
fixed by the Earth symbol. This
symbol is printed onto the wire,
it may however be omitted from General Points
harness drawings. Where a load 1. Wires continue to have the same number even
is switched negative, the wire after passing through a connector block to
number from the load to the another harness.
switch shall be different to that
of the wire from the switch to the 2. The descriptions are applicable to JCB
earth. specification wiring harnesses. The machine
may be installed with some wiring that does
not conform to the JCB specifications, typically
Figure 614. when it is part of equipment supplied by other
manufacturers.
600
Table 258. Wires 800-999, 8000-9999
Wires 800-999 These numbers are reserved
and 8000-9999 for switched supplies to electri-
cal loads, i.e. to lights, etc. Pow-
er supplies output by a control
module.
33 - 78 9813/7400-1 33 - 78
12 - Harness
00 - General
Repair 2. Using the correct sized splice, attach the new

section of wire required or auxiliary flying
Special Tools lead to the existing harness and secure using
Description Part No. Qty. the crimp tool. Note that each of the splices
Wiring Crimp Tool 892/00349 1 detailed is colour-coded to make size and range
readily visible. They are secured using the
Butane Heater 892/00350 1 corresponding size and matching colour-coded
jaws of the crimp tool to ensure joint security.
Consumables This tool also incorporates a ratchet closing
Description Part No. Size mechanism which will not release until the splice
Wiring Splice 892/00351 - is fully closed to the correct compression size.
(0.5-1.5mm Red,
Consumable: Wiring Splice (0.5-1.5mm Red,
contains 50 off)
contains 50 off)
Wiring Splice 892/00352 - Consumable: Wiring Splice (1.5-2.5mm Blue,
(1.5-2.5mm Blue, contains 50 off)
contains 50 off) Consumable: Wiring Splice (3-6mm Yellow,
Wiring Splice (3-6mm 892/00353 - contains 50 off)
Yellow, contains 50 off)
3. With the Butane heater assembly, seal the
Instances occur where it is necessary to incorporate connection.
auxiliary electrical components into existing electrical Special Tool: Butane Heater (Qty.: 1)
circuits and although unlikely with present wiring
harnesses, repair or replace specific individual wires 3.1. Remove the cap from the end of the
within a harness. This will also apply to other disposable gas cartridge.
machines in addition to those of manufacture.
Figure 617.
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 618.
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 616.
A
C Reflector element
D Red ring
3.3. Position the tube hanging down from inside
the reflector assembly into the hole at the
top of the gas cartridge. Then press the gas
A Distance for splice (check size)
33 - 79 9813/7400-1 33 - 79
12 - Harness
00 - General
cartridge up into the reflector assembly as Figure 621.

far as possible until the two elements are
clasped firmly together. An audible click will
be heard.
Figure 619.
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 620. 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 622.
E Small ring
F Air holes
3.5. Turn the red ring to the right (in the direction
of the plus sign) in order to turn on the E Small ring
gas. Important: Before turning the heater F Air holes
on, make sure that the cartridge is not hotter
than the reflector element. This may occur 3.7. The heater can be used in two modes:
if the cartridge is held in the hand for a long
time. The temperature difference between 3.8. Side wings down, reflector head completely
the cartridge and the reflector element may open. In this mode the infra-red heat waves
cause long yellow flames to appear on are dominant (recommended for the light
ignition. coloured plastic splices).
33 - 80 9813/7400-1 33 - 80
12 - Harness
00 - General
Figure 623. 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 624.
be plugged into the black socket (sometimes, this
socket is also marked by a -, or E or marked as
COMMON or COM). The red test lead should be
plugged into the red socket marked with +, V or
Ω.
2. When you make a measurement, make sure that
the test probes have a good clean contact with
bare metal, free from grease, dirt, and corrosion
as these can cause a false reading.
3. When you measure a voltage, make sure that
the correct range is selected, that it is set to the
selector value equal to or greater than that you
are about to measure. e.g. If asked to measure
12 Volts, set the selector to the 12V range. If
D Red ring there is no 12V range, set the selector to the next
G Side wings range higher, 20V for instance. If the meter is set
to a range that is too low, it may be damaged.
e.g. setting to the 2V range to measure 12V.
Measuring DC Voltage
1. Select the correct range on the multimeter.
1.1. On the digital multimeter, turn the switch to
position B.
33 - 81 9813/7400-1 33 - 81
12 - Harness
00 - General
Figure 625. Fluke 85 Multimeter Figure 626. 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 627. Typical Analogue Multimeter
2. Connect the black probe to the nearest available

suitable earth point, usually this will be the starter
motor earth, the battery negative, or the chassis.
Connect the red probe to the wire or contact from
which you are measuring the voltage.
33 - 82 9813/7400-1 33 - 82
12 - Harness
00 - General
Measuring Resistance Measuring Frequency

1. Make sure that there is no power to the part of The AVO meter and the analogue meter are not
the circuit you are about to measure. capable of measuring frequency, therefore a digital
multimeter must be used.
2. Connect one probe at one end of the component
or wire to be checked and the other probe at the 1. Insert the black plug into the COM socket on
other end. It does not matter which way round the the meter and attach the probe to the nearest
two probes are placed. suitable earth point on the chassis, for example,
the battery negative terminal.
3. Select the correct range on the multimeter.
2. Insert the red probe into socket J.
3.1. On the digital multimeter. Turn the switch to
position C and check that the W sign at the 3. Turn the selector switch to position A and
right hand side of the display window is on. depress G repeatedly until F is highlighted on the
If the F sign is on instead, press the blue top row of the display.
button G to change the reading to Ω. Touch
the meter lead probes together and press 4. Press button H once.
the REL3 key on the meter to eliminate the
lead resistance from the meter reading. 5. Touch or connect the red probe to the frequency
source to be measured. Press and hold the
3.2. On the AV0 meter, move the right hand button if an average reading is required.
slider switch to position B, and the left hand
slider switch to the appropriate Ohms (Ω) Testing a Diode or a Diode Wire
range.
3.3. On an analogue meter, move the dial to the A diode wire is a diode with male connector installed
appropriate Ohms (Ω) range. on one end and a female connector installed on the
other end. The diode is sealed in heatshrink sleeving.
Measuring Continuity To test a Diode or a Diode Wire.
1. Make sure that there is no power to the part of 1. On the digital multimeter:
the circuit you are checking for continuity.
1.1. Turn the switch to position D.
2. Connect one probe to one end of the component 1.2. Press the HOLD button and check that the
or wire to be checked and the other probe to the H sign appears at the top right hand side of
other end. It does not matter which way round the the display window.
two probes are placed.
1.3. Connect the black probe to the end of the
3. Select the correct range on the multimeter. diode with a band or to the male connector
of the diode wire. Connect the red probe
3.1. On the digital multimeter, turn the switch to the other end of the diode or diode wire.
to position C and check that the beeper If the beeper does not sound the diode or
symbol appears at the left hand side of diode wire is faulty.
the display window. If the F sign is on
instead, press the button labelled F. If there 1.4. Connect the red probe to the end of the
is continuity in the circuit, the beeper will diode marked with a band, or to the male
sound. If there is no continuity (open circuit), connector of the diode wire, the black probe
the beeper will not sound. should be connected to the other end of the
diode or diode wire. If the beeper sounds or
3.2. On the AV0 meter, move the right hand the meter does not read O.L., the diode or
slider switch to position B, and the left diode wire is faulty.
hand slider switch to position C. If there is
continuity (i.e. very low resistance) between 1.5. Press the HOLD button and check that the
two points the buzzer will sound. H sign disappears from the right hand side
of the display window.
3.3. On an analogue meter, turn the dial to
the lowest Ohms (Ω) range. If there is 2. On the AV0 meter:
continuity (i.e. very low resistance) between
two points the needle will move across fully 2.1. Move the right hand slider to position A, and
(or almost fully) to the right hand side of the the left hand slider switch to position C.
scale. 2.2. Connect the black probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the red probe
should be connected to the other end of the
33 - 83 9813/7400-1 33 - 83
12 - Harness
00 - General
diode or diode wire. If the Avo meter does

not buzz the diode is faulty.
2.3. Connect the red probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the black probe
diode or diode wire. If the Avo meter does
not read 1 the diode is faulty.
3. On an analogue meter:
3.1. Select the Ohms 1000s (1k) range, connect
the black probe to the end of the diode
marked with a band, or to the male
connector of the diode wire, the red probe
diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the
diode is faulty.
3.2. Select the Ohms 100s range, connect the
red probe to the end of the diode marked
with a band, or to the male connector of
the diode wire, the black probe should
be connected to the other end of the
diode or diode wire. The meter should read
300-400Ω, if it reads less than this the diode
is faulty.
33 - 84 9813/7400-1 33 - 84
12 - Harness
04 - Chassis
04 - Chassis
Diagram
33 - 85 9813/7400-1 33 - 85
Notes:
33 - 86 9813/7400-1 33 - 86
12 - Harness
04 - Chassis
Page 33-88 Figure 628. 721-X1873-1 (sheet 1 of 5) Page 33-89
33 - 87 9813/7400-1 33 - 87
12 - Harness
04 - Chassis
33-88 33-89
Page 33-89
33 - 88 9813/7400-1 33 - 88
12 - Harness
04 - Chassis
33-88 33-89
Page 33-88
33 - 89 9813/7400-1 33 - 89
12 - Harness
04 - Chassis
33 - 90 9813/7400-1 33 - 90
12 - Harness
04 - Chassis
33 - 91 9813/7400-1 33 - 91
12 - Harness
04 - Chassis
33-92 33-93
Page 33-93
33 - 92 9813/7400-1 33 - 92
12 - Harness
04 - Chassis
33-92 33-93
Page 33-92
33 - 93 9813/7400-1 33 - 93
12 - Harness
04 - Chassis
33 - 94 9813/7400-1 33 - 94
12 - Harness
04 - Chassis
33 - 95 9813/7400-1 33 - 95
12 - Harness
04 - Chassis
33-96 33-97
Page 33-97
33 - 96 9813/7400-1 33 - 96
12 - Harness
04 - Chassis
33-96 33-97
Page 33-96
33 - 97 9813/7400-1 33 - 97
12 - Harness
04 - Chassis
Figure 631. 721-X1873-1 (sheet 4 of 5)
33 - 98 9813/7400-1 33 - 98
12 - Harness
04 - Chassis
Figure 632. 721-X1873-1 (sheet 5 of 5)
33 - 99 9813/7400-1 33 - 99
12 - Harness
06 - Lift Arm
06 - Lift Arm
Diagram
33 - 100 9813/7400-1 33 - 100

12 - Harness
06 - Lift Arm
Page 33-102 Figure 633. Hose Tray -

721-X1871-1 (sheet 1 of 1) Page 33-103
33 - 101 9813/7400-1 33 - 101

12 - Harness
06 - Lift Arm
33-102 33-103
Page 33-103
33 - 102 9813/7400-1 33 - 102

12 - Harness
06 - Lift Arm
33-102 33-103
Page 33-102
33 - 103 9813/7400-1 33 - 103

12 - Harness
06 - Lift Arm
33 - 104 9813/7400-1 33 - 104

12 - Harness
06 - Lift Arm
Page 33-106 Figure 634. Telescopic Lift Arm

- 721-X1872-1 (sheet 1 of 1) Page 33-107
33 - 105 9813/7400-1 33 - 105

12 - Harness
06 - Lift Arm
33-106 33-107
Page 33-107
33 - 106 9813/7400-1 33 - 106

12 - Harness
06 - Lift Arm
33-106 33-107
Page 33-106
33 - 107 9813/7400-1 33 - 107

12 - Harness
09 - Engine
09 - Engine
Diagram
33 - 108 9813/7400-1 33 - 108

12 - Harness
09 - Engine
Page 33-110 Figure 635. 320/09953 issue 1-Sheet 1 of 3 Page 33-111
33 - 109 9813/7400-1 33 - 109

12 - Harness
09 - Engine
33-110 33-111
Page 33-111
33 - 110 9813/7400-1 33 - 110

12 - Harness
09 - Engine
33-110 33-111
Page 33-110
33 - 111 9813/7400-1 33 - 111

12 - Harness
09 - Engine
33 - 112 9813/7400-1 33 - 112

12 - Harness
09 - Engine
Page 33-114 Figure 636. 320/09953 issue 1-Sheet 2 of 3 Page 33-115
33 - 113 9813/7400-1 33 - 113

12 - Harness
09 - Engine
33-114 33-115
Page 33-115
33 - 114 9813/7400-1 33 - 114

12 - Harness
09 - Engine
33-114 33-115
Page 33-114
33 - 115 9813/7400-1 33 - 115

12 - Harness
09 - Engine
Figure 637. 320/09953 issue 1-Sheet 3 of 3
33 - 116 9813/7400-1 33 - 116

12 - Harness
Diagram
33 - 117 9813/7400-1 33 - 117

Notes:
33 - 118 9813/7400-1 33 - 118

12 - Harness
33 - 119 9813/7400-1 33 - 119

12 - Harness
33-120 33-121
Page 33-121
33 - 120 9813/7400-1 33 - 120

12 - Harness
33-120 33-121
Page 33-120
33 - 121 9813/7400-1 33 - 121

12 - Harness
33 - 122 9813/7400-1 33 - 122

12 - Harness
33 - 123 9813/7400-1 33 - 123

12 - Harness
33-124 33-125
Page 33-125
33 - 124 9813/7400-1 33 - 124

12 - Harness
33-124 33-125
Page 33-124
33 - 125 9813/7400-1 33 - 125

12 - Harness
Figure 640. 721-X1874-1 (sheet 3 of 6)
33 - 126 9813/7400-1 33 - 126

12 - Harness
33 - 127 9813/7400-1 33 - 127

12 - Harness
33-128 33-129
Page 33-129
33 - 128 9813/7400-1 33 - 128

12 - Harness
33-128 33-129
Page 33-128
33 - 129 9813/7400-1 33 - 129

12 - Harness
Figure 642. 721-X1874-1 (sheet 5 of 6)
33 - 130 9813/7400-1 33 - 130

12 - Harness
Figure 643. 721-X1874-1 (sheet 6 of 6)
33 - 131 9813/7400-1 33 - 131

12 - Harness
Diagram
Figure 644. 332/X9705 issue 1 - sheet 1
33 - 132 9813/7400-1 33 - 132

12 - Harness
57 - Heating, Ventilating and Air-

Conditioning (HVAC)
Diagram
33 - 133 9813/7400-1 33 - 133

12 - Harness
58 - Heater
58 - Heater
Diagram
33 - 134 9813/7400-1 33 - 134

12 - Harness
59 - Compressor
59 - Compressor
Diagram
33 - 135 9813/7400-1 33 - 135

12 - Harness
61 - Throttle
61 - Throttle
Diagram
33 - 136 9813/7400-1 33 - 136

12 - Harness
Diagram
33 - 137 9813/7400-1 33 - 137

12 - Harness
33 - 138 9813/7400-1 33 - 138

12 - Harness
69 - Reverse Warning Alarm
69 - Reverse Warning Alarm
Diagram
33 - 139 9813/7400-1 33 - 139

12 - Harness
76 - Window Washer/Wipe
Diagram
Figure 652. 721/X1780 issue 3
33 - 140 9813/7400-1 33 - 140

12 - Harness
77 - Front Window Washer/Wiper
77 - Front Window Washer/Wiper
Diagram
Figure 653. 721/X1781 issue 3
33 - 141 9813/7400-1 33 - 141

15 - Alarm
15 - Alarm
Contents Page No.
33-15-03 Reverse Warning .......................................................................................................... 33-143
33 - 142 9813/7400-1 33 - 142

15 - Alarm
03 - Reverse Warning
03 - Reverse Warning Introduction

Introduction .................................................. 33-143 The reverse alarm will sound when the machine is
Remove and Install ..................................... 33-144 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 - 143 9813/7400-1 33 - 143

15 - Alarm
03 - Reverse Warning
Remove and Install 4. Disconnect the electrical connector.
.............................................. Page 33- 5. Remove the cable tie securing the harness to the
engine compartment cover.
.............................................. Page 33-
Remove
7. Remove the reverse alarm from the machine.
Figure 655.
(PIL 06-06).
4. Disconnect the electrical connection.
5. Remove the bolt (x2) and the washer (x2).
6. Remove the reverse alarm from the machine.
Figure 654.
B
B
C
A
D C
A Reverse alarm
A B Electrical connector
C Bolts (x2)
D Cable tie
Install
A Reverse alarm step.
B Grommet
C Washer 2. Replace the cable tie.
D Bolt
Install
removal procedure.
Remove
(PIL 06-06).
33 - 144 9813/7400-1 33 - 144

24 - Instruments
24 - Instruments
Contents Page No.
33-24-00 General ......................................................................................................................... 33-147

33-24-10 Hourmeter .................................................................................................................... 33-157
33 - 145 9813/7400-1 33 - 145

Notes:
33 - 146 9813/7400-1 33 - 146

24 - Instruments
00 - General
Introduction .................................................. 33-147 The right hand display and switch panel (EMS) forms
Operation ..................................................... 33-148 part of a system comprising of a 3620 ECU and a
Fault-Finding ................................................ 33-156 left hand switch panel (optional). The EMS panel
Check (Pressure) ........................................ 33-156 communicates information to the operator about the
systems on the machine and warns of any abnormal
conditions that may occur. The EMS panel comprises
of:
• Fuel level gauge

• Coolant temperature gauge
• Hydraulic temperature gauge
• Warning/status LED's
• Ignition switch
• 5 membrane switches for controlling different
standard functions on the machine
• 3 membrane switches for navigating the
screens of the LCD info message display
• Warning buzzer
Description
The logic control is divided into two sections.
Table 260. Logic Control

Logic Description
Operator Logic This section displays in-
formation for the oper-
ator: Engine Running
hours, Clock, Tachome-
ter, error display and pin
code start.
Advanced Logic This section is used for
the service engineer to
alter the machine set-up.
A machine option is indicated by *
33 - 147 9813/7400-1 33 - 147

24 - Instruments
00 - General
Operation
Operator Logic Control

Use the up and down buttons and the “i” button
on the right hand switch panel to scroll through the
information screens to show information.
Figure 656.
Screen Description
No Error Code The alternate screen if
Table 261.
no active error codes
Screen Description are present.
Key On Display Displays the time to next ISO Control Pattern When the park brake or
service and illuminates lift arm is selected, the
for 3 seconds. selected control pattern
Engine Running Hours Displays for 3 Seconds is displayed for 3 Se-
after time to service. conds.
Tachometer Displays the engine ISO Control Pattern When the park brake or
speed. lift arm is selected the
Clock Displays the time. selected control pattern
is displayed for 3 sec-
Error Error is active. onds and then the se-
Error Code Error code menu. lected work mode is dis-
Work Mode Displays the work mode played.
selected. 1, 2 or 3.
Auto Idle Auto Idle is off. Advanced Logic Control
Auto Idle Auto Idle is on.
To enter the advanced logic control, press and hold
Error Code Messages Error code menu.
the “i” button for 5 seconds. Use the up and down
Error Each press of the Up or buttons and the “i” button on the right hand switch
Down button will cycle to panel to scroll through the information screens to
the next higher or lower show information. To exit the advanced logic control
error code respectively. press and hold the “i” button for 5 seconds.
33 - 148 9813/7400-1 33 - 148

24 - Instruments
00 - General
33 - 149 9813/7400-1 33 - 149

24 - Instruments
00 - General
33-150 33-151
Page 33-151
33 - 150 9813/7400-1 33 - 150

24 - Instruments
00 - General
33-150 33-151
Page 33-150
33 - 151 9813/7400-1 33 - 151

24 - Instruments
00 - General
Table 262.
Item Screen Graphic Description
A Key On Display Key On Display 5 Se-
conds. Displays the time
to next Service and illumi-
nates for 3 seconds.
B Vehicle Running Hours Displays hours with the
key switch ON.
C Engine Running Hours Displays hours with the

engine > ERT.
D Time Until Next Service Preceded with “-” if inter-

val is exceeded. Pre and
hold the “i” button for 3
seconds to reset to 500H.
E Clock Set Mode When this screen is dis-
played press the “i” button
to enter clock set mode.
Use the up arrow to ad-
vance hours. Use the
down arrow to advance
minutes.
Press the “i” button to dis-
play screens F, G, H, J
and K.
F Units Displays the units infor-
mation.
G Metric Press the “i” button to set

the units to metric.
H Imperial Press the “i” button to set

the units to imperial.
J Clock 12 Press the “i” button to set

the clock to 12H.
K Clock 24 Press the “i” button to set

the clock to 24H.

play screens L, M and N.
33 - 152 9813/7400-1 33 - 152

24 - Instruments
00 - General

L Vehicle Data Displays the vehicle VIN
and model information.
M Vin Number Displays the vehicle iden-

tification number (next
screen).
N Model Number Displays the model num-

ber (next screen).

play screens P, Q and R.
P Temperatures Displays the vehicle pres-
sures.
Q Coolant Temperature Displays the engine

coolant temperature.
R Hydraulic Oil Tempera- Displays the hydraulic oil

ture temperature.

play screens S, T, U and
V.
S Pressures Displays the hydraulic
pressures.
T Charge Pressure Displays the charge pres-

sure.
U Float/Lift Pressure Displays the float/lift pres-

sure.
V Park brake Pressure Displays the park brake

pressure.

play screens W, X, Y, Z
and AA.
33 - 153 9813/7400-1 33 - 153

24 - Instruments
00 - General

W Vehicle (electrical) Displays the vehicle elec-
trical information.
X Fuel Level Sender Displays the resistance

from the fuel level sender.
Y Alternator Voltage Displays the alternator

voltage.
Z Alternator Frequency Displays the alternator

frequency.
AA Joystick Voltage Displays the joystick pro-

portional signal voltage.

play screens AB, AC, AD,
AE, AF, AG, AH, AJ and
AK.
AB Versions Displays the electronic
versions.
AC Chassis ECU (Electronic Displays the ECU hard-

Control Unit) hardware ware version.
AD Chassis ECU software Displays the ECU soft-

ware version.
AE Electro hydraulic ECU Displays the ECU hard-

hardware ware version.
AF Electro Hydraulic ECU Displays the ECU soft-

Software ware version.
AG Right hand EMS (Elec- Displays EMS hardware

tronic Monitoring System) version.
Hardware
33 - 154 9813/7400-1 33 - 154

24 - Instruments
00 - General

AH Right hand EMS Software Displays the EMS soft-
ware version.
AJ Left hand EMS Hardware Displays EMS hardware

version.
AK Left hand EMS Software Displays the EMS soft-

ware version.

play screens AL, AM, AN,
AP, AQ and AR if the key-
less start feature is en-
abled.
AL Versions Displays the PIN informa-
tion.
AM PIN Owner PIN code required

to continue.
AN PIN 1 PIN 1 is displayed and

number entry is possible.
AP PIN 2 PIN 2 is displayed and

AQ PIN 3 PIN 3 is displayed and

AR PIN 4 PIN 4 is displayed and

33 - 155 9813/7400-1 33 - 155

24 - Instruments
00 - General
Fault-Finding Check (Pressure)

For the full list of fault codes, refer to (PIL 33-57).
The instrument panel can be used to self check
machine pressures. Refer to (PIL 33-24) Operation
- Logic Control. Pressures which can be measured
are:
• Charge Pressure
• Float/Lift Pressure
• Park Brake Pressure
33 - 156 9813/7400-1 33 - 156

24 - Instruments
10 - Hourmeter
10 - Hourmeter Introduction
Introduction .................................................. 33-157 The hourmeter is a device that records the operating
Remove and Install ..................................... 33-158 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 - 157 9813/7400-1 33 - 157

24 - Instruments
10 - Hourmeter

Remove procedure.

2. Disconnect the electrical harness from the
hourmeter.
3. Remove the bolts, locknuts and washers that
secure the hourmeter mounting bracket to the
body.
4. Remove the mounting bracket.
5. Remove the bracket from the hourmeter.
Figure 658.
C,D,E
A
A Bracket
B Hourmeter
C Bolt
D Locknut
E Washer
33 - 158 9813/7400-1 33 - 158

27 - Interior Switch
Contents Page No.
33-27-15 Hand Throttle Control ................................................................................................... 33-161
33 - 159 9813/7400-1 33 - 159

Notes:
33 - 160 9813/7400-1 33 - 160

15 - Hand Throttle Control
15 - Hand Throttle Control
Introduction
The hand throttle control is located on the right hand

instrument panel in the operator station.
It receives the battery voltage supply and has a built

in 5V regulator. It gives the 0.5–4.5V signal to the
chassis controller ECU (Electronic Control Unit).
Figure 659.
A Hand throttle control switch

B Instrument panel
33 - 161 9813/7400-1 33 - 161

40 - Bulb
40 - Bulb
Contents Page No.
33-40-00 General ......................................................................................................................... 33-163
33 - 162 9813/7400-1 33 - 162

40 - Bulb
00 - General
Introduction .................................................. 33-163 Make sure the bulbs are replaced with the same type
Technical Data ............................................. 33-164 and rating as the damaged bulb.
33 - 163 9813/7400-1 33 - 163

40 - Bulb
00 - General
Technical Data
Table 263.
Application Rating Type
W
Work lights 55 H3
Headlights 55 H3
Dip beam 55 H7
Side lights 4 T4W
Direction indica- 21
tor lights
Brake lights 21
Interior light 10
Warning lights 1.2
Beacon (if fit- 55
ted)
33 - 164 9813/7400-1 33 - 164

42 - Exterior Light
42 - Exterior Light
Contents Page No.
33-42-00 General ......................................................................................................................... 33-167

33-42-15 Front Work Light .......................................................................................................... 33-168
33-42-18 Rear Road Light ........................................................................................................... 33-169
33-42-30 Rear Work Light ........................................................................................................... 33-170
33 - 165 9813/7400-1 33 - 165

Notes:
33 - 166 9813/7400-1 33 - 166

42 - Exterior Light
00 - General
00 - General
Introduction
The exterior lights comprise of the front work lights

and the rear work lights.
Figure 660.
2
1
1 Front work light

2 Rear work light
33 - 167 9813/7400-1 33 - 167

42 - Exterior Light
15 - Front Work Light
15 - Front Work Light
Remove and Install
Remove
The front worklights are mounted on a bracket at the
top corner of the operator station roof frame.

2. Disconnect the electrical connection at the rear
of the worklight.
3. Remove the nut and washer, remove the
worklight from the mounting bracket.
Figure 661.
B,C
A Light
B Nut
C Washer
Install
removal procedure.
33 - 168 9813/7400-1 33 - 168

42 - Exterior Light
18 - Rear Road Light
18 - Rear Road Light
Remove and Install
Machines that travel on the road require the road light 2. Remove the screws, remove the housing.
kit to be installed on the machine. The rear road lights
are installed inside a housing and mounted to the 3. Disconnect the electrical connection at the rear
rear body. of the light.
4. Remove the screw/nut and washer, remove the
Remove relevant light from the housing.
Figure 662.
7
6 4 3 2 1
5
1 Stop light led 2 Seal

3 Indicator light led 4 Housing
5 Screw 6 Washer
7 Nut
Install
procedure. For bulb specifications, refer to
Bulbs-Technical Data (PIL 33-40).
33 - 169 9813/7400-1 33 - 169

42 - Exterior Light
30 - Rear Work Light
30 - Rear Work Light
Remove and Install
Remove
The rear work lights are mounted on a bracket at the
rear top corner of the operator station roof frame.

2. Disconnect the electrical connection at the rear
of the worklight.
3. Remove the bolt and washer, remove the
worklight and mounting bracket.
4. Remove the nut, collect the bolt and washer,
remove the worklight from the mounting bracket.
Figure 663.
B
C
G
F
D
E
A Worklight
B Bolt
C Washer
D Bracket
E Bolt
F Washer
G Nut
Install
removal procedure.
33 - 170 9813/7400-1 33 - 170

45 - Control Module
45 - Control Module
Contents Page No.
33-45-00 General ......................................................................................................................... 33-173

33-45-06 Engine .......................................................................................................................... 33-176
33-45-37 Electro Hydraulic (EH) ................................................................................................. 33-177
33-45-49 Chassis ......................................................................................................................... 33-179
33 - 171 9813/7400-1 33 - 171

Notes:
33 - 172 9813/7400-1 33 - 172

45 - Control Module
00 - General
Introduction .................................................. 33-173 Modern machines use ECU (Electronic Control Unit)
Health and Safety ........................................ 33-174 to control machine systems such as hydraulics,
Operation ..................................................... 33-174 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 664.
Figure 664. 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.

Refer to: Schematic Circuit (Page 33-5).
33 - 173 9813/7400-1 33 - 173

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
version and operation. Refer to electrical system-
Parts of the machine are made from cast iron, welds electronic diagnostic, refer to (PIL 33-57).
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable ECU Inputs
Always connect the welder earth (ground) cable to There are two main types of input, digital and
the same component that is being welded to avoid analogue.
the welder earth (ground) cable a distance from the Digital inputs (On-Off switch type inputs)
part being welded no more than 0.6m.
Digital type inputs are on-off type inputs (i.e.
Notice: Do not disconnect the battery while the switches). The digital inputs can be low side inputs or
engine is running, otherwise the electrical circuits high side inputs. The low side inputs are inputs that
may be damaged. provide a ground to the ECU. The high side inputs
are the inputs that provide a positive feed to the ECU.
Low side input
The low side input is the most frequently used input

on an electrical system. The low side input can be in
the form of rocker switches or pressure switches.
Figure 665.
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 - 174 9813/7400-1 33 - 174

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 670.
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 - 175 9813/7400-1 33 - 175

45 - Control Module
06 - Engine
06 - Engine
Introduction
Central to the engine control system is the ECM The ECM controls fuel injection by energising
(Engine Control Module). The prime function of the electrical actuators in the fuel injectors, high pressure
ECM is to initiate fuel injection. The engine cannot fuel pump and the common fuel rail.
run without the ECM.
Note: Other devices are connected to the ECM to
Signals from electrical sensors are continually control other engine related systems, refer to (PIL
monitored and processed by the ECM to determine 15-84).
when, how much and to which cylinder fuel must be
injected.
Figure 671.
TDC 2 3
5
4
C1 C2
D1 D2 6

3 Camshaft target disc 4 Crankshaft position sensor
5 Crankshaft mounted target disc 6 Fuel injector
33 - 176 9813/7400-1 33 - 176

45 - Control Module
37 - Electro Hydraulic (EH)
37 - Electro Hydraulic (EH) Introduction

Introduction .................................................. 33-177 The EH (Electro-Hydraulic) controller ECU
Remove and Install ..................................... 33-178 (Electronic Control Unit) is installed below the
operator station.
Figure 672.
A EH controller ECU
B Screw
33 - 177 9813/7400-1 33 - 177

45 - Control Module
37 - Electro Hydraulic (EH)
Remove and Install
Remove
3. Raise the operator station and get access
to the EH (Electro-Hydraulic) controller ECU
(Electronic Control Unit). Refer to (PIL 09-00).
4. Do not touch the electrical connector pins on the
EH controller ECU.
5. Disconnect the electrical connector from the EH
controller ECU.
6. Support the EH controller ECU and remove the
screw (x4).
7. Remove the EH controller ECU from the
machine.
Figure 673.
A EH controller ECU
B Screw (x4)
Install
step.
33 - 178 9813/7400-1 33 - 178

45 - Control Module
49 - Chassis
49 - Chassis Introduction
Introduction .................................................. 33-179 The chassis controller ECU (Electronic Control Unit)
Remove and Install ..................................... 33-180 is installed below the operator station.
Figure 674.
A Chassis controller ECU

B Screw
33 - 179 9813/7400-1 33 - 179

45 - Control Module
49 - Chassis
Remove and Install
Remove
3. Raise the operator station and get access to the
chassis controller ECU (Electronic Control Unit).
4. Do not touch the electrical connector pins on the
chassis controller ECU.
chassis controller ECU.
6. Support the chassis controller ECU and remove
the screw (x4).
7. Remove the chassis controller ECU from the
machine.
Figure 675.
A Chassis controller ECU

B Screw (x4)
Install
step.
33 - 180 9813/7400-1 33 - 180

48 - Entertainment
48 - Entertainment
Contents Page No.
33-48-03 Radio ............................................................................................................................ 33-183
33 - 181 9813/7400-1 33 - 181

Notes:
33 - 182 9813/7400-1 33 - 182

48 - Entertainment
03 - Radio
03 - Radio Introduction
Introduction .................................................. 33-183 The manufacturer is not responsible for any
Technical Data ............................................. 33-184 radio or TV interference caused by unauthorized
Diagram ....................................................... 33-185 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 - 183 9813/7400-1 33 - 183

48 - Entertainment
03 - Radio
Technical Data
Specifications subject to change without notice.
Table 264. General

Power Supply Require- 12 Volts DC, Negative
ments Ground
Chassis Dimensions 131.6mm (Width) x
47.5mm (Depth) x
86mm (Height)
Loading Impedance 4 - 8 ohms per channel
Tone Controls Bass (at 100 Hz), 10 dB;
Treble (at 10 kHz), 10
dB
Current Drain 1.5 Ampere (max)
Table 265. FM Tuner

Tuning range 87.5 - 108.0
FM mono sensitivity 1.5uV
Stereo separation @ 1 >25dB
kHz
Table 266. AM Tuner

Tuning range 522-1710
Sensitivity <30uV
Table 267. Weather Band

Sensitivity <1uV
Table 268. Amplifier

Total system power 15 Watts Maximum
Signal to Noise >70dB
33 - 184 9813/7400-1 33 - 184

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 676.
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 - 185 9813/7400-1 33 - 185

Contents Page No.
33-54-00 General ......................................................................................................................... 33-187

33-54-03 Tank .............................................................................................................................. 33-190
33-54-09 Front Motor ................................................................................................................... 33-192
33 - 186 9813/7400-1 33 - 186

00 - General
Introduction .................................................. 33-187 The wash/wipe system is used to remove rain and
Component Identification ............................. 33-188 debris from the front or rear window. The main
Diagram ....................................................... 33-189 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 - 187 9813/7400-1 33 - 187

00 - General
Figure 677.
H
J
B K
P
L
E
R
F
G
A
M Q D
A Wiper motor B Wiper arm

C Wiper blade D Slave pivot
E Adaptor F Wash/Wipe cab front harness
G Switch panel H Actuator
J Switch K Screw
L Bollhoff hex M Wash/wipe cab floor harness
N Straight connector P PVC Tube
Q Wiper mounting nut R Mounting screws, Wiper motor
33 - 188 9813/7400-1 33 - 188

00 - General
Diagram
Figure 678.
B C
A Front Washer Motor B Front Wiper/Wash Switch

C Front Wiper Motor
33 - 189 9813/7400-1 33 - 189

03 - Tank
03 - Tank Drain and Fill

Consumables
Drain and Fill ............................................... 33-190
JCB Screenclear 4006/0504 1L
Drain
2. Get access to the window wash tank. Refer to
access covers (PIL 06-06).
3. Disconnect the electrical connection to the
washer/wipe pump.
4. Disconnect the washer hose and allow the fluid
to drain into a suitable container..
Fill
procedure.
2. Fill the tank with the recommended washer fluid.
Important: Do not use antifreeze.
Consumable: JCB Screenclear
33 - 190 9813/7400-1 33 - 190

03 - Tank
Remove and Install
Remove
to the ground. Refer to (PIL 01-03).
2. Unlock the rear cover (if a lock is installed).
3. Open the rear cover and insert the lynch pin to
keep the cover open.
4. Disconnect the electrical connection to the
washer/wipe pump.
5. Disconnect the washer/wipe tank hose.
6. Drain the tank, refer to Washer/Wipe tank-Drain
and Fill (PIL 33-54)
7. Support the tank, remove the bolts.
8. Remove the washer/wipe tank from the rear
cover.
Install
procedure.
2. Fill the tank with a recommended washer fluid,
refer to Washer/Wipe tank - Drain and Fill (PIL
33-54)
33 - 191 9813/7400-1 33 - 191

09 - Front Motor
09 - Front Motor
Remove and Install
Remove 5. Disconnect the electrical harness.
1. Make the machine safe with the lift arm lowered. 6. Disconnect the wash/wiper pipes.
7. Remove the wiper mounting nut.
8. Remove the wiper motor screws and remove the
3. Remove the screw. wiper motor from the machine.
4. Remove the cover.
Figure 679.
H
J
B K
P
L
E
R
F
G
A
M Q D
A Wiper motor B Wiper arm

C Wiper blade D Slave pivot
E Adaptor F Wash/Wipe cab front harness
G Switch panel H Actuator
J Switch K Screw
33 - 192 9813/7400-1 33 - 192

09 - Front Motor
L Bollhoff fitting M Wash/wipe cab floor harness

N Straight connector P Pvc washer pipe
Q Wiper mounting nut R Wiper motor screws
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09 - Front Motor
Install
1. Installation is the opposite of the removal
procedure.
2. Tighten the wiper motor screws and the wiper
mounting nut to the correct torque value.

Item Description Nm
Q Wiper mounting nut 16
R Wiper motor screws 11
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57 - Electronic Diagnostic
Contents Page No.
33-57-00 General ......................................................................................................................... 33-197

33-57-03 Servicemaster .............................................................................................................. 33-199
33-57-90 Fault Codes .................................................................................................................. 33-232
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Notes:
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00 - General
Introduction .................................................. 33-197 JCB machines use the latest developments in
Health and Safety ........................................ 33-198 electronic management of machine systems. This
means that machine systems such as service
hydraulics, engine, transmission and steering are
controlled using ECU (Electronic Control Unit)'s. The
ECU process inputs from electrical sensors and
then output 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:
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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.
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03 - Servicemaster
03 - Servicemaster Introduction
Introduction .................................................. 33-199 JCB Servicemaster is an application to allow
Operation ..................................................... 33-216 engineers to diagnose and setup the various
Preparation .................................................. 33-217 electronic control units within the JCB product range.
Disconnect and Connect ............................. 33-231 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 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 680. Typical Front Screen View engine operating parameters in real time.
Perform engine electrical actuator tests. View, save
or clear ECM fault code log.
Figure 683. Flash Programmer tool
View ECM software file version. Upload and

Reprogramme software updates to the ECM
memory. Upload revisions to software.
Figure 684. 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 685. 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 681. Machine/Engine Set-up tool

Engine Hour records, Service Dealership Codes.
Figure 686. 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 682. Diagnostics tool need to be installed. These tools are denoted by the
following symbol:
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Figure 687. 2. Start JCB Servicemaster on the laptop computer.

Figure 689.
To install these applications you need to take the

following steps:
1. On the front end, click the other tab.

2. Click on general.
3. Click onto "extra applications".
4. Choose the relevant tool which you require to be
installed and run the installer.
Once the installer has been run, the icon should have
changed within the machine tool page. e.g. the above
3. Make sure that the correct DLA (Data Link
icon has now become:
Adaptor) is selected in the chooser. Click on
Figure 688. Utilities, DLA Setup. The DLA Chooser window
opens. Check the button to match to the Current
Device. Click Apply.
Figure 690.
Diagnostics Tool - User Guide

Introduction
The diagnostics software tool is part of the
JCB Servicemaster software suite. The diagnostics
software is designed to be an easy to use fault finding
tool.
Connecting the Diagnostics

Diagnostics Overview
To use Diagnostics your laptop computer must be
There are several key elements to the diagnostics
connected to the machine CAN bus.
tool. These can be seen labelled below. Each
element is explained in detail in later sections.
Starting the Diagnostics
1. Turn ON the machine ignition and additionally
start the engine if required (taking normal
precautions).
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03 - Servicemaster
Figure 691.
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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03 - Servicemaster
Navigating within Diagnostics Menu Bar-Options Menu
Navigation is designed to be via a mouse. On Laptop Figure 693.

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 694.
'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 692. 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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03 - Servicemaster
Menu Bar-Help Menu function keys, F2, F3 etc. can also be used to select
pages as required.
Figure 695.
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 698.
• 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 696.
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 699.
In the top left corner of the main window is displayed
a list of pages which can be displayed.
Figure 697.
Table 270.
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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03 - Servicemaster
Fault Codes Page
Figure 700.
This page allows the engineer to access fault codes The Engine Setup Up tool can be used to view
logged by the ECM. The ECM logs a fault code if and 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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03 - Servicemaster
4. Select Engine Tools from the drop down list and

then start the vehicle set up tool running by
clicking on the Engine Setup icon.
Figure 703.
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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03 - Servicemaster
General
Figure 704.
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03 - Servicemaster
Wheels
Figure 705.
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03 - Servicemaster
Options
Figure 706.
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03 - Servicemaster
Injector Calibration
Figure 707.
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 708. 3. Click on the Browse button and select the correct
data file. Click Open.
Figure 711.
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 709.
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 theECM 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 712.
5. The Flashloader tool will then open.

Figure 710.
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 714.
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 713.
5. The Additional Info Tab should have the correct

Make, Model and Power Rating.
Figure 715.
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 and which
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 717. do not invoke it during the flash.
15. Pressing Yes will flash the ECM.
Figure 719.
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 720.
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 724.
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 722.
24. Ensure Injector Calibration is complete and

correct.
Figure 725.
22. Both Ecomax and Dieselmax Press Restore

Default Press Yes.
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03 - Servicemaster
25. Ecomax Press Write Injector Codes.

26. DieselMax Press Write.
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03 - Servicemaster
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 726.
3. The Servicemaster window will open.

Figure 727.
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, (PIL
57-03).
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03 - Servicemaster
Preparation
Set-up Servicemaster Servicemaster Setup - First Time

The procedures below describe how to set up 1. Install Servicemaster on your laptop/PC through
Servicemaster for USB (Universal Serial Bus) the DVD.
compatible equipment. There are other procedures
and options. These are described in detail in the 2. Run the "Servicemaster Web Update".
Servicemaster help files contained on the JCB 3. Open Servicemaster on your laptop/PC.
Service Information DVD (Digital Versatile Disc).
4. Install the "DLA laptop driver software" on your
Before you start Servicemaster set up procedure laptop/PC.
make sure that you have following:
5. Configure the DLA type and communications
1 A Microsoft Windows compatible laptop port.
computer with a DVD drive and/or a USB port.
Refer to Figure 729. 6. Make sure that the DLA flash memory contains
the latest firmware file.
a Make a note that Servicemaster is
compatible with Windows 98, 2000, ME, 7. Connect Servicemaster to the machine
XP, Vista, and 7 operating systems (32 bit through the CAN (Controller Area Network)bus
and 64bit). connections.
2 The latest Servicemaster software (DVD and
internet connection for web updates). Refer to JCB Servicemaster - New Installation
Figure 729.
3 A JCB compatible DLA (Data Link Adaptor). This topic covers the new installation of JCB
Refer to Figure 729. Servicemaster on a new laptop/PC (Personal
4 The correct connection cables. Refer to Figure Computer).
729.
a Do not connect any cables to the laptop, 1. Insert the CD (Compact Disk) into your computer/
DLA or machine at this time. laptop.
Figure 729. 2. Open the "My Computer" option to select the

"SM2_V10-0-3 (D:)" CD drive.
3. Select and open the "SM2_V10-0-3 (D:)" CD
drive to explore its contents. Refer to Figure 730.
A Laptop computer
B Servicemaster software
C DLA
D Connection cables
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03 - Servicemaster
7. A warning message window will appear on the

screen. Refer to Figure 733.
7.1. Click the "OK" option.
Figure 733.
8. A new window "JCB Servicemaster Installation

Wizard" will appear on the screen. Refer to
Figure 734.
4. Select and open the "Setup.exe" application. 8.1. Click the "Next" option to proceed.
5. A new window "JCB Servicemaster Setup" will Figure 734.
appear on the screen.
5.1. Click the "Install V10.0.3" option to start the
setup application. Refer to Figure 731.
Figure 731.
9. Put "User Name" and "Organization" details into

6. A new window "Select Setup Language" will the "Customer Registration" screen. Refer to
appear on the screen. Refer to Figure 732. Figure 735.
6.1. Use the drop down option to select the 9.1. Click the "Next" option when you inserted
suitable language. details.
6.2. Click the "OK" option to confirm selected
language.
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03 - Servicemaster
10. Select all the "Setup Type" screen options for the 12. The language "Error" windows will appear on the
complete installation. Refer to Figure 736. screen during the installation process. Refer to
Figure 738.
Figure 736.
12.1. Click the "Ignore" option to skip the error
windows.
12.2. These language "Error" windows will be
installed after through the web update of
Servicemaster.
Figure 738.
11. The "Ready to Install this Program" screen will

show you its setup location in your computer.
11.1. Click the "Next" option to start installation.
13. A new message window will appear on the

screen, after the installation. Refer to Figure 739.
13.1. Click the "OK" button.
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03 - Servicemaster
Figure 739. Update" program. Do the below steps to download

and install the JCB web update.
1. Use the web address www.business.jcb.com to

install JCB web update.
2. A web page will open on the screen. Refer to
Figure 742.
Figure 742.
14. A new "Completed" message will appear on

the "JCB Servicemaster_2V10.0.3 Installation
Wizard" screen. Refer to Figure 740.
14.1. Click the "Finish" option.
14.2. The JCB portal will open for Servicemaster
web update, after the installation.
Figure 740.
3. If you do not already have a User ID and

Password, click the "Get Support" option.
3.1. Apply for an account to get access to
JDS (JCB Distribution System) and SPP
(Service Parts Pro).
4. Once you logged in, you will find a link "JDS" on
the left side tool bar. Refer to Figure 743.
4.1. Click the "JDS" link.
15. The two program shortcuts will be created on the

computer desktop. Refer to Figure 741.
Figure 741.
JCB Servicemaster Web Update - New

Installation
Once you installed JCB Servicemaster on your
laptop/PC you will need to keep it updated. JCB
Servicemaster is updated through the "JCB Web
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03 - Servicemaster
6.1. Click the "click here" link which is the orange

colour text sentence to download JCB web
update.
7. A new "File Download - Security Warning"
window will appear on the screen. Refer to Figure
746.
Figure 746.
5. A new screen "JCB DISTRIBUTION SYSTEM"

will open. Refer to Figure 744.
Figure 744.
7.1. Click the "Run" option to start download.

8. Because of the computer system firewall, you
may get warning window "Internet Explorer -
Security Warning". Refer to Figure 747.
8.1. Click the "Run" option to proceed.
5.1. Click the "SM Web Update" link option of the Figure 747.
left side tool bar.
6. A new "Servicemaster Web Update" screen will
open. Refer to Figure 745.
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9. A new "JCB Web Update (V2.02) Installation 2. After the installation you will need to authorise the
Wizard" window will open. Refer to Figure 748. download to ensure that you get future updates.
9.1. Once the download is finished, it will 3. Get access to the "Servicemaster Web Update"
automatically run. screen. Refer to Figure 750.
Figure 748. 4. The "Servicemaster Web Update" screen will
have one of the red or orange dialogue box.
4.1. The dialogue box depends on the download
privileges attached to your name (red for
pre-release and orange for full release
only).
Figure 750.
10. The"JCB Web Update" program shortcut will be

created on the computer desktop. Refer to Figure
749.
Figure 749.
5. Click the dialogue box to start the authorisation
process. Refer to Figure 751.
5.1. A new window "Servicemaster Pre-Release
Initiating New Authorisation" will open.
Figure 751.
11. Refer to the below section "JCB Web Update 6. After the system download authorisation
Downloads - Authorisation" to authorise your process, "Download" option will reflect on the
downloads. window. Refer to Figure 752.
JCB Web Update Downloads - 6.1. Click the "Download" option to download
the JCB web update.
Authorisation
Figure 752.
The below authorisation procedure is needed to
access the downloads through the "JCB Web
Update" on a laptop/PC.
1. It is necessary to authorise the download after

the installation, to make sure that you get future
updates.
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7. The authorisation process of "JCB Web Update" 1. Once you complete the DLA driver software
is now complete. installation procedure, it will not require to do
again on your laptop/PC.
Servicemaster Updates - "JCB Web 2. Do not connect the DLA or cables to the machine
Update" Program or laptop/PC before to install the DLA driver
software.
The updates for Servicemaster is downloaded
through the "JCB Web Update" program on a laptop/ 3. Open Servicemaster on your laptop computer.
PC. Refer to the below steps.
4. Click the "Other" tab to get access to the
1. Run the "JCB WebUpdate" program either by "General Support" icon.
using desktop shortcut or "Help" menu within
Servicemaster, to do a Servicemaster update. 5. Click the "General Support" icon to get access to
the "DLA" icon.
2. The "JCB WebUpdate" program will check for
updates and inform you if there is any to 6. Click the "DLA" icon. Refer to Figure 755.
download. Refer to Figure 753.
Figure 755.
Figure 753.
2.1. You may click the "Details" option to check

which files have been changed, added or
removed.
2.2. Click the "Download" option to download
the updates.
3. Once the updates downloaded, the "JCB Web
Update" will give option to install them. Refer to
7. Select and open the USB driver icon. Refer to
Figure 754.
Figure 756.
3.1. You may select options to install the
7.1. Make a note that the other drivers icon
updates immediately or at a later date.
are also available for the computers with
Figure 754. serial ports (no USB ) and other versions of
Microsoft Windows.
7.2. If your laptop does not have a USB port,
select and open the correct driver icon.
Figure 756.
DLA Driver Software - Installation

When you use Servicemaster first time on
your laptop/PC (which is newly installed with
Servicemaster software), the DLA driver software is
necessary to install first. Do the below steps to install
the DLA driver software.
33 - 223 9813/7400-1 33 - 223

03 - Servicemaster
8. A new window "Driver Installer" will open. Refer 7.2. Make a note that the older DLA and laptop
to Figure 757. computers may not be compatible with the
USB ports. Select the "Parallel/Serial DLA"
8.1. Obey the window instructions to the device in the DLA chooser.
complete the DLA driver software
installation. Figure 759.
Figure 757.
DLA Type and Communications Port -

Configuration
When you use Servicemaster first time on
your laptop/PC (which is newly installed with
Servicemaster software) make sure that the correct
DLA and laptop/PC port is selected to communicate DLA Firmware File - Check
with the DLA. Do the below steps to configuration the
DLA with the laptop/PC. The DLA has software embedded in its own flash
memory. This file must be replaced with a new one
1. Once you complete the DLA configuration, it will when new firmware is released. You will only have to
not require to do again on your laptop/PC. Check the DLA firmware file version if you receive a
new Servicemaster version or use a different DLA.
2. Open Servicemaster on your laptop computer.
1. Make sure that the DLA is connected to the
3. Click the "Other" tab to get access to the laptop computer.
"General Support" icon.
2. Open Servicemaster on your laptop computer.
4. Click the "General Support" icon to get access to
the "DLA" icon. 3. Click the "Other" tab to get access to the
"General Support" icon.
5. Click the "DLA" icon.
4. Click the "General Support" icon to get access to
6. Select and open the "COM Port Chooser" icon. the "DLA" icon.
5. Click the "DLA" icon.
Figure 758.
6. Select and open the USBDLA Flashloader" icon.
6.1. Make a note that the older DLA and
laptop computers may not be compatible
with the USB ports. Select and open the
"Flashloader for Serial/Parallel DLA" icon.
Figure 760.
7. A new "DLA Chooser" window will open. Refer to

Figure 759.
7.1. Select the USB /Serial DLA" device and
click the "Apply" option to confirm.
33 - 224 9813/7400-1 33 - 224

03 - Servicemaster
7. A window USB Device Flash Update Tool" will and application version (for example - 2.01).
open. Refer to Figure 761. Refer to Figure 763.
7.1. The firmware details in the DLA are Figure 763.
displayed with the application version (for
example - 1.04). Refer to Figure 761.
Figure 761.
A
A Start option
9. Load a new firmware file.
A Browse option 9.1. If the firmware in the DLA is not up to date,

load the new file.
8. Check for a new firmware file.
10. Click the "Start" option and obey the on-screen
8.1. Click the "Browse" option and find the instructions.
file stored within the JCB Servicemaster
directory on your laptop hard drive. Refer to Servicemaster Engine Diagnostic Page
Figure 762. Function (T4 Final Engine)
8.2. Select the file and click the "Open" option.
The T4 final Ecomax engine platform is available on
Figure 762. Servicemaster updates.
If you load the T4 final platform, you will need a

different process to enter the old T3 common rail
diagnostic page for live data and fault codes.
The engine setup page and the flash loader pages

will still work normally, but to identify the fault codes
and sensor readings, you will need to follow the
following instructions:

2. Turn the ignition switch to the OFF position.
3. Launch Servicemaster in the normal way and
click on the original JCB Dieselmax icon. Refer
8.3. The selected file appears in the firmware to Figure 764.
file name' field together with its release date
33 - 225 9813/7400-1 33 - 225

03 - Servicemaster
Figure 764.
4. The standard diagnostic page will appear on the 5. Click the green activation option at the top left
screen. corner of the screen. Refer to Figure 765.
33 - 226 9813/7400-1 33 - 226

03 - Servicemaster
Figure 765.
6. Click the accept button. Refer to Figure 766. 7. The engine selection screen will appear. Refer to
Figure 767.
Figure 766.
33 - 227 9813/7400-1 33 - 227

03 - Servicemaster
Figure 767.
7.1. Select the "TierII/TierIII" option. 8. The detected engine page will confirm your
selection. Refer to Figure 768.
33 - 228 9813/7400-1 33 - 228

03 - Servicemaster
Figure 768.
8.1. Click the "OK" option. 9. The diagnostic page will appear as before, but
there will be no data displayed yet. Refer to
Figure 769.
Figure 769.
10. Turn the ignition switch to the ON position. Refer

to Figure 770.
33 - 229 9813/7400-1 33 - 229

03 - Servicemaster
Figure 770.
10.1. The data will appear on the diagnostic 11. The active fault codes will see on the diagnostic
page. page. Refer to Figure 771.
Figure 771.
33 - 230 9813/7400-1 33 - 230

03 - Servicemaster
Disconnect and Connect Note: Older DLA and laptop computers may not be
compatible with USB ports. Use the serial PC cable
Special Tools to connect the DLA to the laptop serial port.
1. Make sure the machine ignition system is OFF.
Machine Cable 718/20237 1
Data Link Adaptor 892/01174 1 2. To use the Servicemaster diagnostic tool,
(DLA) Kit connect the laptop computer to the machine.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
To use Servicemaster, connect your laptop computer
1)
to the machine CAN (Controller Area Network) bus.
Special Tool: Machine Cable (Qty.: 1)
Connection is made using the DLA (Data Link
Adaptor) and the applicable cables. 3. Connect the USB PC Cable to the DLA and a free
port on the laptop computer.
Figure 772.
4. Connect the Machine Cable to the DLA. The
Machine Cable has a 15-way D-type connector
on one end and a 9-way CAN connector on the
other. Plug the 15-way connector into the DLA
and tighten the thumb screws.
D Figure 773.
B
E
C
D
A USB PC Cable
B Serial PC cable
A C Centre pin location tab
B D Locking ring
5. Connect the 9-way CAN connector into the
machines Diagnostics Connector as follows:
5.1. Position the CAN connector to align the
centre pin location tab with the diagnostics
connector.
A USB PC Cable - 718/20235 5.2. Couple the connectors. Turn the locking
B Serial PC Cable - 718/20236 ring clockwise to secure the connectors.
C USB DLA - 728/26500
D Machine Cable - 718/20237
E Kit - 892/01174 (contains items A, B, C and D)
Note: Connect the USB cable directly to the laptop

computer. Do not connect the cable via a USB hub.
33 - 231 9813/7400-1 33 - 231

90 - Fault Codes
90 - Fault Codes Introduction

Introduction .................................................. 33-232 Should faults occur related to an ECU (Electronic
Technical Data ............................................. 33-235 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 (eg starter relay).
• 6th and 7th characters - referred to as the
'Failure Type Byte' (FTB) which indicates the
particular failure (eg 11 = short circuit to
ground). See FTB Numbers below for a full list.
Some specific fault codes are defined by

international standard, while other codes may be
defined by individual vehicle manufacturers.
Fault Code Display Systems

Depending on the machine specification fault codes
recorded by the engine ECU can be accessed and
displayed in several ways:
CAN Enabled Display

The machine may be equipped with a CAN enabled
display. Such a display will be capable of displaying
all recorded codes, for example P0047. All logged
codes will be displayed. The operator may also
have a facility to erase the fault code log. See
the applicable machine documentation for further
information.
CAN BUS Connected Computer

Fault codes logged can be accessed via a
suitable laptop computer running the applicable
diagnostics software, JCB 444 Engine Diagnostics
for example. The computer must be connected to the
machine CAN BUS socket using a DLA (Data Link
Adaptor). Once connected all recorded codes can be
displayed. The engineer also has a facility to erase
the fault code log.
33 - 232 9813/7400-1 33 - 232

90 - Fault Codes
Failure Type Byte (FTB) Numbers Number Failure Type Byte (FTB) De-
scription
92 Performance or incorrect opera-
Table 271. 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 774.
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 774.
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 a 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 on other applicable
26 Signal rate of change below system warning can come on. These lights can show
threshold. a blink code. Refer to Electronic Diagnostic, Fault
27 Signal rate of change above codes, Introduction, Blink Codes (PIL 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 272.
failure.
1 Blink
47 Watchdog / microcontroller / 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, Fault
33 - 233 9813/7400-1 33 - 233

90 - Fault Codes
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. Refer to (PIL 33-57) or use JCB
Servicemaster and a laptop computer connected to
machine CANbus to see the codes. Refer to (PIL
33-57).
33 - 234 9813/7400-1 33 - 234

90 - Fault Codes
Technical Data
Table 273. Engine Fault Codes

J2012 Fault Codes Lamps
J2012 P J2012 FTB Amber Red DTC Sever- Dash Display Fault Description
Code (HM ity as per
Byte) STD00236
P0001 13 Y SERVICE P0001-13-Please IMV driver fault is de-
Contact JCB tected
Dealer
P0002 1B Y SERVICE P0002-1B-Please Rail pressure control
Contact JCB Error (pressure Error
Dealer too high).
P0002 1A Y SERVICE P0002-1A-Please Rail pressure control
Contact JCB Error (pressure Error
Dealer too low).
P0002 00 Y SERVICE P0002-00-Please Rail pressure Neg-
Contact JCB ative Control Error
Dealer During 'IMV-Only'
control. PID controller
not able to stabilise
the RPC value
P0002 00 Y CRITICAL P0002-00-Please Rail pressure Positive
Contact JCB Control Error Dur-
Dealer ing 'IMV-Only' con-
trol. PID controller not
able to stabilise the
RPC value
P0003 18 Y CRITICAL P0003-18-Please Rail pressure control
Contact JCB feedback low Error
Dealer
Contact JCB tected
Dealer
P0004 19 Y SERVICE P0004-19-Please Rail pressure control
Contact JCB feedback high Error
Dealer
Contact JCB tected
Dealer
P007A 00 Y SERVICE P007A-00-Please Charge Air Cooler
Contact JCB temperature Sensor
Dealer Circuit
P007C 23 Y SERVICE P007C-23-Please Charge Air Cooler
Dealer Circuit Low
P007D 24 Y SERVICE P007D-24-Please Charge Air Cooler
Dealer Circuit High
P0087 23 Y CRITICAL P0087-23-Please Rail pressure build
Contact JCB low fault
Dealer
P0087 23 Y CRITICAL P0087-23-Please Rail pressure build
Contact JCB normal fault
Dealer
33 - 235 9813/7400-1 33 - 235

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P0087 00 Y SERVICE P0087-00-Please Rail pressure Control
Contact JCB Error Positive
Dealer
P0087 00 Y CRITICAL P0087-00-Please RPC Variable lim-
Contact JCB it Capacity (VLC)
Dealer Torque reduction
clamped
P0087 00 Y SERVICE P0087-00-Please RPC Variable lim-
Contact JCB it Capacity (VLC)
Dealer Torque reduction
above its threshold
P0088 00 Y SERVICE P0088-00-Please Rail pressure con-
Contact JCB trol Error during HPV
Dealer control (over max cal-
ibrated system pres-
sure)
Contact JCB Error during IMV con-
Dealer trol (over max cali-
brated system pres-
sure)
Contact JCB undefined Error (over
Dealer max calibrated sys-
tem pressure)
P0088 00 Y CRITICAL P0088-00-Please Rail pressure Over
Contact JCB pressure timeout
Dealer
P0089 00 Y SERVICE P0089-00-Please Check that HPV is
Contact JCB not stuck during IMV
Dealer regulation.
P0089 00 Y SERVICE P0089-00-Please HPV open loop slope
Contact JCB fault detected
Dealer
Contact JCB Error
Dealer
P0089 00 Y CRITICAL P0089-00-Please Rail pressure Neg-
Dealer During 'HPV-Only'
the RPC value
Dealer ing 'HPV-Only' con-
RPC value
33 - 236 9813/7400-1 33 - 236

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P0089 00 Y SERVICE P0089-00-Please Rail pressure Neg-
Dealer During 'RVD-Only'
the RPC value
Dealer ing 'RVD-Only' con-
RPC value
P0090 13 Y SERVICE P0090-13-Please HPV driver in ECU
Dealer
P0091 23 Y SERVICE P0091-23-Please Check HPV regula-
Contact JCB tion control trim low
Dealer
P0091 23 Y SERVICE P0091-23-Please Check HPV hardware
Contact JCB current control trim
Dealer low
P0091 23 Y SERVICE P0091-23-Please HPV current feed-
Contact JCB back low fault detect-
Dealer ed
P0091 11 Y SERVICE P0091-11-Please HPV driver in ECU
Dealer
P0092 24 Y SERVICE P0092-24-Please Check HPV regula-
Contact JCB tion control trim high.
Dealer
P0092 24 Y SERVICE P0092-24-Please Check HPV hardware
Contact JCB current control trim
Dealer high
P0092 24 Y CRITICAL P0092-24-Please HPV current feed-
Contact JCB back high fault de-
Dealer tected
P0092 12 Y CRITICAL P0092-12-Please HPV driver in ECU
Dealer
P0097 23 Y SERVICE P0097-23-Please Intake manifold tem-
Contact JCB perature Sensor
Dealer (M2) signal low fault
(Intake Manifold 2
Temp)
P0098 24 Y SERVICE P0098-24-Please Intake manifold tem-
Contact JCB perature Sensor (M2)
Dealer signal high signal
fault (Intake Manifold
2 Temp)
P0100 00 Y SERVICE P0100-00-Please "AMF fault (glob-
Contact JCB al). Set if plau, grad
Dealer or electrical flt is
present"
33 - 237 9813/7400-1 33 - 237

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P0100 00 Y SERVICE P0100-00-Please AMF High Side Driver
Contact JCB fault (Global
Dealer
P0100 00 Y SERVICE P0100-00-Please AMF High Side Dri-
Contact JCB ver fault Open circuit
Dealer (OC) Or Short circuit
to battery (SC2VBAT)
P0100 00 Y SERVICE P0100-00-Please AMF High Side Dri-
Contact JCB ver fault Short circuit
Dealer (SC)
P0100 11 Y SERVICE P0100-11-Please AMF High Side Driver
Contact JCB fault Short circuit To
Dealer ground (SC2G)
P0100 00 Y SERVICE P0100-00-Please AMF electrical Sen-
Contact JCB sor fault (ADC)
Dealer
Contact JCB sor low fault
Dealer
Contact JCB sor high fault
Dealer
P0105 00 Y SERVICE P0105-00-Please Intake Manifold Ab-
Contact JCB solute pressure Sen-
Dealer sor global fault
Dealer sor signal drift high
fault
Dealer sor signal drift low
fault
P0112 23 Y SERVICE P0112-23-Please Inlet Air temperature
Contact JCB (IAT) Sensor signal
Dealer low fault detected
P0113 24 Y SERVICE P0113-24-Please Inlet Air temperature
Contact JCB (IAT) Sensor signal
Dealer high fault detected
P0115 00 Y SERVICE P0115-00-Please Coolant Sensor sig-
Contact JCB nal fault
Dealer
P0120 00 Y SERVICE P0120-00-Please Foot pedal signal
Contact JCB track 1 fault
Dealer
Dealer
P0180 00 Y SERVICE P0180-00-Please Fuel temperature
Contact JCB ADC fault
Dealer
33 - 238 9813/7400-1 33 - 238

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
Contact JCB Sensor gradient fault
Dealer
Contact JCB Sensor low fault
Dealer
Contact JCB Sensor high fault
Dealer
P0190 27 Y SERVICE P0190-27-Please Rail pressure Sensor
Contact JCB signal grad fault
Dealer
P0191 24 Y SERVICE P0191-24-Please Rail pressure Sen-
Contact JCB sor fault. Above Maxi-
Dealer mum threshold (out of
range at key-on)
P0191 23 Y SERVICE P0191-23-Please Rail pressure Sen-
Contact JCB sor fault. below mini-
Dealer mum threshold (out of
range at key-on)
Contact JCB fault. Exceeds thresh-
Dealer old (out of range at
key-on)
Contact JCB signal low fault
Dealer
Contact JCB signal high fault
Dealer
P0194 00 Y CRITICAL P0194-00-Please Rail pressure Sensor
Contact JCB signal drop fault
Dealer
P0195 00 Y SERVICE P0195-00-Please Oil temperature Sen-
Contact JCB sor signal global
Dealer
Contact JCB sor signal external
Dealer Voltage (V-Ref) fault
Contact JCB sor signal plausability
Dealer fault
Contact JCB sor signal gradient
Dealer fault
Contact JCB sor signal
Dealer
Contact JCB sor signal high fault
Dealer
33 - 239 9813/7400-1 33 - 239

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P0201 11 Y CRITICAL P0201-11-Please Injector 2 Open circuit
Contact JCB fault (OC)
Dealer
P0201 00 Y CRITICAL P0201-00-Please Injector 2 Short circuit
Contact JCB HSD to LSD
Dealer
Dealer
Dealer
Dealer
Dealer
Dealer
Dealer
Dealer
Dealer
P0235 00 Y SERVICE P0235-00-Please Boosted air pressure
Contact JCB Sensor fault: ADC
Dealer
Contact JCB Sensor low fault
Dealer
Contact JCB Sensor high fault
Dealer
Contact JCB trol Error (IMV current
Dealer trim drift).
Dealer trim drift).
Dealer trim drift).
Dealer trim drift).
33 - 240 9813/7400-1 33 - 240

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
Dealer trim drift).
Contact JCB by the IMV. Occurs at
Dealer high fuel delivery for
low (negative) current
trim
Contact JCB fault by the IMV. Oc-
Dealer curs at high fuel deliv-
ery for high (positive)
current trim
P0261 1B Y SERVICE P0261-1B-Please Injector and wiring
Contact JCB harness resistance
Dealer too high/low (inj 2)
P0261 1A Y SERVICE P0261-1A-Please Injector and wiring
Dealer drop (Inj 2)
Dealer drop (Inj 2)
P0263 00 Y SERVICE P0263-00-Please Cylinder balancing
Contact JCB fault injector 2 stuck
Dealer closed
Dealer drop (Inj 1)
Dealer drop (Inj 1)
Dealer closed
Dealer drop (Inj 3)
33 - 241 9813/7400-1 33 - 241

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
Dealer drop (Inj 3)
Dealer closed
Dealer drop (Inj 0)
Dealer drop (Inj 0)
Dealer closed
P029A 00 Y CRITICAL P029A-00-Please Injector drift fault de-
Contact JCB tection on Injector
Dealer 3. Fault which is set
when the Injector 3
MDP trim exceeds
the Maximum cali-
brated threshold lim-
it. Maximum APC raw
trim at high rail pres-
sure
P029A 00 Y CRITICAL P029A-00-Please Injector drift fault de-
when the Injector 2
MDP trim exceeds
the Maximum cali-
brated threshold limit.
Max APC raw trim at
low rail pressure
P029A 00 Y CRITICAL P029A-00-Please Injector drift fault
Contact JCB detection on Injec-
Dealer tor 2. Fault which is
set when Injector 2
MDP trim exceeds
the Maximum cali-
Max APC raw trim at
medium rail pressure
P029B 00 Y CRITICAL P029B-00-Please Fault which is set
Contact JCB when the Injector 3
Dealer absolute MDP value
is below a calibrated
threshold
33 - 242 9813/7400-1 33 - 242

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P029B 00 Y CRITICAL P029B-00-Please Injector drift fault
set when Injector 2
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
high rail pressure
set when Injector 2
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
low rail pressure
set when Injector 2
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
P029E 00 Y CRITICAL P029E-00-Please Injector drift fault de-
when the Injector 1
MDP trim exceeds
the Maximum cali-
it. Maximum APC raw
sure
P029E 00 Y CRITICAL P029E-00-Please Injector drift fault de-
when the Injector 1
MDP trim exceeds
the Maximum cali-
Max APC raw trim at
low rail pressure
P029E 00 Y CRITICAL P029E-00-Please Injector drift fault
set when Injector 1
MDP trim exceeds
the Maximum cali-
Max APC raw trim at
33 - 243 9813/7400-1 33 - 243

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P029F 00 Y CRITICAL P029F-00-Please Fault which is set
threshold
P029F 00 Y CRITICAL P029F-00-Please Injector drift fault
set when Injector 1
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
high rail pressure
set when Injector 1
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
low rail pressure
set when Injector 1
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
P02A2 00 Y CRITICAL P02A2-00-Please Injector drift fault de-
when the Injector 2
MDP trim exceeds
the Maximum cali-
it. Maximum APC raw
sure
when the Injector 3
MDP trim exceeds
the Maximum cali-
Max APC raw trim at
low rail pressure
33 - 244 9813/7400-1 33 - 244

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P02A2 00 Y CRITICAL P02A2-00-Please Injector drift fault
set when Injector 3
MDP trim exceeds
the Maximum cali-
Max APC raw trim at
P02A3 00 Y CRITICAL P02A3-00-Please Fault which is set
threshold
set when Injector 3
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
high rail pressure
set when Injector 3
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
low rail pressure
set when Injector 3
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
when the Injector 0
MDP trim exceeds
the Maximum cali-
it. Maximum APC raw
sure
33 - 245 9813/7400-1 33 - 245

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
when the Injector 0
MDP trim exceeds
the Maximum cali-
Max APC raw trim at
low rail pressure
set when Injector 0
MDP trim exceeds
the Maximum cali-
Max APC raw trim at
P02A7 00 Y CRITICAL P02A7-00-Please Fault which is set
threshold limit. MIN
APC raw trim at high
rail pressure
set when Injector 0
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
high rail pressure
set when Injector 0
MDP trim exceeds
the Maximum cali-
Max APC raw trim at
low rail pressure
set when Injector 0
MDP trim exceeds
the Maximum cali-
Min APC raw trim at
P0335 85 Y CRITICAL P0335-85-Please Crank signal
Contact JCB
Dealer
33 - 246 9813/7400-1 33 - 246

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P0340 54 Y SERVICE P0340-54-Please Cam signal last learnt
Contact JCB value is outside of
Dealer limits
P0341 00 Y SERVICE P0341-00-Please Cam signal drift high-
Contact JCB er than threshold
Dealer
P0341 31 Y SERVICE P0341-31-Please Cam signal lost (no
Contact JCB Cam signal seen in 2
Dealer Crank rotations)
P0341 31 Y SERVICE P0341-31-Please Cam signal fault
Contact JCB (missing event within
Dealer the expected window)
P0341 85 Y CRITICAL P0341-85-Please Cam signal fault
Contact JCB (overspeed detected)
Dealer
P0371 00 Y SERVICE P0371-00-Please Crank signal one
Contact JCB
Dealer
P0372 31 Y SERVICE P0372-31-Please Elapsed time be-
Contact JCB tween CPS events is
Dealer too high
P0374 31 Y SERVICE P0374-31-Please Crank signal lost (no
Contact JCB CPS signal seen in 1
Dealer Cam rotation)
P0400 00 Y SERVICE P0400-00-Please EGR flow reached
Contact JCB
Dealer
P0470 00 Y SERVICE P0470-00-Please Exhaust manifold
Contact JCB pressure (P3) signal
Dealer ADC fault
Dealer drifted low
Dealer low fault
Dealer drifted high
Dealer high fault
P0521 00 Y CRITICAL P0521-00-Please Oil pressure Sensor
Contact JCB signal global fault
Dealer
P0522 23 Y CRITICAL P0522-23-Please High Oil pressure
Contact JCB During Engine Run-
Dealer ning
P0522 23 Y CRITICAL P0522-23-Please High Oil pressure
Contact JCB During Engine
Dealer Stopped
33 - 247 9813/7400-1 33 - 247

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P0523 24 Y CRITICAL P0523-24-Please Low Oil pressure Dur-
Contact JCB ing Engine Running
Dealer
P0544 00 Y SERVICE P0544-00-Please Turbo in temperature
Contact JCB fault
Dealer
Contact JCB count low fault
Dealer
Contact JCB count high fault
Dealer
P0562 23 Y SERVICE P0562-23-battery battery Voltage moni-
Voltage Low toring signal low fault
P0563 24 Y SERVICE P0563-24-Please battery Voltage moni-
Contact JCB toring signal high fault
Dealer
P0602 00 Y SERVICE P0602-00-Please C2I data not pro-
Contact JCB grammed
Dealer
Contact JCB grammed
Dealer
Contact JCB grammed
Dealer
Contact JCB grammed
Dealer
P0602 00 Y CRITICAL P0602-00-Please RAM corruption af-
Contact JCB fecting Injector C2I
Dealer data
P0602 00 Y CRITICAL P0602-00-Please Functional Safety
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
P0603 00 Y CRITICAL P0603-00-Please ECU memory integri-
Contact JCB ty fault (data / cal in-
Dealer tegrity)
Contact JCB ty fault (RAM integri-
Dealer ty)
Contact JCB ty fault (code integri-
Dealer ty)
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
33 - 248 9813/7400-1 33 - 248

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
P060A 00 Y CRITICAL P060A-00-Please Functional Safety
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
P060B 00 Y CRITICAL P060B-00-Please ADC circuit fault
Contact JCB (Global)
Dealer
P060B 00 Y CRITICAL P060B-00-Please Functional Safety
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
33 - 249 9813/7400-1 33 - 249

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P060B 00 Y SERVICE P060B-00-Please HPV current feed-
Contact JCB back ADC fault de-
Dealer tected
P060C 00 Y CRITICAL P060C-00-Please Functional Safety
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
P060C F0 Y CRITICAL P060C-F0-Please Functional Safety
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
P060D 00 Y CRITICAL P060D-00-Please Functional Safety
Contact JCB Fault
Dealer
P060D 00 Y CRITICAL P060D-00-Please Functional Safety
Contact JCB Fault
Dealer
P060E 00 Y CRITICAL P060E-00-Please Functional Safety
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
33 - 250 9813/7400-1 33 - 250

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
Contact JCB Fault
Dealer
P0627 13 Y SERVICE P0627-13-Please Lift pump global fault
Contact JCB
Dealer
Contact JCB
Dealer
Contact JCB
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
P062D 11 Y CRITICAL P062D-11-Please Injector Bank 0 fault
Contact JCB shorted to ground
Dealer (SC2GND)
P062D 12 Y CRITICAL P062D-12-Please Injector Bank 0 fault
Dealer (SC2VBAT)
33 - 251 9813/7400-1 33 - 251

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P062E 11 Y CRITICAL P062E-11-Please Injector Bank 1 fault
Dealer (SC2GND)
P062E 12 Y CRITICAL P062E-12-Please Injector Bank 1 fault
Dealer (SC2VBAT)
P062F 00 Y SERVICE P062F-00-Please ECU non volatile
Contact JCB memory fault
Dealer
P062F 00 Y SERVICE P062F-00-Please "ECU non volatile
Contact JCB memory fault (C2I,
Dealer MDP)"
Contact JCB memory fault (RP, PL,
Dealer STE)"
Contact JCB memory fault
Dealer (WDOG)
Contact JCB memory fault (CAN,
Dealer KW)"
Contact JCB memory fault (SMC)
Dealer
Contact JCB memory fault (ICV, Inj
Dealer Cnt)"
Contact JCB memory fault (FM)
Dealer
Contact JCB memory fault (APP)
Dealer
P0641 00 Y CRITICAL P0641-00-Please ECU internal 5V Sup-
Contact JCB ply 1 fault
Dealer
P0641 4B Y CRITICAL P0641-4B-Please ECU internal 5V Sup-
Dealer
P0651 00 Y CRITICAL P0651-00-Please ECU internal 5V Sup-
Dealer
P0651 4B Y CRITICAL P0651-4B-Please ECU internal 5V Sup-
Dealer
P0668 23 Y SERVICE P0668-23-Please ECU internal temper-
Contact JCB ature Sensor low fault
Dealer
P0669 24 Y SERVICE P0669-24-Please ECU internal tem-
Contact JCB perature Sensor high
Dealer fault
33 - 252 9813/7400-1 33 - 252

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
P0685 00 Y CRITICAL P0685-00-Please Main ECU relay stuck
Contact JCB
Dealer
P0685 00 Y CRITICAL P0685-00-Please Main relay unexpect-
Contact JCB ed low state
Dealer
P0697 00 Y CRITICAL P0697-00-Please ECU internal
Contact JCB
Dealer
P0697 4B Y CRITICAL P0697-4B-Please ECU internal
Contact JCB
Dealer
P1101 00 Y CRITICAL P1101-00-Please Rail pressure Control
Contact JCB Error Positive fault
Dealer
P1102 00 Y CRITICAL P1102-00-Please Rail pressure Control
Contact JCB Error Negative fault
Dealer
P1104 00 Y SERVICE P1104-00-Please Fault which is set
Contact JCB when no MDP up-
Dealer dates occur on Injec-
tor 3 due to environ-
mental conditions (as
defined by the update
strategy)
tor 3 due to a fault
within the update
strategy
strategy)
within the update
strategy
strategy)
33 - 253 9813/7400-1 33 - 253

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
within the update
strategy
P110A 00 Y SERVICE P110A-00-Please Fault which is set
strategy)
P110B 00 Y SERVICE P110B-00-Please Fault which is set
within the update
strategy
Contact JCB fault set (triggers limp
Dealer home mode)
Contact JCB fault set (triggers re-
Dealer duced torque mode)
P1503 00 Y SERVICE P1503-00-Please Hand pedal signal
Contact JCB fault set (triggers limp
Dealer home mode)
Contact JCB fault set (triggers re-
Dealer duced torque mode)
P1506 00 Y SERVICE P1506-00-Please Pedal global
Contact JCB
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Contact JCB Fault
Dealer
Dealer
Dealer
33 - 254 9813/7400-1 33 - 254

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
Dealer
Dealer
P2135 00 Y SERVICE P2135-00-Please Foot Pedal Correla-
Contact JCB tion track 1 over track
Dealer 2 fault detected
Contact JCB correlation fault
Dealer
P2228 23 Y SERVICE P2228-23-Please Atmospheric Sensor
Contact JCB low fault
Dealer
P2229 24 Y SERVICE P2229-24-Please Atmospheric Sensor
Contact JCB high fault
Dealer
P2264 00 Y SERVICE P2264-00-Please Water in fuel Sensor
Contact JCB feedback signal
Dealer
P2265 64 Y SERVICE P2265-64-Please Water in fuel Sen-
Contact JCB sor feedback signal 1
Dealer plausibility fault
P2265 64 Y SERVICE P2265-64-Please Water in fuel Sen-
Contact JCB sor feedback signal 2
Dealer plausibility fault
P2266 23 Y SERVICE P2266-23-Please Water in fuel Sensor
Contact JCB feedback signal low
Dealer fault
P2267 24 Y SERVICE P2267-24-Please Water in fuel fault
Contact JCB
Dealer
P2269 00 Y SERVICE P2269-00 -Water Water in fuel Sensor
In Fuel feedback signal set-
ting fault
P250B 00 Y P250B-00 - En- Oil level Sensor sig-
gine Oil Low nal global fault
P250B 00 Y P250B-00-Engine Oil level Sensor sig-
Oil Low nal global fault
U040B 97 Y SERVICE U040B-97-Please CAN communication
Contact JCB Error: EGR obstruc-
Dealer tion
U040B 98 Y SERVICE U040B-98-Please CAN communication
Contact JCB Error: EGR over tem-
Dealer perature
U040B 4B Y SERVICE U040B4B-Please CAN communication
Contact JCB Error: EGR over tem-
Dealer perature
U040D 96 Y SERVICE U040D-96-Please CAN communication
Contact JCB Error: VGT hardware
Dealer
33 - 255 9813/7400-1 33 - 255

90 - Fault Codes

Code (HM ity as per
Byte) STD00236
U040D 98 Y SERVICE U040D-98-Please CAN communication
Contact JCB Error: VGT over tem-
Dealer perature
U040D 54 Y SERVICE U040D-54-Please CAN communica-
Contact JCB tion Error: VGT span
Dealer learn
Machine Fault Codes

Table 274.
Fault Code Cause Remedy
C111 Short circuit to positive connection Check Fuel Sender
at Fuel Sender
C114 Short circuit to positive connection Check Hydraulic Oil temperature
at Hydraulic Oil temperature Sen- Sender
der
C116 Short circuit to positive connection Check Fan Solenoid
at Fan Solenoid
C117 Short circuit to positive connection Check High Flow Solenoid
at High Flow Solenoid
C118 Short circuit to positive connection Check Charge pump Transducer
at Charge pump Transducer
C119 Short circuit to positive connection Check Parallel Lift Solenoid
at Parallel Lift Solenoid
C125 Short circuit to positive connection Check Implement Pilot Solenoid
at Implement Pilot Solenoid
C126 Short circuit to positive connection Check Auxiliary A Solenoid
at Auxiliary A Solenoid
C127 Short circuit to positive connection Check Auxiliary B Solenoid
at Auxiliary B Solenoid
C130 Short circuit to positive connection Check Quick Hitch A
at Quick Hitch A
C131 Short circuit to positive connection Check Quick Hitch B
at Quick Hitch B
C134 Short circuit to positive connection Check SRS Solenoid 1
at SRS Solenoid 1
C135 Short circuit to positive connection Check Two-Speed Solenoid
at Two-Speed Solenoid
C136 Short circuit to positive connection Check LH Turn signal
at LH Turn signal
C137 Short circuit to positive connection Check RH Turn signal
at RH Turn signal
C140 Short circuit to positive connection Check Transmission Pilot Solenoid
at Transmission Pilot Solenoid
C141 Short circuit to positive connection Check Crowd Solenoid
at Crowd Solenoid
C142 Short circuit to positive connection Check Dump Solenoid
at Dump Solenoid
C143 Short circuit to positive connection Check Float Transducer
at Float Transducer
C144 Short circuit to positive connection Check Lower Solenoid
at Lower Solenoid
33 - 256 9813/7400-1 33 - 256

90 - Fault Codes

C145 Short circuit to positive connection Check Transmission X1F Solenoid
at Transmission X1F Solenoid
C146 Short circuit to positive connection Check Park brake Transducer
at Park brake Transducer
C147 Short circuit to positive connection Check Transmission X2F Solenoid
C150 Short circuit to positive connection Check Raise Solenoid
at Raise Solenoid
C151 Short circuit to positive connection Check Transmission X1R Solenoid
at Transmission X1R Solenoid
C152 Short circuit to positive connection Check Transmission X2R Solenoid
C156 Short circuit to positive connection Check Starter relay
at Starter relay
C157 Short circuit to positive connection Check Reverse Alarm
at Reverse Alarm
C158 Short circuit to positive connection Check Brake Light
at Brake Light
C171 Short circuit to positive connection Check Auxiliary Roller
at Auxiliary Roller
at SRS Solenoid 2
at SRS Solenoid 3
C198 Short circuit to positive connection Check Reversing Fan Solenoid
at Reversing Fan Solenoid
C211 Short circuit to negative connection Check Fuel Sender
at Fuel Sender
C214 Short circuit to negative connection Check Hydraulic Oil Temp Sender
at Hydraulic Oil Temp Sender
C216 Short circuit to negative connection Check Fan Solenoid
at Fan Solenoid
C217 Short circuit to negative connection Check High Flow Solenoid
at High Flow Solenoid
C218 Short circuit to negative connection Check Charge pump Transducer
at Charge pump Transducer
C219 Short circuit to negative connection Check Parallel Lift Solenoid
at Parallel Lift Solenoid
C225 Short circuit to negative connection Check Implement Pilot Solenoid
at Implement Pilot Solenoid
C226 Short circuit to negative connection Check Auxiliary A Solenoid
at Auxiliary A Solenoid
C227 Short circuit to negative connection Check Auxiliary B Solenoid
at Auxiliary B Solenoid
C230 Short circuit to negative connection Check Quick Hitch A
at Quick Hitch A
C231 Short circuit to negative connection Check Quick Hitch B
at Quick Hitch B
C234 Short circuit to negative connection Check SRS Solenoid 1
at SRS Solenoid 1
C235 Short circuit to negative connection Check Two-Speed Solenoid
at Two-Speed Solenoid
C240 Short circuit to negative connection Check Transmission Pilot Solenoid
at Transmission Pilot Solenoid
33 - 257 9813/7400-1 33 - 257

90 - Fault Codes

C241 Short circuit to negative connection Check Crowd Solenoid
at Crowd Solenoid
C242 Short circuit to negative connection Check Dump Solenoid
at Dump Solenoid
C243 Short circuit to negative connection Check Float Transducer
at Float Transducer
C244 Short circuit to negative connection Check Lower Solenoid
at Lower Solenoid
C245 Short circuit to negative connection Check Transmission X1F Solenoid
C246 Short circuit to negative connection Check Park brake Transducer
at Park brake Transducer
C247 Short circuit to negative connection Check Transmission X2F Solenoid
C250 Short circuit to negative connection Check Raise Solenoid
at Raise Solenoid
C251 Short circuit to negative connection Check Transmission X1R Solenoid
C252 Short circuit to negative connection Check Transmission X2R Solenoid
C256 Short circuit to negative connection Check Starter relay
at Starter relay
C257 Short circuit to negative connection Check Reverse Alarm
at Reverse Alarm
C258 Short circuit to negative connection Check Brake Light
at Brake Light
C271 Short circuit to negative connection Check Auxiliary Roller
at Auxiliary Roller
C285 Short circuit to negative connection Check D+ Terminal
at D+ Terminal
at SRS Solenoid 2
at SRS Solenoid 3
C298 Short circuit to negative connection Check Reversing Fan Solenoid
at Reversing Fan Solenoid
C316 Open circuit at Fan Solenoid Check Fan Solenoid
C317 Open circuit at High Flow Solenoid Check High Flow Solenoid
C319 Open circuit at Parallel Lift Sole- Check Parallel Lift Solenoid
noid
C325 Open circuit at Implement Pilot So- Check Implement Pilot Solenoid
lenoid
C326 Open circuit at Auxiliary A Solenoid Check Auxiliary A Solenoid
C327 Open circuit at Auxiliary B Solenoid Check Auxiliary B Solenoid
C330 Open circuit at Quick Hitch A Check Quick Hitch A
C331 Open circuit at Quick Hitch B Check Quick Hitch B
C334 Open circuit at SRS Solenoid 1 Check SRS Solenoid 1
C335 Open circuit at Two-Speed Sole- Check Two-Speed Solenoid
noid
C336 Open circuit at LH Turn signal Check LH Turn signal
C337 Open circuit at RH Turn signal Check RH Turn signal
C340 Open circuit at Transmission Pilot Check Transmission Pilot Solenoid
Solenoid
33 - 258 9813/7400-1 33 - 258

90 - Fault Codes

C341 Open circuit at Crowd Solenoid Check Crowd Solenoid
C342 Open circuit at Dump Solenoid Check Dump Solenoid
C344 Open circuit at Lower Solenoid Check Lower Solenoid
C345 Open circuit at Transmission X1F Check Transmission X1F Solenoid
Solenoid
C347 Open circuit at Transmission X2F Check Transmission X2F Solenoid
Solenoid
C350 Open circuit at Raise Solenoid Check Raise Solenoid
C351 Open circuit at Transmission X1R Check Transmission X1R Solenoid
Solenoid
C352 Open circuit at Transmission X2R Check Transmission X2R Solenoid
Solenoid
C356 Open circuit at Starter relay Check Starter relay
C378 No signal at Left motor speed Sen- Check Left motor speed Sensor
sor
C379 No signal at Right motor speed Check Right motor speed Sensor
Sensor
C385 Open circuit at D+ Terminal Check D+ Terminal
C398 Open circuit at Reversing Fan So- Check Reversing Fan Solenoid
lenoid
C411 signal out of range HI at Fuel Sen- Check Fuel Sender
der
C414 signal out of range HI at Hydraulic Check Hydraulic Oil Temp Sender
Oil Temp Sender
C418 signal out of range HI at Charge Check Charge pump Transducer
pump Transducer
C443 signal out of range HI at Float Check Float Transducer
Transducer
C446 signal out of range HI at Park Check Park brake Transducer
brake Transducer
C471 signal out of range HI at Auxiliary Check Auxiliary Roller
Roller
C472 signal out of range HI at Hand Check Hand Throttle
Throttle
C473 signal out of range HI at Foot Check Foot Throttle
Throttle
C514 signal out of range LOW at Hy- Check Hydraulic Oil Temp Sender
draulic Oil Temp Sender
C518 signal out of range LOW at Charge Check Charge pump Transducer
pump Transducer
C543 signal out of range LOW at Float Check Float Transducer
Transducer
C546 signal out of range LOW at Park Check Park brake Transducer
brake Transducer
C571 signal out of range LOW at Auxil- Check Auxiliary Roller
iary Roller
C572 signal out of range LOW at Hand Check Hand Throttle
Throttle
C573 signal out of range LOW at Foot Check Foot Throttle
Throttle
33 - 259 9813/7400-1 33 - 259

90 - Fault Codes

C678 signal Compare Failure at Left mo- Check Left motor speed Sensor
tor speed Sensor
C679 signal Compare Failure at Right Check Right motor speed Sensor
motor speed Sensor
C690 signal Inconsistent at Isolation Bar Check Isolation Bar Switch
Switch
C691 signal Inconsistent at LH Arm Rest Check LH Arm Rest Down Switch
Down Switch
C701 Power Supply Over Voltage at Check ECU J1
ECU J1
C878 Uncommanded motion at Left mo- Check Left motor speed Sensor
tor speed Sensor
C879 Uncommanded motion at Right Check Right motor speed Sensor
motor speed Sensor
C980 Missing Calibration at Drive Pump Check Drive Pump
D703 Power Supply Over Voltage at Check RHC J3
RHC J3
Fault Code Description

U059E CANbus mes-
Table 275. SCR Fault Codes
sage Error for
Fault Code Description O2 signal status
U059E CANbus mes- from upstream
sage Error from NOx Sensor
upstream NOx U059E CANbus mes-
Sensor sage Error for
U059E CANbus Off power signal
Error from up- status from up-
stream NOx stream NOx
Sensor Sensor
U059E CANbus mes- U059E CANbus mes-
sage Error for sage Error for
NH3 level from Temp signal
upstream NOx status from up-
Sensor stream NOx
U059E CANbus mes- Sensor
sage Error for U059F CANbus mes-
NO2 level from sage Error for
upstream NOx Temp signal sta-
Sensor tus from down-
U059E CANbus mes- stream NOx
sage Error for Sensor
NOx level from U059F CANbus mes-
upstream NOx sage Error from
Sensor downstream
U059E CANbus mes- NOx Sensor
sage Error for U059F CANBUS OFF
O2 level from Error from down-
upstream NOx stream NOx
Sensor Sensor
U059E CANbus mes- U059F CANbus mes-
sage Error for sage Error for
NOX signal sta- heater ratio from
tus from up- downstream
stream NOx NOx Sensor
Sensor
33 - 260 9813/7400-1 33 - 260

90 - Fault Codes
Fault Code Description Fault Code Description

U059F CANbus mes- P060C Monitoring Error
sage Error for on DCU
NH3 level from P0606 Peripheral mon-
downstream itoring Error on
NOx Sensor DCU
U059F CANbus mes- P06A7 Sensor supply
sage Error for monitoring Error
NO2 level from through DCU
downstream P0658 Short circuit to
NOx Sensor ground of actua-
U059F CANbus mes- tor relay 1
sage Error for P0659 Short circuit to
NOx level from battery of actua-
downstream tor relay 1
NOx Sensor
P2A00 Upstream NOx
U059F CANbus mes- Sensor not
sage Error for mounted or
NOx level from loose
downstream
NOx Sensor P2A01 NOx Sensor
unmounted or
U059F CANbus mes- loose
sage Error for
O2 level from P20A0 Open load Er-
downstream ror of backflow
NOx Sensor pump actuator
power stage
U059F CANbus mes-
sage Error for P20A1 Error for over
NOX signal sta- temperature of
tus from down- backflow pump
stream NOx actuator power
Sensor stage
U059F CANbus mes- P20A2 Error for Short to
sage Error for ground of back-
O2 signal sta- flow pump actu-
tus from down- ator power stage
stream NOx P20A3 Error for Short to
Sensor battery of back-
U059F CANbus mes- flow pump actu-
sage Error for ator power stage
power signal sta- P20AD Error on Supply
tus from down- module tempera-
stream NOx ture cold start
Sensor P20AD Supply module
U059F CANbus mes- temperature du-
sage Error for ty cycle above
Temp signal Maximum range
status from up- P20AD Supply module
stream NOx temperature duty
Sensor cycle below min-
P0350 Error monitoring imum range
for System pro- P20BA Error for over
tection based on temperature of
ignition switch Urea backflow
input line heater actu-
P060A Monitoring Error ator power stage
on DCU
33 - 261 9813/7400-1 33 - 261

90 - Fault Codes

P20BB Error for Short to P20BF Error for Short to
ground or open ground or open
load on heater load on heater
relay of backflow relay of pressure
line line
P20BB Error for Short to P20B5 Open load Error
ground of Urea of Supply mod-
backflow line ule heater actua-
heater actuator tor power stage
power stage P20B6 Error for over
P20BC Error for Short to temperature of
battery of Urea Supply module
backflow line heater actuator
heater actuator power stage
power stage P20B6 Supply module
P20BD Error for open heater temper-
load on heater ature duty cycle
relay of pressure above Maximum
LINE range
P20BD Open load Er- P20B6 Supply module
ror of Urea pres- heater temper-
sure LINE heater ature duty cycle
actuator power below minimum
stage range
P20BE Error on relays P20B7 Error for Short to
for Short to bat- ground of Supply
tery module heater
P20BE Error for over actuator power
temperature of stage
Urea pressure P20B8 Error for Short to
LINE heater ac- battery of Supply
tuator power module heater
stage actuator power
P20BF Error for Short to stage
ground of Urea P20B9 Error for open
pressure line load on heater
heater actuator relay of backflow
power stage line
P20B9 Open load Error P20BE Error on Supply
of Urea backflow module heater
line heater actu- P20BE Error on Supply
ator power stage module heater
P20C0 Error for Short to temperature
battery of Urea Sensor
pressure line P20C1 Open load Error
heater actuator of Urea suction
power stage line heater actu-
P20C1 Error for open ator power stage
load on heater P20C2 Error for over
relay of suction temperature of
line Urea suction line
P20C3 Error for Short to heater actuator
ground or open power stage
load on heater
relay of suction
line
33 - 262 9813/7400-1 33 - 262

90 - Fault Codes

P20C3 Error for Short P204C Pump pressure
to ground of signal below the
Urea suction line minimum Volt-
heater actuator age limit
power stage P204C Error for pump
P20C4 Error for Short pressure physi-
to battery of cal signal below
Urea suction line lower limit
heater actuator P204D Pump pressure
power stage signal above the
P20EA DCU relay, early Maximum Volt-
opening age limit
P20EB DCU relay stuck P204F Error to detect
P20E8 Under pressure clogged filter
Error in metering P204F Error for leakage
control state during no dose
P20E9 Over pressure P205B Error to indicate
Error in metering overheating of
control state Ad-blue tank
P20E9 Over pressure P205B Error in increase
Error regardless of Urea tank
of Supply mod- temperature
ule state P205B Error for Ad-blue
P202A Open load Er- tank header unit
ror of Urea tank P205C Tank tempera-
heater actuator ture signal Volt-
power stage age, below mini-
P202B Error for Short to mum limit
ground of Urea P205D Tank tempera-
tank heater actu- ture signal Volt-
ator power stage age, Above Max-
P202C Error for Short to imum limit
battery of Urea P207F Ad-blue quality
tank heater actu- P208A Pump communi-
ator power stage cations Error
P203B Urea tank level P208A Open load Error
P203F Low / empty of Supply mod-
Reagent tank ule pump motor
level P208B Error on Supply
P204B Error on pres- module pump
sure line while speed deviation
monitoring for P208B Error on Supply
blockage module pump
P204B Error on pres- speed perma-
sure line and nent deviation
dosing valve P208B Over temper-
while monitoring ature Error of
for blockage Supply module
P204B Error while mon- pump motor
itoring the stabil- P208B Supply mod-
isation of pres- ule internal du-
sure ty cycle in invalid
P204B Error while mon- range
itoring of pres-
sure build-up
33 - 263 9813/7400-1 33 - 263

90 - Fault Codes

P208B Supply module P242B Error on cata-
internal duty cy- lyst temperature
cle below MIN Sensor static
range plausibility below
P208B Supply module MIN threshold
motor speed du- P242B Error on SCR
ty cycle above catalyst Up-
Maximum range stream tempera-
P208B Supply module ture Sensor stat-
motor speed du- ic plausibility
ty cycle below P242B Exhaust catalyst
minimum range temperature T4
P208C Short circuit to physical signal
ground Error of below minimum
Supply module limit
pump motor P242C Exhaust catalyst
P208D Short circuit to temperature T4
battery Error of Voltage signal
Supply module Above Maximum
pump motor limit
P209F Error for over P242D Exhaust catalyst
temperature of temperature T4
Urea tank heater Voltage signal
actuator power below minimum
stage limit
P21A9 Short circuit to P2043 CAN message
battery of actua- from head unit
tor relay 4 P2200 Upstream NOx
P21AB Short circuit to Sensor Open cir-
ground of actua- cuit
tor relay 4 P2200 Upstream NOx
P219D Open load Error Sensor Short cir-
of Urea heater cuit to ground or
relay actuator battery
power stage P2200 Invalid signal
P219D Error for over from upstream
temperature NOx Sensor af-
of Urea heater ter heater re-
relay actuator lease
power stage P2200 Lambda sig-
P219E Error for Short to nal above Max-
battery of Urea imum limit FOR
heater relay ac- upstream NOx
tuator power Sensor
stage P2200 Lambda signal
P219F Error for Short to below minimum
ground of Urea for upstream
heater relay ac- NOx Sensor
tuator power P2200 Upstream NOx
stage Sensor wire di-
P242B Error on cata- agnosis-Error IN
lyst tempera- Voltage supply
ture Sensor sta- P2201 Downstream
tic plausibili- NOx Sensor
ty Above max. Open circuit
threshold
33 - 264 9813/7400-1 33 - 264

90 - Fault Codes

P2201 Downstream P2208 Downstream
NOx Sensor NOx Sensor
Short circuit to heater not avail-
ground or bat- able
tery P2208 Downstream
P2201 Invalid signal NOx Sensor
from down- heater not heat-
stream NOx ed quickly
Sensor after P2209 Upstream NOx
heater release Sensor heater
P2201 Invalid signal not available
from down- P2209 Upstream NOx
stream NOx Sensor heater
Sensor after not heated
heater release quickly
P2201 Lambda signal P2428 Exhaust Gas
above Maximum temperature Too
limit FOR down- High
stream NOx P2670 Short circuit to
Sensor ground of actua-
P2201 Lambda signal tor relay 2
below minimum P2671 Short circuit to
limit for down- battery of actua-
stream NOx tor relay 2
Sensor
P2685 Short circuit to
P2201 Downstream ground of actua-
NOx Sensor wire tor relay 3
diagnosis-Error
IN Voltage sup- P2686 Short circuit to
ply battery of actua-
tor relay 3
P2201 Downstream
NOx offset MAX P3401 Error for after
Error detection treatment 1 SCR
catalyst Reagent
P2201 Downstream Property
NOx offset MIN
Error detection P3402 Concentration
too high for Er-
P2202 Upstream NOx ror for after treat-
Sensor reading ment 1 SCR cat-
below minimum alyst Reagent
threshold properties
P2202 Downstream P3403 Concentration
NOx Sensor too low for after
reading below treatment 1 SCR
minimum thresh- catalyst Reagent
old Property
P2203 Upstream NOx P3404 Excessive am-
Sensor read- bient / Operat-
ing exceeds ing temperature
above Maximum for Error for after
threshold treatment 1 SCR
P2203 Downstream catalyst Reagent
NOx Sensor Property
reading exceeds P3405 Temperature
above Maximum too high for after
threshold treatment 1 SCR
catalyst Reagent
properties
33 - 265 9813/7400-1 33 - 265

90 - Fault Codes
Fault Code Description

P3406 Temperature
too low for after
treatment 1 SCR
catalyst Reagent
properties
P3407 Sensor Open cir-
cuit Error after
treatment 1 SCR
catalyst Reagent
temperature
P3408 Sensor Short cir-
cuit Error after
treatment 1 SCR
catalyst Reagent
temperature
P3409 Excessive ambi-
ent / Operating
level Error for
after treatment
1 SCR catalyst
Reagent Proper-
ty
P3410 Level too high
after treatment
1 SCR catalyst
Reagent proper-
ties
P3411 Level too low
after treatment
1 SCR catalyst
Reagent proper-
ties
P3412 Tank level Open
circuit Error after
treatment 1 SCR
catalyst Reagent
temperature
P3413 Tank level Short
circuit Error after
treatment 1 SCR
catalyst Reagent
temperature
33 - 266 9813/7400-1 33 - 266

84 - Sensor
84 - Sensor
Contents Page No.
33-84-07 Hydraulic Pressure ....................................................................................................... 33-269

33-84-41 Lift Arm ......................................................................................................................... 33-271
33-84-85 Platform Down Limit ..................................................................................................... 33-273
33 - 267 9813/7400-1 33 - 267

Notes:
33 - 268 9813/7400-1 33 - 268

84 - Sensor
07 - Hydraulic Pressure
07 - Hydraulic Pressure Introduction

Introduction .................................................. 33-269 The lift arm crowd ram pressure sensor measures
Remove and Install ..................................... 33-270 the pressure in the crowd ram circuit. It is located
under the lift arm control valve block.
Figure 775.
A Crowd pressure sensor
33 - 269 9813/7400-1 33 - 269

84 - Sensor
07 - Hydraulic Pressure
Remove and Install
Remove
1. Make the machine safe. Refer to PIL (01-03).
2. Discharge the hydraulic pressure. Refer to PIL
(30-00).
3. Raise the operator station. Refer to PIL (09-00).
5. Remove the pressure sensor.
Figure 776.
A Lift arm crowd pressure sensor
Install
steps.
2. Tighten the sensor to the correct torque value.

Item Nm
A 17–20
33 - 270 9813/7400-1 33 - 270

84 - Sensor
41 - Lift Arm

Introduction .................................................. 33-271 The lift arm sensor detects when the lift arm is fully
Adjust .......................................................... 33-272 raised or fully lowered. It is located under the lift arm
Remove and Install ..................................... 33-272 pivot.
Figure 777.
A Lift arm sensor
33 - 271 9813/7400-1 33 - 271

84 - Sensor
41 - Lift Arm

1. Make the machine safe with the lift arm fully
lowered. Refer to (PIL 01-03).
Remove
2. Check that the air gap between the stop position
bolt and the lift arm sensor is within the specified 2. Disconnect the battery. Refer to (PIL 33-03).
amount.
Length/Dimension/Distance: 4.5–5.5mm 3. Disconnect the electrical connector.
A
A
B
C
A Air gap A Lift arm sensor

B Lock nut B Bolts (x2)
C Stop position bolt C Electrical connector
3. If the air gap is not within the specified amount: 4. Remove the bolts (x2).
3.1. Loosen the lock nut. 5. Remove the sensor from the machine.
3.2. Adjust the stop position bolt until the air gap Install
is within the specified amount.
3.3. Tighten the lock nut. 1. The installation procedure is the opposite of the
4. Start the engine and fully raise the lift arm. step.
5. Stop the engine and make sure that the safety 2. Check that the air gap between the sensor and
strut is installed. Refer to (PIL 01-03). the stop position bolts is correct. Refer to (PIL
33-84-41).
6. Repeat 2 and 3.
33 - 272 9813/7400-1 33 - 272

84 - Sensor
85 - Platform Down Limit
85 - Platform Down Limit Introduction

Introduction .................................................. 33-273 The ground level sensor measures the angle of the
Remove and Install ..................................... 33-274 Quickhitch and attachments. It is located inside the
Quickhitch.
Figure 780.
A Ground level sensor
33 - 273 9813/7400-1 33 - 273

84 - Sensor
85 - Platform Down Limit
Remove and Install
Remove
1. Remove any attachments from the machine.
Refer to the relevant operators manual.
Figure 781.
B
C
A Ground level sensor

B Bolts (x2)
6. Remove the ground level sensor from the
machine.
Install
removal procedure.
33 - 274 9813/7400-1 33 - 274

86 - Solenoid
86 - Solenoid
Contents Page No.
33-86-14 Transmission ................................................................................................................ 33-277

33-86-15 Transmission Pilot ........................................................................................................ 33-279
33-86-41 Lift Arm ......................................................................................................................... 33-283
33-86-50 Implement Pilot ............................................................................................................ 33-286
33-86-78 Hydraulic Hi-Flow ......................................................................................................... 33-288
33-86-92 Cooling Fan .................................................................................................................. 33-290
33 - 275 9813/7400-1 33 - 275

Notes:
33 - 276 9813/7400-1 33 - 276

86 - Solenoid
14 - Transmission
14 - Transmission Introduction
Introduction .................................................. 33-277 The transmission solenoids are mounted under the
Remove and Install ..................................... 33-278 cab on the transmission pump.
The typical solenoid resistance of each coil is 4Ω.
The solenoids are controlled by PWM (Pulse Width

Modulation).
The software interpretation of the joystick signals

determines the applied voltage. The positive side of
the coils are fed from independent pins on the EH
(Electro-Hydraulic) control ECU (Electronic Control
Unit).
The negative sides of the coils are paired together:
• RH Forward/RH Reverse.
• LH Forward/LH Reverse.
Each pair returns to the controller so current through

the circuit can be measured.
Figure 782.
B
D C
E
A Transmission pump
B RH forward
C RH reverse
D LH forward
E LH reverse
The forward and reverse solenoids are reversed on

tracked machines.
33 - 277 9813/7400-1 33 - 277

86 - Solenoid
14 - Transmission
Remove and Install
Remove
3. Raise the operator station. Refer to (PIL 09-00).
4. Disconnect the relevant electrical connection.
5. Remove the relevant transmission solenoid from
the transmission pump.
Figure 783.
B
D C
E
A Transmission pump
B RH forward solenoid
C RH reverse solenoid
D LH forward solenoid
E LH reverse solenoid
Install
removal procedure.
33 - 278 9813/7400-1 33 - 278

86 - Solenoid
15 - Transmission Pilot
15 - Transmission Pilot Introduction

Introduction .................................................. 33-279 The transmission pilot solenoid is mounted under the
Remove and Install ..................................... 33-280 cab on the transmission pump.
The solenoids are controlled by an on/off signal from

the controller. The battery voltage is applied when on.
Figure 784.
B
A Transmission pump
B Transmission pilot solenoid
33 - 279 9813/7400-1 33 - 279

86 - Solenoid
15 - Transmission Pilot
Remove and Install
Remove
5. Remove the transmission pilot solenoid from the
transmission pump.
Figure 785.
B
A Transmission pump
B Transmission pilot solenoid
Install
removal procedure.
33 - 280 9813/7400-1 33 - 280

86 - Solenoid

Introduction .................................................. 33-281 There are two SRS (Smooth Ride System) solenoids
Remove and Install ..................................... 33-282 mounted under the cab on the SRS valve block at the
front of the machine on the right hand side.

Figure 786.
B E
A D
A SRS valve
B SRS solenoid 1
C SRS solenoid 2
D Float transducer
E SRS solenoid 3
33 - 281 9813/7400-1 33 - 281

86 - Solenoid
Remove and Install
Remove
5. Remove the SRS (Smooth Ride System)
solenoid 1, SRS solenoid 2 and SRS solenoid 3.
Figure 787.
B E
A D
A SRS valve
B SRS solenoid 1
C SRS solenoid 2
D Float transducer
E SRS solenoid 3
Install
removal procedure.
33 - 282 9813/7400-1 33 - 282

86 - Solenoid
41 - Lift Arm

Introduction .................................................. 33-283 The lift arm solenoids are mounted on the lift arm
Remove and Install ..................................... 33-284 valve block under the cab on the right hand side of
the machine.
The typical solenoid resistance of each coil is 5.6Ω.
The solenoids are controlled by PWM (Pulse Width

Modulation).
The software interpretation of the joystick signals

determines the applied voltage. The positive side of
the coils is fed from the independent pins on the EH
(Electro-Hydraulic) control ECU (Electronic Control
Unit) or chassis control ECU for the auxiliary.
The negative sides of the coils are paired together:
• Crowd/ Dump.
• Raise/ Lower.
• Aux A/ Aux B.
Each pair returns to the controller so current through

the circuit can be measured.
Figure 788.
B
A
C D
E F
A Crowd B Dump
C Raise D Lower
E Aux A F Aux B
33 - 283 9813/7400-1 33 - 283

86 - Solenoid
41 - Lift Arm
Remove and Install
Remove 4. Mark all the electrical connectors to help

installation.
Refer to (PIL 01-03). 5. Disconnect the relevant electrical connection.
2. Disconnect the battery. Refer to (PIL 33-03). 6. Remove the relevant solenoid.
Figure 789.
B
A
C D
E F
A Crowd B Dump
C Raise D Lower
E Aux A F Aux B
33 - 284 9813/7400-1 33 - 284

86 - Solenoid
41 - Lift Arm
Install
removal procedure.
33 - 285 9813/7400-1 33 - 285

86 - Solenoid
50 - Implement Pilot
50 - Implement Pilot Introduction

Introduction .................................................. 33-286 The implement pilot solenoid is mounted under the
Remove and Install ..................................... 33-287 cab on the lift arm valve block.
The solenoid is controlled by an on/off signal from the

controller. The battery voltage is applied when on.
Figure 790.
A Lift arm valve block

B Implement pilot solenoid
33 - 286 9813/7400-1 33 - 286

86 - Solenoid
50 - Implement Pilot
Remove and Install
Remove
5. Remove the implement pilot solenoid.
Figure 791.
A Lift arm valve block

B Implement pilot solenoid
Install
removal procedure.
33 - 287 9813/7400-1 33 - 287

86 - Solenoid
78 - Hydraulic Hi-Flow
78 - Hydraulic Hi-Flow Introduction

Introduction .................................................. 33-288 The high flow solenoid is mounted under the cab on
Remove and Install ..................................... 33-289 the transmission pump.
The option is set through the options in the

servicemaster.

Figure 792.
33 - 288 9813/7400-1 33 - 288

86 - Solenoid
78 - Hydraulic Hi-Flow
Remove and Install
Remove
5. Remove the hi-flow solenoid from the
transmission pump.
Figure 793.
Install
removal procedure.
33 - 289 9813/7400-1 33 - 289

86 - Solenoid
92 - Cooling Fan
92 - Cooling Fan Introduction

Introduction .................................................. 33-290 The fan solenoid is mounted in two different
Remove and Install ..................................... 33-291 locations:
• Without reversing fan option - mounted on the

hydraulic motor above the engine, Refer to
Figure 794.
• With reversing fan option - mounted on the
reversing fan valve block in front of the engine,
The solenoid is controlled by PWM (Pulse Width

Modulation).
The applied voltage will depend on the cooling

needs, which is determined by the controller. If there
is no voltage going to the fan solenoid this will result
in full fan speed, maximum voltage will result in fan
off.
Figure 794. Without reversing fan option
A Hydraulic motor
B Fan solenoid
33 - 290 9813/7400-1 33 - 290

86 - Solenoid
92 - Cooling Fan
Figure 795. With reversing fan option Remove and Install
Remove
B 4. Disconnect the electrical connection.

5. Remove the fan solenoid.
5.1. Without reversing fan option - mounted on
C the hydraulic motor above the engine, Refer
to Figure 796.
5.2. With reversing fan option - mounted on the
reversing fan valve block in front of the
B Fan solenoid engine, Refer to Figure 797.
C Reversing fan valve block
Figure 796. Without reversing fan option
A Hydraulic motor
B Fan solenoid
33 - 291 9813/7400-1 33 - 291

86 - Solenoid
92 - Cooling Fan
Figure 797. With reversing fan option
B Fan solenoid
C Reversing fan valve block
Install
removal procedure.
33 - 292 9813/7400-1 33 - 292

72 - Fasteners and Fixings
Contents Page No.
72-00 Fasteners and Fixings

72-00-00 General ............................................................................................................................. 72-3
72-03 Screws
72-03-00 General ............................................................................................................................. 72-7
72-06 Bolts
72-06-00 General ........................................................................................................................... 72-11
72-18 Bearings
72-18-00 General ........................................................................................................................... 72-15
72-21 Clips
72-21-03 Worm Drive .................................................................................................................... 72-17
72-36 Threaded Insert
72-36-00 General ........................................................................................................................... 72-23
9813/7400-1
2017-03-16
Notes:
9813/7400-1
2017-03-16
Contents Page No.
72-00-00 General ............................................................................................................................. 72-3
72 - 1 9813/7400-1 72 - 1
Notes:
72 - 2 9813/7400-1 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 277. • 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 278. 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 798.
ver-grey), Dull
Zinc and heavy Silver (Bright iri- V (e.g.
trivalent passi- descent) 1315/3712V)
vated with seal
Zinc Nickel - sil- Dark, dull silver Not assigned
ver/grey grey
72 - 3 9813/7400-1 72 - 3
00 - General
Figure 798.
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 799.
+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 800.
Figure 800.
+180°
+90°
5. Tighten the bolt so that the line on the bolt

aligns with the angle(s) marked on the item to
be clamped - remember, to ensure complete
accuracy an angle gauge should be used.
72 - 4 9813/7400-1 72 - 4
03 - Screws
03 - Screws
Contents Page No.
72-03-00 General ............................................................................................................................. 72-7
72 - 5 9813/7400-1 72 - 5
Notes:
72 - 6 9813/7400-1 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 279. 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 280. From September 2017

no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black
72 - 7 9813/7400-1 72 - 7
03 - Screws
00 - General
Technical Data
Table 281. Torque Settings - Internal

Hexagon Headed Capscrews (Zinc)
Bolt Size
mm N·m
3 2
4 6
5 11
6 19
8 46
10 91
12 159
16 395
18 550
20 770
24 1,332
72 - 8 9813/7400-1 72 - 8
06 - Bolts
06 - Bolts
Contents Page No.
72-06-00 General ........................................................................................................................... 72-11
72 - 9 9813/7400-1 72 - 9
Notes:
72 - 10 9813/7400-1 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 282. 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 283. 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 801.
72 - 11 9813/7400-1 72 - 11
06 - Bolts
00 - General
Technical Data Table 286. 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
6 1 10 9.9 9
1.2. Locking type fasteners (those with a nylon
8 1.25 13 24 22
insert, or with distorted thread nuts such as
Cleveloc). 10 1.5 17 47 43
12 1.75 19 83 74
2. For information on fastener conditions, refer to 14 2 22 132 119
fasteners and fixings, bolts, general, introduction
(PIL 72-06-00). 16 2 24 205 184
20 2.5 30 400 360
24 3 36 690 621
Table 284. Torque Settings - UNF S Fasteners
30 3.5 46 1,372 1,235
Bolt Treads Hexa- Condi- Condi- 36 4 55 2,399 2,159
Size per Inch gon (A/ tion 1 tion 2
F) Table 287. Torque Settings - Coarse
in in in N·m N·m Metric Grade 10.9 Fasteners
(1/4 in) 28 7/16 11.2 10 Bolt Thread Hexa- Condi- Condi-
(5/16 in) 24 1/2 22.3 20 Size Pitch gon (A/ tion 1 tion 2
(3/8 in) 24 9/16 40 36 F)
(7/16 in) 20 5/8 64 57 mm mm mm N·m N·m
(1/2 in) 20 3/4 98 88 4 0.7 7 4 3.6
(9/16 in) 18 13/16 140 126 5 0.8 8 8.1 7.3
(5/8 in) 18 15/16 196 177 6 1 10 13.9 12.5
(3/4 in) 16 1 1/8 343 309 8 1.25 13 34 30
(7/8 in) 14 1 15/16 547 492 10 1.5 17 67 60
(1 in) 12 1 1/2 814 732 12 1.75 19 116 104
(1 1/8 in) 12 1 7/8 1,181 1,063 14 2 22 185 167
(1 1/4 in) 12 2 1/4 1,646 1,481 16 2 24 288 259
20 2.5 30 562 506
24 3 36 971 874
Table 285. Torque Settings - UNF X Fasteners
30 3.5 46 1,930 1,737
Bolt Treads Hexa- Condi- Condi-
36 4 55 3,374 3,036
Size per Inch gon (A/ tion 1 tion 2
F)
Table 288. Torque Settings - Coarse
in in in N·m N·m Metric Grade 12.9 Fasteners
(1/4 in) 28 7/16 17.6 15.9
Bolt Thread Hexa- Condi- Condi-
(5/16 in) 24 1/2 35.2 31.6 Size Pitch gon (A/ tion 1 tion 2
(3/8 in) 24 9/16 64 57 F)
(7/16 in) 20 5/8 101 91 mm mm mm N·m N·m
(1/2 in) 20 3/4 155 139 4 0.7 7 4.8 4.4
(9/16 in) 18 13/16 221 199 5 0.8 8 9.8 8.8
(5/8 in) 18 15/16 310 279 6 1 10 16.6 15
(3/4 in) 16 1 1/8 542 488 8 1.25 13 40 36
(7/8 in) 14 1 15/16 864 777 10 1.5 17 80 72
(1 in) 12 1 1/2 1,285 1,156 12 1.75 19 139 125
(1 1/8 in) 12 1 7/8 1,865 1,679 14 2 22 223 200
(1 1/4 in) 12 2 1/4 2,598 2,339 16 2 24 345 311
72 - 12 9813/7400-1 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 289. Torque Settings - Rivet Nuts / Bolts

Bolt Size
mm N·m
3 1.2
4 3
5 6
6 10
8 24
10 48
12 82
72 - 13 9813/7400-1 72 - 13
18 - Bearings
18 - Bearings
Contents Page No.
72-18-00 General ........................................................................................................................... 72-15
72 - 14 9813/7400-1 72 - 14
18 - Bearings
00 - General
00 - General
Check (Condition)
1. Carefully inspect all rollers, cages and cups
for wear, chipping, or nicks to determine the
condition of the bearings for further use.
2. Do not replace a bearing cone or cup individually.
Replace the mating cup and the cone at the same
time.
3. After inspection, lubricate the bearings with a
suitable clean oil.
4. Wrap the bearings in clean lint free cloth or paper
to protect them until you install the bearings
again.
72 - 15 9813/7400-1 72 - 15
21 - Clips
21 - Clips
Contents Page No.
72-21-03 Worm Drive .................................................................................................................... 72-17
72 - 16 9813/7400-1 72 - 16
21 - Clips
03 - Worm Drive
03 - Worm Drive Introduction

Introduction .................................................... 72-17 There are three types of the plain worm drive clips.
Technical Data ............................................... 72-18
Component Identification ............................... 72-20 • Standard worm drive clip
• Heavy duty worm drive clip
• Spring assisted worm drive clip
Spring assisted worm drive clip contains a spring

insert on the inside of the band to provide
compensation against hose compression set.
Use the torque setting tables (Technical Data) only

where no torque setting is specified in the text.
72 - 17 9813/7400-1 72 - 17
21 - Clips
03 - Worm Drive
Technical Data
Dimensions
Figure 802.
C
J
H
Table 290.
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Standard worm drive clips and spring assisted worm drive clips
8–16mm 0.7mm 13mm 9mm 7mm 21mm 11mm
12–22mm 21mm
16–27mm up 0.8mm 14.6mm 12mm 30mm 12.5mm
to 60–80mm
70–90mm 36mm
up to 160–
180mm
72 - 18 9813/7400-1 72 - 18
21 - Clips
03 - Worm Drive
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Heavy duty worm drive clips
172–206mm 0.7mm 23.1mm 16mm 7mm 37mm 13mm
Torque Values
Table 291. 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 292. 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 293. Spring Assisted Worm Drive Clip

range
16–27mm 2206/1627 5 -0/+0.5N·m
20–32mm 2206/2032 5 -0/+0.5N·m
25–40mm 2206/2540 5 -0/+0.5N·m
30–45mm 2206/3045 5 -0/+0.5N·m
35–50mm 2206/3550 5 -0/+0.5N·m
40–60mm 2206/4060 5 -0/+0.5N·m
50–70mm 2206/5070 5 -0/+0.5N·m
60–80mm 2206/6080 5 -0/+0.5N·m
70–90mm 2206/7090 5 -0/+0.5N·m
72 - 19 9813/7400-1 72 - 19
21 - Clips
03 - Worm Drive
Component Identification Figure 805. Spring Assisted Worm Drive Clip

A B
Figure 803. 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 804. Heavy Duty Worm Drive Clip
A Extended bridge
B Band width (16mm)
C Identification of clamping range
72 - 20 9813/7400-1 72 - 20
36 - Threaded Insert
Contents Page No.
72-36-00 General ........................................................................................................................... 72-23
72 - 21 9813/7400-1 72 - 21
Notes:
72 - 22 9813/7400-1 72 - 22
00 - General
Introduction .................................................... 72-23 A threaded insert also known as a rivet nut is a
Technical Data ............................................... 72-24 one piece fastener installed blind from one side of
Remove and Install ....................................... 72-24 the machine body/framework. The threaded insert is
compressed so that a section of its shank forms an
upset against the machine body/framework, leaving
a durable thread.
Figure 806.
A Threaded insert
B Durable thread
Threaded inserts are installed to various parts of

the machine body and framework. They are used in
a number of applications, for instance, hose clamp
and hydraulic valve retention etc. Various sized
threaded inserts are available, refer to technical data
to determine the correct size of threaded insert to be
used for particular applications.
If for any reason a new threaded insert is required,

the correct installation procedure must be followed.
Refer to Remove and Install.
72 - 23 9813/7400-1 72 - 23
00 - General
Technical Data Remove and Install

Consumables
Table 294. 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 807.
A Threaded insert
4. Wind the body of the installation tool down the
threaded mandrel until it touches the head of the
threaded insert.
72 - 24 9813/7400-1 72 - 24
00 - General
Figure 808.
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 809.
C Handle
D Nut
E Body/Framework
7. Remove the installation tool.
72 - 25 9813/7400-1 72 - 25
Notes:
72 - 26 9813/7400-1 72 - 26
75 - Consumable Products
Contents Page No.
75-00 Consumable Products

75-00-00 General ............................................................................................................................. 75-3
75-00-03 Parts List .......................................................................................................................... 75-6
75-03 Oil
75-03-00 General ............................................................................................................................. 75-9
75-03-03 Engine ............................................................................................................................ 75-10
75-03-21 Refrigerant ...................................................................................................................... 75-12
75-06 Grease
75-06-00 General ........................................................................................................................... 75-15
75-09 Fluids
75-09-00 General ........................................................................................................................... 75-19
75-09-03 Antifreeze ....................................................................................................................... 75-20
75-10 Locking Fluids
75-10-00 General ........................................................................................................................... 75-23
75-14 Solvents and Primers
75-14-00 General ........................................................................................................................... 75-27
75-15 Adhesive
75-15-00 General ........................................................................................................................... 75-31
75-16 Sealant
75-16-00 General ........................................................................................................................... 75-37
75-18 Fuel
75-18-00 General ........................................................................................................................... 75-43
9813/7400-1
2016-11-17
Acronyms Glossary
PTFE Polytetrafluoroethylene
9813/7400-1
2016-11-17
Contents Page No.
75-00-00 General ............................................................................................................................. 75-3

75-00-03 Parts List .......................................................................................................................... 75-6
75 - 1 9813/7400-1 75 - 1
Notes:
75 - 2 9813/7400-1 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
on JCB machines. However, you could use other
lubricants that are equivalent to the JCB standards
and quality or offer the same machine component
protection.
Before you start work, make sure that:
• All safety precautions are observed in

accordance with the information contained
within the relevant support documentation.
• The consumables are used in accordance with
the manufacturer's recommendations.
• The consumables shown are available in the
correct quantity.
Consumables other than those listed may be

required. It is expected that general consumables will
be available in any well equipped workshop or be
available locally.
75 - 3 9813/7400-1 75 - 3
00 - General
Health and Safety
Oil Waste Disposal

Oil is toxic. If you swallow any oil, do not induce CAUTION It is illegal to pollute drains, sewers
vomiting, seek medical advice. Used engine oil or the ground. Clean up all spilt fluids and/or
contains harmful contaminants which can cause skin lubricants.
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves Used fluids and/or lubricants, filters and
to prevent skin contact. Wash skin contaminated with contaminated materials must be disposed of in
oil thoroughly in warm soapy water. Do not use petrol, accordance with local regulations. Use authorised
diesel fuel or paraffin to clean your skin. waste disposal sites.
Fluid Under Pressure CAUTION Damaged or spent batteries and
any residue from fires or spillage must be
Fine jets of fluid at high pressure can penetrate the put in a closed acid proof receptacle and
skin. Keep face and hands well clear of fluid under must be disposed of in accordance with local
pressure and wear personal protective equipment. environmental waste regulations.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help All waste products must be disposed of in
immediately. accordance with all the relevant regulations.
Fuel The collection and disposal of used oil must be in
Fuel is flammable, keep naked flames away from the accordance with any local regulations. Never pour
fuel system. Stop the engine immediately if a fuel used engine oil into sewers, drains or on the ground.
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
injury if you do not follow these precautions.
until it cools before beginning maintenance.
Hygiene
New Oil
JCB lubricants are not a health risk when used
correctly for their intended purposes. There are no special precautions needed for the
handling or use of new oil, beside the normal care
However, excessive or prolonged skin contact can and hygiene practices.
remove the natural fats from your skin, causing
dryness and irritation. Used Oil
Low viscosity oils are more likely to do this, so take Used engine crankcase lubricants contain harmful
special care when handling used oils, which might be contaminants.
diluted with fuel contamination.
Here are precautions to protect your health when
Whenever you are handling oil products you must handling used engine oil:
maintain good standards of care and personal and
plant hygiene. For details of these precautions we • Avoid prolonged, excessive or repeated skin
advise you to read the relevant publications issued contact with used oil
by your local health authority, plus the following. • Apply a barrier cream to the skin before
handling used oil. Note the following when
Storage removing engine oil from skin:
• Wash your skin thoroughly with soap and
Always keep lubricants out of the reach of children. water
• Using a nail brush will help
Never store lubricants in open or unlabelled • Use special hand cleansers to help clean
containers. dirty hands
• Never use petrol, diesel fuel, or paraffin for
washing
• Avoid skin contact with oil soaked clothing
• Don't keep oily rags in pockets
• Wash dirty clothing before re-use
75 - 4 9813/7400-1 75 - 4
00 - General
• Throw away oil-soaked shoes Battery

Warning Symbols
The following warning symbols may be found on the
battery.
Figure 810.
A B C D E F
A Keep away from children B Shield eyes

C No smoking, no naked flames, no sparks D Explosive gas
E Battery acid F Note operating instructions
First Aid - Oil Swallowing
Eyes Do not induce vomiting. Drink large quantities of

water or milk. Then drink milk of magnesia, beaten
In the case of eye contact, flush with water for 15min. egg or vegetable oil. Get medical help.
If irritation persists, get medical attention.
Skin
Swallowing
Flush with water, remove affected clothing. Cover
If oil is swallowed do not induce vomiting. Get burns with a sterile dressing then get medical help.
medical advice.
Skin
In the case of excessive skin contact, wash with soap
and water.
Spillage
Absorb with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a
chemical disposal area.
Fires
WARNING Do not use water to put out an oil fire.
This will only spread it because oil floats on water.
Extinguish oil and lubricant fires with carbon
dioxide, dry chemical or foam. Fire fighters must
use self contained breathing apparatus.
First Aid - Electrolyte

Eyes
In the case of eye contact, flush with water for 15min.
always get medical attention.
75 - 5 9813/7400-1 75 - 5
03 - Parts List
03 - Parts List Introduction

Consumables
Antifreeze HP/Coolant ASTM D6210 Concentrate 4006/1101 5L
4006/1120 20L
4006/1103 200L
Black Polyurethane Sealant 4102/2310 0.31L
Black Primer/Activator 4104/2304 0.1L
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
Clear Silicone Sealant 4102/0901 0.31L
EP Hammer Grease 4003/2107 0.4kg
4003/2106 12.5kg
Extreme Performance Moly Grease 4003/1327 0.4kg
4003/1326 12.5kg
Glass Replacement Kit 993/55701 -
Graphite/Calcium Fluoride Based Metal Free Anti-Seize Compound 4004/7545 -
Hand Cleaner 4104/1310 -
JCB Activator 4104/0251 0.2L
4104/0253 1L
JCB Autogrease 4003/2305 0.5kg
JCB Chain Lubricant 4004/0237A 0.3L
JCB Glass Cleaner 4006/3175 0.75L
JCB High Strength Threadlocker 4102/0551 0.05L
JCB Screenclear 4006/0504 1L
JCB Threadlocker and Sealer (High Strength) 4101/0550 0.01L
4101/0552 0.2L
JCB Threadlocker and Sealer (Medium Strength) 4101/0250 0.01L
4101/0251 0.05L
Polyurethane Adhesive 4103/2110 0.31L
4003/2006 12.5kg
4003/2005 50kg
Special Hammer Grease 4003/1119 0.4kg
Special MPL-EP Grease 4003/1501 0.4kg
4003/1506 12.5kg
4003/1510 50kg
Special Slew Pinion Grease 4003/1619 0.4kg
Special Slide Grease 4003/1115 0.4kg
Threaded Insert (M10 x 23mm) 826/01104 -
Threaded Insert (M10 x 26mm) 826/01105A -
Waxoyl 4004/0501A 0.4L
4004/0502 5L
4004/0505 200L
Wiring Splice (0.5-1.5mm Red, contains 50 off) 892/00351 -
75 - 6 9813/7400-1 75 - 6
03 - Parts List

Wiring Splice (1.5-2.5mm Blue, contains 50 off) 892/00352 -
Wiring Splice (3-6mm Yellow, contains 50 off) 892/00353 -
75 - 7 9813/7400-1 75 - 7
03 - Oil
03 - Oil
Contents Page No.
75-03-00 General ............................................................................................................................. 75-9

75-03-03 Engine ............................................................................................................................ 75-10
75-03-21 Refrigerant ...................................................................................................................... 75-12
75 - 8 9813/7400-1 75 - 8
03 - Oil
00 - General
00 - General
Introduction
New Oil
There are no special precautions needed for the
handling or use of new oil, besides the normal
health and safety practices mentioned in the relevant
section of this service manual.
Used Oil
Used engine crankcase lubricants contain harmful
contaminants. Here are precautions to protect your
health when handling used engine oil:
1. Avoid prolonged, excessive or repeated skin

contact with used oil.
2. Apply a barrier cream to the skin before handling
used oil.
3. Note the following when removing engine oil from
skin:
3.1. Wash your skin thoroughly with soap and
water.
3.2. Using a nail brush will help.
3.3. Use special hand cleansers to help clean
dirty hands.
3.4. Never use petrol, diesel fuel, or paraffin for
washing.
4. Avoid skin contact with oil soaked clothing.
5. Don't keep oily rags in pockets.
6. Wash dirty clothing before re-use.
7. Throw away oil-soaked shoes.
First Aid
EYES - In the case of eye contact, flush with water for
15 minutes. If irritation persists, get medical attention.
SWALLOWING - If oil is swallowed do not induce

vomiting. Get medical advice.
SKIN - In the case of excessive skin contact, wash

with soap and water.
SPILLAGE - Absorb on sand or a locally approved

brand of absorbent granules. Scrape up and remove
to a chemical disposal area.
FIRES - Extinguish with carbon dioxide, dry chemical

or foam. Firefighters should use self-contained
breathing apparatus.
75 - 9 9813/7400-1 75 - 9
03 - Oil
03 - Engine
03 - Engine Introduction
Introduction .................................................... 75-10 New engines DO NOT require a running-in period.
Technical Data ............................................... 75-11 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).
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.
When selecting the oil viscosity grade, make

sure that the oil conforms with or exceeds the
recommended specification.
75 - 10 9813/7400-1 75 - 10
03 - Oil
03 - Engine
Technical Data
Table 295.
Engine Code Oil API Specifica- Viscosity Minimum Maximum
tion Temperature°C (°F) Temperature°C (°F)
SA, SB, SC, SK, CF/ CH-4 SAE 5W30 -30°C (-22.0°F) 30°C (86.0°F)
SG, SD, SE, SF, CH-4 SAE 15W40 -5°C (23.0°F) 50°C (121.9°F)
DA, DB, DC, DE, CH-4 SAE 10W40 -15°C (5.0°F) 40°C (103.9°F)
DG, DD, DK, DF,
EC, EE, EF, EK CH-4 SAE 5W40 -30°C (-22.0°F) 40°C (103.9°F)
Table 296.
SL, SH, DH CH-4 SAE 5W40 -30°C (-22.0°F) 40°C (103.9°F)
CJ-4 SAE 5W40 -30°C (-22.0°F) 40°C (103.9°F)
Table 297.
SJ, DJ, FJ, FL CJ-4 SAE 5W40 -30°C (-22.0°F) 40°C (103.9°F)
CJ-4 SAE 5W30 -30°C (-22.0°F) 30°C (86.0°F)
CJ-4 SAE 10W30 -15°C (5.0°F) 40°C (103.9°F)
Table 298. Capacity

Engine Code Minimum Maximum
SA, SB, SC, SK, SG, SD, SE, SF, 11.5L 14L
DA, DB, DC, DE, DG, DD, DK, DF,
SL, SH, DH, SJ, DJ
EC, EE, EF, EK 20L 24L
FJ, FL 12.3L 14.5L
For information on how to identify the correct engine

code. Refer to Operator Station, Identification Label,
Engine (PIL 06-63-06).
75 - 11 9813/7400-1 75 - 11
03 - Oil
21 - Refrigerant
21 - Refrigerant Introduction
Introduction .................................................... 75-12 Refrigerants are the basic ingredient of all air
Health and Safety .......................................... 75-13 conditioning systems and are used to transfer the
heat energy around the system. Refrigerant type
R134a is used in the air conditioning system. It's
full chemical name is: 1, 1, 1, 2 - Tetrafluoroethane
(CH²FCF²).
R134a is a HFC (Hydrofluorocarbon) and is non-

toxic, non-flammable and non-explosive at normal
atmospheric temperature and pressure. It can be
flammable under certain pressure and air mixtures.
Due to environmental concerns, the use of ozone

depleting chlorofluorocarbons (CFCs) in the air
conditioning systems is being gradually phased
out. The R-12 refrigerant used in some systems
contains CFCs. Air conditioning systems using
R-134a refrigerant are not compatible with systems
using R-12 refrigerant. No attempt should be made
to charge R-134a systems with R- 12 refrigerant.
Important: Refer to the safety procedures within the

Air conditioning section before handling refrigerants.
Good installation practice is required to avoid

the release of refrigerant into the atmosphere.
Refrigerant R134a contains no chlorine and has an
Ozone Depleting Potential (ODP) of zero, and a
Global Warming Potential (GWP) of 0.1.
PAG Type Refrigerant Oil

The system requires a PAG type refrigerant oil to
lubricate the compressor. The oil mixes with the
refrigerant and is carried around the system.
It is important that the recommended grade of

refrigerant oil is used. Mineral oil is not suitable for
R134a refrigerant systems. Do not mix oil types.
The compressor is supplied with an oil charge, but

additional oil will be required when the receiver drier
is replaced. The oil is added to the compressor
through the oil filling plug before the evacuation
procedure is started.
Only use fresh, unused oil. Oil that has been exposed
to the air will have absorbed water.
75 - 12 9813/7400-1 75 - 12
03 - Oil
21 - Refrigerant
Health and Safety

CAUTION Polyalkylene Glycol (PAG) type oil is
an irritant. It can cause skin irritation. Breathing
PAG vapour can cause irritation of the eyes,
nose and 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.
75 - 13 9813/7400-1 75 - 13
06 - Grease
06 - Grease
Contents Page No.
75-06-00 General ........................................................................................................................... 75-15
75 - 14 9813/7400-1 75 - 14
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
Attachment 8. JCB Special Slew Pinion Grease
Consumable: Special Slew Pinion Grease
Consumables
Description Part No. Size Greasing Procedure
EP Hammer Grease 4003/2107 0.4kg 1. Make the machine safe. Refer to (PIL 01-03).
4003/2106 12.5kg
Extreme Performance 4003/1327 0.4kg 2. If necessary, install any maintenance or
Moly Grease articulation struts. Refer to (PIL 06-69) (PIL
4003/1326 12.5kg 06-27).
JCB Autogrease 4003/2305 0.5kg
Special HP Grease 4003/2017 0.4kg 3. Make a note of the following:
4003/2006 12.5kg 3.1. The machine must always be greased after
4003/2005 50kg pressure washing or steam cleaning.
Special Hammer 4003/1119 0.4kg 3.2. Greasing must be done with a grease gun.
Grease Normally, two strokes of the gun should be
Special MPL-EP 4003/1501 0.4kg sufficient.
Grease 4003/1506 12.5kg Special Tool: Grease Gun (Qty.: 1)
4003/1510 50kg Special Tool: Grease Gun Attachment (Qty.:
Special Slew Pinion 4003/1619 0.4kg 1)
Grease 3.3. Stop greasing when fresh grease appears
Special Slide Grease 4003/1115 0.4kg at the joint.
There are various greasing points on the machine. 3.4. Use only the recommended type of grease.
You must grease the machine regularly to keep 3.5. Do not mix different types of grease, keep
it working efficiently. Regular greasing will also them separate.
lengthen the machine's working life. You must grease
the machine as stated in the maintenance schedule. 4. Count off the grease points as you grease each
Refer to (PIL 78-24). one.
JCB grease is manufactured to provide significant 5. Install the dust caps after greasing (if installed).
load protection for your machine. It is recommended
to use only JCB grease on your machine because JCB Special HP Grease
they are specifically designed for the particular
application. The list of JCB greases comprises: JCB Special HP grease is a premium quality,
extreme pressure grease. It is recommended
1. JCB Special HP Grease for use in arduous operating conditions, such
Consumable: Special HP Grease as high temperatures, excessive loading and
extensive exposure to water. The sophisticated
2. JCB Special MPL-EP Grease additive package combines with excellent adhesive
properties to give high performance protection to
Consumable: Special MPL-EP Grease your machine.
3. JCB Extreme Performance Moly Grease
Table 299. JCB Special HP Grease Properties
Consumable: Extreme Performance Moly
Description Data
Grease
Colour Blue
4. JCB Special Slide Grease Soap type Lithium complex
Consumable: Special Slide Grease
5. JCB Autogrease
75 - 15 9813/7400-1 75 - 15
06 - Grease
00 - General
Description Data Table 302. JCB Special Slide Grease Properties

Drop point 245°C (472.7°F) Description Data
Working temperature -20–150°C (-4.0– Colour Dark grey
range 301.8°F) Soap type Lithium
Drop point 180°C (355.7°F)
JCB Special MPL-EP Grease Working temperature -20–120°C (-4.0–
range 247.8°F)
JCB Special MPL-EP grease is a true multipurpose
grease. It is recommended for a wide range of
lubricating applications, such as pivot pins and wheel JCB Autogrease
bearings, where excellent anti wear and anti rust
performance is required. Its EP additive makes it JCB Autogrease is for use with the automatic
particularly suitable for the shock load and vibrating greasing system. It is a mineral oil based paste.
conditions found on machines. It contains an aluminium complex soap and solid
lubricants. It is suitable for use under water or in
Table 300. JCB Special high ambient temperatures. The specially designed
MPL-EP Grease Properties cartridges screw into the automatic greasing system
installed on the machine. Refer to (PIL 06-95).
Description Data
Colour Brown The clear cartridge allows the operator to easily
Soap type Lithium monitor the grease usage from inside of the operator
Drop point 180°C (355.7°F) station.
Working temperature -20–130°C (-4.0– Table 303. JCB Autogrease
range 265.8°F)
Description Data
JCB Extreme Performance Moly Grease Colour Black
Soap type Aluminium complex, sol-
JCB Extreme Performance Moly grease is an id lubricants
advanced performance, multipurpose grease. It is Drop point 260°C (499.6°F)
recommended for heavily loaded bearing surfaces Working temperature -20–110°C (-4.0–
and in particular where limited or oscillating range 229.8°F)
motion causes fretting. The addition of molybdenum
disulphide provides extra protection against scoring
and wear. This grease is ideal for automotive, JCB EP Hammer Grease
industrial, agricultural and earthmoving equipment.
JCB EP Hammer grease is a unique formulation
Table 301. JCB Extreme aluminium complex grease for use where extremes
Performance Moly Grease Properties of pressure and temperature are likely to be
encountered. It is suitable for the hammer
Description Data applications where resistance to water washing and
Colour Grey Black migration may be critical.
Soap type Lithium
Drop point 185°C (364.7°F) Table 304. JCB EP Hammer Grease
Working temperature -20–120°C (-4.0– Description Data
range 247.8°F) Colour Black
Soap type Aluminium complex
JCB Special Slide Grease Drop point 250°C (481.6°F)
Working temperature -20–160°C (-4.0–
JCB Special Slide grease is formulated to provide range 319.8°F)
excellent protection under heavy load and extreme
pressure, where water and dirt are prevalent. It
maintains a film of lubrication on slow moving slides. JCB Special Hammer Grease
It has an excellent resistance to squeeze out and
superb corrosion resistance. JCB Special Hammer grease provides a highly
effective lubricant on slow moving slides and an
excellent corrosion resistant property. It combines
the self healing action of oils and the resistance to
drip of viscous compounds.
75 - 16 9813/7400-1 75 - 16
06 - Grease
00 - General
Table 305. JCB Special Hammer Grease

Description Data
Colour Dark grey
Soap type Lithium
Drop point 185°C (364.7°F)
Working temperature -15–120°C (5.0–
range 247.8°F)
JCB Special Slew Pinion Grease

JCB Special Slew Pinion grease is a soft, black and
tenacious grease. It is designed specifically for the
lubrication of large and heavy duty open gears. It has
an excellent corrosion protection and load carrying
properties throughout a large temperature range.
Table 306. 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 - 17 9813/7400-1 75 - 17
09 - Fluids
09 - Fluids
Contents Page No.
75-09-00 General ........................................................................................................................... 75-19

75-09-03 Antifreeze ....................................................................................................................... 75-20
75 - 18 9813/7400-1 75 - 18
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 - 19 9813/7400-1 75 - 19
09 - Fluids
03 - Antifreeze
03 - Antifreeze Introduction
Introduction .................................................... 75-20
Health and Safety .......................................... 75-21
Coolant Mixtures
Technical Data ............................................... 75-21 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 307.
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 - 20 9813/7400-1 75 - 20
09 - Fluids
03 - Antifreeze

when the coolant is hot. When you remove the Table 308.
cap, hot coolant can spray out and burn you. Item Fluid
Make sure that the engine is cool before you work
on the cooling system. Engine coolant Antifreeze HP/Coolant
ASTM D6210
CAUTION Antifreeze can be harmful. Obey the
manufacturer's instructions when handling full
strength or diluted antifreeze.
75 - 21 9813/7400-1 75 - 21
10 - Locking Fluids
10 - Locking Fluids
Contents Page No.
75-10-00 General ........................................................................................................................... 75-23
75 - 22 9813/7400-1 75 - 22
10 - Locking Fluids
00 - General
Introduction .................................................... 75-23 All locking fluids should be used at all times in line
Technical Data ............................................... 75-24 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 - 23 9813/7400-1 75 - 23
10 - Locking Fluids
00 - General
Technical Data
Table 309. 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 fluores- (1,159.4– ameter where disassembly is unlikely and
R.A.S. cent 1,739.1psi) for locking bearings etc. onto shafts and
threadlock breakaway into housing. Has a maximum gap fill of
for studs strength 0.05mm.
(red)
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 cent 2,173.9psi) plated and clean parts.
prevailing
strength
High Loctite 4101/0600 Green, 365d More than Designed for holding gears and sprockets
strength 648 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 1,739.1psi)
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 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 - 24 9813/7400-1 75 - 24
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 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
75 - 25 9813/7400-1 75 - 25
14 - Solvents and Primers
Contents Page No.
75-14-00 General ........................................................................................................................... 75-27
75 - 26 9813/7400-1 75 - 26
00 - General
Introduction .................................................... 75-27 This section contains information on primers,
Technical Data ............................................... 75-28 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 - 27 9813/7400-1 75 - 27
00 - General
Technical Data
Table 310. 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 - 28 9813/7400-1 75 - 28
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 - 29 9813/7400-1 75 - 29
15 - Adhesive
15 - Adhesive
Contents Page No.
75-15-00 General ........................................................................................................................... 75-31
75 - 30 9813/7400-1 75 - 30
15 - Adhesive
00 - General
Introduction .................................................... 75-31 All adhesives should be used at all times in line with
Technical Data ............................................... 75-32 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 - 31 9813/7400-1 75 - 31
15 - Adhesive
00 - General
Technical Data
Table 311. 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 - 32 9813/7400-1 75 - 32
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 - 33 9813/7400-1 75 - 33
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 - 34 9813/7400-1 75 - 34
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 - 35 9813/7400-1 75 - 35
16 - Sealant
16 - Sealant
Contents Page No.
75-16-00 General ........................................................................................................................... 75-37
75 - 36 9813/7400-1 75 - 36
16 - Sealant
00 - General
Introduction .................................................... 75-37 All sealants should be used at all times in line
Technical Data ............................................... 75-38 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 - 37 9813/7400-1 75 - 37
16 - Sealant
00 - General
Technical Data
Table 312. 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 (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 breaking imum width =2mm, minimum depth =2mm.
strength Recommended depth of joint = width of
joint.
Medium Loctite 4102/3500 Green - 172bar Used for locating pins in radiator assem-
to high 620 (2,492.7psi) blies, sleeves into pump housings and
strength shear bearings in auto transmissions. Not suitable
strength for plastics.
Medium Loctite 4102/2000 Red, flu- 365d 90bar Typically used as form-in-place gasket on
strength 518 ores- (1,304.3psi) rigid flanged connections.
cent tensile
strength
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 (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 - 38 9813/7400-1 75 - 38
16 - Sealant
00 - General

name
Low Loctite 4102/1100 White 730d 40–100bar PTFE (Polytetrafluoroethylene) filler low
strength 572 opaque (579.7– strength sealant
1,449.3psi)
breakaway
torque
Gas- Loctite 4102/3200 Blue to 0.2mm 72h full Easy disassembly, used as form-in-place
keting 509 green gap strength on gasket.
medium filling steel
strength
Gas- Loctite 4102/1200 Red 730d 2h working Does not creep or relax after curing, no bolt
keting 574 strength re-tightening is required. Oil resistant. Ideal
medium Per- for formed in-situ gaskets.
strength mabond
A136
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
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 sures up tling.
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- paste 40min ment.
canising
75 - 39 9813/7400-1 75 - 39
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.
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) atmospheric moisture to form a rubber like
solid.
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.
75 - 40 9813/7400-1 75 - 40
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 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 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
75 - 41 9813/7400-1 75 - 41
18 - Fuel
18 - Fuel
Contents Page No.
75-18-00 General ........................................................................................................................... 75-43
75 - 42 9813/7400-1 75 - 42
18 - Fuel
00 - General
00 - General
Health and Safety

Fuel
fuel system. Stop the engine immediately if a fuel
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
injury if you do not follow these precautions.
WARNING! Do not use petrol in this machine. Do not
mix petrol with the diesel fuel. In storage tanks the
petrol will rise to the top and form flammable vapours.
75 - 43 9813/7400-1 75 - 43
Notes:
75 - 44 9813/7400-1 75 - 44
78 - After Sales
Contents Page No.
78-24 Maintenance Schedules

78-24-00 General ............................................................................................................................. 78-3
78-24-03 Maintenance Intervals ...................................................................................................... 78-4
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-5
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-8
78-81 Clothing and Personal Protective Equipment (PPE)
78-81-00 General ........................................................................................................................... 78-11
78-93 Special Tools
78-93-00 General ........................................................................................................................... 78-13
78-93-03 Parts List ........................................................................................................................ 78-14
78-96 Units of Measurement
78-96-00 General ........................................................................................................................... 78-41
9813/7400-1
2016-04-29
Notes:
9813/7400-1
2016-04-29
78 - After Sales
24 - Maintenance Schedules
Contents Page No.
78-24-00 General ............................................................................................................................. 78-3

78-24-03 Maintenance Intervals ...................................................................................................... 78-4
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-5
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-8
78 - 1 9813/7400-1 78 - 1
Notes:
78 - 2 9813/7400-1 78 - 2
78 - After Sales
00 - General
00 - General
Introduction
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 313.
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 - 3 9813/7400-1 78 - 3
78 - After Sales
03 - Maintenance Intervals
03 - Maintenance Intervals
Introduction
Table 314.
Interval (h) Calendar Equivalent
10 Daily
50 Weekly
500 Six months
1000 Yearly
2000 Two years
78 - 4 9813/7400-1 78 - 4
78 - After Sales
06 - Pre-start Cold Checks, Service Points and Fluid Levels
06 - Pre-start Cold Checks, Service

Points and Fluid Levels
Introduction
Table 315.
Component Task 10 50 500 1,000 1,500 2,000
Attachments/Optional Equipment
As required Lubricate
As required Check (condition)
Body and Framework
General Clean
General Check (condition)
Pivot pins Lubricate
Boom wear pads Check
Boom wear pads- Runways Waxoyl
Operator Station
Operator protective structure Check (condition)
Seat, seat belt Check (condition)
Cab heater/air-conditioning fil- Replace
ter
Engine
Oil Check (leaks)
Oil Check (level)
Oil
(1)
Replace
FEAD belt Check (condition)
FEAD belt
(3)
Replace
Air inlet security/air cleaner el- Check (condition)
ements
Exhaust system security Check (condition)
Exhaust spark arrester Clean
Fuel tank water and sediment Clean
Fuel level Check (level)
Air Filter
Air filter (outer)
(2)
Replace
Air filter (inner) Replace
Air filter (dust valve) Change
Crankcase ventilation filter (if Clean
installed)
Fuel System
Fuel system Check (leaks)
Main fuel filter/sedimenter Replace
Main fuel filter/sedimenter Clean
78 - 5 9813/7400-1 78 - 5
78 - After Sales
Component Task 10 50 500 1,000 1,500 2,000

Engine fuel filter Replace
Cooling System
Coolant Check (leaks)
Coolant Check (condition)
Coolant Check (level)
Coolant Replace
Cooling pack Clean
Tracks
Track tension Check (operation)
Wheels and Tyres
Wheel nuts security Check (condition)
Tyre pressures Check (condition)
Hydraulics
Hose and pipework Check (leaks)
Oil Check (level)
Oil Replace
Hydraulic tank breather Replace
Charge filter Replace
Return filter Replace
Rams Check (condition)
Return filter Replace
Charge filter Replace
Transmission
Drive chain case oil Check (level)
Drive chain case oil Replace
Track sprocket security Check (condition)
Electrics
Wiring Check (condition)
Battery Clean
Battery electrolyte level (if ap- Check (level)
plicable)
Battery isolator Check (operation)
Starter motor Check (condition)
Alternator Check (condition)
Window washer fluid level Check (level)
Miscellaneous
Fire extinguisher Check (condition)
Safe working load stickers Check (condition)
(UK) - renew as required
Safety labels - renew as re- Check (condition)
quired
78 - 6 9813/7400-1 78 - 6
78 - After Sales
Component Task 10 50 500 1,000 1,500 2,000

Lifting points Check (condition)
Fit for purpose test
(4)
Complete
(1) If operating under arduous conditions, do an engine oil flush (use the normal recommended engine oil)
every 250 hours and replace the engine oil and filter. Service times may depend on fuel used.
(2) If operating in dusty condition do these tasks more frequently.
(3) Replace every 3000 hours.
(4) All lifting equipment (for example forks, lifting hooks and shackles) need regular inspection and testing by a
competent person to ensure they are fit for purpose. This may be required every six months or at least annually
in some countries to meet and comply with legislation and for insurance purposes. Check with your local JCB
distributor for further advice.
78 - 7 9813/7400-1 78 - 7
78 - After Sales
09 - Functional Tests and Final Inspection
09 - Functional Tests and Final

Inspection
Introduction
Table 316.
Component Task 10 50 500 1,000 1,500 2,000
Body and Framework
Lever and pedal locks Check (operation)
Doors and locks Check (condition)
Control Locks Check (operation)
Engine
(2)
Engine Stop Check (operation)

General Check (condition)
Hydraulics
Services Check (operation)
Park brake Check (operation)
Fuel System
(2)
Fuel system Check (leaks)

Electrics
General Check (operation)
Alternator - output Check (condition)
(1) Dusty conditions only.
(2) More frequent checks of engine components than the engine manufacturer recommends do not invalidate
emissions warranty.
78 - 8 9813/7400-1 78 - 8
78 - After Sales
81 - Clothing and Personal Protective Equipment (PPE)
Contents Page No.
78-81-00 General ........................................................................................................................... 78-11
78 - 9 9813/7400-1 78 - 9
Notes:
78 - 10 9813/7400-1 78 - 10
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 - 11 9813/7400-1 78 - 11
78 - After Sales
93 - Special Tools
93 - Special Tools
Contents Page No.
78-93-00 General ........................................................................................................................... 78-13

78-93-03 Parts List ........................................................................................................................ 78-14
78 - 12 9813/7400-1 78 - 12
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 - 13 9813/7400-1 78 - 13
78 - After Sales
93 - Special Tools
03 - Parts List
03 - Parts List Introduction

Introduction .................................................... 78-14
Tool Category Part No. Description Qty. Comments

Special Tool 993/68100 Slide Hammer Kit 1

Special Tool 892/00913 Grease Gun 1
Attachment

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 892/01160 Lifting Brackets 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 320/09062 Lifting Bracket Front 1
Special Tool 320/09063 Lifting Bracket Rear 1
Special Tool 721/10855 Servicemaster 1
Special Tool 892/00278 Pressure Gauge (0-40 1
Bar)
Special Tool 892/00292 Oil Filter Removal Tool 1
General Tool 892/00298 Digital Multimeter 1
Special Tool 892/01033 Servicemaster 1 Unless otherwise stated, you
892/01174 Electronic Test Kit can use any of the tools shown.
Data Link Adaptor
(DLA) Kit
78 - 14 9813/7400-1 78 - 14
78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool 892/01147 Crankshaft Turning Tool 1
(95.25mm PCD)- JCB
4 Cylinder Ecomax and
Dieselmax
Special Tool 892/01148 Crankshaft / 2
Camshaft Timing Pin
(444/448/672 Engine)
Special Tool 892/01149 Template for Sealant Oil 1
Sump - Pressed
Special Tool 892/01150 Oil Sump Location 2
Dowel
Special Tool 892/01152 Valve Stem Seal 1
Installation Tool
(444/448/762 Engine)
Special Tool 892/01156 Crankshaft Rear Oil 1
Special Tool 892/01157 Crankshaft Front Oil 1
Special Tool 892/01158 Crankshaft Rear Oil 1
Seal Alignment Tool
Special Tool 892/01174 Data Link Adaptor 1
(DLA) Kit
Special Tool 892/01176 Template for Sealant 1
Flywheel Housing to
Gear Case (4 Cyl and 6
Cyl Elec)
Special Tool 892/01380 Valve Clearance 1
Service Kit
Special Tool 892/01382 Engine Lifting Spreader 1
Bar
Flywheel Housing to
Gear Case (4 Cyl Elec )
Recommended Tool 892/12351 Deep Socket 1
Special Tool 892/12354 Template for Sealant Oil 1
Sump (Cast)
Bedplate to Crankcase
(4 Cyl)
General Tool 993/70111 Torque Wrench 1
(10-100Nm)
Special Tool 998/11051 Digital Hydraulic 1
Pressure Test Kit

Recommended Tool 331/27987 Socket 17MM Offset - 1
(HP Fuel pipes)
Special Tool 721/10855 Servicemaster 1
Special Tool 892/01033 Servicemaster 1 Unless otherwise stated, you
892/01174 Electronic Test Kit can use any of the tools shown.
78 - 15 9813/7400-1 78 - 15
78 - After Sales
93 - Special Tools
03 - Parts List

Data Link Adaptor
(DLA) Kit
Special Tool 892/01147 Crankshaft Turning Tool 1
(95.25mm PCD)- JCB
4 Cylinder Ecomax and
Dieselmax
Special Tool 892/01148 Crankshaft / 1
Camshaft Timing Pin
(444/448/672 Engine)
Special Tool 892/01154 Tamperproof Cover 1
Removal Tool
Special Tool 892/01155 Pump Gear Removal 1
Tool
(DLA) Kit
Special Tool 892/01179 C-Shaped Ring 1
Spanner
Special Tool 892/12346 Injector Seal Installation 1
Tool (Electronic Engine)
Special Tool 892/12348 Injector Sleeve 1
Installation/Removal
Tool
Special Tool 892/12350 Injector Leak-off Test 1
Kit (Tier 4)
Special Tool 892/12359 Injector Cap Kit 1
General Tool 993/70111 Torque Wrench 1
(10-100Nm)
27 - Driveline

Special Tool 825/10002 Oil Seal Assembly Tool 1
Special Tool 825/10003 Oil Seal Installation Tool 1
Bar)
Bar)
Attachment
General Tool 992/11300 Grease Gun 1

Special Tool 892/00167 Ram Protection Sleeve 1
(90mm rod diameter)
Special Tool 892/00239 Accumulator Charging 1
Kit (Piston Type)
Special Tool 892/00334 Ram Seal Installation 1
Tool
(25mm rod diameter)
78 - 16 9813/7400-1 78 - 16
78 - After Sales
93 - Special Tools
03 - Parts List

(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 892/01255 Hydraulic Flushing Rig 1

Special Tool 718/20237 Machine Cable 1
General Tool 892/00349 Wiring Crimp Tool 1
General Tool 892/00350 Butane Heater 1
(DLA) Kit

Attachment
General Tool 992/11300 Grease Gun 1
78 - 17 9813/7400-1 78 - 17
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 320/09062 - Lifting Bracket Front
Special Tool - 320/09063 - Lifting Bracket Rear
Recommended Tool - 331/27987 - Socket 17MM Offset - (HP Fuel pipes)

Use to remove and replace high pressure fuel pipes.
Use with 993/70111 torque wrench.
Special Tool - 718/20237 - Machine Cable
78 - 18 9813/7400-1 78 - 18
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 721/10855 - Servicemaster Electronic Test Cable
C D
B E
A
J F
H G
Special Tool - 825/10002 - Oil Seal Assembly Tool
78 - 19 9813/7400-1 78 - 19
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 825/10003 - Oil Seal Installation Tool
Special Tool - 892/00167 - Ram Protection Sleeve (90mm rod diameter)
78 - 20 9813/7400-1 78 - 20
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00239 - Accumulator Charging Kit (Piston Type)

Use with Hydac bladder type accumulators. Kit
comprises the following: 1. Pressure gauge, 2.
Connection hose, 3. Mounting bracket (pressure
gauge), 4. Gas bottle adaptor G2 (Some territories
require a different adaptor), 5. Hydac bladder
accumulator adaptor, 6. Testing and charging unit, 7.
Spare seal (accumulator plug)
Special Tool - 892/00278 - Pressure Gauge (0-40 Bar)
Special Tool - 892/00292 - Oil Filter Removal Tool

Use to install or remove spin-on filter canister.
78 - 21 9813/7400-1 78 - 21
78 - After Sales
93 - Special Tools
03 - Parts List
General Tool - 892/00298 - Digital Multimeter
Special Tool - 892/00334 - Ram Seal Installation Tool
General Tool - 892/00349 - Wiring Crimp Tool
General Tool - 892/00350 - Butane Heater
78 - 22 9813/7400-1 78 - 22
78 - After Sales
93 - Special Tools
03 - Parts List
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.
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)
78 - 23 9813/7400-1 78 - 23
78 - After Sales
93 - Special Tools
03 - Parts List
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)
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 - 892/00913 - Grease Gun Attachment
78 - 24 9813/7400-1 78 - 24
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01020 - Ram Protection Sleeve - Slew (50mm rod diameter)
78 - 25 9813/7400-1 78 - 25
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01022 - Ram Protection Sleeve - Slew (60mm rod diameter)
78 - 26 9813/7400-1 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
Special Tool - 892/01033 - Servicemaster Electronic Test Kit

No longer available to order.
Replaced by special tool 892/01174 (Data Link Adaptor
(DLA) Kit)
78 - 27 9813/7400-1 78 - 27
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01147 - Crankshaft Turning Tool (95.25mm PCD)- JCB 4 Cylinder Ecomax
and Dieselmax
Use to manually turn the crankshaft, for instance when
setting top dead centre (TDC). 4 x mounting holes to
suit crankshaft pulley.
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 - 892/01149 - Template for Sealant Oil Sump - Pressed

Use to ensure correct sealant application, correct
positioning of the sealant is critical to prevent leaks.
Special Tool - 892/01150 - Oil Sump Location Dowel

Use to correctly align the sump, prevent sump
movement during fitting, correct positioning of the sump
is critical to ensure a good joint and prevent leaks.
78 - 28 9813/7400-1 78 - 28
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01152 - Valve Stem Seal Installation Tool (444/448/762 Engine)
Use to ensure positive engagement of the valve stem
seals.
Special Tool - 892/01154 - Tamperproof Cover Removal Tool

Use to gain access to the mechanical fuel injection
pump gear retaining locknut. The tool is used to remove
the tamperproof cover.
Special Tool - 892/01155 - Pump Gear Removal Tool

Use to remove the gear from the fuel injection pump
shaft.
Special Tool - 892/01156 - Crankshaft Rear Oil Seal Installation Tool

Use to correctly install the crankshaft rear oil seal.
Special Tool - 892/01157 - Crankshaft Front Oil Seal Installation Tool

Use to correctly install the crankshaft front oil seal.
78 - 29 9813/7400-1 78 - 29
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01158 - Crankshaft Rear Oil Seal Alignment Tool

Use to position the crankshaft rear oil seal before using
installation tool 892/01156. This tool must be used to
position the seal, otherwise the lip of the seal may
be inverted during the installation process - leading to
potential oil leak.
Special Tool - 892/01160 - Lifting Brackets
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.
78 - 30 9813/7400-1 78 - 30
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01176 - Template for Sealant Flywheel Housing to Gear Case (4 Cyl and 6
Cyl Elec)
Special Tool - 892/01179 - C-Shaped Ring Spanner

Use to access the inner mounting nut of the fuel
injection pump.
Special Tool - 892/01255 - Hydraulic Flushing Rig
78 - 31 9813/7400-1 78 - 31
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01380 - Valve Clearance Service Kit

Use to measure and adjust valve clearances without
removal of the rocker cover.
Special Tool - 892/01382 - Engine Lifting Spreader Bar
Special Tool - 892/12346 - Injector Seal Installation Tool (Electronic Engine)

Use to correctly set and install the rocker cover injector
seals.
78 - 32 9813/7400-1 78 - 32
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/12348 - Injector Sleeve Installation/Removal Tool

Use to install and remove the injector sleeves. The
sleeves are pre-fitted on cylinder head assemblies.
Special Tool - 892/12349 - Template for Sealant Flywheel Housing to Gear Case (4 Cyl Elec )
Special Tool - 892/12350 - Injector Leak-off Test Kit (Tier 4)

Use to confirm a defective injector. You need 2 of these
kits for tier 2, 6 cylinder engines
78 - 33 9813/7400-1 78 - 33
78 - After Sales
93 - Special Tools
03 - Parts List
Recommended Tool - 892/12351 - Deep Socket
Special Tool - 892/12354 - Template for Sealant Oil Sump (Cast)

Special Tool - 892/12356 - Template for Sealant Bedplate to Crankcase (4 Cyl)

78 - 34 9813/7400-1 78 - 34
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/12359 - Injector Cap Kit
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 - 35 9813/7400-1 78 - 35
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 - 36 9813/7400-1 78 - 36
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 993/68100 - Slide Hammer Kit

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 - 37 9813/7400-1 78 - 37
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 998/11051 - Digital Hydraulic Pressure Test Kit

1 998/11052 Hand Held 1
4-Channel
ServiceMaster Unit
2 998/11053 SensoWin Software 1
Kit and PC Cable
3 998/11054 Equipment Case 1
4 998/11055 0-600 Bar Pressure 2
Transducer
5 998/11056 0-100 Bar 2
PressureTransducer
6 998/11057 RPM Tachometer 1
(includes fixed
cable, 2 metres)
7 998/11058 5 Metre Connecting 1
Cable
8 998/11059 M16 Metric 4
Adaptors for Test
Points
9 998/11060 400mm Test Hose 2
90° HSP to M16
10 998/11061 400mm Test Hose 2
Straight HSP to M16
78 - 38 9813/7400-1 78 - 38
78 - After Sales
96 - Units of Measurement
Contents Page No.
78-96-00 General ........................................................................................................................... 78-41
78 - 39 9813/7400-1 78 - 39
Notes:
78 - 40 9813/7400-1 78 - 40
78 - After Sales
00 - General
00 - General Table 322. 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 323. Area
Standard Units Measurement Convert to Multiply by
(unit)
Table 317. 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 324. Torque
Table 318. 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 325. Pressure
Yard (yd) 1.094 Measurement Convert to Multiply by
Kilometre (km) Mile (mile) 0.621 (unit)
Bar Pound force/ 14.5
Table 319. Mass inch² (psi)
Measurement Convert to Multiply by Table 326. 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 320. Speed lon
Measurement Convert to Multiply by Table 327. 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 321. Volume Table 328. 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 329. 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 - 41 9813/7400-1 78 - 41
78 - After Sales
00 - General
Table 330. Current

Measurement (unit)
Ampere (A)
Table 331. Voltage

Measurement (unit)
Volt (V)
Table 332. Noise Levels

Measurement (unit)
Sound pressure level (LpA)
Sound power level (LwA)
78 - 42 9813/7400-1 78 - 42

Service Manual: Foreword

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Service Manual: Foreword

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Foreword

The Operator's Manual

You and others can be killed or seriously injured

SERVICE MANUAL Do not operate the machine without an Operator's

Treat the Operator's Manual as part of the machine.

03 - Attachments, Couplings and Load

12 - Heating, Ventilating and Air-

18 - Fuel and Exhaust System

SERVICE MANUAL SERVICE MANUAL

3TS-8T, 3TS-8W 3TS-8T, 3TS-8W

SERVICE MANUAL SERVICE MANUAL

3TS-8T, 3TS-8W 3TS-8T, 3TS-8W

Acronyms Glossary .................................................................................................................................... 01-2

PIL Parts Identification List

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual and on the machine, there are safety

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system (shown) also helps to identify

Figure 1. The safety alert system

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

15 - Safety Practice An applicable worksite organisation is required in

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

You can complete most of the maintenance

If you raise the lift arm to get access for maintenance,

If the cab is to be lifted to get access for

Release the hydraulic pressure.

A Lift arm lowered B Lift arm raised

Lift Arm Lowered Lift Arm Raised

A Lift arm strut

2. Stop the engine and remove the ignition key. If

Health and Safety

06 - About this Manual

Contents Page No.

01-06-03 Model and Serial Number .............................................................................................. 01-19

03 - Model and Serial Number

06 - Using the Manual

Machine Variants • Use the applicable Servicemaster diagnostics

Contents Page No.

01-09-12 Main Component Locations ........................................................................................... 01-23

12 - Main Component Locations

The illustration shows a typical machine model. Your

A ROPS/FOPS cab B Fuel tank filler point

15 - Service Point Locations

A Coolant expansion bottle B Fuel sedimenter

A Coolant expansion bottle B Fuel sedimenter

The 1,000h and 2,000h checks which are

The label shows a picture of the machine. On the

Figure 10. 250, 260, 300, 3TS-8W, 330