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.
LOADER
419S Contents
01 - Machine
03 - Attachments, Couplings and Load

Handling
EN - 9813/6500
ISSUE 1 - 02/2017 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). 25 - Steering System
27 - Driveline
30 - Hydraulic System
Copyright 7-02-20 © JCB SERVICE
All rights reserved. No part of this publication may 33 - Electrical System
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means, 72 - Fasteners and Fixings
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
75 - Consumable Products
www.jcb.com
78 - After Sales
Notes:
9813/6500-1
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
419S 419S
EN 9813/6500 EN 9813/6500
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
419S 419S
EN 9813/6500 EN 9813/6500
9813/6500-1
Notes:
9813/6500-1
01 - Machine
Contents Page No.
Acronyms Glossary .................................................................................................................................... 01-2
01-03 Safety
01-03-03 Safety - Yours and Others ............................................................................................... 01-3
01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01-06 About this Manual
01-06-03 Model and Serial Number .............................................................................................. 01-19
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 ................................................................................................. 01-24
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-29
9813/6500-1
2017-02-23
Acronyms Glossary
FOPS Falling Object Protective Structure

PIL Parts Identification List
ROPS Roll-Over Protective Structure
9813/6500-1
2017-02-23
01 - Machine
03 - Safety
03 - Safety
Contents Page No.
01-03-03 Safety - Yours and Others ............................................................................................... 01-3

01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01 - 1 9813/6500-1 01 - 1
Notes:
01 - 2 9813/6500-1 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 9813/6500-1 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 9813/6500-1 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 9813/6500-1 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 injury.
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 9813/6500-1 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 9813/6500-1 01 - 7
01 - Machine
03 - Safety
18 - Operating Safety
18 - Operating Safety Worksites

Worksites can be hazardous. Examine the site
Introduction before working on it. You could be killed or injured
if the ground gives way under your machine or if
piled material collapses onto it. Check for potholes
Training and hidden debris, logs, ironwork etc. Any of these
Make sure that you have had adequate training and could cause you to lose control of your machine.
that you are confident in your ability to operate the Check for utilities such as electric cables (overhead
machine safely before you use it. Practice using the and underground), gas and water pipes etc. Mark
machine and its attachments until you are completely the positions of the underground cables and pipes.
familiar with the controls and what they do. With Make sure that you have enough clearance beneath
a careful, well trained and experienced operator, overhead cables and structures.
your machine is a safe and efficient machine. With Communications
an inexperienced or careless operator, it can be
dangerous. Do not put your life, or the lives of others, Bad communications can cause accidents. Keep
at risk by using the machine irresponsibly. Before you people around you informed of what you will be
start to work, tell your colleagues what you will be doing. If you will be working with other people,
doing and where you will be working. On a busy site, make sure any hand signals that may be used are
use a signalman. understood by everybody. Worksites can be noisy, do
not rely on spoken commands.
Before doing any job not covered in this manual, find
out the correct procedure. Your local JCB distributor Parking
will be glad to advise you. An incorrectly parked machine can move without an
Fuel operator. Follow the instructions in the Operator's
Manual to park the machine correctly.
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel Banks and Trenches
leak is suspected. Do not smoke while refuelling or Banked material and trenches can collapse. Do not
working on the fuel system. Do not refuel with the work or drive too close to banks and trenches where
engine running. Completely wipe off any spilt fuel there is danger of collapse.
which could cause a fire. There could be a fire and
injury if you do not follow these precautions. Safety Barriers
Machine Condition Unguarded machines in public places can be
dangerous. In public places, or where your visibility
A defective machine can injure you or others. Do not is reduced, place barriers around the work area to
operate a machine which is defective or has missing keep people away.
parts. Make sure the maintenance procedures in this
manual are completed before using the machine. Sparks
Machine Limits Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
Operating the machine beyond its design limits can machine in closed areas where there is flammable
damage the machine, it can also be dangerous. material, vapour or dust.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with Hazardous Atmospheres
unapproved modifications or additional equipment. This machine is designed for use in normal out
Engine/Steering Failure door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
If the engine or steering fails, stop the machine as Do not use the machine in a potentially explosive
quickly as possible. Do not operate the machine until atmosphere, i.e. combustible vapours, gas or dust,
the fault has been corrected. without first consulting your JCB dealer.
Exhaust Gases Regulations
Machine exhaust gases can harm and possibly kill Obey all laws, worksite and local regulations which
you or bystanders if they are inhaled. Do not operate affect you and your machine.
the machine in closed spaces without making sure
there is good ventilation. If possible, install an
exhaust extractor. If you begin to feel drowsy, stop
the machine at once and get into fresh air.
01 - 8 9813/6500-1 01 - 8
01 - Machine
03 - Safety
18 - Operating Safety
Electrical Power Cables Hands and Feet

You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine.
the machine or its attachments too close to electrical When using the machine, keep your hands and feet
power cables. clear of moving parts. Keep your hands and feet
You are strongly advised to make sure that the safety within the operator compartment while the vehicle is
arrangements on site comply with the local laws in motion.
and regulations concerning work near electric power Controls
lines.
You or others can be killed or seriously injured
Before you start using the machine, check with your if you operate the control levers from outside the
electricity supplier if there are any buried power machine. Operate the control levers only when you
cables on the site. are correctly seated.
There is a minimum clearance required for working Passengers
beneath overhead power cables. You must obtain
details from your local electricity supplier. Passengers in or on the machine can cause
accidents. Do not carry passengers.
Working Platform
Fires
Using the machine as a working platform is
hazardous. You can fall off and be killed or injured. If your machine is equipped with a fire extinguisher,
Never use the machine as a working platform make sure it is checked regularly. Keep it in the
unless with approved man-basket or man-crate (if correct machine location until you need to use it.
applicable). Do not use water to put out a machine fire, you could
Machine Safety spread an oil fire or get a shock from an electrical
fire. Use carbon dioxide, dry chemical or foam
Stop work at once if a fault develops. Abnormal extinguishers. Contact your nearest fire department
sounds and smells can be signs of trouble. Examine as quickly as possible. 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 - 9 9813/6500-1 01 - 9
01 - Machine
03 - Safety
21 - Worksite Safety
21 - Worksite Safety An applicable worksite organisation is required in

order to minimise hazards that are caused by
restricted visibility. The worksite organisation is a
Introduction collection of rules and procedures that coordinates
the machines and people that work together in
WARNING You or others can be killed or seriously the same area. Examples of worksite organisation
injured if you do unfamiliar operations without first include:
practising them. Practise away from the worksite
on a clear area. Keep other people away. Do not • Restricted areas
perform new operations until you are sure you can • Controlled patterns of machine movement
do them safely. • A system of communication.
WARNING There could be dangerous materials
such as asbestos, poisonous chemicals or other You and/or your company could be legally liable for
harmful substances buried on the site. If you any damage you may cause to public utilities. It is
uncover any containers or you see any signs of your responsibility to make sure that you know the
toxic waste, stop the machine and advise the site locations of any public utility cables or pipes on the
manager immediately. worksite which could be damaged by your machine.
WARNING Before you start using the machine,
check with your local gas company if there are
any buried gas pipes on the site.
If there are buried gas pipes we recommend that
you ask the gas company for any specific advice
regarding the way you must work on the site.
Some modern gas pipes cannot be detected by
metal detectors, so it is essential that an accurate
map of buried gas pipes is obtained before any
excavation work commences.
Hand dig trial holes to obtain precise pipe
locations. Any cast iron pipes found must be
assumed to be gas pipes until contrary evidence
is obtained.
Older gas pipes can be damaged by heavy
vehicles driving over the ground above them.
Leaking gas is highly explosive.
If a gas leak is suspected, contact the local gas
company immediately and warn all personnel on
the site. Ban smoking, make sure that all naked
lights are extinguished and switch off any engines
which may be running.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
gas pipes.
CAUTION Before you start using the machine,
check with your local public water supplier if there
are buried pipes and drains on the site. If there
are, obtain a map of their locations and follow the
advice given by the water supplier.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
pipes and drains.
CAUTION If you cut through a fibre optic cable,
Do not look into the end of it, your eyes could be
permanently damaged.
01 - 10 9813/6500-1 01 - 10
01 - Machine
03 - Safety
24 - Risk Assessment
24 - Risk Assessment Loading/Unloading Area

• Is it level? Any slope of more than 2.5% (1 in
Introduction 40) must be carefully considered.
• Is more than one direction of approach to the
load possible? Approaching across the slope
It is the responsibility of the competent people that must be avoided, if possible.
plan the work and operate the machine to make a • Is the ground solid? Will it support the weight of
judgement about the safe use of the machine, they the machine when loaded?
must take into account the specific application and • How rough is the ground? Are there any
conditions of use at the time. sharp projections which could cause damage,
particularly to the tyres?
It is essential that a risk assessment of the work to be • Are there any obstacles or hazards in the area,
done is completed and that the operator obeys any for example, debris, excavations, manhole
safety precautions that the assessment identifies. covers, power lines?
• Is the space sufficient for safe manoeuvring?
If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be
a specific task, contact your JCB dealer who will be in or to enter the area while operations are in
pleased to advise you. progress?
The following considerations are intended as
suggestions of some of the factors to be taken into The Route to be Travelled
account when a risk assessment is made. Other • How solid is the ground, will it provide sufficient
factors may need to be considered. traction and braking? Soft ground will affect the
stability of the machine and this must be taken
A good risk assessment depends on the training and into account.
experience of the operator. Do not put your life or the • How steep are any slopes, up/down/across?
lives of others at risk. A cross slope is particularly hazardous, is it
possible to detour to avoid them?
Personnel
• Are all persons who will take part in the Weather
operation sufficiently trained, experienced and • How windy is it? High wind will adversely affect
competent? Are they fit and sufficiently rested? the stability of a loaded machine, particularly if
A sick or tired operator is a dangerous operator. the load is bulky.
• Is supervision needed? Is the supervisor • Is it raining or is rain likely? The ground that
sufficiently trained and experienced? was solid and smooth when dry will become
• As well as the machine operator, are any uneven and slippery when wet, and it will not
assistants or lookouts needed? give the same conditions for traction, steering
or braking.
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres still at the correct pressure and
in good condition and is there sufficient fuel to
complete the job (if applicable)?
The Load
• How heavy is it? Is it within the capabilities of
the machine?
• How bulky is it? The greater the surface area,
the more affected it will be by wind speeds.
• Is it an awkward shape? How is the weight
distributed? Uneven loads are more difficult to
handle.
• Is there a possibility of the load shifting while
being moved?
01 - 11 9813/6500-1 01 - 11
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-12 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.
Lift Arm Lowered

Figure 2.
1. If necessary, empty the shovel.

2. Make sure that the machine is parked correctly in
the straight-ahead position on solid, level ground.
3. Apply the park brake.
4. Lower the lift arm and put the attachment flat on
the ground.
5. Stop the engine.
6. Remove the ignition key.
7. Put chocks on both sides of all the wheels.
8. Remove the battery isolation key. Refer to (PIL
33-03).
9. Install the articulation lock. Refer to (PIL 06-27).
10. Operate the controls to release the residual
pressure. Refer to (PIL 30-00).
11. If you are working on an area that you cannot
reach when standing on the ground, you must
use a suitable, safe work platform.
01 - 12 9813/6500-1 01 - 12
01 - Machine
03 - Safety
Lift Arm Raised 5. Run the engine at idle for a few minutes to let the
turbocharger cool.
Figure 3.
Duration: 2–3min
6. Stop the engine.
8. Put chocks on both sides of all the wheels.
9. Install the articulation lock. Refer to (PIL 06-27).
10. Remove the maintenance struts from the tool
box.
11. Install the maintenance strut in correct position
around the ram.
12. Make sure that the maintenance strut is seated
correctly on the ram.
If you must raise the lift arm to get access to perform 13. Install the strap around the maintenance strut
a non-routine maintenance procedure, a lift arm and the ram.
support devices must be used.
14. Start the engine.
Lift arm support devices are supplied with a machine
as an option and your machine may not be equipped 15. Slowly lower the lift arm onto the maintenance
with them. Do not attempt to carry out maintenance struts. Stop the movement immediately when the
operations beneath a raised lift arm unless you use maintenance struts support the weight of the lift
the correct lift arm support devices. arm.
Install the Maintenance Struts (If supplied) 16. Be careful when you lower the lift arm onto the
maintenance strut. 'Feather' the control lever to
1. If necessary, empty the shovel. lower the lift arm slowly.
2. Make sure that the machine is parked correctly in 17. Stop the engine.
the straight-ahead position on solid, level ground.
3. Make sure that the park brake is engaged and
the transmission is in neutral. 19. Remove the battery isolation key. Refer to (PIL
33-03).
4. Raise the lift arm sufficiently to install the
maintenance struts.
Figure 4.
A B C D
A Maintenance strut 1 B Strap 1
01 - 13 9813/6500-1 01 - 13
01 - Machine
03 - Safety
C Strap 2 D Maintenance strut 2
01 - 14 9813/6500-1 01 - 14
01 - Machine
03 - Safety
Stow the Maintenance Struts

1. Make sure the park brake is engaged and the
transmission is in neutral.
2. Install the battery isolation key. Refer to (PIL
33-03).
4. Raise the lift arm sufficiently to remove the weight
from the maintenance struts.
5. Stop the engine.
7. Remove the strap from the maintenance strut.
8. Remove the maintenance strut.
10. Lower the lift arm to the ground.
11. Stop the engine.
12. Put the maintenance strut in the tool box.
13. Remove the articulation lock.
14. Remove the chocks.
01 - 15 9813/6500-1 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 9813/6500-1 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 9813/6500-1 01 - 17
Notes:
01 - 18 9813/6500-1 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:
419S 2439651
01 - 19 9813/6500-1 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 9813/6500-1 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 ................................................................................................. 01-24
01 - 21 9813/6500-1 01 - 21
Notes:
01 - 22 9813/6500-1 01 - 22
01 - Machine
09 - Description
12 - Main Component Locations
12 - Main Component Locations
Introduction
Figure 5.
E
A
L
G
K
J H
A Loader arms B Quickhitch

C ROPS (Roll-Over Protective Structure)/FOPS D Engine cover
(Falling Object Protective Structure) Cab
E Hydraulic fluid filler point F Hydraulic fluid tank sight glass
G Battery isolator H Battery cover
J Diesel filler point K Articulation lock
L Transmission filler point
01 - 23 9813/6500-1 01 - 23
01 - Machine
09 - Description
15 - Service Point Locations
Introduction
Figure 6.
C
E B
F
H D
A Engine fuel filter B Fuel filter

C Engine oil dipstick D Engine oil filler cap
01 - 24 9813/6500-1 01 - 24
01 - Machine
09 - Description
E Hydraulic oil filler cap F Air filter

G Washer bottle H Radiator
J Coolant expansion tank
Figure 7. Figure 9.
D
A
A Engine oil drain

Figure 8.
A
A
B B
A Battery isolator
B Battery compartment
A Transmission oil filler point
B Transmission oil level sight glass
C Tank filler point (blue)
D Fuel filler point
Figure 10.
A Hydraulic level gauge
01 - 25 9813/6500-1 01 - 25
01 - Machine
09 - Description
Figure 11.
D
C
A Dipstick B Drain plug - Output

C Drain plug D Drain plug (Optional)
01 - 26 9813/6500-1 01 - 26
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-29
01 - 27 9813/6500-1 01 - 27
Notes:
01 - 28 9813/6500-1 01 - 28
01 - Machine
33 - Cleaning
00 - General
00 - General Introduction
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-29 or other chemicals, you must adhere to
Preparation .................................................... 01-30 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 - 29 9813/6500-1 01 - 29
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 - 30 9813/6500-1 01 - 30
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
03-09-06 Hydraulic Quickhitch ........................................................................................................ 03-8
03-12 Hitch
03-12-12 Mechanical Tow .............................................................................................................. 03-17
03-12-13 Hydraulic Tow ................................................................................................................. 03-21
03-30 Shovel
03-30-00 General ........................................................................................................................... 03-31
03-33 Fork
03-33-15 Grass .............................................................................................................................. 03-35
9813/6500-1
2017-02-08
Acronyms Glossary
HBCV Hose Burst Check Valve
9813/6500-1
2017-02-08
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9813/6500-1 03 - 1
Notes:
03 - 2 9813/6500-1 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 9813/6500-1 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 9813/6500-1 03 - 4
09 - Lift Arm Quickhitch
Contents Page No.
03-09-00 General ............................................................................................................................. 03-7

03-09-06 Hydraulic Quickhitch ........................................................................................................ 03-8
03 - 5 9813/6500-1 03 - 5
Notes:
03 - 6 9813/6500-1 03 - 6
00 - General
00 - General
Introduction
Quickhitches are used on machines to allow the rapid

change of buckets, shovels and other attachments
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 9813/6500-1 03 - 7
06 - Hydraulic Quickhitch
06 - Hydraulic Quickhitch Introduction

WARNING If two people are doing this job make
Introduction ...................................................... 03-8 sure that the person working the controls is a
Disconnect and Connect ................................. 03-9 competent operator. If the wrong control lever is
Lubricate ........................................................ 03-12 moved, or if the controls are moved violently, the
Remove and Install ....................................... 03-13 other person could be killed or injured.
WARNING Do not retract the locking pins when
the lift arm is raised, the shovel could fall and kill
or seriously injure someone. Retract the locking
pins only after the attachment has been placed on
the ground.
Keep other people clear of the area while you engage

the attachment. If a second person is to be involved
in this procedure, make sure that they keep clear of
the machine and attachment until signalled by you to
proceed.
For more information on the servo-control lever and

the auxiliary controls
A Quickhitch isolator valve is installed on all

machines. This valve can be used to hydraulically
operate the locking pins to lock an attachment to the
Quickhitch. The valve is operated by the Quickhitch
isolator switch in the cab.
When the Quickhitch isolator switch is operated

at the same time as the auxiliary buttons/lever,
hydraulic pressure is diverted to the locking pins.
• When the locking pins are fully out, they are

disengaged.
• When the locking pins are partially out, they are
partially engaged.
• When the locking pins are fully in, they are fully
engaged.
The red indicators show the position of the pins, the

main pins are fully engaged when the red indicators
can't bee seen anymore.
03 - 8 9813/6500-1 03 - 8
Figure 12. Disconnect and Connect
Disengage the Attachment

Figure 13.
A
B A Locking pins
A
1. Park the machine on solid, level ground.
A Locking pins
B Indicators 2. Engage the park brake and put the transmission
in neutral.
Lubricate 2.1. If necessary, disconnect the hydraulic
hoses.
Remove the attachments before you grease the
locking pins. Total of 2 grease points. Refer to Figure 3. Push and hold the Quickhitch isolator switch.
12.
4. Disengage the locking pins:Refer to Figure 13.
When working in difficult conditions, grease and
4.1. Proportional lever control with an auxiliary
operate the locking-pins every 10 hours.
button: Push the auxiliary 1 button until the
locking pins are retracted.
4.2. Refer to loader control decal in the cab for
exact location of button as different loader
control levers are available.
03 - 9 9813/6500-1 03 - 9
Figure 14. 6.1. Proportional lever control: Move the lever to

C D the right and tilt the Quickhitch forward and
lower the lift arm.
6.2. Multi lever control option: Move the lever
forward and tilt the Quickhitch forward and
F lower the lift arm.
7. When the pivot shaft has disengaged from the
A B hooks, reverse the machine clear.
Figure 16.
E A B
A Hooks
B Pivot shaft
Engage the Attachment

A Auxiliary button 1 1. Align the machine square with the attachment.
B Auxiliary button 2 (option)
C Horn 2. Lower the lift arm until the pivot shaft is below
D Differential lock the level of the hooks on the attachment. Refer
E Transmission kickdown switch to Figure 17.
F Forward/reverse switch
Figure 17.
4.3. Multi lever control option: Push the lever A B
until the locking pins are retracted.
Figure 15.
A B
C
D
A Hooks
B Pivot shaft
H
3. Drive the machine slowly forward, stop when the
pivot shaft just touches the attachment.
E 4. Engage the park brake and put the transmission
in neutral.
F
G 5. Raise the lift arms and engage the pivot shaft into
A Lift arm (lower/raise) the hooks. Stop the movement as soon as the
B Shovel ram (crowd/dump) pivot shaft is engaged.
C Auxiliary 1
6. Engage the attachment:
D Auxiliary 2 (option)
E Differential lock 6.1. Proportional lever control: Move the lever to
F Horn the left and tilt the Quickhitch fully back.
G Transmission kickdown switch
H Forward/reverse switch 6.2. Refer to loader control decal in the cab for
exact location of button as different loader
5. Release the Quickhitch isolator switch. control levers are available.
6. Disengage the attachment:
03 - 10 9813/6500-1 03 - 10
Figure 18. 8.1. Proportional lever control with an auxiliary

C D button: Push the auxiliary 1 button until the
locking pins are engaged.
8.2. Multi lever control option: Push the lever
until the locking pins are engaged.
F 9. Make sure the locking pins in the base of the
Quickhitch are fully engaged. Refer to Figure 20.
A B
Figure 20.
A
A Red locking pins
10. Release the quickhitch isolator switch.
11. If necessary connect the hydraulic hoses.
A Auxiliary button 1
B Auxiliary button 2 (option)
C Horn
D Differential lock
E Transmission kickdown switch
F Forward/reverse switch
6.3. Multi lever control option: Move the lever to
the rear and tilt the Quickhitch fully back.
Figure 19.
A B
C
D
F
G
A Lift arm (lower/raise)
B Shovel ram (crowd/dump)
C Auxiliary 1
D Auxiliary 2 (option)
E Differential lock
F Horn
G Transmission kickdown switch
H Forward/reverse switch
7. Push and hold the quickhitch isolator switch.
8. Engage the locking pins in the attachment:
03 - 11 9813/6500-1 03 - 11
Lubricate
There are two greasing points for the lubrication of

the quickhitch. Refer to Figure 21.
Figure 21.
03 - 12 9813/6500-1 03 - 12
Remove and Install Figure 23.
Special Tools
Description Part No. Qty.
Slide Hammer Kit 993/68100 1 E
Hydraulic Pressure
D
Before connecting or removing any hydraulic hose, C
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be
started while the hoses are open.
Remove
1. Make the machine safe with the lift arm lowered.
Refer to (PIL 01-03). C Bolts (x4)
2. Install the articulation strut. Refer to (PIL 06-27). D Pivot pins (x4)
E Quickhitch
3. Isolate the battery from the electrical circuit.
Refer to (PIL 33-03). 8. Remove the quickhitch from the lift arms.
4. Use suitable lifting equipment to support the 9. Check the condition of the bushes and seals.
quickhitch. 10. Replace the bushes and seals if they are
5. Disconnect the hydraulic hoses. damaged or worn.
Figure 22. 11. Use a suitable press or puller to remove the bush.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
B steps.
B 2. Use a press to install the new bush and then

replace the seal.
B Hydraulic hoses (x2)

6. Remove the bolts (x4) and washers.
7. Use the slide hammer kit to remove the pivot pin
(x4). Refer to (PIL 06-30).
Special Tool: Slide Hammer Kit (Qty.: 1)
03 - 13 9813/6500-1 03 - 13
Figure 24.
H Shims
3. Install the spacer shims as necessary.
03 - 14 9813/6500-1 03 - 14
12 - Hitch
12 - Hitch
Contents Page No.
03-12-12 Mechanical Tow .............................................................................................................. 03-17

03-12-13 Hydraulic Tow ................................................................................................................. 03-21
03 - 15 9813/6500-1 03 - 15
Notes:
03 - 16 9813/6500-1 03 - 16
12 - Hitch
12 - Mechanical Tow
12 - Mechanical Tow Introduction

Introduction .................................................... 03-17 The tow hitch is attached to the rear of the chassis
Component Identification ............................... 03-18 connecting the trailer to the machine.
Disconnect and Connect ............................... 03-19
Check (Condition) .......................................... 03-19 The tow hitch installed on this machine is a Rockinger
automatic type with a flange. It is prepared for
mechanical remote control.
03 - 17 9813/6500-1 03 - 17
12 - Hitch
12 - Mechanical Tow
Component Identification
Figure 25.
D
E B
A Tow hitch assembly B Rockinger hitch

C Support plate D Trailer socket
E Trailer brake coupling
03 - 18 9813/6500-1 03 - 18
12 - Hitch
12 - Mechanical Tow
Disconnect and Connect Check (Condition)

Consumables
Connect Description Part No. Size
Special HP Grease 4003/2017 0.4kg
1. Bring the drawbar of the trailer near to the hitch.
4003/2006 12.5kg
2. Place the drawbar eye at the centre of the funnel. 4003/2005 50kg
3. Press the lever upwards until it engages. 1. Apply specified grease at regular intervals to
reduce wear on the coupling and the drawbar
4. Make sure that the coupling is in the hitching eye.
condition in accordance with the regulations.
Consumable: Special HP Grease
5. After you do the hitching operation, make sure
that the control pin does not project out of the Figure 27.
control sleeve.
6. If the control pin protrudes, do the following.
Refer to Figure 26.
6.1. Stretch the coupling. A
6.2. Drive the trailer forward to the specified
distance and backwards.
Distance: 1m B
6.3. Check the control pin again. A Lubrication nipple
B Drawbar eye seat
Figure 26.
2. Make sure that the distance between the funnel
and the flange collar with a light load on the lower
edge in the driving position is within the specified
value.
Dimension: 3mm
3. Make sure that the maximum vertical clearance
is within the specified value. Refer to Figure 28.
Dimension: 2.5mm
Figure 28.
6.4. If necessary, do the step 6.2 again.
7. Connect the trailer brakes. Refer to (PIL 24-36).
Disconnect
1. Disconnect the trailer brakes. Refer to (PIL
24-36).
2. Put chocks on the trailer wheels.
3. Open the coupling.
4. Move the machine forwards. 4. Make sure that the maximum play in the lower
bolt guide is within the specified value.
5. Make a note that you must close the coupling
with the lever to protect the lower sleeve against Dimension: 2.5mm
dirt, when you operate the machine without a
trailer. 5. Make sure that the maximum wear of the
coupling pin or the boring is within the specified
6. Do not reach into the funnel. value.
Dimension: 2.5mm
03 - 19 9813/6500-1 03 - 19
12 - Hitch
12 - Mechanical Tow
Table 3. Diameter of the coupling pin

Type Nominal di- Minimum wear
mension limit
850 30.6 ± 0.1 28.6
Figure 29.
03 - 20 9813/6500-1 03 - 20
12 - Hitch
13 - Hydraulic Tow
13 - Hydraulic Tow Introduction

Introduction .................................................... 03-21 The tow hitch is attached to the rear of the chassis
Component Identification ............................... 03-22 connecting the trailer to the machine.
Disconnect and Connect ............................... 03-23
Lubricate ........................................................ 03-24 The hydraulic tow hitch is operated hydraulically from
the operator station through the auxiliary port of the
Disassemble and Assemble .......................... 03-25 lift arm control valve block.
The main components of the hydraulic tow hitch are:
• Cylinder ram.
• Diverter valve.
• HBCV (Hose Burst Check Valve).
• Release cable.
03 - 21 9813/6500-1 03 - 21
12 - Hitch
13 - Hydraulic Tow
Figure 30.
D
E
A Hydraulic tow hitch B Release cable

C Cylinder ram D Diverter valve
E Main pump F Lift arm control valve block
03 - 22 9813/6500-1 03 - 22
12 - Hitch
13 - Hydraulic Tow
Disconnect and Connect
The disconnect and connect procedure for the tow

hitch is given in the Operator's Manual.
03 - 23 9813/6500-1 03 - 23
12 - Hitch
13 - Hydraulic Tow
Lubricate
There are 7 grease points for the lubrication of the The greasing for the hydraulic tow hitch must be done
hydraulic tow hitch. You must grease all four sides of daily. Refer to Maintenance Schedules (PIL 78-24).
the tow hitch leg.
Figure 31.
A Grease nipple points - daily check B Grease all four sides of the tow hitch leg - daily
check
03 - 24 9813/6500-1 03 - 24
12 - Hitch
13 - Hydraulic Tow
Disassemble and Assemble Figure 32.

A E
Special Tools D
Description Part No. Qty. B,C
Slide Hammer Kit 993/68100 1
F
CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
G
Make sure that you obey all of the health and safety
precautions before you start disassembly.
Make sure you record the location of all components

before you start disassembly.
Disassemble
A Bolts 1
1. Make the machine safe. Refer to (PIL 01-03). B Nuts 1
C Washers 1
2. Discharge the hydraulic pressure. Refer to (PIL D Pivot pins 1
30-00). E Shims 1
3. Get access to the tow hitch assembly. F Rams 1
G Hoses
4. Disconnect the hydraulic hoses from the rams 1
(x2). 9. Support the tow hitch assembly.
4.1. Put a label on the hoses to help installation. 10. Remove the bolts 2 (x4), washers 2 (x4) and nuts
2 (x4) that attach the chassis pivot bracket (x2)
4.2. Plug all the open ports and hoses to prevent to the chassis.
contamination.
Figure 33.
5. Remove the bolts 1 (x2), washers 1 (x4) and nuts
1 (x2).
6. Support the tow hitch ram.
7. Use the slide hammer kit to remove the pivot pins
1 (x2). Refer to (PIL 06-30).
L
8. Remove the shims 1 (x8) from the piston end of
the rams.
J, K
H
H Bolts 2
J Nuts 2
K Washers 2
L Chassis pivot bracket
11. Lower the tow hitch assembly, do the step 11.1
and 11.5.
11.1. Disconnect the wire cable from the tow
hitch release cable.
11.2. Disconnect the electrical connection from
the trailer socket.
03 - 25 9813/6500-1 03 - 25
12 - Hitch
13 - Hydraulic Tow
11.3. Disconnect the hydraulic hoses from the Figure 35.

tow hitch ram, trailer brake and quick
release coupling.
11.4. Put a label on the hoses to help
installation.
11.5. Plug all the open ports and hoses to
prevent contamination.
Figure 34.
U
N
P
M R, S
Q
T
N P Tow hitch release cable
Q Bolt 3
R Nut 3
S Washer 3
T Release lever
U Spring
M Wire cable 16. Remove the bolts 4 (x2), washers 4 (x4) and nuts
N Hoses 4 (x2).
12. Remove the tow hitch assembly from the 17. Use the slide hammer kit to remove the pivot pins
machine. 2 (x2). Refer to (PIL 06-30).
13. Put the tow hitch assembly on a clean surface. Special Tool: Slide Hammer Kit (Qty.: 1)
14. Remove the bolt 3, washer 3 and nut 3 that attach 18. Remove the release lever.
the tow hitch release cable to the release lever.
19. Remove the shims 2.
15. If necessary, remove the spring from the tow
hitch release cable. 20. Remove the rams 1 (x2) from the assembly.
03 - 26 9813/6500-1 03 - 26
12 - Hitch
13 - Hydraulic Tow
Figure 36. Figure 37.

F
AB
AH
V Z
AG
AF
AC
AA
X Y AE
W
F Rams 1
V Bolts 4
W Nuts 4 AD
X Washers 4 AB Support point
Y Pivot pins 2 AC Bolt 5
Z Release lever AD Nut 5
AA Shims 2 AE Washers 5
AF Pivot pin 3
21. Support the tow hitch with suitable lifting AG Inner leg
equipment. AH Outer leg
22. Remove the bolt 5, washers 5 (x2) and nut 5. 26. Remove the circlip from the pivot pin 4.
23. Support the inner leg. 27. Support the ram 2.
24. Use the slide hammer kit to remove the pivot pin 28. Use the slide hammer kit to remove the pivot pin
3. Refer to (PIL 06-30). 4. Refer to (PIL 06-30).
Special Tool: Slide Hammer Kit (Qty.: 1) Special Tool: Slide Hammer Kit (Qty.: 1)
25. Remove the inner leg from the outer leg. 29. Remove the ram 2 from the outer leg.
Figure 38.
AK
AJ
AL
AH
AH Outer leg
AJ Circlip
AK Ram 2
AL Pivot pin 4
AM Outer leg
30. If necessary, remove the chassis pivot bracket
from the tow hitch assembly.
03 - 27 9813/6500-1 03 - 27
12 - Hitch
13 - Hydraulic Tow
31. If required, remove the trailer socket.

32. If required, remove the trailer brake coupling.
33. If required, remove the quick release coupling.
Figure 39.
AN
AQ
AP
AN Trailer socket
AP Trailer brake coupling
AQ Quick release coupling
Assemble
1. The assembly procedure is the opposite of
the disassembly procedure. Additionally do the
following steps.
2. Check and clean all the parts thoroughly.
3. Tighten the bolts to the correct torque value.
Table 4. Torque Values

Item Nm
H 205
V 47
03 - 28 9813/6500-1 03 - 28
30 - Shovel
30 - Shovel
Contents Page No.
03-30-00 General ........................................................................................................................... 03-31
03 - 29 9813/6500-1 03 - 29
Notes:
03 - 30 9813/6500-1 03 - 30
30 - Shovel
00 - General
Introduction .................................................... 03-31 A shovel can be installed on many different types of
Health and Safety .......................................... 03-32 earthmoving machines. The shovel can be directly
Component Identification ............................... 03-32 mounted on to a lift arm assembly or mounted to the
Remove and Install ....................................... 03-33 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 - 31 9813/6500-1 03 - 31
30 - Shovel
00 - General
Health and Safety Component Identification

be removed or handled using a suitable lifting Figure 40. Typical Shovel Assembly
method and device.
03 - 32 9813/6500-1 03 - 32
30 - Shovel
00 - General
Remove and Install
Refer to Quickhitch Disconnect and Connect (PIL

03-09).
03 - 33 9813/6500-1 03 - 33
33 - Fork
33 - Fork
Contents Page No.
03-33-15 Grass .............................................................................................................................. 03-35
03 - 34 9813/6500-1 03 - 34
33 - Fork
15 - Grass
15 - Grass Introduction
Introduction .................................................... 03-35 The grass forks can be installed on many different
Technical Data ............................................... 03-36 types of earthmoving machines. The grass fork can
Component Identification ............................... 03-36 be directly mounted on to a lift arm assembly or
Operation ....................................................... 03-37 mounted to the lift arm via a quickhitch assembly.
Remove and Install ....................................... 03-37 You must only use this attachment for the handling of
uncompacted grass, maize or whole crop for storage
in silage clamps. Do not use this attachment as a
lifting device, for movement of palletised loads, as an
access platform or industrial waste handling.
This machine can be installed with the following two

types of grass forks:
High Capacity Grass Forks

The high capacity grass forks are specifically
designed for handling large volumes of grass for
silage work. They are installed with rear spill guard
and forged tines.
Folding Grass Forks

The folding grass forks are specifically designed
for agricultural contractors. These have hydraulically
operated side extensions to allow the width to be
reduced for transportation.
03 - 35 9813/6500-1 03 - 35
33 - Fork
15 - Grass
Technical Data Component Identification
Table 5. Figure 41. High Capacity Grass Fork

Description Data
9ft High Capacity Grass Forks (980/A7716)
Width 2,745mm
Height 1,450mm
Length 1,400mm
Weight 1,015kg
Maximum rated capacity 3.6m³
10ft High Capacity Grass Forks (980/A7717)
Width 3,048mm
Height 1,450mm
Length 1,400mm
Weight 1,125kg
Maximum rated capacity 4m³
12ft Folding Grass Forks (980/A1210)
Width 3,658mm
Height 1,300mm
Length 1,313mm Figure 42. Folding Grass Fork
Weight 1,600kg
Maximum rated capacity 4.5m³ A
A Open position
B Closed position
03 - 36 9813/6500-1 03 - 36
33 - Fork
15 - Grass
Operation Remove and Install
Before you operate this type of attachment, make a Refer to Quickhitch Disconnect and Connect (PIL
note of the following: 03-09).
• Do not roll this product back so far that the load

falls off towards the operator.
• Do not lift any load that is taller than the height
of the fork.
• Avoid the tines and toe plate scraping the
ground with excessive forces as this will
increase wear.
Filling
As the fork enters the pile, start rolling the fork back
while raising it at the same time. This will sweep the
fork up the pile, gathering material as it goes.
When you are loading from a pile of loose material,

start at the bottom and follow up the face. Approach
the pile with the shovel level and skimming the
ground. In tightly packed material, start at the top and
work down.
When removing material from a stockpile, start at the

forks height from the base. Once the height of the
stockpile has been reduced, begin loading from the
base.
Positioning
Approach the load so that the weight will be at the
centre on the floor of the attachment. If the load has
a heavy side, then that side should be closest to the
rear of the forks rather than near the forks edge.
Roll back (crowd) the grapple to the fullest extent

possible.
If the load is placed on fewer than four fork tines this

can result in damage.
03 - 37 9813/6500-1 03 - 37
Notes:
03 - 38 9813/6500-1 03 - 38
06 - Body and Framework
Contents Page No.
06-03 Chassis
06-03-00 General ............................................................................................................................. 06-3
06-06 Moveable Panel and Cover
06-06-00 General ............................................................................................................................. 06-7
06-06-03 Battery .............................................................................................................................. 06-8
06-06-06 Engine Compartment ....................................................................................................... 06-9
06-06-07 Cooling Compartment .................................................................................................... 06-10
06-06-30 Undershield .................................................................................................................... 06-12
06-06-36 Cab Heater ..................................................................................................................... 06-16
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-19
06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-28
06-12-14 Pivot Link Lever (Intermediate) ...................................................................................... 06-31
06-12-15 Pivot Link Lever (Lower) ................................................................................................ 06-33
06-27 Transportation Lock
06-27-00 General ........................................................................................................................... 06-37
06-27-15 Articulated Joint .............................................................................................................. 06-39
06-27-18 Lift Arm ........................................................................................................................... 06-42
06-30 Pivot Pins
06-30-00 General ........................................................................................................................... 06-45
06-33 Articulated Joint
06-33-00 General ........................................................................................................................... 06-49
06-63 Identification Label
06-63-00 General ........................................................................................................................... 06-59
06-63-03 Machine .......................................................................................................................... 06-60
06-63-06 Engine ............................................................................................................................ 06-61
06-63-15 Operator Protective Structure ........................................................................................ 06-62
06-66 Tools
06-66-00 General ........................................................................................................................... 06-65
06-66-03 Toolbox ........................................................................................................................... 06-66
06-69 Maintenance Strut
06-69-00 General ........................................................................................................................... 06-69
06-69-03 Lift Arm ........................................................................................................................... 06-70
06-75 Fire Extinguisher
06-75-00 General ........................................................................................................................... 06-73
06-95 Automatic Greasing System
06-95-00 General ........................................................................................................................... 06-75
9813/6500-1
2017-02-20
Acronyms Glossary

HVAC Heating Ventilation Air Conditioning
LED Light Emitting Diode
PIN Product Identification Number
SPP Service Parts Pro
9813/6500-1
2017-02-20
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-3
06 - 1 9813/6500-1 06 - 1
Notes:
06 - 2 9813/6500-1 06 - 2
03 - Chassis
00 - General
Introduction ...................................................... 06-3 The chassis is the underpart of the vehicle or
Health and Safety ........................................... 06-4 machine, consisting of the frame on which the body
Component Identification ................................. 06-5 or cab is mounted.
06 - 3 9813/6500-1 06 - 3
03 - Chassis
00 - General
Health and Safety

method and device.
06 - 4 9813/6500-1 06 - 4
03 - Chassis
00 - General
Figure 43.
E C B
A Front chassis B Rear chassis

C Articulation strut D Upper centre pivot
E Lower centre pivot
06 - 5 9813/6500-1 06 - 5
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ............................................................................................................................. 06-7

06-06-03 Battery .............................................................................................................................. 06-8
06-06-06 Engine Compartment ....................................................................................................... 06-9
06-06-07 Cooling Compartment .................................................................................................... 06-10
06-06-30 Undershield .................................................................................................................... 06-12
06-06-36 Cab Heater ..................................................................................................................... 06-16
06 - 6 9813/6500-1 06 - 6
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 - 7 9813/6500-1 06 - 7
03 - Battery
03 - Battery
Open and Close

1. Make the machine safe.
2. If necessary, unlock and remove the lock from the
battery compartment latch.
3. Carefully lift the battery compartment cover/steps
off the latch and lower to the required position.
3.1. The cover can be latched halfway down on
the brackets or fully lowered.
4. To close the cover, reverse the procedure.
Figure 44.
A
A Battery compartment latch

B Bracket
C Battery compartment cover/steps
06 - 8 9813/6500-1 06 - 8
06 - Engine Compartment
06 - Engine Compartment
Open and Close
WARNING The engine has exposed rotating 2. Unlock the security lock in the release button to
parts. Switch off the engine before working in the open it.
engine compartment. Do not use the machine
with the engine cover open. 3. Allow the cover to open with the assistance of the
gas struts.
Open Close
Before you stop the engine, you must let the engine 1. Pull down the engine cover until the latch
run at low idle for 4min. The delay lets the coolant engages.
temperatures stabilise before you open the engine
cover. 2. Make sure the cover is securely latched.
1. Make the machine safe with the lift arm lowered. 3. Lock the security lock and remove the key.
Figure 45.
A Engine cover B Release button
06 - 9 9813/6500-1 06 - 9
07 - Cooling Compartment
Remove and Install
Working Under the Machine 3. Remove the screws 1 (x9) from the clamp plate
(x4).
Make sure that any attachments on the machine are 4. Remove the clamp plate (x4).
the ignition key, disconnect the battery. If the machine 5. Remove the rubber mat cooling bay seal.
movement. 6. Remove the screws 2 (x4).
7. Remove the right cooling bay plate.
Remove
8. Remove the screws 3 (x4).
1. Make the machine safe. Refer to (PIL 01-03).
9. Remove the left cooling bay plate.
2. Open the undershield cover. Refer to (PIL 06-06).
10. If necessary, remove the edge seals.
Figure 46.
B
A
H
G
F
H
C
A Right cooling bay plate B Left cooling bay plate

C Rubber mat cooling bay seal D Clamp plate
E Screws 1 (x9) F Screw 2 (x4)
G Screw 3 (x3) H Edge seal
06 - 10 9813/6500-1 06 - 10
Install
steps.
2. Make sure that the edge seals are not damaged.
If necessary, replace them.
3. Tighten the screws to the correct torque value.

Item Description Nm
E Screws 1 (x9) 24
F Screws 2 (x4) 24
G Screws 3 (x4) 9.9
06 - 11 9813/6500-1 06 - 11
30 - Undershield
30 - Undershield Introduction
Introduction .................................................... 06-12 The undershields are designed to protect the
Component Identification ............................... 06-13 underside of the machine from stones, rocks, water
Remove and Install ....................................... 06-14 and mud deposits.
06 - 12 9813/6500-1 06 - 12
30 - Undershield
Figure 47.
F
D
E
B
A Front undershield B Centre undershield

C Rear chassis D Rear left undershield
E Rear right undershield F Lower undershield
06 - 13 9813/6500-1 06 - 13
30 - Undershield
Remove and Install
Working Under the Machine 3. Support the undershield from the underside of
the machine.
Make sure that any attachments on the machine are 4. Remove the bolt 1 (x8) and the washer 1 (x8)
correctly attached. Engage the park brake, remove from the front and centre undershield.
has wheels use blocks to prevent unintentional 5. Remove the front and centre undershield from
movement. the machine.
Remove 6. Remove the bolt 2 (x20), washer 1 (x20) from the

rear undershield.
Refer to (PIL 01-03). 7. Remove the rear undershield from the machine.
2. Install the articulation strut. Refer to (PIL 06-27).
Figure 48.
G
E
D
F
A Front undershield B Centre undershield

C Rear chassis D Rear undershield
E Bolt 1 F Washer 1
G Bolt 2 H Washer 2
06 - 14 9813/6500-1 06 - 14
30 - Undershield
Install
step.
Refer to (PIL 72-06).
06 - 15 9813/6500-1 06 - 15
36 - Cab Heater
36 - Cab Heater
Open and Close
Open 3. Open the HVAC (Heating Ventilation Air

Conditioning) access cover with the ignition key
4. The HVAC access cover is supported on its gas
2. Install the articulation strut. Refer to (PIL 06-27). strut.
Figure 49.
B
A HVAC access cover B Ignition key

C Gas strut
Close
1. Push the area around the ignition key to close the
HVAC access cover.
2. Make sure the HVAC access cover is latched. It
is recommended that the door is kept locked.
06 - 16 9813/6500-1 06 - 16
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-19

06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-28
06-12-14 Pivot Link Lever (Intermediate) ...................................................................................... 06-31
06-12-15 Pivot Link Lever (Lower) ................................................................................................ 06-33
06 - 17 9813/6500-1 06 - 17
Notes:
06 - 18 9813/6500-1 06 - 18
12 - Lift Arm
00 - General
Introduction .................................................... 06-19 The lift arm or loader assembly is a fabricated steel
Health and Safety .......................................... 06-20 construction. It usually has a front mounted shovel
Technical Data ............................................... 06-21 connected to the end of two lift arms.
Check (Condition) .......................................... 06-23
The lift arm assembly is permanently mounted to
Lubricate ........................................................ 06-24 the machine. The shovel can be replaced with other
Remove and Install ....................................... 06-25 devices or tools for example, forks to lift heavy pallets
or shipping containers, and a hydraulically opening
clam shovel allows the lift arm to act as a light dozer
or scraper.
06 - 19 9813/6500-1 06 - 19
12 - Lift Arm
00 - General
Health and Safety

Lifting Equipment
equipment. You must identify the weight of the item to
equipment is in good condition and complies with all
local regulations.
WARNING! Do not work under raised lift arms unless
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 - 20 9813/6500-1 06 - 20
12 - Lift Arm
00 - General
Technical Data
Figure 50.
A
B
D D
C C
A Pivot pin (with keep plate) B Pivot pin (without keep plate)
C Length D Diameter
Figure 51.
G
G
H
J
K
06 - 21 9813/6500-1 06 - 21
12 - Lift Arm
00 - General
Table 7.
Item Pivot Pin (Refer to Fig- Diameter Length
ure 50. )
E (x2) With keep plate 49.92–49.97mm 167mm
F (x6) With keep plate 64.92–64.97mm 200mm
G (x4) With keep plate 64.92–64.97mm 160mm
H (x2) Without keep plate 64.92–64.97mm 139mm
J (x2) Without keep plate 49.9–49.94mm 129mm
K (x4) With keep plate 49.92–49.97mm 141mm
L (x4) With keep plate 49.92–49.97mm 142mm
06 - 22 9813/6500-1 06 - 22
12 - Lift Arm
00 - General
Check (Condition)
1. Make sure that the bushes and the pivot pins
are within the permitted tolerances. Replace the
pivot pin or bushes as necessary.
2. Examine the lift arm structure for wear, damage
or corrosion. Replace as necessary.
3. Examine the pivot levers for wear, damage or
corrosion. Replace as necessary.
06 - 23 9813/6500-1 06 - 23
12 - Lift Arm
00 - General
Lubricate
There are 14 grease points for the lubrication of the

lift arm. Refer to Figure 52.
Figure 52.
5 6
4
3
7
2 8
1
9
10
13 11
14 12
06 - 24 9813/6500-1 06 - 24
12 - Lift Arm
00 - General
Remove and Install
Special Tools 5. Remove the nuts and bolts. Remove both lift ram
Description Part No. Qty. pivot pins. Important: Care must be taken when
Slide Hammer Kit 993/68100 1 removing the lift ram pivot pin, once the pin is
removed the ram will drop. Either hold the ram
Consumables using a sling or have a second person hold the
ram before removing the pin.
Description Part No. Size
Special HP Grease 4003/2017 0.4kg 6. Lower the lift arms to the ground using the slings,
4003/2006 12.5kg it may be necessary to retract the lift rams to
4003/2005 50kg enable the lift arms to rest fully on the ground.
Make sure that the lift rams do not foul when
Make a note that the illustration shows a typical retracted.
machine assembly. The actual machine may look 7. Vent the hydraulic pressure, refer to (PIL 30-00).
different.
8. Disconnect the shovel ram hoses and auxiliary
Observe all Health and Safety information, refer to hoses (if installed) at both sides of the machine.
(PIL 06-12).
9. Disconnect the electrical connection to the loader
Remove shovel reset switch (if installed). Disconnect
the electrical connection to the quickhitch (if
1. Remove any lift arm attachments (e.g. shovel or installed).
quickhitch).
10. Remove pivot pin retaining bolts (x4).
2. Park the machine and make it safe. Refer to (PIL
01-03). 11. Sling the lift arms as shown. Make sure that the
sling is wrapped around the lift arms only and not
3. Raise the lift arms to give access to the lift ram the pivot levers.
pivot pins.
4. Sling the lift arms. Make sure that the slings are
taut and therefore holding the weight of the lift
arms.
06 - 25 9813/6500-1 06 - 25
12 - Lift Arm
00 - General
Figure 53.
12. Remove the klipring and shim. 17. Use a slide hammer to remove the pivot pin.
13. Secure the pivot lever linkage, otherwise the 18. Repeat steps 16 and 17 for the opposite lift arm
pivot lever linkage could pivot about its centre pivot pin.
and cause injury and/or damage.
19. When all the pivot pins have been removed,
14. Use a slide hammer to remove the pivot pin, refer carefully reverse the machine clear of the lift
to (PIL 06-30). arms.
Install
15. Repeat steps 12 to 14 for the opposite lever link
pivot pin. 1. Replacement is the opposite of the removal
procedure. During the replacement procedure do
16. Remove the nut, bolt and retaining ring. the following work:
06 - 26 9813/6500-1 06 - 26
12 - Lift Arm
00 - General
2. Install pivot pins with the extraction hole on the

outside of the machine.
3. Check the operation of the shovel reset switch (if
installed)
4. Apply grease to all mainframe bores.
5. Apply rust inhibiting oil to all pivot pins.
06 - 27 9813/6500-1 06 - 27
12 - Lift Arm
12 - Pivot Link Lever (Upper)
Remove and Install
Special Tools Special Tool: Slide Hammer Kit (Qty.: 1)

6. Support the crowd ram, then remove the bolt 2
Slide Hammer Kit 993/68100 1 and washer 2 from the upper pivot pin.
Remove 7. Remove the upper pivot pin.
1. Make the machine safe with the lift arm lowered. 8. Support the crowd ram lever, then remove the
Refer to (PIL 01-03). bolt 3 and washer 3 from the pivot pin1.
2. Install the articulation strut. Refer to (PIL 06-27). 9. Remove the pivot-pin 1.
3. Use suitable lifting equipment to lift and support 10. Remove the crowd ram lever from the machine.
the lift arm.
11. Check the condition of the bushes and seals.
4. Remove the bolt 1 and washer 1 from the lower
pivot pin. 12. Replace the bushes and seals, if damaged or
worn.
5. Support the chassis link, then remove the lower
pivot pin. Refer to Pivot Pin Removal (PIL 06-30). 13. Use a press to remove the bush and seal.
06 - 28 9813/6500-1 06 - 28
12 - Lift Arm
Figure 54.
K
H
B
P
D
F N
E
C
B Lift arm assembly C Bolt 1

D Washer 1 E Lower pivot pin
F Chassis link G Crowd ram lever
H Bolt 2 J Washer 2
K Upper pivot pin L Bolt 3
M Washer 3 N Pivot pin 1
P Bushes and seals (x3)
06 - 29 9813/6500-1 06 - 29
12 - Lift Arm
Install
The installation procedure is the opposite of the
removal procedure.
1. Use a press to install the new bush and seal.

06 - 30 9813/6500-1 06 - 30
12 - Lift Arm
14 - Pivot Link Lever (Intermediate)
Remove and Install
Remove 6. Remove the bolt 2, washer 2 from the pivot pin 2.
1. Make the machine safe with the lift arm lowered. 7. Remove the pivot pin 2.
Refer to: Safety (Page 01-1). Refer to: General (Page 06-45).
2. Install the articulation strut. 8. Remove the intermediate plate from the
machine.
Refer to: Articulated Joint (Page 06-39).
3. Support the intermediate plate.
10. Replace the bushes and seals, if damaged or
4. Remove the bolt 1 and washer 1 from the pivot worn.
pin1.
11. Use a press to remove the bush and seal.
5. Remove the pivot pin 1.
Refer to: General (Page 06-45).
Figure 55.
J H
D C B
A
G F
J H E
A Intermediate plate B Bolt 1

C Washer 1 D Pivot pin 1
E Bolt 2 F Washer 2
G Pivot pin 2 H Bush (x2)
J Seal (x2)
06 - 31 9813/6500-1 06 - 31
12 - Lift Arm
Install
removal procedure.

06 - 32 9813/6500-1 06 - 32
12 - Lift Arm
15 - Pivot Link Lever (Lower)
Remove and Install
Special Tools Special Tool: Slide Hammer Kit (Qty.: 1)

5. Support the link.
6. Remove the bolt 2, washer and pivot pin 2 from
Remove the shovel.
1. Make the machine safe with the lift arm lowered. 7. Remove the link from the machine.
Refer to: Safety (Page 01-1).
9. Replace the bushes and seals, if damaged or
2. Install the articulation strut. Refer to (PIL 06-27). worn.
3. Support the crowd ram. 10. Use a press or puller to remove the bush and
seal.
4. Remove the bolt 1, nut and the pivot pin 1 from
the ram end. Refer to Pivot Pin Removal (PIL
06-30).
06 - 33 9813/6500-1 06 - 33
12 - Lift Arm
Figure 56.
F E
J
G H
B Crowd ram C Bolt 1

D Nut E Pivot pin 1
F Link G Bolt 2
H Washer J Pivot pin 2
K Seal
06 - 34 9813/6500-1 06 - 34
12 - Lift Arm
Install
removal procedure.

06 - 35 9813/6500-1 06 - 35
27 - Transportation Lock
Contents Page No.
06-27-00 General ........................................................................................................................... 06-37

06-27-15 Articulated Joint .............................................................................................................. 06-39
06-27-18 Lift Arm ........................................................................................................................... 06-42
06 - 36 9813/6500-1 06 - 36
00 - General
Introduction .................................................... 06-37 Make sure that all machine locks are in the transport
Health and Safety .......................................... 06-38 position before you transport the machine.
06 - 37 9813/6500-1 06 - 37
00 - General
Health and Safety

WARNING Make sure the articulation lock is in
the transport position before you transport the
machine. The articulation lock must also be in
the transport position if you are carrying out daily
checks or doing any maintenance work in the
articulation danger zone. If the articulation lock is
not in the transport position you could be crushed
between the two parts of the chassis.
06 - 38 9813/6500-1 06 - 38
15 - Articulated Joint
15 - Articulated Joint Introduction

Introduction .................................................... 06-39
Remove and Install ....................................... 06-40
Transport Position
The articulation lock is attached to the side of the

machine. The articulation lock is installed with the
machine in the 'straight ahead' position.
1. Steer the machine to put the front and rear

wheels in a straight line.
2. Engage the park brake, put the transmission in
neutral and stop the engine and remove the
starter key.
3. Remove the pins to release the articulation lock
from its drive (stowage) position.
4. Place the articulation lock into the transport
position, as shown.
5. Use the pins removed in step 3 to secure the
articulation lock in the transport position, as
shown. If the pins do not fit, turn the steering
wheel to align the holes in the chassis with the
holes in the articulation lock. When the pins are
installed, make sure that the pins are correctly
secured with the correct locking devices to
prevent the articulation lock becoming insecure.
Figure 57.
A B
A Pin (with the articulation lock in the transport

position)
B Pin (with the articulation lock in the transport
position)
C Articulation lock (installed in transport position)
06 - 39 9813/6500-1 06 - 39
If the articulation lock is damaged, contact your JCB Remove and Install
dealer.
WARNING Always make sure the articulation lock
Drive (Stowage) Position has been removed before attempting to drive the
machine. The machine cannot be steered with the
WARNING Always make sure the articulation lock articulation lock installed.
has been removed before attempting to drive the
machine. The machine cannot be steered with the
articulation lock installed. The articulation lock is stowed near the battery box
on the left side of the machine. The articulation lock
must be installed with the machine in the straight
1. Make sure the park brake is engaged, the ahead position.
transmission is in neutral with the engine
stopped. Remove the starter key.
Install
2. Remove the pins securing the articulation lock in
the transport position. 1. Make the machine safe. Refer to (PIL 01-03).
3. Remove the articulation lock. 2. Apply the park brake.
4. Keep the articulation lock at its correct position in 3. Remove the articulation lock from its stowage
the engine compartment. position. Refer to Figure 59.
5. Make sure that the pins are correctly secured Figure 59. Stowage position
with the correct locking devices to the articulation
lock.
Figure 58.
A
B
A B
A Articulation lock
B Pivot pin
B 4. Put the articulation lock in position. Refer to
A Articulation lock Figure 60.
B Pin 5. Install the pivot pin 1.
6. Install the pivot pin 2 into the articulation lock.
7. If the pivot pin 2 does not align with the
installation holes, do as follows:
7.1. Release the park brake.
7.2. Turn the steering wheel slightly to align the
holes for pivot pin 2.
7.3. Install the pivot pin 2 into the articulation
lock.
06 - 40 9813/6500-1 06 - 40
Figure 60. Installation position
A C B
A Pivot pin 1
B Pivot pin 2
C Articulation lock
Remove
1. Remove the pivot pins.
2. Put the articulation lock in the stowage position.
3. Install the pivot pins. Refer to Figure 59.
06 - 41 9813/6500-1 06 - 41
18 - Lift Arm
18 - Lift Arm
Introduction
Lift Arm Control Isolator Switch

To prevent the hydraulic lift arm controls from being
operated accidentally when the driver is entering
or leaving the cab, an isolation switch has been
installed.
• Lift arm controls, unlocked or active: Switch ON

(illuminated).
• Lift arm controls locked: Switch OFF.
The lift arm controls must always be locked before

the driver leaves the cab.
The lift arm controls must only be unlocked when the

driver is correctly seated and there is no danger of
accidentally knocking against the loader arm control
levers.
Figure 61.
06 - 42 9813/6500-1 06 - 42
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ........................................................................................................................... 06-45
06 - 43 9813/6500-1 06 - 43
Notes:
06 - 44 9813/6500-1 06 - 44
30 - Pivot Pins
00 - General
Introduction .................................................... 06-45 Pivot pins are a short shaft or pin that supports
Remove and Install ....................................... 06-46 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 - 45 9813/6500-1 06 - 45
30 - Pivot Pins
00 - General
Remove and Install Figure 62. Typical Machine
Special Tools
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 - 46 9813/6500-1 06 - 46
Contents Page No.
06-33-00 General ........................................................................................................................... 06-49
06 - 47 9813/6500-1 06 - 47
Notes:
06 - 48 9813/6500-1 06 - 48
00 - General
Introduction .................................................... 06-49 The articulated joint is a device which has a
Technical Data ............................................... 06-50 permanent or semi-permanent pivoting joint in its
Component Identification ............................... 06-51 construction, by which two or more sections of a
Lubricate ........................................................ 06-53 vehicle are linked together so as to allow greater
capacity, flexibility of movement etc.
06 - 49 9813/6500-1 06 - 49
00 - General
Technical Data d+t+0.05mm Shims to be used

1.88–1.92mm Shim 1 + Shim 5
Table 8. 1.93–1.97mm Shim 1 + Shim 2 + Shim
6
Description Data
1.98–2.02mm Shim 1 (x2)
Lower pivot pin
2.03–2.07mm Shim 1 + Shim 3 + Shim
Outside diameter 64.9–64.94mm 5
Length 138mm 2.08–2.12mm Shim 4 (x2) + Shim 5
Upper pivot pin 2.13–2.17mm Shim 1 (x2) + Shim 3
Outside diameter 69.87–69.89mm 2.18–2.22mm Shim 4 + Shim 5 + Shim
Inside diameter 36–40mm 6
Length 248.5–249mm 2.23–2.27mm Shim 1 (x2)+ Shim 2
2.28–2.32mm Shim 6 (x2)+ Shim 5
Select the shims from the table corresponding to
the sum of the dimension to put below the bearing
locator.
Table 9. Shim Thickness

Description Part number Thickness
Shim 1 819/00106 1mm
Shim 2 819/00107 0.25mm
Shim 3 819/00108 0.15mm
Shim 4 819/00109 0.6mm
Shim 5 819/00110 0.9mm
Shim 6 819/00111 0.7mm
Table 10. Shim requirement

d+t+0.05mm Shims to be used
0.83–0.87mm Shim 4 + Shim 2
0.88–0.92mm Shim 5
0.93–0.97mm Shim 6 + Shim 2
0.98–1.02mm Shim 1
1.03–1.07mm Shim 5 + Shim 3
1.08–1.12mm Shim 4 + Shim 2 (x2)
1.13–1.17mm Shim 1 + Shim 3
1.18–1.22mm Shim 4 (x2)
1.23–1.27mm Shim 1 + Shim 2
1.28–1.32mm Shim 4 + Shim 6
1.33–1.37mm Shim 4 (x2) + Shim 3
1.38–1.42mm Shim 6 (x2)
3
1.48–1.52mm Shim 4 + Shim 5
1.53–1.57mm Shim 6 (x2) + Shim 3
1.58–1.62mm Shim 1 + Shim 4
3
1.68–1.72mm Shim 1 + Shim 6
3
1.78–1.82mm Shim 5 (x2)
6
06 - 50 9813/6500-1 06 - 50
00 - General
Figure 63. Upper Articulated Joint
G B
K
C
D
G
H E
C
F
D
C E
H
B J
A Pivot pin B Capscrew

C Washers D End plate
E Grease point F Shims
G Seals H Bearing
J Bolt K Nut
L Split pin
06 - 51 9813/6500-1 06 - 51
00 - General
Figure 64. Lower Articulated Joint
C
D E
G
J
H
A G
F
F
A Pivot pin B Capscrew

C Washers D End plate
E Grease point F Shims
G Seals H Bearing
J Keep plate
06 - 52 9813/6500-1 06 - 52
00 - General
Lubricate
There are 7 grease points for the lubrication of the • Four grease points (4 to 7) for the lubrication of
articulation joint as follows: steer ram. Refer to Figure 65.
• Three grease points (1 to 3) for the lubrication

of centre pivot pins. Refer to Figure 65.
Figure 65.
6,7
4,5
06 - 53 9813/6500-1 06 - 53
00 - General
Remove and Install
Special Tools 11. Support the front and rear chassis with suitable
Description Part No. Qty. blocks.
Slide Hammer Kit 993/68100 1 12. Place a trolley jack under the lower pivot flange
of the front chassis.
Consumables
Description Part No. Size 13. Use the slide hammer kit to remove the lower
Special HP Grease 4003/2017 0.4kg pivot pin. Refer to (PIL 06-30).
4003/2006 12.5kg Special Tool: Slide Hammer Kit (Qty.: 1)
4003/2005 50kg
13.1. Remove the screw, the washer 1 and the
spacer.
Remove
13.2. Take out the lower pivot pin. Carefully keep
1. Make the machine safe with the lift arm lowered. the shims 1 and bearing 1.
13.3. Remove and discard the seals.
2. Securely block all the road wheels on both sides.
14. Remove the upper pivot as follows.
3. Remove the cab. Refer to (PIL 09-00).
14.1. Remove the split pin and the castellated
4. Remove the pin from each steering ram rod end nut. Remove the bolt 1 with washers 2.
at the front chassis. 14.2. Remove the bolt 2 and the washer 3 and
remove the upper end cap.
5. Move the steering rams away from the front
chassis. 14.3. Remove the bolt 3 and the washer 3 and
remove the lower end cap.
6. Disconnect the drive shaft from the brake disc
flange. 14.4. Remove the upper pivot pin. Keep the
shim 2 to shim 7 and the washers 4.
7. Mark all four flanges to make sure of the correct 14.5. Remove and discard the bearing 2.
assembly.
14.6. Remove and discard the lip seals.
8. Disconnect the hydraulic pipe clamp and release
the hydraulic pipework. 15. Remove the blocks from under the front wheels.
9. Make sure that sufficient slack is provided for the 16. Release the parking brake.
hydraulic pipe when the front and rear chassis
are separated. 17. Manually separate the front and rear chassis just
sufficient for the work to be carried out at the
10. Make sure that there is no strain on the hydraulic centre pivot.
pipe while working without disconnecting the
pipes.
06 - 54 9813/6500-1 06 - 54
00 - General
Figure 66.
K J
M
N
Q P
S
T
U
V
W
X
Y
AA Z
H
C
D
AA
A
Z
E Y
G R
P
F M
G
AB
E
L
A Lower pivot pin B Screw

C Washer 1 D Spacer
E Shim 1 F Bearing 1
G Seals H Upper pivot pin
J Split pin K Castellated nut
L Bolt 1 M Washers 2
N Bolt 2 P Washers 3
Q Upper end cap R Bottom end cap
S Shim 2 T Shim 3
U Shim 4 V Shim 5
W Shim 6 X Shim 7
Y Washers 4 Z Bearings 2
AA Lip seals AB Bolt 3
06 - 55 9813/6500-1 06 - 55
00 - General
Install 3. Attach the bottom bearing 2 cup to the housing

and install the bolts 3 and washers 3.
1. Install a new bearing 2 during assembly. Use a
dummy boss and a bearing locator when setting 4. Tighten the bolt 3 to the correct torque value.
up the shim 2 to shim 7 to get the correct
clearance. Do the following also: 5. Make sure that the bearing is completely filled
with grease.
2. Apply grease on the face of the bottom end cap.
6. Put the dummy boss on the bottom bearing 2.
Figure 67.
AC
AD
AE
AC Gap between top of the bearing locator and AD Bearing locator

the face
AE Dummy boss
7. Put the top bearing 2 on top of the dummy boss. 12.1. For details of the shims to be used, refer
Refer to Figure 67. to SPP (Service Parts Pro).
8. Hold the top bearing and rotate the dummy boss 13. If the dimension is not stamped on the front
three or four times to seat the rollers. module, read the dimension as zero.
9. Put the bearing locator into the top bearing 2. 14. The bearing locator will project above the face
Refer to Figure 67. by an amount equivalent to the front module
dimension with ± 0.025 mm tolerance.
10. Measure the gap between the top of the bearing
locator and the face. Refer to Figure 67. 15. Remove the bearing locator, the shim pack, the
top bearing and the dummy boss.
11. Add the measured gap dimension with the front
module dimension which is stamped on it. The 16. Install the new lip seals over the large diameter
sum of these two dimensions is equal to the portion of the rear module pivot boss, or
shims thickness which is necessary to give the alternatively rolled inside out to protect the seal
correct clearance. lips when the chassis is attached.
12. Select the shims from the table corresponding 17. Put the top bearing cone on the lower pivot pin
to the sum of the dimension and put below the to the specified dimension.
bearing locator. Refer to Technical Data (PIL Dimension: 178mm
06-33).
06 - 56 9813/6500-1 06 - 56
00 - General
Figure 68.
AF
AF 178mm
18. Apply locking fluid to the bottom portion of the 32. Install the bolt 1, the washer 2 and the castellated
rear module pivot bore. nut.
19. Remove the bottom end cap, install the washer 33. Tighten the castellated nut to the correct torque
4 and replace the bottom end cap. value.
20. Install the washer 3 and the bolt 3. 34. Install a new split pin.
21. Tighten the bolt 3 to the correct torque value. 35. If necessary, tighten the castellated nut until the
next castellation lines up with the split pin drilling
22. Carefully attach the front and rear chassis. in the bolt.
23. Install the lower pivot pin, the shims 1, the 36. Install the new lip seals.
bearing 1 and new seals.
37. Apply grease through each of the grease nipples
24. Install the spacer, the washer 1 and the screw. until it comes out through the lip seals.
25. Tighten the screw to the correct torque value. Consumable: Special HP Grease
26. Apply locking fluid to the top portion of the upper 38. The remaining steps are the opposite of the
pivot pin and assembly through the housing and removal procedure.
boss.
27. Make sure that the bearing is completely filled
Item Description Nm
with grease.
B Screw 244
K Castellated nut 68
28. Install the shim pack and the washers 4. N Bolt 2 98
AB Bolt 3 98
29. Apply grease on the face of the top end cap.
30. Install the washer 3 and the bolt 2.
31. Tighten the bolt 2 to the correct torque value.
06 - 57 9813/6500-1 06 - 57
63 - Identification Label
Contents Page No.
06-63-00 General ........................................................................................................................... 06-59

06-63-03 Machine .......................................................................................................................... 06-60
06-63-06 Engine ............................................................................................................................ 06-61
06-63-15 Operator Protective Structure ........................................................................................ 06-62
06 - 58 9813/6500-1 06 - 58
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 - 59 9813/6500-1 06 - 59
03 - Machine
03 - Machine
Introduction
Your machine has an identification plate. The new one, the serial number on the identification plate
PIN (Product Identification Number), weight, engine will be wrong. Either get a replacement identification
power, year of manufacture and serial number of the plate from your JCB dealer or simply remove the
machine are shown on the identification plate. old number. This will prevent the wrong unit number
being quoted when replacement parts are ordered.
The serial number of each major unit is also shown
on the unit itself. If a major unit is replaced by a
Figure 69.
A
A Identification plate (location)
The machine model and build specification are

indicated by the PIN. The PIN has 17 digits and must
be read from left to right.
Table 12. Typical PIN

JCB 411 O S D 01323456
Table 13. Explanation of the PIN

Digit Description
1 to 3 World manufacturer identification. For ex-
ample, JCB = UK Build.
4 to 6 Machine type and model
7 O = HT loader end
8 Designation: O = Non-Farmmaster, S = Far-
mmaster, I = India
9 Random check letter. The check let-
ter is used to verify the authenticity of a
machine's PIN.
10 to Machine serial number
17
06 - 60 9813/6500-1 06 - 60
06 - Engine
06 - Engine
Introduction
The engine data label is attached to the rocker cover The data label includes the engine identification
as shown. number.
Figure 70.
A
A Engine data label - rocker cover
06 - 61 9813/6500-1 06 - 61
15 - Operator Protective Structure
15 - Operator Protective Structure • Level II Impact Protection - impact strength for

protection from heavy falling objects (e.g. trees,
rocks) for machines involved in site clearing,
Introduction overhead demolition or forestry.
ROPS and FOPS Data Plate

WARNING You could be killed or seriously injured
if you operate a machine with a damaged or
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/
FOGS has been in an accident, do not use the
machine until the structure has been renewed.
Modifications and repairs that are not approved
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS/FOGS certification.
WARNING Do not use the machine if the falling
objects protection level provided by the structure
is not sufficient for the application. Falling objects
can cause serious injury.
WARNING Machines with a ROPS, FOPS,FOGS
or TOPS are equipped with a seat belt. The
ROPS, FOPS,FOGS or TOPS is designed to give
you protection in an accident. If you do not wear
the seat belt you could be thrown off the machine
and crushed. You must wear a seat belt when
using the machine. Fasten the seat belt before
starting the engine.
A machine built to the ROPS (Roll-

Over Protective Structure)/FOPS (Falling Object
Protective Structure) standard has a data plate
attached to the inside of the cab.
Figure 71.
If the machine is used in any application where there

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

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

for protection from small falling objects
(e.g. bricks, small concrete blocks, hand
tools) encountered in operations such as
highway maintenance, landscaping and other
construction site services.
06 - 62 9813/6500-1 06 - 62
66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ........................................................................................................................... 06-65

06-66-03 Toolbox ........................................................................................................................... 06-66
06 - 63 9813/6500-1 06 - 63
Notes:
06 - 64 9813/6500-1 06 - 64
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 - 65 9813/6500-1 06 - 65
66 - Tools
03 - Toolbox
03 - Toolbox
Introduction
The toolbox is located behind the step frame to the

right side of the machine. Keep the tools in the
toolbox unless you need to use them.
It is recommended to lock the toolbox to avoid theft

or tampering of the tools.
Figure 72.
C
A
A Toolbox
B Cover
C Latch
06 - 66 9813/6500-1 06 - 66
69 - Maintenance Strut
Contents Page No.
06-69-00 General ........................................................................................................................... 06-69

06-69-03 Lift Arm ........................................................................................................................... 06-70
06 - 67 9813/6500-1 06 - 67
Notes:
06 - 68 9813/6500-1 06 - 68
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 - 69 9813/6500-1 06 - 69
03 - Lift Arm
03 - Lift Arm
Remove and Install
Refer to Maintenance Positions (PIL 01-03-27).
06 - 70 9813/6500-1 06 - 70
75 - Fire Extinguisher
Contents Page No.
06-75-00 General ........................................................................................................................... 06-73
06 - 71 9813/6500-1 06 - 71
Notes:
06 - 72 9813/6500-1 06 - 72
00 - General
00 - General
Check (Condition)
In addition to the operator check the extinguisher

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

leaks.
2. Make sure the fire extinguisher is correctly
attached.
3. Make sure that the gauge indicates that the
extinguisher is charged i.e. the needle is in the
green segment
3.1. If the needle is in or very near the red
segment at either end of the gauge, the
extinguisher must be serviced or replaced.
4. Make sure the safety pin is correctly installed.
Figure 73.
A Gauge
B Safety Pin
06 - 73 9813/6500-1 06 - 73
95 - Automatic Greasing System
Contents Page No.
06-95-00 General ........................................................................................................................... 06-75
06 - 74 9813/6500-1 06 - 74
00 - General
Introduction .................................................... 06-75 The automatic greasing system does the greasing of
Component Identification ............................... 06-76 the following points:
Diagram ......................................................... 06-77
Drain and Fill ................................................. 06-78 • Shovel pivot pins
• Lift arm pivot pin
Check (Operation) ......................................... 06-79 • Centre pivot and steering rams
Figure 74.
TWI N
F
B C
.
Aut omat ic
Greasing
Syst em
A
SWI TCH
A Switch-button
B 3-digit display
C Decimal dot
D System activation indicator LED (Light Emitting
Diode)
E Low grease level indicator LED
F Alarm indicator LED
You must do the greasing of all other greasing points

as per the service schedule.
When the ignition is on, the greasing system

performs all the functions automatically. When
switched on, the system will default to normal duty
mode.
For normal operation, normal duty mode is required.

When working in arduous conditions, heavy duty
mode should be selected.
06 - 75 9813/6500-1 06 - 75
00 - General
Figure 75. HT Machines
A Pump B Port block

C Display unit D Cable harness cabin
E Cable harness pump & pressure switch
06 - 76 9813/6500-1 06 - 76
00 - General
Diagram
Figure 76. HT Machines
From Det ent

( Loader Valve) ( DS)
From EMS
Feed
Eart h splice
- 31
GY ( 7)
GY ( 8)
Black ( 2)
Purple ( 6)
Red ( 1)
Fuse C10
+ 15
( 10)
( 11)
600BQ
125D
104A
852B
Weighload
Plug
Weighload/ Aut olube

Plug ( GV)
GY ( 1)
GY ( 2)
GY ( 3)
GY ( 4)
A B C
GY ( 1)
GY ( 2)
GY ( 3)
GY ( 4)
A B C
GY ( 6)
GY ( 2)
GY ( 1)
GY ( 1)
GY ( 2)
GY ( 3)
GY ( 6)
GY ( 1)
GY ( 2)
GY ( 3)
GY ( 6)
GY ( 7)
GY ( 8)
06 - 77 9813/6500-1 06 - 77
00 - General
Drain and Fill
Fill plate is the plate on top of the grease inside the

tank.
1. Remove the dust cap from the filler coupling.
6. Remove the filler hose.
2. Clean the area around the filler coupling and the
coupling on the filler hose. 7. Clean the area around the filler coupling and
install the dust cap.
3. Attach the filler hose to the coupling.
8. Air may be introduced into the tank when you
4. Make sure that you use the correct type of fill the grease. This air will exit through the tank
grease. Refer to PIL (75-06). vent. If a large amount of air is present, do
the continuous greasing cycles for the specified
5. Fill the tank until the top of the follower plate is duration.
level with the maximum level mark. The follower
Duration: 1min
Figure 77.
A
B
C
E
A Tank B Filler coupling

C Dust cap D Follower plate
E Test button
06 - 78 9813/6500-1 06 - 78
00 - General
Check (Operation)
When it is necessary to check the system for correct

operation, carry out the single greasing cycle.
When it is necessary to prime the system after

cleaning the machine or to venting the system, carry
out the continuous greasing cycle.
Single Greasing Cycle

1. Turn the ignition switch to IGN.
2. Press the test button for the specified duration.
Duration: 3–5s
3. The system will perform the single cycle check.
Continuous Greasing Cycle

1. Turn the ignition switch to IGN.
2. Press the test button for more than specified
duration.
Duration: 6s
3. The system will perform the continuous cycle
check.
4. The continuous greasing cycle will continue to
run until the ignition switch is turned to OFF.
06 - 79 9813/6500-1 06 - 79
Notes:
06 - 80 9813/6500-1 06 - 80
Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-00-03 Cab Frame ....................................................................................................................... 09-4
09-00-06 Operator Protective Structure .......................................................................................... 09-8
09-09 Window
09-09-00 General ........................................................................................................................... 09-11
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-19
09-12-06 Slide Mechanism ............................................................................................................ 09-21
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-23
09-27 Controls
09-27-03 Lift Arm ........................................................................................................................... 09-25
09-27-54 Service Brake Pedal ...................................................................................................... 09-28
09-27-57 Park Brake ..................................................................................................................... 09-31
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-33
09-36 Steering Wheel
09-36-00 General ........................................................................................................................... 09-37
09-48 Floor mat
09-48-00 General ........................................................................................................................... 09-41
09-51 Air Vent
09-51-00 General ........................................................................................................................... 09-43
09-81 Mount
09-81-00 General ........................................................................................................................... 09-45
9813/6500-1
2017-01-25
Acronyms Glossary

9813/6500-1
2017-01-25
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3

09-00-03 Cab Frame ....................................................................................................................... 09-4
09-00-06 Operator Protective Structure .......................................................................................... 09-8
09 - 1 9813/6500-1 09 - 1
Notes:
09 - 2 9813/6500-1 09 - 2
00 - General
00 - General
Health and Safety

Raised Equipment
Never walk or work under raised equipment unless
it is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails
or if the control is operated (even with the engine
stopped).
Make sure that no-one goes near the machine while
you install or remove the mechanical device.
Lifting Equipment
equipment. You must identify the weight of the item to
equipment is in good condition and complies with all
local regulations.
09 - 3 9813/6500-1 09 - 3
03 - Cab Frame
03 - Cab Frame
Remove and Install
CAUTION This component is heavy. It must only 5. Remove the trim panel and side skirt as follows:
method and device. 5.1. Remove the mounting bolts that secure the
front trim panel.
Remove 5.2. Remove the lower securing bolts from the

front trim panel.
1. Make the machine safe. Refer to (PIL 01-03). 5.3. Remove the front trim panel from the cab.
2. Install the articulation strut. Refer to (PIL 06-27). 5.4. Remove the screws that secure the side
skirt.
3. Open the engine compartment cover. Refer to
(PIL 06-06). 5.5. Remove the side skirt.
4. Disconnect the battery cables. Refer to (PIL

33-03).
Figure 78.
A
C B
A Trim panel B Side skirt
09 - 4 9813/6500-1 09 - 4
03 - Cab Frame
C HVAC (Heating Ventilation Air Conditioning)

cover
6. Remove the side skirt from the other side of the pressurised refrigerant. No part of the
machine. system should be disconnected until
the system has been discharged by a
7. Disconnect the chassis harness connectors at refrigeration engineer or a suitably trained
the rear of the cab. person. You can be severely frostbitten or
injured by leaking refrigerant.
8. Remove the securing bolt and disconnect the cab
earth cable from the chassis. 10.2. Important: Do not operate the air
conditioning system when there is no
9. Drain the cooling system. Refer to (PIL 21-00). refrigerant in the system, otherwise the
compressor will be damaged.
10. Discharge the HVAC system. Refer to (PIL
12-00). 11. Disconnect the hose from the water valve.
10.1. Important: The air conditioning system 12. Disconnect the air conditioning hoses from the
is a closed loop system and contains connections at the bottom of the cab floor.
Figure 79.
G
F
F Water valve G Water valve hose

H Cab floor connections J Air conditioning hose
K Heater hose
13. Disconnect the heater hoses.

14. Put a label on the steer unit hoses to help during
installation. Disconnect and put plugs on the
steer unit hoses.
09 - 5 9813/6500-1 09 - 5
03 - Cab Frame
Figure 80. 15. Attach the lifting frame to the cab roof.
16. Use suitable lifting equipment to support the cab.
17. Remove the cab mounts as follows:
17.1. Remove the bolt, rubber mount, rebound
pad and locking plate from the front cab
mounts (x2).
17.2. Remove the bolt, rubber mount, rebound
pad and locking plate from the rear cab
L L mounts (x2).
L Steer unit hose
Figure 81.
P
Q
S
P
Q
M Bolt N Rubber mount

P Rebound pad Q Locking plate
R Front cab mount S Rear cab mount
18. Use suitable lifting equipment to raise the cab 19. Disconnect the electrical connections from the
sufficiently to access the components below the park brake.
cab.
20. Disconnect the electrical connector from the
throttle pedal.
09 - 6 9813/6500-1 09 - 6
03 - Cab Frame
21. Put a label on the servo hoses and disconnect Figure 84.
from the connectors below the cab.
X
Figure 82.
V Servo hoses
22. Disconnect the hoses from the brake valve
connectors.
X Cab assembly
Figure 83.
Install
1. The installation procedure is the reversal of the
removal procedure.
2. Inspect the cab mounts for wear or damage,
replace as necessary.
3. Tighten the cab mounting bolts and nuts to the
correct torque value.
4. Adjust the park brake. Refer to (PIL 24-18).
5. Recharge the air conditioning system and check
operation. Make sure there are no leaks. Refer
to (PIL 12-00).
W
6. Make sure that the air conditioning drain hoses
are routed correctly.
W Brake hoses 7. Check the hydraulic oil level and add as

necessary. Refer to (PIL 30-00).
23. Lift the cab assembly away from the chassis.
8. Fill the cooling system and check for leaks. Refer
to (PIL 21-00).
9. Fill the washer tank. Refer to (PIL 33-54).

Item Nm
B 12
M 330
09 - 7 9813/6500-1 09 - 7
06 - Operator Protective Structure Health and Safety

Health and Safety ........................................... 09-8 if you operate a machine with a damaged or
Check (Condition) ............................................ 09-9 missing ROPS/FOPS/FOGS. If the ROPS/FOPS/
WARNING When replacing or repairing the
ROPS/FOPS/FOGS structure you must replace
the fixings. Never re-use fixings. Use only new
genuine JCB fixings tightened to the torque
figures specified in the operator's manual.
09 - 8 9813/6500-1 09 - 8
Check (Condition)
if you operate a machine with a damaged or
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/
1. Check the structure for damage.

2. Make sure that all the ROPS (Roll-Over
Protective Structure)/FOPS (Falling Object
Protective Structure) mounting bolts are in place
and not damaged.
Figure 85.
3. Make sure that the ROPS/FOPS mounting bolts

are tightened to the correct torque setting.

Item Nm
A 330
09 - 9 9813/6500-1 09 - 9
09 - Window
09 - Window
Contents Page No.
09-09-00 General ........................................................................................................................... 09-11
09 - 10 9813/6500-1 09 - 10
09 - Window
00 - General
Introduction .................................................... 09-11 The service procedures, explain how to correctly
Health and Safety .......................................... 09-12 remove and install panes of glass that are directly
Preparation .................................................... 09-12 bonded to the cab frame apertures. When you carry
Remove and Install ....................................... 09-14 out any service procedure, you must always refer to
the relevant safety precautions, Health and Safety
(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 - 11 9813/6500-1 09 - 11
09 - Window
00 - General
Health and Safety Preparation

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

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

otherwise they may be absorbed into the old sealant
and ultimately prevent the new glass from bonding.
New Glass
1. Make sure that the new glass correctly fits the
frame aperture.
1.1. Put two spacer blocks on to the bottom part
of the frame aperture.
Special Tool: Rubber Spacer Blocks (Qty.:
2)
1.2. Install the new glass on the spacer blocks
- Always use glass lifters. Check that there
is an equal sized gap all round the edge
of the glass. Note: The spacer blocks are
rectangular in section to give two common
gap widths. If necessary they can be
trimmed to a smaller size to give an equal
sized gap around the glass. Important: The
glass edges must not touch the frame,
otherwise movement of the frame will chip
and eventually break the newly installed
glass.
Special Tool: Glass Lifter (Qty.: 2)
09 - 12 9813/6500-1 09 - 12
09 - Window
00 - General
4. Clean the glass.

4.1. Use surface cleaner to thoroughly clean
and prime the black ceramic ink band
printed on the glass (see Note). Use a lint
A Frame aperture free cloth to apply the cleaner, allow to
B Spacer blocks dry. Important: Do not touch the glass after
C Glass lifters cleaning with the surface cleaner.
2. After checking for size, remove the new glass Duration: 5min
and place it on a purpose made glass stand. Consumable: Surface Cleaning Fluid
Small panes of glass will need locating on a
600 x 700 mm x 15 to 19 mm thick plywood 4.2. If the glass does not have a black ceramic
board, sourced locally to fit the glass stand. It is ink band, paint a band on the glass using
recommended that an access hole is cut in the Black Primer. Make sure that the band
board to accommodate the glass lifter, making it measures the correct width and that the
easier and safer to handle small panes of glass. edge is a neat straight line.
The board should be covered with felt or carpet Dimension: 25mm
to give an anti-scratch surface. Resting the glass Consumable: Black Primer/Activator
on four spacer blocks will ensure clearance of
the cartridge nozzle tip during application of the Figure 89.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 87.
5. Install the Ultra Fast Adhesive cartridge into a

suitable applicator gun:
Special Tool: Static Oven (240V) (Qty.: 1)
Special Tool: Mobile Oven (12V) (Qty.: 1)
Special Tool: Cartridge Gun (Qty.: 1)
Consumable: Polyurethane Adhesive
5.1. Remove the aluminium disc cover from
3. Make sure the glass is positioned on the stand the base of the cartridge and discard the
the correct way up (i.e. with the black ceramic dessicant capsule.
ink band upwards) ready for application of primer
etc. 5.2. Make sure that the rolled edge of the
cartridge is not damaged - if necessary, the
edges should be pressed flat, otherwise it
09 - 13 9813/6500-1 09 - 13
09 - Window
00 - General
will be difficult to remove the cartridge from Remove and Install

the applicator gun.
Special Tools
5.3. Pierce the front nozzle end of the cartridge
to its maximum diameter. Description Part No. Qty.
Glass Lifter 892/00842 2
5.4. Install the pre-cut nozzle.
Glass Extractor 892/00846 1
5.5. Install the cartridge in the applicator gun. (Handles Only)
Note: Cold material will be very difficult to Nylon Spatula 892/00847 1
extrude. The cartridges must be pre-heated
Wire Starter 892/00848 1
in a special oven for 1 hour to a temperature
of 80°C (176°F). Pre-heating the cartridges Braided Cutting Wire 892/00849 1
makes the adhesive more workable and Rubber Spacer Blocks 926/15500 2
also brings the curing time down to 30 Cut-Out Knife 992/12800 1
minutes. 'L' Blades 992/12801 1
Figure 90.
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 91. old sealant has been cut away, after which
it will be possible to lift the broken screen
away from its frame housing in one piece.
2.2. Toughened glass - remove as much of the
shattered glass as possible prior to cutting
out the old sealant.
3. Cut out the old sealant, leaving approximately 1
to 2 mm on the cab frame. There are several tools
and techniques for doing this:
3.1. Pneumatic Knife - This provides one of the
A Nozzle guide easiest methods of removing the sealant
7. After applying the adhesive, leave a small around laminated glass. The tool, powered
amount of sealant protruding from the nozzle. by compressed air, should be sourced
This will prevent any adhesive left in the cartridge locally. Press the handle to start the knife
from curing. blade oscillating. Important: This tool must
not be used on toughened glass. Insert the
knife blade into the sealant. Slowly move
the knife along the sealant with the blade
positioned as close to the glass as possible.
09 - 14 9813/6500-1 09 - 14
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 93.

the sealant will melt.
Figure 92.
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 94.
A Glass
3.4. Craft Knife - The blades are replaceable.
Insert the knife blade into the sealant. Pull
the knife along and cut out the old sealant.
09 - 15 9813/6500-1 09 - 15
09 - Window
00 - General
Figure 95. 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 97. 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 98.
face of the cab frame aperture.
Figure 96.
A 1.5mm
6. Apply a coat of Black Primer to the paintwork if:
Consumable: Black Primer/Activator
6.1. Paintwork was damaged or scratched
during the glass/sealant removal
procedures. 2.3. Make sure that the glass is correctly
positioned, then gently press around the
6.2. The old sealant was inadvertently cut back edges of the glass and ensure full adhesive
to the cab frame during the glass/sealant contact is achieved. Do not press too hard
removal procedures. or too much adhesive will squeeze out.
Installing new Glass 3. Make the inside seal smooth:
1. If the internal trim strip is damaged, renew it (cut 3.1. Wearing surgical gloves, dip your finger in
to length as required) before installing the new a soapy water solution.
09 - 16 9813/6500-1 09 - 16
09 - Window
00 - General
3.2. Use your finger to make the inside seal

smooth.
4. All exposed edges must be sealed using Black
Polyurethane Sealant. Important: Use extreme
caution when wiping the inside of the new glass
- pushing too hard on the inside of the glass will
affect the integrity of the bonded seal.
Special Tool: Nylon Spatula (Qty.: 1)
Consumable: Black Polyurethane Sealant
5. Clean the glass after installation:
5.1. Small amounts of sealant can be cleaned
from the glass using the surface cleaner.
5.2. Large amounts of excess sealant should be
left to cure and then cut off with a sharp
knife. Note: On completion of the glass
replacement procedures, the sealant curing
time is 30 minutes. This means that the
machine can be driven and used after 30
minutes, but it must not be used during the
curing period of 30 minutes.
5.3. Clean the glass using a purpose made
glass cleaner.
Consumable: Hand Cleaner
Consumable: JCB Glass Cleaner
6. On completion of the glass installation
procedures tidy the work area:
6.1. Remove all broken glass from the cab area.
6.2. Remove the protective covers from the cab
seat and control pedestals.
6.3. Renew all safety and instructional labels so
that the new installation conforms with the
original cab installation.
09 - 17 9813/6500-1 09 - 17
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-19

09-12-06 Slide Mechanism ............................................................................................................ 09-21
09 - 18 9813/6500-1 09 - 18
12 - Operator Seat
00 - General
00 - General Check (Condition)

Check (Condition) .......................................... 09-19 1. Check that the seat adjustments operate
Remove and Install ....................................... 09-20 correctly.
2. Check the seat is undamaged.
3. Check the seat mounting bolts are undamaged,
correctly installed and tight.
4. Make sure the seat is clear from unwanted
materials and hazards at all times.
09 - 19 9813/6500-1 09 - 19
12 - Operator Seat
00 - General
Remove and Install 2. Tighten the bolts to the correct torque value.
CAUTION This component is heavy. It must only Table 16. Torque Values
be removed or handled using a suitable lifting Item Nm
method and device.
B 24
Remove
3. Disconnect the electrical connections to the
armrest assembly.
4. Remove the bolts that attach the seat to the seat
base.
Figure 99.
B Bolt (x4)
C Seat plinth
D Seat
5. Attach suitable lifting equipment to the seat.
6. Use the lifting equipment to remove the seat from
the machine.
Install
removal procedure.
09 - 20 9813/6500-1 09 - 20
12 - Operator Seat
06 - Slide Mechanism
06 - Slide Mechanism
Remove and Install
Remove
2. Remove the seat. Refer to (PIL 09-12).
3. Fully move back the seat slide adjustment, then
remove the front fixing bolts from the slide rails.
4. Fully move the seat slide adjustment forward and
remove the rear fixing bolts from the slide rails.
5. Remove the slide adjustment assembly.
Figure 100.
A E
B C
D
A Seat securing bolts (x6)

B Washers (x6)
C Front fixing bolts (x2)
D Slide rails
E Rear fixing bolts (x2)
Install
1. Installation is the opposite of the removal
procedure.
09 - 21 9813/6500-1 09 - 21
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-23
09 - 22 9813/6500-1 09 - 22
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 - 23 9813/6500-1 09 - 23
27 - Controls
27 - Controls
Contents Page No.
09-27-03 Lift Arm ........................................................................................................................... 09-25

09-27-54 Service Brake Pedal ...................................................................................................... 09-28
09-27-57 Park Brake ..................................................................................................................... 09-31
09 - 24 9813/6500-1 09 - 24
27 - Controls
03 - Lift Arm
03 - Lift Arm
Remove and Install
For: 419S, Multi Lever Controls 3. Install the articulation strut. Refer to (PIL 06-27).
................................................... Page 09-25
For: 419S, Proportional Controls 4. Remove the upper and lower top controls
................................................... Page 09-26 moulding.
5. Remove the screws (x3) and clip, then remove
(For: 419S, Multi Lever Controls) the outer pod and inner pod.
Remove 6. Disconnect all hydraulic and electrical

connections from the multi lever control.
Refer to (PIL 01-03). 7. Remove the capscrew (x4) and the washer (x4).
2. Discharge the hydraulic system. Refer to (PIL 8. Remove the top controls with the lever and the
30-00). mounting bracket.
Figure 101.
D
F
A Lever B Top controls moulding

C Inner pod D Outer pod
E Capscrew F Washer
09 - 25 9813/6500-1 09 - 25
27 - Controls
03 - Lift Arm
Install 2. Discharge the hydraulic system. Refer to (PIL

30-00).
procedure. 3. Install the articulation strut. Refer to (PIL 06-27).
2. Tighten the capscrew to the correct torque value. 4. Remove the fasteners, then remove the outer
pod and inner pod.
3. Charge the hydraulic system. Refer to (PIL
30-00). 5. Disconnect all hydraulic and electrical
connections from the joystick.
6. Remove the bolt (x3) and the locknut (x3).
Item Description Nm
E Capscrew 2.9 7. Remove the joystick.
(For: 419S, Proportional Controls)
Remove
Figure 102.
C
B
A Joystick B Inner pod

C Outer pod D Electrical connections
E Bolt F Locknut
09 - 26 9813/6500-1 09 - 26
27 - Controls
03 - Lift Arm
Install
procedure.
2. Tighten the locknut to the correct torque value.
30-00).

Item Description Nm
F Locknut 9
09 - 27 9813/6500-1 09 - 27
27 - Controls
54 - Service Brake Pedal
54 - Service Brake Pedal Component Identification

Component Identification ............................... 09-28 Refer to Brake Valve- Component Identification, refer
Check (Pressure) .......................................... 09-29 to (PIL 24-03-09).
09 - 28 9813/6500-1 09 - 28
27 - Controls
Check (Pressure) 18. Install the pressure sensor.
Special Tools Figure 103.

Accumulator Charging 892/00239 1
Kit (Piston Type)
1. Make sure that the brake pedal is fully up.

2. Make sure that there is a little free play between
E
the brake valve plunger and the brake pedal
assembly. A F
3. Stop the engine and release the brake pressure.
Refer to (PIL 01-03)
D
5. Adjust the pedal stop 2 until the pedal touches
the brake valve plunger. G
6. Make sure that the free play space between G

brake valve plunger and pedal assembly is as
specified.
Dimension: 0mm
7. Put an identification mark on the position of the
pedal stop 2. E
8. Adjust the pedal stop 2 by 2/3 turn in an upward C F

direction.
8.1. This pre-engages the valve plunger by
specified dimension. B
Dimension: 1mm
9. Tighten the stop locking nut 2. G
10. Remove the pressure sensor.
G
11. Connect the adaptor, a test point and the
specified pressure gauge.
Special Tool: Accumulator Charging Kit (Piston A Free play space between brake valve plunger
Type) (Qty.: 1) and pedal assembly (0mm)
B Stop locking nut 1
12. Make the brake system operational. Push the C Pedal stop 1
brake pedal slowly until the pressure gauge D Pressure sensor switch
shows the correct brake operational pressure. E Pedal stop 2
Refer to Brakes, Technical Data (PIL 24-00). F Stop locking nut 2
G Test points
13. Hold the brake pedal in this position and adjust
the pedal stop 1 until it touches the pedal.
14. Release and push the pedal a few times. Make
sure that the pressure gauge reading does not
go above the given brake operational pressure
each time.
15. Tighten the stop locking nut 1.
16. Check the pressure.
17. Remove the test point and gauge.
09 - 29 9813/6500-1 09 - 29
27 - Controls
Remove and Install
Refer to Brake Valve- Remove and Install. Refer to

(PIL 24-03-09).
09 - 30 9813/6500-1 09 - 30
27 - Controls
57 - Park Brake
57 - Park Brake
Remove and Install
The electrical park brake switch is installed on the

right side console panel.
Observe all the health and safety information. Refer

to Electrical system - Health and Safety (PIL 33-00).
Remove
2. Disconnect the battery. Refer to (PIL 33-03).
3. Remove the switch panel.
4. Make a note of the switch orientation to help
installation.
5. If you remove multiple switches, make sure you
label the switch harness connectors to help
identification.
6. Disconnect the harness connector.
7. Press the tabs and push the switch from the
switch panel.
Figure 104.
A
B
A Tabs
B Park brake switch
C Harness connector
Install
procedure.
09 - 31 9813/6500-1 09 - 31
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-33
09 - 32 9813/6500-1 09 - 32
00 - General
Introduction .................................................... 09-33 The safety labels are strategically placed around the
Health and Safety .......................................... 09-34 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 - 33 9813/6500-1 09 - 33
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 - 34 9813/6500-1 09 - 34
36 - Steering Wheel
36 - Steering Wheel
Contents Page No.
09-36-00 General ........................................................................................................................... 09-37
09 - 35 9813/6500-1 09 - 35
Notes:
09 - 36 9813/6500-1 09 - 36
36 - Steering Wheel
00 - General
Introduction .................................................... 09-37 The steering wheel is used to direct the machine. The
Remove and Install ....................................... 09-38 operator can turn the steering wheel in the direction
he wants to go.
The steering wheel incorporates an assister knob for

single handed operation.
Figure 105.
A Steering wheel
B Assister knob
09 - 37 9813/6500-1 09 - 37
36 - Steering Wheel
00 - General
Remove and Install Table 19. Torque Values

Item Nm
C 50
Remove
3. Carefully pry out and remove the centre disc from
the steering wheel, take care not to damage.
4. Mark the position of the steering wheel with
respect to the steering column.
5. Remove the nut and washer that secures the
steering wheel to the steering column.
6. Remove the steering wheel.
Figure 106.
E
B
B Centre disc
C Nut
D Washer
E Steering wheel
Install
1. Put the steering wheel in position against the
steering column. Make sure the marks made
during removal are aligned.
2. Install the washer and the nut.
3. Tighten the nut to the correct torque value.
4. Install the centre disc on the steering wheel, take
care not to damage.
09 - 38 9813/6500-1 09 - 38
48 - Floor mat
48 - Floor mat
Contents Page No.
09-48-00 General ........................................................................................................................... 09-41
09 - 39 9813/6500-1 09 - 39
Notes:
09 - 40 9813/6500-1 09 - 40
48 - Floor mat
00 - General
00 - General
Remove and Install
Remove
2. If necessary, remove the operator seat. Refer to
(PIL 09-12).
3. Remove the clamp 1.
4. Remove the carpet.
5. Remove the clamp 2.
6. Remove the floor mat.
Figure 107.
B D
A
A Clamp 1
B Carpet
C Clamp 2
D Floor mat
Install
removal procedure.
09 - 41 9813/6500-1 09 - 41
51 - Air Vent
51 - Air Vent
Contents Page No.
09-51-00 General ........................................................................................................................... 09-43
09 - 42 9813/6500-1 09 - 42
51 - Air Vent
00 - General
00 - General
Introduction
There are six circular adjustable air vents on the front

console. The air vents are located on each side of
the steering wheel. Refer to Figure 108.
Figure 108.
A Air vents
Adjust the air vents to direct the air flow where

required. When the air vents are open, hot or cold air
flows directly into the cab.
The most effective procedure to de-mist the front

window is to close the air vents and operate the air
re-circulation system.
09 - 43 9813/6500-1 09 - 43
81 - Mount
81 - Mount
Contents Page No.
09-81-00 General ........................................................................................................................... 09-45
09 - 44 9813/6500-1 09 - 44
81 - Mount
00 - General
Introduction .................................................... 09-45 The cab mounts are mounted directly under the
Check (Condition) .......................................... 09-46 operator station.
The mounts are a type of vibration isolator, they
provide the interface between the operator station
and the chassis, they allow a certain amount of
movement. The movement minimises the noise and
vibrations caused when the machine is moving over
an uneven surface.
09 - 45 9813/6500-1 09 - 45
81 - Mount
00 - General
Check (Condition) Remove and Install

1. Check the condition of the cab mounts, any
damaged or defective mounts must be replaced.
Remove
2. Remove the operator station from the machine.
3. Remove the bolt and locking plate.
4. Remove the rebound pads.
5. Remove the mounts.
Figure 109.
A
B
A Mounts
B Locking plate
C Bolt
D Rebound pad
Install
step.

Item Nm
C 330
09 - 46 9813/6500-1 09 - 46
12 - Heating, Ventilating and
Air-Conditioning (HVAC)
Contents Page No.
12-00 Heating, Ventilating and Air-Conditioning (HVAC)

12-00-00 General ............................................................................................................................. 12-3
12-03 HVAC Unit
12-03-00 General ........................................................................................................................... 12-23
12-03-03 Evaporator ...................................................................................................................... 12-29
12-03-06 Pressure Switch ............................................................................................................. 12-32
12-03-09 Expansion Valve ............................................................................................................. 12-34
12-03-12 Blower Motor .................................................................................................................. 12-37
12-03-15 Thermostat ..................................................................................................................... 12-40
12-03-18 Heater Coil ..................................................................................................................... 12-43
12-09 Compressor
12-09-00 General ........................................................................................................................... 12-45
12-12 Receiver Drier
12-12-00 General ........................................................................................................................... 12-49
12-15 Condenser
12-15-00 General ........................................................................................................................... 12-53
12-18 Filter
12-18-00 General ........................................................................................................................... 12-59
12-18-06 Fresh Air ........................................................................................................................ 12-60
12-18-09 Recirculation ................................................................................................................... 12-62
12-96 Pipe
12-96-00 General ........................................................................................................................... 12-67
9813/6500-1
2017-01-18
Acronyms Glossary
ATC Automatic Temperature Control

PAG Polyalkyline Glycol
RPM Revolutions Per Minute
9813/6500-1
2017-01-18
12 - Heating, Ventilating and Air-Conditioning (HVAC)
Contents Page No.
12-00-00 General ............................................................................................................................. 12-3
12 - 1 9813/6500-1 12 - 1
Notes:
12 - 2 9813/6500-1 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 ......................................................... 12-7 with recirculated air, over an evaporator matrix in the
Diagram ........................................................... 12-8 air conditioning unit.
Fault-Finding .................................................... 12-9
Discharge and Pressurise ............................. 12-12 The air conditioning system is a closed circuit
through which the refrigerant is circulated, its state
Check (Condition) .......................................... 12-15 changing from gas to liquid and back to gas again,
Check (Leaks) ............................................... 12-20 as it is forced through the system. The major
Check (Level) ................................................ 12-20 components of the system are the:
• Compressor
• Condenser matrix
• Receiver drier
• Expansion valve
• Evaporator matrix
12 - 3 9813/6500-1 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 9813/6500-1 12 - 4
00 - General
Technical Data
Table 21. Binary pressure switch settings

Item Specification
Low pressure 2.05bar (29.7psi)
High pressure 23.5bar (340.6psi)
Table 22. Thermostat switch settings

Item Specification
Cut-out 0–1.1°C (32.0–34.0°F)
Cut-in 6.6–7.7°C (43.9–45.8°F)
Table 23. Refrigerant

Item Specification
Type R143a gas
Quantity 2.05kg
Table 24. Oil

Item Specification
Type PAG (Polyalkyline Gly-
col) oil
Quantity -
Recharge the system 0.043L
Component replacement -
Condenser 0.057L
Evaporator 0.085L
Hoses 0.057–0.114L
Receiver Drier 0.057L
Compressor None- pre-charged
12 - 5 9813/6500-1 12 - 5
00 - General
Figure 110.
D
C
G B
E
A
F
A HVAC (Heating Ventilation Air Conditioning) unit B Compressor

C Receiver drier D Condenser
E Compressor drive belt F Recirculation filter
G HVAC control H Pressure sensing switch
J Binary pressure switch
12 - 6 9813/6500-1 12 - 6
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 - 7 9813/6500-1 12 - 7
00 - General
Diagram
Refer to Electrical System, General, Schematic

Circuit (PIL 33-00).
12 - 8 9813/6500-1 12 - 8
00 - General
Fault-Finding
Fault
Poor performance. Table 25. Page 12-9
Inadequate Cooling (Discharge air from HVAC (Heating Ventilation Air Table 26. Page 12-9
Conditioning) vents is only slightly cool)
Inadequate cooling during hot part of the day. Table 27. Page 12-10
Gradual loss over time of cooling and air flow during HVAC operation. Table 28. Page 12-10
Compressor clutch cycles too rapidly or discharge air warms excessively Table 29. Page 12-10
during compressor clutch “OFF” cycle.
Compressor clutch continually cuts out. Table 30. Page 12-10
Inadequate or no heat. (Discharge air only slightly warm, or neutral). Table 31. Page 12-11
Blower operates on fan speed 3 only. Table 32. Page 12-11
Blower does not operate. Table 33. Page 12-11
Table 25. Poor performance.

Cause Remedy
Low system pressure Evacuate and recharge system.
Condenser matrix air flow restricted Remove debris from around matrix using
compressed air or low pressure water.
Air filter blocked Remove and replace.
Compressor drive belt too slack Adjust to correct tension.
Table 26. Inadequate Cooling (Discharge air from HVAC (Heating Ventilation Air Conditioning) 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 Refer to Water Valve-Check Operation. NOTE:
may be diminished at engine idle. Increased Complete all remaining HVAC system checks before
engine and compressor speed will improve HVAC Water Valve-Check Operation. Keep supply hose to
cooling). Clamp off the heater hose supplying the valve clamped shut during remaining checks.
coolant valve 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 HVAC. Observe
not engage, or remain engaged. for low pressures. If low pressures are observed,
check all HVAC 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.
12 - 9 9813/6500-1 12 - 9
00 - General
Cause Remedy
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 27. 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.
Table 28. Gradual loss over time of cooling and air flow during HVAC 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 29. 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 30. Compressor clutch continually cuts out.

Cause Remedy
Condenser matrix blockage Remove debris from around matrix/renew condenser.
Overcharging of refrigerant system Evacuate and recharge system.
Blocked expansion valve/condenser Clear blocked component.
12 - 10 9813/6500-1 12 - 10
00 - General
Table 31. 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.
Table 32. Blower operates on fan speed 3 only.

Cause Remedy
Blower resistor failed Replace resistor.
Table 33. Blower does not operate.

Cause Remedy
Blower motor failed Replace complete blower unit.
Fuse blown Replace fuse and retest.
12 - 11 9813/6500-1 12 - 11
00 - General
Discharge and Pressurise Figure 111.
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.
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 - 12 9813/6500-1 12 - 12
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 112.
Figure 113.
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 - 13 9813/6500-1 12 - 13
00 - General
recharging with gas follow the manufacturers Figure 115.

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 114.
A396790
Table 34.
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 - 14 9813/6500-1 12 - 14
00 - General
Check (Condition)
Normal Function Normal gauge readings will depend on the system

components and ambient conditions. Make sure that
The air conditioning system gauge pressure readings the valves are closed and the readings are stable,
at high and low sides are normal. The sight glass and that the system has a full charge.
indication is clear and discharged air is cold.
The gauge hoses are normally colour coded, blue for
The pressures displayed on the manifold gauges low side and red for high side gauges.
at 25°C (77.0°F) with the engine at 1500 RPM
(Revolutions Per Minute), the blower on maximum Table 35. Normal Gauge Pressures
and the thermostat set to maximum, must be as Parameter Pressure
shown (i.e. typically, the high pressure is nominally
Low side (blue) 2bar (29.0psi)
6 to 8 times greater than the low pressure). Refer to
Figure 116. High side (red) 14.8bar (214.5psi)
Figure 116.
70 80 200 250
60 0
15
90
0
30
0 110 00
30 40 5
50 100
0
1
350
20
12
50
40
0 0
30 3
0 1
0
500 45
C
A
A High pressure and high temperature gas B Low pressure and low temperature gas
C High pressure liquid
12 - 15 9813/6500-1 12 - 15
00 - General
Low Refrigerant (R-134a) Charge The receiver drier is clogged and the refrigerant flow
is obstructed by dirt.
The air conditioning system gauge pressure readings
at high and low sides are low. The sight glass Complete the below corrective actions to diagnose.
indicates the visible bubbles continuously in the
refrigerant. Refer to Figure 117. 1. Evacuate the air conditioning system.
Because of the leakage or incorrect refrigerant 2. Replace the receiver drier.

charge, the air conditioning system charge is low. 3. Charge the air conditioning system with R-134a
refrigerant.
Complete the below corrective actions to diagnose.
4. Operate the air conditioning system and check
1. Do a leak test of the air conditioning system. the performance.
2. Evacuate the air conditioning system. Table 37. Poor Refrigerant Circulation
3. If any leakage is found, repair the leak(s). Parameter Pressure
Low side (blue) -1–0bar (-14.5–0.0psi)
4. Charge the air conditioning system with R-134a High side (red) 5.4bar (78.3psi)
refrigerant.
Figure 118.
the performance.
70 80 200 250
Table 36. Low Gauge Pressures 60
15
0
90
0
30
110 100
30 40 5
Parameter Pressure
50 100
0
350
Low side (blue) 0.76bar (11.0psi)
20
0
12
0
High side (red) 8.3bar (120.3psi) 0
40
5
0 0
30 3
0 1
0
500 45
Figure 117.
70 80 200 250
60 0
15
90
0
30
110 100
30 40 5
50 100
0
350
20
0
12
0
40
5
0 0
30 3
0 1
0
500 45
No Refrigerant Circulation
The air conditioning system gauge pressure reading
at low side is ranging from zero to negative value and
at high side is low. Frost or moisture on the tubes
before and after the receiver drier. Refer to Figure
119.
The refrigerant flow is obstructed by dirt, moisture or

gas leakage from the expansion valve heat sensing
tube.
Poor Refrigerant Circulation
at low side is ranging from zero to negative value 1. Evacuate the air conditioning system.
and at high side is low. Frost on the tubes from the
receiver drier to the evaporator unit. Refer to Figure 2. Check the heat sensing tube at the expansion
118. valve. Replace the expansion valve, if necessary.
12 - 16 9813/6500-1 12 - 16
00 - General
3. Remove the expansion valve and try to remove 4. Charge the air conditioning system with R-134a
dirt from it. If not removed, replace the expansion refrigerant.
valve.
4. Replace the receiver drier. the performance.
5. Charge the air conditioning system with R-134a Table 39. Insufficient Condenser
refrigerant. Cooling or Refrigerant Overcharge
6. Operate the air conditioning system and check Parameter Pressure
the performance. Low side (blue) 3bar (43.5psi)
High side (red) 22.1bar (320.3psi)
Table 38. No Refrigerant Circulation
Parameter Pressure Figure 120.
Low side (blue) -1–0bar (-14.5–0.0psi)
70 80 200 250
60 0
15
Figure 119.
90
0
30
0 110 00
30 40 5
50 100
0
1
350
20
12
0
50
40
0 0
30 3
0 1
200 250 0
70 80 500 45
60 0
15
90
0
30
110 100
30 40 5
50 100
0
350
20
0
12
50
40
0 0
30 3
0 1
0
500 45
Air in System
at high and low sides are high. The sight glass
indicates the visible bubbles during the system
Insufficient Condenser Cooling or operation. The low pressure pipes are hot. Refer to
Refrigerant Overcharge Figure 121.
The air conditioning system gauge pressure readings The air is present in the air conditioning
at high and low sides are high. The sight glass system, possibly because of inadequate evacuation
indicates no visible bubbles even at lower engine procedure.
RPM. Refer to Figure 120.
The condenser insufficient cooling problem is
caused due to the refrigerant overcharge, clogged 1. Evacuate the air conditioning system.
condenser cooling fins or the cooling fans
malfunctioning. 2. Check the compressor oil level and oil for
contamination. Add or replace the compressor
Complete the below corrective actions to diagnose. oil, if necessary.
1. Clean the condenser cooling fins. 3. Charge the air conditioning system with R-134a
refrigerant.
2. Check the cooling fan operation.
3. Evacuate the air conditioning system. the performance.
12 - 17 9813/6500-1 12 - 17
00 - General
Table 40. Air in System Figure 122.

Parameter Pressure
70 80 200 250
60
High side (red) 22.1bar (320.3psi) 15
0
90
0
30
110 100
30 40 5
50 100
0
350
Figure 121.
20
0
12
0
0
40
5
0 0
30 3
0 1
0
500 45
70 80 200 250
60 0
15
90
0
30
0 110 00
30 40 5
50 100
0
1
350
20
12
0
0
50 0 40
30 3
0 1
0
500 45
Defective Compressor
at low side is high and at high side is low. Refer to
Figure 123.
The compressor is defective due to internal leakage

or mechanically broken parts.
Defective Expansion Valve (Wide
Opening) Complete the below corrective actions to diagnose.
The air conditioning system gauge pressure readings 1. Evacuate the air conditioning system.
at high and low sides are high. The large amount
of frost or moisture on the low side pipes. Refer to 2. Repair or replace the compressor.
Figure 122. 3. Charge the air conditioning system with R-134a
refrigerant.
The excessive refrigerant in low side pipes causes
due to wide opening of the expansion valve. 4. Operate the air conditioning system and check
the performance.
1. Do a leak test of the air conditioning system. Table 42. Defective Compressor
2. Evacuate the air conditioning system. Parameter Pressure
3. If any leakage is found, repair the leak(s).
4. Charge the air conditioning system with R-134a
refrigerant.
the performance.
Table 41. Defective Expansion Valve

Parameter Pressure
12 - 18 9813/6500-1 12 - 18
00 - General
70 80 200 250 70 80 200 250

60 0 60 0
15 15
90
90
0
0
30
30
110 100
30 40 5
110 100
30 40 5
50 100
50 100
0
350
350
20
20
0
0
12
12
0
0
50 0
40
40
0 0
5
0 0
30 3 30 3
0 1 0 1
0 0
500 45 500 45
Some Moisture in the System

at low side is normal, sometimes drops to below zero
and at high side is normal, sometimes goes high.
Refer to Figure 124.
The moisture in the system freezes which stops

the cycle temporarily and normal system operation
returns when the ice melts.
1. Evacuate the air conditioning system.

2. Repair or replace the compressor.
3. Remove the moisture by continuously
evacuating the air conditioning system.
4. Charge the air conditioning system with R-134a
refrigerant.
the performance.
Table 43. Moisture in the System

Parameter Pressure
Low side (blue) -2.1bar (-30.4psi)
12 - 19 9813/6500-1 12 - 19
00 - General
Check (Leaks) Check (Level)
The refrigerant is heavier than air and will leak The state of refrigerant at the receiver drier sight
downwards from the defective component. Check in glass is an indication of the pressure in the system,
still conditions but in a well ventilated area. i.e. the refrigerant charge level. The receiver drier is
mounted beneath the engine cover towards the right-
Hose or pipe connections are likely leakage points of side on a vertical bulkhead at the rear of the engine.
any refrigerant circuit.
Check the level of refrigerant as follows:
It is essential that an electronic leak detector is used
to locate leaks accurately. However, if a leak detector 1. Make machine safe with the lift arm lowered.
is not available, an approximate source can be found Refer to (PIL 01-03).
by applying a soap solution to the suspect area.
2. Open the engine cover.
To test for leaks in the high pressure side of
the system i.e. from the compressor output to the 3. Start the engine and run at idle.
expansion valve, run the air conditioning for a few 4. Switch on the HVAC (Heating Ventilation Air
minutes then switch off the engine and test for Conditioning) system to circulate the refrigerant.
leakage using an electronic leak detector or soapy
water. 5. Stop the engine and check the level at the sight
glass.
To test for leakage in the low pressure side of the
system, switch off the air conditioning and leave for Figure 125.
a few minutes before testing.
A
Leaking Hoses
The refrigerant hoses have crimped ferrule end
fittings. The hose connectors have an O-ring seal
which compresses when the connection is tight,
creating an air tight seal.
Hoses are used to connect the inlets and outlets

of the compressor, condenser, receiver drier and
expansion valve (the evaporator coil is connected to A Sight glass
the expansion valve within the air conditioning unit
using rigid pipes). If the level of charge is correct the sight glass will
be clear. If the charge is low bubbles will be visible.
If leakage is detected from a hose connector, either Bubbles may also be an indication of inadequate
by means of an electronic leak detector or soapy cooling, due to a restriction of air flow around
water, tighten the connector up and repeat the the condenser coil. If the system is not providing
leakage test. If leakage is still evident, it will be adequate cooling, refer to fault-finding. Refer to (PIL
necessary to discharge the system and renew the 12-00).
connector O-ring seal. Refer to (PIL 12-00).
When R143a refrigerant is used slight bubbles are
visible at the system sight glass. This is normal for
this type of refrigerant.
12 - 20 9813/6500-1 12 - 20
03 - HVAC Unit
03 - HVAC Unit
Contents Page No.
12-03-00 General ........................................................................................................................... 12-23

12-03-03 Evaporator ...................................................................................................................... 12-29
12-03-06 Pressure Switch ............................................................................................................. 12-32
12-03-09 Expansion Valve ............................................................................................................. 12-34
12-03-12 Blower Motor .................................................................................................................. 12-37
12-03-15 Thermostat ..................................................................................................................... 12-40
12-03-18 Heater Coil ..................................................................................................................... 12-43
12 - 21 9813/6500-1 12 - 21
Notes:
12 - 22 9813/6500-1 12 - 22
03 - HVAC Unit
00 - General
Introduction .................................................... 12-23 The HVAC unit and the automatic temperature
Component Identification ............................... 12-24 control system contains a blower motor, evaporator,
Remove and Install ....................................... 12-25 heater radiator, filters and a thermostat. It is located
on the right side of the cab.
Sensors
Cab air temperature sensor
This sensor monitors the average cab air
temperature and is located in the re-circulation vent
behind the filter. It is necessary that re circulated air is
unrestricted to allow the correct temperature control.
Evaporator core probe

This sensor prevents the evaporator core from icing
up. Make sure that the probe is properly engaged
with the evaporator fins and properly tightened.
High side pressure transducer

This sensor is attached into the liquid line on the
HVAC (Heating Ventilation Air Conditioning) unit
assembly and performs the following functions:
• Allows for diagnostic monitoring of the high side

pressure through the control panel diagnostic
display.
• AC compressor clutch cut out on excessive
refrigerant high side pressure. It cuts out when
pressure is above 24bar (347.8psi) and cuts in
when pressure is below 19bar (275.4psi).
• Lost refrigerant charge clutch lock out.
12 - 23 9813/6500-1 12 - 23
03 - HVAC Unit
00 - General
Figure 126.
E F
A
B
A Filter cover B Filter

C Thermostat D Expansion valve
E Evaporator core F Heater core
G Blower motor
12 - 24 9813/6500-1 12 - 24
03 - HVAC Unit
00 - General
Remove and Install
Air Conditioning Maintenance as the refrigerant will need to be discharged from the
system.
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the 1. Make the machine safe. Refer to (PIL 01-03).
system should be disconnected until the system
has been discharged by a refrigeration engineer 2. Install the articulation strut. Refer to (PIL 06-27).
or a suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant. 3. Open the access panel on the right hand side
of the cab to get access to the HVAC (Heating
Ventilation Air Conditioning) unit. Refer to (PIL
06-06).
harmful to your skin or eyes. 4. Remove the screws and washers that attach the
RH skirt.
Remove
5. Remove the RH skirt.
The removal of the unit will require the assistance of
a refrigeration engineer or suitably qualified person,
Figure 127.
A
C B
A Trim panel B RH skirt
12 - 25 9813/6500-1 12 - 25
03 - HVAC Unit
00 - General
C HVAC cover
6. Remove the access door of the HVAC unit. 8. Remove the recirculation filter.
7. Remove the fresh air filter.
Figure 128.
E
F
E Flanged bolt (x11) F Shroud

G Recirculation filter H Fresh air filter
9. Remove the flanged bolts that attach the HVAC 11. Disconnect the harnesses from the blower
shroud. motor connector and recirculation door actuator
connector.
10. Remove the shroud.
12 - 26 9813/6500-1 12 - 26
03 - HVAC Unit
00 - General
Figure 129.
M
J Blower motor connection K Recirculation door actuator

L ATC (Automatic Temperature Control) control M Evaporator probe
unit
12. If the ATC unit is installed then additionally 13. Remove the RH console panel.
disconnect the harness from the thermistor, ATC
control unit and evaporator probe. 14. Remove the grommet from the drain pipe.
Figure 130.
R
Q
P
12 - 27 9813/6500-1 12 - 27
03 - HVAC Unit
00 - General
N Thermistor P Grommet
Q Hoses R Screws (x4)
15. Disconnect the hoses from the HVAC unit.

16. Remove the screws that attach the HVAC unit to
the machine.
17. Remove the HVAC unit from the machine.
Install
procedure.
2. Always install new O-rings for the pipes.
3. Tighten the evaporator and suction pipes to the
4. The HVAC system will need to be recharged
with refrigerant by a refrigeration engineer or a
suitably trained and qualified person.

Item Description Nm
- Evaporator pipe 16.5
- Suction pipe 32.5
12 - 28 9813/6500-1 12 - 28
03 - HVAC Unit
03 - Evaporator
03 - Evaporator Introduction
Introduction .................................................... 12-29 The evaporator works in the opposite way as the
Remove and Install ....................................... 12-30 condenser, here the liquid refrigerant is converted
to gas, absorbing the heat from the air in the
compartment.
The evaporator is located inside the HVAC (Heating

Ventilation Air Conditioning) unit.
12 - 29 9813/6500-1 12 - 29
03 - HVAC Unit
03 - Evaporator

The air conditioning system is a closed loop system A
and contains pressurised refrigerant. No part of the
system should be disconnected until the system
B
or a suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
Remove
2. Open the access panel on the right hand side of
the machine. Refer to (PIL 06-06).
3. Remove the complete HVAC (Heating Ventilation
Air Conditioning) unit from the machine. Refer to
(PIL 12-00).
4. Put the HVAC unit on a clean work bench.
5. Remove all the screws that attach the cover to
the air conditioning cabinet and then remove the A Screw
cover. B Cover
6. Remove the bolt that attaches the expansion
valve to the air conditioning cabinet.
12 - 30 9813/6500-1 12 - 30
03 - HVAC Unit
03 - Evaporator
Figure 132.
C D
C Bolt
D Expansion valve
7. Carefully remove the evaporator unit with
the expansion valve from the air conditioning
cabinet.
Install
step.
2. Charge the HVAC system. Refer to (PIL 12-00).
12 - 31 9813/6500-1 12 - 31
03 - HVAC Unit
06 - Pressure Switch
06 - Pressure Switch Introduction

Introduction .................................................... 12-32 The binary pressure switch assembly has a low and
Check (Condition) .......................................... 12-33 high pressure switch designed to operate at specified
Remove and Install ....................................... 12-33 pressure values. Refer to Technical Data (PIL 12-00).
When the refrigerant pressure is within the specified

limits, the pressure switches will be closed and if the
thermostat and on/of switches are closed, current
will be supplied to the field coil of the clutch. Due
to the electromagnetic action the field coil clutch will
be pulled towards the compressor's clutch and the
refrigeration cycle will start.
12 - 32 9813/6500-1 12 - 32
03 - HVAC Unit
06 - Pressure Switch
If the fault finding table indicates that the pressure The HVAC system must be discharged before the
switch assembly is defective, the fault may be pressure switch is removed.
electrical or due to an incorrect system pressure.
Check the refrigerant charge level. Refer to: Check gloves, eye protection and protective clothing must
(Level) (Page 12-20). be worn. Refrigerant may be released which can be
If the refrigerant charge level is correct, do the
electrical pressure switch test to find out the fault, Remove
also refer to Servicemaster (PIL 33-57).
1. Discharge the HVAC system. Refer to (PIL
Pressure switch test 12-00).
1. Switch the engine off so that the air conditioning 2. Disconnect the electrical connections.
system cannot operate.
3. Remove the screws and then remove the
2. Disconnect the pressure switch harness from the pressure switch.
side control harness and connect an external
24V power supply between the pressure switch Install
harness connector and the chassis.
1. Screw the pressure switch into the pressure
2.1. If both pressure switches are working switch port and tighten sufficiently to form a gas-
correctly, and the system is at the correct tight seal.
charge level, the compressor clutch will
operate. 2. Connect the electrical connections.
2.2. If the compressor clutch does not operate 3. Charge the HVAC system. Refer to (PIL 12-00).
with the external power supply, one of
the pressure switches in the assembly is 4. Run the HVAC system and check the pressure
faulty or the level of refrigerant charge is switches for leaks.
insufficient to close the low pressure switch.
4.1. If any leaks are found, tighten the pressure
3. Replace the pressure switch assembly. switch further until the leak stops.
3.1. If the clutch still fails to operate, then check
all electrical connections.
12 - 33 9813/6500-1 12 - 33
03 - HVAC Unit
09 - Expansion Valve
09 - Expansion Valve Introduction

Introduction .................................................... 12-34 The purpose of the expansion valve is to remove
Remove and Install ....................................... 12-35 pressure from the liquid refrigerant and to allow the
refrigerant to change from liquid to vapour in the
evaporator. The expansion valve is located in the
HVAC unit.
12 - 34 9813/6500-1 12 - 34
03 - HVAC Unit
Remove and Install
Air Conditioning Maintenance 2. Install the articulation strut. Refer to (PIL 06-27).
The air conditioning system is a closed loop system 3. Open the access panel on the right hand side
and contains pressurised refrigerant. No part of the of the cab to get access to the HVAC (Heating
system should be disconnected until the system Ventilation Air Conditioning) unit.
or a suitably trained person. You can be severely 4. Discharge the HVAC system. Refer to (PIL
frostbitten or injured by escaping refrigerant. 12-00).
CAUTION! When working on the HVAC System 4.1. Make sure the discharge operation is
gloves, eye protection and protective clothing must performed by a refrigeration engineer or a
be worn. Refrigerant may be released which can be suitably trained and qualified person.
5. If required, remove the HVAC shroud to get
The expansion valve is a non-serviceable access to the expansion valve.
component and should be replaced if damaged.
6. Clean the area around the expansion valve.
Remove
7. Disconnect the evaporator and suction pipes
1. Make the machine safe. Refer to (PIL 01-03). from the bottom of the expansion valve.
Figure 133.
A Expansion valve B Evaporator pipe

C Suction pipe
8. Remove the insulation from the hoses on top of

the expansion valve.
12 - 35 9813/6500-1 12 - 35
03 - HVAC Unit
Figure 134.
E
F
A Expansion valve
D Insulation
E Top hoses
F Bolt
9. Disconnect the pipes from the top of the
expansion valve.
10. Remove the nut, washer and the bolt that
attaches the expansion valve.
11. Remove the expansion valve from the
evaporator inlet.
12. Remove and discard the O-rings from the top
pipes.
Install
procedure.
2. Always install new O-rings for the pipes.
3. Tighten the evaporator and suction pipes to the
4. The HVAC system will need to be recharged
with refrigerant by a refrigeration engineer or a
suitably trained and qualified person.

Item Nm
B 16.5
C 32.5
12 - 36 9813/6500-1 12 - 36
03 - HVAC Unit
12 - Blower Motor
12 - Blower Motor Introduction

Introduction .................................................... 12-37 The blower motor is an electrically operated fan in the
Remove and Install ....................................... 12-38 HVAC system that supplies air to the operator station.
The blower motor is located inside the HVAC unit.
The only serviceable component inside the motor is
the resistor. The resistor controls the fan speed rate
at which the blower motor supplies the air.
Other faults, with the exception of wiring defects,

necessitate the replacement of the blower motor
assembly.
Note: The blower motor can be removed from the

HVAC unit with the assembly in the machine.
12 - 37 9813/6500-1 12 - 37
03 - HVAC Unit
12 - Blower Motor
Remove and Install
Remove 4. Remove the HVAC unit from the machine. Refer

to (PIL 12-03).
CAUTION When working on the HVAC System
gloves, eye protection and protective clothing 5. Remove the screws that attach the rear cover to
must be worn. Refrigerant may be released which the HVAC housing assembly.
can be harmful to your skin or eyes.
6. Remove the HVAC rear cover.
1. Make the machine safe with the lift arm lowered. 7. Remove the fixings that attach the blower motor
Refer to PIL (01-03). assembly to the blower bulkhead assembly.
2. Install the articulation strut. Refer to PIL (06-27). 8. Remove the blower motor assembly slowly from
3. Open the HVAC (Heating Ventilation Air the HVAC unit until the wiring connections of the
Conditioning) access panel. Refer to (PIL 06-06). motor are accessible.
Figure 135. 9. Put a label on the electrical connections to help

installation.
10. Disconnect the electrical connections.
B
11. Remove the thermostat from the heater blower
support tray.
12. Remove the blower motor assembly from the
machine.
B Access panel
12 - 38 9813/6500-1 12 - 38
03 - HVAC Unit
12 - Blower Motor
Figure 136.
A Blower motor assembly
Install
removal procedure.
12 - 39 9813/6500-1 12 - 39
03 - HVAC Unit
15 - Thermostat
15 - Thermostat Introduction
Introduction .................................................... 12-40 The thermostat is located within the HVAC unit next
Remove and Install ....................................... 12-41 to the blower motor.
The thermostat monitors the external temperature of

the evaporator so that the system's temperature is
maintained near the desired setpoint. The thermostat
does this by switching the heating or cooling devices
on or off, or regulating the flow of the heat transfer
fluid as needed, to maintain the correct temperature.
12 - 40 9813/6500-1 12 - 40
03 - HVAC Unit
15 - Thermostat
Remove and Install
Remove 3. Open the HVAC (Heating Ventilation Air

Conditioning) cover with the ignition key.
Refer to (PIL 01-03). 4. If necessary, remove the grille.
2. Isolate the battery. Refer to (PIL 33-03). 5. Remove the nut (x2).
6. Remove the thermostat from the HVAC unit.
Figure 137.
A Thermostat B Nut (x2)

C Grille D HVAC cover
12 - 41 9813/6500-1 12 - 41
03 - HVAC Unit
15 - Thermostat
Install
removal procedure.
12 - 42 9813/6500-1 12 - 42
03 - HVAC Unit
18 - Heater Coil
18 - Heater Coil
Introduction
The heater coil is a tube and fin construction, with the

inlet and outlet on one end of the coil. Hoses connect
the coil to the engine.
The heat energy for heating cab air comes from the
hot engine coolant. The heater systems are designed
to transfer heat energy from the engine coolant to the
air in the cab.
12 - 43 9813/6500-1 12 - 43
09 - Compressor
09 - Compressor
Contents Page No.
12-09-00 General ........................................................................................................................... 12-45
12 - 44 9813/6500-1 12 - 44
09 - Compressor
00 - General
Introduction .................................................... 12-45 The compressor is located at the front of the engine,
Check (Condition) .......................................... 12-46 it is the heart of the air conditioning system since it
produces the refrigerant flow.
The compressor is driven by the engine drive belt,

refer to (PIL 15-18).
Refer to Component Identification (PIL 12-00).
12 - 45 9813/6500-1 12 - 45
09 - Compressor
00 - General
Check (Condition)
2. 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.
3. Make sure that the compressor is securely
attached to its bracket.
4. Make sure that the bracket is securely attached
to the engine.
5. Make sure that the compressor clutch assembly
and the drive pulley are securely installed.
6. Check the condition of the drive belt. Refer to
(PIL 15-18).
12 - 46 9813/6500-1 12 - 46
12 - Receiver Drier
12 - Receiver Drier
Contents Page No.
12-12-00 General ........................................................................................................................... 12-49
12 - 47 9813/6500-1 12 - 47
Notes:
12 - 48 9813/6500-1 12 - 48
12 - Receiver Drier
00 - General
Introduction .................................................... 12-49 The Receiver/Drier is a device that removes
Check (Condition) .......................................... 12-50 moisture from the refrigerant as well as filtering any
contaminants or particulates from it. It also acts as a
tank to store excess coolant.
Refer to Component Identification (PIL 12-00).
12 - 49 9813/6500-1 12 - 49
12 - Receiver Drier
00 - General
Check (Condition) Figure 139.

2. Clean the sight glass on the top housing of the
receiver drier.
3. Check the sight glass.
3.1. Make sure that the sight glass is clear.
4. Check the pipe connections to the receiver drier
for signs of cracks or wear.
3. Clouded - Dessicant breakdown in the receiver
5. Make sure that the pipes are correctly clamped. drier. Refer to Figure 140.
5.1. If necessary, replace the pipes and clamps. Figure 140.
6. Do not remove the pipes from the charged HVAC

(Heating Ventilation Air Conditioning) system.
Sight glass indications

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

supply cool air. The indication then is that the
system is completely discharged of refrigerant.
Figure 138.
2. Foam or bubbles - Refrigerant is low and needs

of charging. Some slight bubbling is to be
expected when R134a refrigerant is used. Refer
to Figure 139.
12 - 50 9813/6500-1 12 - 50
15 - Condenser
15 - Condenser
Contents Page No.
12-15-00 General ........................................................................................................................... 12-53
12 - 51 9813/6500-1 12 - 51
Notes:
12 - 52 9813/6500-1 12 - 52
15 - Condenser
00 - General
Introduction .................................................... 12-53 A condenser is a component used to condense
Clean ............................................................. 12-54 a substance from its gaseous to its liquid state,
Check (Condition) .......................................... 12-54 typically by cooling it. In so doing the latent heat is
Remove and Install ....................................... 12-55 given up by the substance, and will transfer to the
condenser coolant.
12 - 53 9813/6500-1 12 - 53
15 - Condenser
00 - General
Clean Check (Condition)
When you are cleaning take extra care not to damage 1. Inspect the condenser coil for a build of dirt. If
the condenser fins or tubes. Damaged fins must necessary, clean the condenser coil. Refer to
be straightened out to make sure of a good airflow (PIL 12-15).
through the coil.
2. Inspect the condenser fins or tubes for damage.
1. Make the machine safe. Refer to PIL 01-03. Straighten out the damaged fins and make sure
of a good airflow through the coil.
2. Raise the grille at the rear of the machine.
The working environment of the machine can build
3. Use compressed air or low pressure water to up airborne particles on the condenser coil over a
back flow through the coil fins. Make sure that the period of time. This restricts the airflow around the
fins are not damaged. condenser coil and reduces the heat dissipation from
the refrigerant to the air. This results in poor air
4. Start the HVAC system and check the cooling conditioning performance.
performance.
The heavy build up on the condenser coil leads to
over pressurisation of the system. This can cause
the high pressure cut-out switch to operate and
switch off the system. The internal blockage of the
condenser coil can also operate the high pressure
cut-out switch.
12 - 54 9813/6500-1 12 - 54
15 - Condenser
00 - General
Remove and Install
Remove 9.2. Remove the clamp from the condenser

bracket.
9.3. Remove the hoses from the clamp.
2. Install the safety strut. Refer to (PIL 06-69).
10. Remove the setscrew 2 (x4), washers 2 (x8) and
3. Discharge the HVAC (Heating Ventilation Air nut 1 (x4).
Conditioning) system. Refer to (PIL 12-00).
11. Support the condenser bracket.
4. Isolate the battery. Refer to (PIL 33-03).
12. Pull the cable from the antiluce fastener.
13. Release the antiluce fastener.
(PIL 06-06).
14. If necessary, remove the grommet.
6. Disconnect the hydraulic hoses from the
condenser. 15. Remove the condenser with the condenser
bracket from the cooling pack.
7. Put a label on the hoses to help installation.
16. If necessary, remove the condenser from the
8. Plug all the open ports and hoses to prevent
condenser bracket.
contamination.
16.1. Remove the bolt (x4), washer 3 (x8) and
9. If necessary, remove the hoses from the clamp
nut 2 (x4).
as follows:
16.2. Remove the condenser from the
9.1. Remove the setscrew 1 and washer 1. condenser bracket.
Figure 141.
H P
K
G
F J
N
L M
A
E
D
C
A Condenser B Condenser bracket

C Setscrew 1 D Washer 1
E Clamp F Setscrew 2 (x4)
G Washer 2 (x4) H Nut 1 (x4)
J Cable K Antiluce fastener
L Nut 2 (x4) M Washer 3 (x8)
N Bolt (x4) P Cooling pack
12 - 55 9813/6500-1 12 - 55
15 - Condenser
00 - General
Install
step.
2. Tighten the fasteners to the correct torque value.

Item Nm
C 24
F 9.9
N 24
12 - 56 9813/6500-1 12 - 56
18 - Filter
18 - Filter
Contents Page No.
12-18-00 General ........................................................................................................................... 12-59

12-18-06 Fresh Air ........................................................................................................................ 12-60
12-18-09 Recirculation ................................................................................................................... 12-62
12 - 57 9813/6500-1 12 - 57
Notes:
12 - 58 9813/6500-1 12 - 58
18 - Filter
00 - General
00 - General
Introduction
CAUTION The filter may be filled with dust. Wear
goggles and a face mask when removing the filter.
The air conditioning filter assemblies are designed to

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

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

cleaning/changing more often than detailed in the
maintenance schedule.
12 - 59 9813/6500-1 12 - 59
18 - Filter
06 - Fresh Air
06 - Fresh Air Clean

Clean ............................................................. 12-60 goggles and a face mask when removing the filter.
2. Remove the fresh air filter.
3. Shake the filter to remove the loose dust.
4. Clean the filter with a low pressure jet of
compressed air.
5. Replace the filter if damaged.
6. An additional secondary filter may be installed
behind the main filter, if applicable, pull the tag
provided to remove the secondary filter.
7. Magnetic strips hold the secondary filter in place.
Make sure that the secondary filter is located
correctly when you install it.
8. Replace the secondary filter if damaged.
9. Install the fresh air filter.
12 - 60 9813/6500-1 12 - 60
18 - Filter
06 - Fresh Air
Remove and Install
Removal 2. Remove the bolts (x6) with the specified Allen

key.
1. Open the HVAC (Heating Ventilation Air
Dimension: 3mm
Conditioning) cover assembly.
Figure 142.
B
G A
C
A Filter lid B Fastener

C Bolt D Filter box
E Gasket F HVAC shroud
G Filter element
3. Turn the fasteners (x6) a quarter of a turn.

4. Remove the filter lid.
5. Remove the filter box and gasket.
6. Remove the filter element from the filter box.
Install
procedure.
2. Make sure that the filter box is free from dust, dirt
and other contaminations before you install the
gasket. This gasket is self-adhesive.
12 - 61 9813/6500-1 12 - 61
18 - Filter
09 - Recirculation
09 - Recirculation Clean
Clean ............................................................. 12-62 goggles and a face mask when removing the filter.
2. Open the right side HVAC (Heating Ventilation Air
Figure 143.
B
C
A Recirculation filter
B Ignition key
C HVAC cover
3. Turn the fasteners (x2) from the grille.
4. Open the grille.
5. Remove the filter element.
Figure 144.
D Grille
E Fasteners (x2)
12 - 62 9813/6500-1 12 - 62
18 - Filter
09 - Recirculation
6. Shake the filter to remove the loose dust. Remove and Install
7. Clean the filter with a low pressure jet of CAUTION The filter may be filled with dust. Wear
compressed air. goggles and a face mask when removing the filter.
8. Put the filter and grille in position.
Remove
9. Install the fasteners (x2).
10. Make sure that the grille is secured.
11. Close the right side HVAC cover with the ignition
2. Open the right side HVAC (Heating Ventilation Air
key.
Figure 145.
B
C
B Ignition key
C HVAC cover
3. Turn the fasteners (x2) from the grille.
4. Open the grille.
12 - 63 9813/6500-1 12 - 63
18 - Filter
09 - Recirculation
Figure 146.
D Grille
E Fasteners (x2)
Install
removal procedure.
12 - 64 9813/6500-1 12 - 64
96 - Pipe
96 - Pipe
Contents Page No.
12-96-00 General ........................................................................................................................... 12-67
12 - 65 9813/6500-1 12 - 65
Notes:
12 - 66 9813/6500-1 12 - 66
96 - Pipe
00 - General
Introduction .................................................... 12-67 The refrigeration pipes are responsible for carrying
Check (Condition) .......................................... 12-68 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 - 67 9813/6500-1 12 - 67
96 - Pipe
00 - General
Check (Condition)
2. Check all the visible pipes and connectors.
3. Look for areas where the hoses flex or are
fastened, clamped, connected, bent or go
through panels. All these areas are potential
wear and damage points.
4. Do not remove the pipes from the charged HVAC
(Heating Ventilation Air Conditioning) system.
5. Tighten the pipes and adaptors to the correct
torque value.
12 - 68 9813/6500-1 12 - 68
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-12 Crankshaft
15-12-27 Damper ........................................................................................................................... 15-31
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-33
15-18-03 Drive Belt ....................................................................................................................... 15-35
15-18-21 Tensioner ........................................................................................................................ 15-39
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-41
15-24 Air Filter
15-24-00 General ........................................................................................................................... 15-49
15-24-09 Dust Valve ...................................................................................................................... 15-54
15-27 Crankcase Ventilation Filter
15-27-00 General ........................................................................................................................... 15-57
15-63 Mount
15-63-00 General ........................................................................................................................... 15-61
15-72 Alternator
15-72-00 General ........................................................................................................................... 15-67
15-75 Starter Motor
15-75-00 General ........................................................................................................................... 15-73
9813/6500-1
2017-02-24
Acronyms Glossary
CCV Crankcase Ventilation

DC Direct Current
DEF Diesel Exhaust Fluid
ECM Engine Control Module
ECU Electronic Control Unit
EGR Exhaust Gas Recirculation
ESOS Engine Shut-Off Solenoid
FEAD Front End Accessory Drive
HP High Pressure
MAF Mass Air Flow
PRV Pressure Relief Valve
PTO Power Take-Off
SCR Selective Catalytic Reduction
TDC Top Dead Centre
VGT Variable Geometry Turbocharger
9813/6500-1
2017-02-24
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9813/6500-1 15 - 1
Notes:
15 - 2 9813/6500-1 15 - 2
15 - Engine
00 - Engine
00 - General
Introduction ...................................................... 15-3 This section contains information about the complete
Health and Safety ........................................... 15-4 engine assembly. For specific engine technical
Technical Data ................................................. 15-5 information refer to the technical data section.
Component Identification ................................. 15-6 Make sure that the correct engine service tools,
consumables and torque figures are used when you
Operation ....................................................... 15-10 perform service procedures. Renewal of oil seals,
Fault-Finding .................................................. 15-13 gaskets, etc., and any component showing obvious
Drain and Fill ................................................. 15-24 signs of wear or damage is expected as a matter
Clean ............................................................. 15-24 of course. 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 6 cylinder diesel engine has fuel ignited by
compression ignition (C.I.). The engine operates on
a four stroke cycle.
The engine is started by an electric starter motor. The

starter motor turns the engine via a pinion and teeth
on the engine flywheel, refer to (PIL 09-75).
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 24 valves,
2 inlet and 2 exhaust valves for each cylinder.
The crankshaft also drives a mechanical high

pressure fuel pump via gears. 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 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.
Authorised Maintenance Level

Procedures
Maintenance Level procedures on the Cummins
engine are restricted to the service maintenance and
repairs as detailed in this manual.
A Maintenance level provider meets the

certification requirements to perform and warrant
customer services including product selection,
15 - 3 9813/6500-1 15 - 3
15 - Engine
00 - Engine
00 - General
troubleshooting, inspection and maintenance on Health and Safety

external components limited to the following engine
components:
Hot Components
• Cooling pump Touching hot surfaces can burn skin. The engine and
• Exhaust manifold machine components will be hot after the unit has
• Starter motor been running. Allow the engine and components to
• Alternator and bracket cool before servicing the unit.
• Fan hub
Turning the Engine
• Drive belt tensioner
• Rocker cover and Gasket Do not try to turn the engine by pulling the fan or fan
• Vibration damper belt. This could cause injury or premature component
• Front cover and gasket failure.
• Thermostat Notice: The engine and other components could
• Oil filler cap be damaged by high pressure washing systems.
• Dipstick and dipstick holder Special precautions must be taken if the machine is
• Oil filter heads to be washed using a high pressure system.Make
• Filters sure that the alternator, starter motor and any other
• Drive belts electrical components are shielded and not directly
• External fuel pipes cleaned by the high pressure cleaning system. Do
• Hoses and fluid components. not aim the water jet directly at bearings, oil seals or
the engine air induction system.
JCB Maintenance dealers are not authorized to
repair failures on internally rotating or reciprocating Notice: Clean the engine before you start
components or external components including engine maintenance. Obey the correct procedures.
but not limited to fuel systems, ECM (Engine Contamination of the fuel system will cause damage
Control Module) , sensors and after-treatment SCR and possible failure of the engine.
(Selective Catalytic Reduction)components. Notice: Do not exceed the correct level of engine
oil in the sump. If there is too much engine oil,
the excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job.Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
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
accordance with local regulations. Use authorised
waste disposal sites.
15 - 4 9813/6500-1 15 - 4
15 - Engine
00 - Engine
00 - General
Technical Data
Table 47.
Description Data
Make Cummins
Model QSB 6.7L
Type 6 cylinder, Turbocharged
Bore diameter 107mm
Stroke length 124mm
Cylinder capacity 6.7L
Gross power output 129kW at 2100 RPM (Revolutions Per Minute)
Idling speed 680-720 RPM
Rated speed (Full load) 2100 RPM
Maximum no load speed 2430 RPM
Maximum net torque at 1500 RPM 841N·m
Weight 519kg
15 - 5 9813/6500-1 15 - 5
15 - Engine
00 - Engine
00 - General
Figure 147. Front View

A B C D E
F
N
G
M
H
L
K
A Alternator mounting B Coolant outlet connection/Thermostat housing

C Fan hub D EGR (Exhaust Gas Recirculation) connection
tube
E EGR F Oil pressure switch
G Engine speed/position sensor (camshaft) H Engine speed/position sensor (crankshaft)
J Vibration damper (viscous) K Front gear cover
L Water pump M Automatic belt tensioner
N Refrigerant compressor mounting location P Alternator
15 - 6 9813/6500-1 15 - 6
15 - Engine
00 - Engine
00 - General
Figure 148. LH Side View

A B C D E E
W H
J
V
K
U
L
S
R Q P N M
A EGR valve B Fuel filter

C Service diagnostic test connection for fuel D Fuel filter supply line
system tests
E Fuel drain tube (fuel rail PRV (Pressure Relief F Rear engine lifting bracket
Valve))
G Crankcase ventilation tube H Fuel filter return line
J Flywheel housing K HP (High Pressure) fuel pump
L Fuel pump actuator M Lubricating oil drain plug
N Gear pump fuel pump P HP fuel supply to rail
Q Lubricating oil level gauge (dipstick) R Main lubricating oil gallery port
S Lubricating oil pan T Alternate dipstick location
U Crankshaft speed indicator ring V ECM (Engine Control Module)
W Air inlet
15 - 7 9813/6500-1 15 - 7
15 - Engine
00 - Engine
00 - General
Figure 149. Rear View

A B
H
D
G
E
A Cylinder head fuel drain (injector) connection B Coolant supply to DEF (Diesel Exhaust Fluid)
dosing valve and tank
C Turbocharger compressor outlet D Exhaust outlet connection
E Flywheel - manual transmissions F Flywheel housing
G Crankcase ventilation tube H Fuel filter
Figure 150. RH Side View

A B C D E F
V
U
T G
S H
R J
Q K
N M L
A EGR cooler B Turbocharger compressor outlet
15 - 8 9813/6500-1 15 - 8
15 - Engine
00 - Engine
00 - General
C VGT (Variable Geometry Turbocharger) coolant D EGR cooler coolant return tube
return tube
E Exhaust pressure sensor tube F Front engine lifting bracket
G Oil filter head/Oil cooler H Oil pressure regulator
J Oil filter K Water inlet connection
L Coolant heater port M VGT oil supply tube
N VGT coolant supply tube P VGT oil drain tube
Q Starter motor R Service access/Barring port
S Gear housing (rear) T VGT actuator
U VGT V Exhaust manifold
Figure 151. Top View

A B C D E F
U
G
T
H
Q P N M L K J
A EGR cooler B De-aeration port

C Crankcase ventilation filter cover D Turbocharger speed sensor
E EGR cooler coolant supply tube F Rocker lever cover
G Crankcase pressure sensor H Injector harness pass-through connector
J Fuel PRV K Fuel rail
L Intake air manifold temperature/pressure sensor M Fuel injector supply lines - HP (x6)
N Fuel rail pressure sensor P Crankcase breather oil drain tube
Q Injector harness pass-through connector R EGR valve
S EGR temperature sensor T Crankcase breather oil drain tube
U Oil fill (rocker lever cover) V Coolant temperature sensor
• On engines equipped with an externally

mounted breather, the crankcase ventilation
filter is located at the rear of the engine.
• On engines equipped with an externally
mounted breather, the crankcase pressure
sensor is located in the crankcase ventilation
filter housing at the rear of the engine.
15 - 9 9813/6500-1 15 - 9
15 - Engine
00 - Engine
00 - General
Operation
The Four Stroke Cycle The stages in the four stroke cycle for each cylinder
are as follows:
This section describes the cycle sequence, for the 6
cylinders of the diesel engine.
Table 48. The Four Stroke Cycle

Stage number Piston operation Valve operation
1 The piston is at the top of its Com- Inlet and exhaust valves closed.
pression stroke and is about to
start its Power stroke.
2 The piston is at the bottom of its Inlet valves closed, exhaust valves
Power stroke and is about to start about to open.
its Exhaust stroke.
3 The piston is at the bottom of its In- Exhaust valves closed, inlet valves
duction stroke and is about to start about to close.
its Compression stroke.
4 The piston is at the top of its Ex- Valve operation exhaust valves
haust stroke and is about to start about to close, inlet valves about to
its Induction stroke. open.
Firing order Power

A cylinder is said to be firing, when the fuel/air mixture The piston continues to rise after the start of fuel
ignites and the piston is about to start its power injection causing a further increase in pressure and
stroke. temperature.
Four Stroke Cycle The temperature rises to a point at which the fuel/air
mixture ignites. A cylinder is said to be firing, when
the fuel/air mixture ignites.
Induction
This combustion causes a very rapid rise in
As the piston travels down the cylinder, it draws both temperature and pressure. The high pressure
filtered air at atmospheric pressure and ambient generated propels the piston downward turning the
temperature through an air filter and inlet valves into crankshaft and producing energy.
the cylinder.
Exhaust
Compression
Once the piston has reached the bottom of its travel,
When the piston reaches the bottom of its stroke the the exhaust valves open and momentum stored
inlet valves close. The piston then starts to rise up the in the flywheel forces the piston up the cylinder
cylinder compressing the air trapped in the cylinder. expelling the exhaust gases.
This causes the temperature and pressure of the air
to rise. Fuel is injected into the cylinder when the In a running engine these four phases are
piston is near to top dead centre. continuously repeated. Each stroke is half a
revolution of the crankshaft, thus, in one cycle of a
four stroke engine, the crankshaft revolves twice.
15 - 10 9813/6500-1 15 - 10
15 - Engine
00 - Engine
00 - General
Figure 152.
3
2
C
B
1 4
746030
1 Induction 2 Compression stroke

3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation BDC Bottom dead centre
TDC TDC (Top Dead Centre)
15 - 11 9813/6500-1 15 - 11
15 - Engine
00 - Engine
00 - General
Figure 153.
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 - 12 9813/6500-1 15 - 12
15 - Engine
00 - Engine
00 - General
Fault-Finding
Fault
Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Table 49. Page 15-13
Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Table 50. Page 15-14
Engine - Will Not Crank or Cranks Slowly Table 51. Page 15-15
Engine - Starts Then Stops Table 52. Page 15-15
Engine - Poor Running Table 53. Page 15-16
Engine - Poor Running at Idle Table 54. Page 15-16
Engine - Noise Excessive Table 55. Page 15-17
Engine - Compression Knocks Table 56. Page 15-18
Engine - Reduced Power Output Table 57. Page 15-18
Engine - Will Not Reach Maximum RPM Table 58. Page 15-19
Engine - RPM Surges Table 59. Page 15-20
Engine - Vibration Excessive Table 60. Page 15-20
Engine - Exhaust Smoke Excessive (Black Smoke) Table 61. Page 15-21
Engine - Exhaust Smoke Excessive (White/Blue Smoke) Table 62. Page 15-21
Engine - Will Not Shut Off Table 63. Page 15-22
Lubricating Oil - Consumption Excessive Table 64. Page 15-22
Lubricating Oil - Contaminated Table 65. Page 15-23
Lubricating Oil - Pressure Low Table 66. Page 15-23
Lubricating Oil - Pressure High Table 67. Page 15-23
Table 49. 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.
15 - 13 9813/6500-1 15 - 13
15 - Engine
00 - Engine
00 - General
Cause Remedy
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Do all the
necessary fault finding checks before removal of the
high pressure fuel pump.
Injectors Contaminated. Check the injectors. Use the Servicemaster test
procedure in Servicemaster Tools Actuator Test. Test
and replace as required.
(1) Some of the remedy procedure in the above table require assistance from the Cummins distributor. For
details refer to Engine, Introduction (PIL 15-00).
Table 50. 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 51. 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.
15 - 14 9813/6500-1 15 - 14
15 - Engine
00 - Engine
00 - General
Table 51. 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.
Table 52. 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.
15 - 15 9813/6500-1 15 - 15
15 - Engine
00 - Engine
00 - General
Table 53. Engine - Poor Running

Cause Remedy
Condition only occurs at idle. For possible poor running at idle faults.
See Also: Table 54. 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.
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 54. 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.
15 - 16 9813/6500-1 15 - 16
15 - Engine
00 - Engine
00 - General
Cause Remedy
inadequate). fuel to the injection pump.
restriction.
clearances.
Table 55. 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 61. 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).
15 - 17 9813/6500-1 15 - 17
15 - Engine
00 - Engine
00 - General
Cause Remedy
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 56. 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.
Table 57. 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.
15 - 18 9813/6500-1 15 - 18
15 - Engine
00 - Engine
00 - General
Cause Remedy
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
Table 58. 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.
15 - 19 9813/6500-1 15 - 19
15 - Engine
00 - Engine
00 - General
Cause Remedy
Turbocharger wastegate actuator diaphragm Repair or replace turbocharger.
ruptured.
Table 59. Engine - RPM Surges

Cause Remedy
Fuel level low. Check the level in the fuel tank, use sight gauge or
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
install new ones.
Fuel tank cap vent/breather blocked. Inspect and rectify as required. Replace cap if
necessary.
system.
Table 60. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. See Also: Table 54. 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.
15 - 20 9813/6500-1 15 - 20
15 - Engine
00 - Engine
00 - General
Cause Remedy
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 61. 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.
Table 62. 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.
15 - 21 9813/6500-1 15 - 21
15 - Engine
00 - Engine
00 - General
Cause Remedy
Coolant leaking into combustion chamber. Check the EGR (Exhaust Gas Recirculation) Cooler
for leaks. Replace Cylinder head gasket if necessary.
Leaking valve stem seals - evident after long idle Replace valve seals.
period and then acceleration.
Piston rings not sealing - evident with persistent blue Check the engine compression.
smoke at all speeds/load.
Table 63. 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 64. Lubricating Oil - Consumption Excessive

Cause Remedy
Oil leaks. Inspect the engine for visible signs of leaks. Pay
particular attentions to seals, gaskets oil cooler and
external connections.
Oil level over-full. Check oil level.
Incorrect lubricating oil (specification of viscosity). Make sure the correct lubricating oil is being used.
Tier 4 Final Engines require a special oil grade. Refer Check for reduced viscosity from dilution with fuel.
to (PIL 75-03). Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review/reduce the lubricating oil change intervals.
Crankcase ventilation (CCV) system blocked. Check the breather tube area for signs of lubricating
oil loss. Check and if necessary replace the CCV
filter.
Lubricating oil cooler leak. Check for lubricating oil in the coolant.
Turbocharger leaking lubricating oil to the air intake Inspect the air crossover tube for evidence of
or exhaust. lubricating oil transfer.
Valve guide seals are leaking. Replace valve guide stem seals as required.
Piston rings not sealing - lubricating oil being Check the engine compression
consumed by the engine (blue smoke from exhaust).
Worn cylinder bores - lubricating oil being consumed Check the engine compression.
by the engine (blue smoke from exhaust).
Glazed cylinder bores. De-glaze bores as required.
15 - 22 9813/6500-1 15 - 22
15 - Engine
00 - Engine
00 - General
Table 65. 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 66. 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 fitted. 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 67. 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 - 23 9813/6500-1 15 - 23
15 - Engine
00 - Engine
00 - General
Drain and Fill Clean

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

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

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

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

2. Make sure that all electrical connectors are
correctly coupled. If connectors are open fit the
correct caps or seal with water proof tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and soft bristle
brush to soak off caked mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical and electronic
components such as ECU (Electronic Control
Unit)'s, alternator or fuel injectors. DO NOT place
the jet nozzle closer than 600mm (24 in) to
any part of the engine or after treatment system
including exhaust sensor ECU (if installed).
15 - 24 9813/6500-1 15 - 24
15 - Engine
00 - Engine
00 - General
9. When the pressure washing is complete move Remove and Install

the machine away from the wash area, or
alternatively, clean away the material washed
from the machine.
The air conditioning system is a closed loop system
10. Before working on specific areas of the engine and contains pressurised refrigerant. No part of the
use a compressed air jet to dry off any moisture. system should be disconnected until the system
When the area is dry use a soft clean brush to has been discharged by a refrigeration engineer
remove any sand or grit particles that remain. or a suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
11. When removing components be aware of any
dirt or debris that may be exposed. Cover any
open ports and clean away the deposits before Remove
proceeding
Remove the Engine, Transmission and
Additional cleaning must be carried out prior to Pump
working on the high pressure fuel system, refer to:
Fuel System - Clean (PIL 18-00). 1. Make the machine safe. Refer to (PIL 01-03).
4. Remove the operator station. Refer to (PIL
09-00).
5. Remove the rear bodywork. Refer to (PIL 06-00).
6. Drain the cooling system. Refer to (PIL 21-00).
7. Remove the propshafts. Refer to (PIL 27-47).
8. Remove the centre undershield. Refer to (PIL
06-06).
9. Remove the SCR (Selective Catalytic Reduction)
unit. Refer to (PIL 18-30).
10. Disconnect the electrical connector from the gear
pump. Refer to (PIL 30-11).
11. Disconnect the hydraulic hoses from the gear
pump. Refer to (PIL 30-11).
Figure 154.
A Hydraulic hoses
15 - 25 9813/6500-1 15 - 25
15 - Engine
00 - Engine
00 - General
12. Disconnect the hoses from the emergency steer 20. Remove the fuel filter assembly from the
pump. machine.
Figure 155. 21. Remove the water separator from the engine.
Figure 157.
K
B H
B M
H Fuel hoses
B Hydraulic hoses J Fuel filter assembly
K Water separator
13. Loosen the clip. M HVAC (Heating Ventilation Air Conditioning)
compressor
14. Disconnect the suction hose from the main
hydraulic pump. 22. Disconnect the HVAC hoses from the HVAC
compressor.
15. Remove the bolts 1.
23. Disconnect the cooler hoses from the
16. Disconnect the hydraulic hoses from the main transmission.
hydraulic pump.
Figure 158.
17. Disconnect the electrical connector from the
main hydraulic pump.
N
Figure 156.
C
C
G
E
C N
F
D
C Hydraulic hoses N Cooler hoses

D Suction hose
24. Disconnect the electrical cables from the starter
E Bolts 1
motor.
F Clip
G Electrical connector 25. Disconnect the electrical connector from the oil
level sensor.
18. Disconnect the fuel hose from the fuel filter
assembly. 26. Disconnect the engine earth cable from the
chassis.
19. Remove the bolts 2 (x2).
15 - 26 9813/6500-1 15 - 26
15 - Engine
00 - Engine
00 - General
27. Support the engine and transmission with Figure 160.

suitable lifting equipment. V
28. Remove the engine from the front engine mount.
Refer to (PIL 15-63). W
29. Remove the bolts 5 (x8) and nuts 3 (x8) from the
transmission mount.
Figure 159. X
V Bolt 6 (x4)
W Washer (x4)
X Pump
5. Remove the bolts 7, cover plate and plastic
cover.
6. Use a suitable tool to turn the flywheel to get
access to the components.
AJ
7. Remove the flywheel to the flexible coupling bolts
(x4) through the cut-out in the case.
AK
Figure 161.
AJ Bolt 5
AK Nut 3
30. Carefully lift the engine and transmission
assembly from the machine. AA
31. Make sure that all the connectors are released. AB

Separate the Transmission, Engine and
Pump Assembly
1. Mount the engine, transmission and pump Y
assembly on a suitable stand.
2. Support the pump. Z
3. Remove the mounting bolts 6 (x4) and washers
Y Bolts 7
(x4).
Z Cover plate
4. Remove the pump from the transmission system. AA Plastic cover
AB Flexible coupling bolts (x4)
8. Remove the bolts 8.
9. Connect the lifting eye to the transmission case.
10. Tighten the bolts 8 to the correct torque value.
11. Connect suitable lifting equipment to the lifting
eyes (x3).
12. Support the weight of the transmission.
13. Remove the bolts 9 (x12).
14. Remove the transmission from the engine.
15 - 27 9813/6500-1 15 - 27
15 - Engine
00 - Engine
00 - General
Figure 162.
AD
AC
AE
AF
AC Bolts 8
AD Lifting eye (x3)
AE Bolts 9 (x12)
AF Transmission
Install
step.

Item Nm
AB 44
AE 43
15 - 28 9813/6500-1 15 - 28
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-27 Damper ........................................................................................................................... 15-31
15 - 29 9813/6500-1 15 - 29
Notes:
15 - 30 9813/6500-1 15 - 30
15 - Engine
12 - Crankshaft
27 - Damper
27 - Damper Figure 164.
Remove and Install
Remove 1 6
3 4
2. Make sure that the engine is safe to work on.
If the engine has been running, make sure the
engine has cooled sufficiently before you start 5 2
the removal.
3. Remove the engine drive belt. Refer to (PIL
15-18).
4. Support the damper. Description Torque Values
5. Remove the screws (x6). - first stage torque 50N·m
- second stage torque 90°
6. Remove the damper from the engine.
Figure 163.
A Damper
B Screws (x6)
Install
step.
2.1. Use the torque and angle tightening
procedure. Refer to (PIL 72-00).
2.2. Make sure that you follow the correct
tightening sequence. Refer to Figure 164.
15 - 31 9813/6500-1 15 - 31
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-33

15-18-03 Drive Belt ....................................................................................................................... 15-35
15-18-21 Tensioner ........................................................................................................................ 15-39
15 - 32 9813/6500-1 15 - 32
15 - Engine
18 - Engine Belt
00 - General
Introduction .................................................... 15-33 A crankshaft pulley is used to drive a FEAD
Health and Safety .......................................... 15-34 (Front End Accessory Drive) belt. The belt drives
Component Identification ............................... 15-34 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 - 33 9813/6500-1 15 - 33
15 - Engine
18 - Engine Belt
00 - General

Turning the Engine Figure 165.
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
engine cover open. D
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
E B
C
G
F H
A Crankshaft pulley
B Fan pulley
C Water pump pulley
D Compressor installation location
E Alternator pulley
F Belt tensioner pulley
G Belt tensioner
H Vibration rubber damper
15 - 34 9813/6500-1 15 - 34
15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Introduction

Introduction .................................................... 15-35 The crankshaft pulley is used to drive the coolant
Health and Safety .......................................... 15-36 pump via a FEAD (Front End Accessory Drive) belt.
Check (Condition) .......................................... 15-36 In addition to the coolant pump the drive belt can
Adjust ............................................................ 15-37 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 - 35 9813/6500-1 15 - 35
15 - Engine
18 - Engine Belt
03 - Drive Belt
Health and Safety Check (Condition)

Notice: A drive belt that is loose can cause
damage to itself and/or other engine parts. At the recommended service interval, visually inspect
the drive belt for damage.
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 166.
B
A
C
A Crack in belt
B Missing piece of belt
C Frayed belt
15 - 36 9813/6500-1 15 - 36
15 - Engine
18 - Engine Belt
03 - Drive Belt
Adjust Remove and Install
Adjustment is not possible with this drive belt. A There are a number of drive belt routes. This
spring loaded tensioning unit ensures that the FEAD procedure does not include all of the routes. Do a
(Front End Accessory Drive) belt is kept at the correct diagram of the drive belt route before removal to help
tension. installation.
The belt tensioner is spring-loaded, it must be

pivoted away from the drive belt. Do not pivot the
belt tensioner in the wrong direction, this can cause
damage.
Make a note that too much force in the opposite

direction of wind-up or when the belt tensioner
is wound-up to the positive-stop, can cause the
tensioner arm to crack or break.
Remove
(PIL 06-06).
4. Hold the tensioner against the spring force and
lift the belt off the drive tensioner pulley.
Figure 167.
E B
C
G
F H
A Crankshaft pulley
B Fan pulley
C Water pump pulley
D Compressor installation location
E Alternator pulley
F Belt tensioner pulley
G Belt tensioner
H Vibration rubber damper
15 - 37 9813/6500-1 15 - 37
15 - Engine
18 - Engine Belt
03 - Drive Belt
Install
1. Use the diagram to correctly route the new drive
belt on the pulleys.
2. Pivot the belt tensioner in the direction of the
spring tang.
3. Install the new drive belt. Put the drive belt over
the water pump pulley last.
4. If it is difficult to install the drive belt, do as follows:
4.1. Put the drive belt over the grooved pulleys
first.
4.2. Hold the belt tensioner up and slide the
drive belt over the water pump pulley.
5. Slowly release the belt tensioner to apply tension
to the drive belt.
6. Check the alignment of the drive belt with the belt
tensioner and the other components.
7. Use the deflection method to measure the
tension in the drive belt.
7.1. Apply the specified force between the
pulleys on the drive belt.
Force: 110N
7.2. If the deflection is more than the thickness
of one drive belt per foot of pulley centre
distance, adjust the drive belt tension.
7.3. If there is too much movement of the drive
belt, replace it.
8. Close the engine compartment cover. Refer to
(PIL 06-06).
9. Run the engine and listen to hear if the drive belt
squeals.
9.1. Too much squeal indicates that the drive
belt is slipping too much.
9.2. Check the route of the drive belt to make
sure it is correctly installed over each pulley.
15 - 38 9813/6500-1 15 - 38
15 - Engine
18 - Engine Belt
21 - Tensioner
21 - Tensioner
Remove and Install
Remove
(PIL 06-06).
3. Remove the engine drive belt. Refer to (PIL
15-18).
4. Remove the capscrew.
5. Remove the belt tensioner from the engine.
6. If necessary, remove the bracket.
Figure 168.
A Belt tensioner
B Capscrew
Install
step.
2. Tighten the capscrew to the correct torque value.

Item Nm
B 43
15 - 39 9813/6500-1 15 - 39
15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ........................................................................................................................... 15-41
15 - 40 9813/6500-1 15 - 40
15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................... 15-41 The oil filter is a spin on type which screws on and
Health and Safety .......................................... 15-42 off the oil filter head. For details on the oil cooler and
Component Identification ............................... 15-42 filter assembly, refer to (PIL 15-69).
Operation ....................................................... 15-43
Check (Level) ................................................ 15-44
15 - 41 9813/6500-1 15 - 41
15 - Engine
21 - Oil Filter
00 - General

Oil Figure 169.
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, D
diesel fuel or paraffin to clean your skin.
CAUTION! It is illegal to pollute drains, sewers F
or the ground. Clean up all spilt fluids and/or E
waste disposal sites. D Filter head
CAUTION! Oil will gush from the hole when the drain E Seal
plug is removed. Keep to one side when you remove F Filter canister
the plug.
CAUTION! The oil filter canister will contain some oil
which could spill out when you remove the canister.
15 - 42 9813/6500-1 15 - 42
15 - Engine
21 - Oil Filter
00 - General
Operation
At Engine Running
The oil pump delivers oil at pressure to the oil filter
via a port. The anti-drain seal is forced off its seat and
oil flows through a large area paper element. Filtered
oil enters the inner part filter before leaving the filter
head via a port.
At Engine Stopped
With the engine stopped oil pressure in the galleries
and filter decays. The anti-drain seal falls on
its seat and oil is prevented from draining from
the filter assembly. The anti-drain pipe prevents
approximately half the filters oil capacity from
draining. These features help protect the engine from
oil starvation on start up.
15 - 43 9813/6500-1 15 - 43
15 - Engine
21 - Oil Filter
00 - General
Check (Level)
1. Make the machine safe. Refer to (PIL 01-03). 3. Open the engine compartment cover. Refer to
(PIL 06-06).
2. Wait for the specified duration after the engine
has stopped before you check the oil level. This 4. Remove the dipstick. Refer to Figure 170.
gives time for the oil to drain into the oil sump.
Duration: 15min
Figure 170.
D
C
A Engine oil filler cap B Dipstick

C Hydraulic filler cap D Fuel filter
5. Check that the oil level is between the two marks

on the dipstick.
6. Never operate the engine with the oil level below
the low mark or above the high mark. Poor
engine performance or damage can occur.
7. If necessary, add oil as follows:
7.1. Remove the filler cap. Refer to Figure 170.
7.2. Add the recommended oil through the filler
point until it is at the correct level on the
dipstick.
8. Install the dipstick.
9. Install the filler cap.
(PIL 06-06).
15 - 44 9813/6500-1 15 - 44
15 - Engine
21 - Oil Filter
00 - General
Remove
Refer to PIL (01-03).
D
PIL (06-06).
F
3. Remove the filler cap. E
4. Drain the engine oil as follows:

4.1. Make sure that the engine is warm.
D Filter head
4.2. Remove the undershield cover. Refer to E Seal
(PIL 06-06). F Filter canister
4.3. Put a suitable container underneath of the
drain hose. Install
4.4. Connect the drain hose to the quick release 1. Fill the new filter canister with the correct grade
coupling. of oil. Refer to (PIL 75-03).
4.5. Allow oil to drain.
2. Make sure that the oil filters are installed with a
4.6. Disconnect the drain hose from the quick filter bypass valve.
release coupling.
3. Apply a thin layer clean oil to the seal.
4.7. Install the undershield cover. Refer to (PIL
06-06). 4. Install the seal on the new filter canister.
Figure 171. 5. Install the new filter canister until it just touches
the filter head.
6. Rotate the filter canister to further 3/4 of a turn.
Figure 173.
A
7. Top up the correct grade of oil through the filler
neck. Refer to (PIL 75-03).
A Quick release coupling 8. Install the filler cap.
5. Remove the filter canister. 9. Close the engine compartment cover. Refer to
PIL (06-06).
6. Make a note that the filter canister will be full of
oil. 10. Start the engine.
7. Clean the surface of the gasket on the filter head. 10.1. If there is no oil pressure within the
specified duration after the engine is
started, stop the engine to decrease the
risk of engine damage.
Duration: 15s
11. Check the system for leaks.
15 - 45 9813/6500-1 15 - 45
15 - Engine
21 - Oil Filter
00 - General

13. Let the engine cool for specified duration.
Duration: 10min
14. Check the oil level again.
15 - 46 9813/6500-1 15 - 46
15 - Engine
24 - Air Filter
24 - Air Filter
Contents Page No.
15-24-00 General ........................................................................................................................... 15-49

15-24-09 Dust Valve ...................................................................................................................... 15-54
15 - 47 9813/6500-1 15 - 47
Notes:
15 - 48 9813/6500-1 15 - 48
15 - Engine
24 - Air Filter
00 - General
Introduction .................................................... 15-49 Engine performance and durability will be severely
Health and Safety .......................................... 15-50 affected if the quality of the air intake is poor.
Check (Condition) .......................................... 15-50
Remove and Install ....................................... 15-51 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 - 49 9813/6500-1 15 - 49
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 - 50 9813/6500-1 15 - 50
15 - Engine
24 - Air Filter
00 - General
Remove and Install
Remove 4. Inspect the hose, as follows:
1. Make the machine safe with the lift arm lowered. 4.1. If damaged, replace the hose.
Refer to (PIL 01-03). 4.2. Make sure that the hose is free from
contamination.
(PIL 06-06). 4.3. If the hose is plugged or full of contaminant
then use a low volume of compressed air to
3. Loosen the clamp and disconnect the hose. clean it.
5. Open the retention latches (x4).
Figure 174.
6. Carefully remove the filter cover in an upward
direction. Refer to Figure 175.
6.1. Use suitable ladder to access the air filter.
7. Push down the filter with the handle 1 and loosen
the seal. This will tilt the filter then remove the
filter element in an upward direction. Refer to
Figure 175.
B
C
A Air filter
B Clamp
C Hose
15 - 51 9813/6500-1 15 - 51
15 - Engine
24 - Air Filter
00 - General
Figure 175.
E
D
D
E
F
D Retention latches E Filter cover

F Handle 1 G Filter element
8. Inspect the safety filter, as follows: Refer to Figure 176.

Figure 176.
8.1. Remove any excess dirt and wipe out the
housing with a damp cloth. H
8.2. Visually inspect the safety filter. J
8.3. Do not remove it unless it is damaged or
due for replacement. The safety filter should
be replaced after every three primary filter
changes.
9. If necessary, remove the safety filter as follows:
9.1. Use the plastic handle on the face of the
safety filter.
9.2. Pull the filter towards the centre of the
housing and remove it.
H Safety filter element

J Handle 2
15 - 52 9813/6500-1 15 - 52
15 - Engine
24 - Air Filter
00 - General
9.3. Make sure that the outlet tube sealing area

is clean and undamaged.
9.4. If the safety filter is removed and the new
filter is not to be installed immediately, be
sure to cover the seal tube with a cloth to
avoid contamination.
9.5. Wipe the air cleaner housing interior with a
clean damp cloth.
Install
removal procedure.
2. Visually check for cuts, tears, or indentations on
the sealing surfaces before installation. If any
damage is visible, do not install.
3. Make sure that the inlet and outlet connections
are in good condition. Replace the rubber
connectors if necessary and reset the service
indicator.
15 - 53 9813/6500-1 15 - 53
15 - Engine
24 - Air Filter
09 - Dust Valve
09 - Dust Valve 11. Check the condition of the hoses. If necessary,

replace them.
Check (Condition) 12. Install the dust valve to the T-piece.

13. If removed, install the hose 1.
The dust valve allows any water in the hose to drain
away. It is recommended to inspect the dust valve, 13.1. Connect the hose 1.
every time you change the air filter. Refer to (PIL 13.2. Install the clamp 2.
78-24).
14. Install the T-piece at its correct position.
15. Install the clamp 1 (x2).
(PIL 06-06).
4. Remove the cooling bay covers. Refer to (PIL
06-06).
5. Loosen the clamp 1 (x2).
6. Remove the T-piece from the hose 1 and hose 2
with the dust valve.
7. If necessary, remove the hose 1.
7.1. Loosen the clamp 2.
7.2. Disconnect the hose 1.
8. Remove the dust valve from the T-piece.
Figure 177.
D
E
C
C
B
A F
A Dust valve
B T-piece
C Clamp 1 (x2)
D Hose 1
E Clamp 2
F Hose 2
G Air filter
9. Clean the dust valve and the T-piece.
10. Make sure that the dust valve and the T-piece are
not damaged. If necessary, replace them.
15 - 54 9813/6500-1 15 - 54
15 - Engine
27 - Crankcase Ventilation Filter
Contents Page No.
15-27-00 General ........................................................................................................................... 15-57
15 - 55 9813/6500-1 15 - 55
Notes:
15 - 56 9813/6500-1 15 - 56
15 - Engine
00 - General
Introduction .................................................... 15-57 The engine is installed with a filtered open loop
Remove and Install ....................................... 15-58 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 - 57 9813/6500-1 15 - 57
15 - Engine
00 - General
Remove and Install
Remove
3. Open the engine compartment access cover.
4. Remove the oil filler cap.
5. Remove the capscrews.
6. Remove the CCV (Crankcase Ventilation) filter
cover.
7. Remove the CCV filter from the rocker cover.
8. Do not disturb the CCV filter gasket located on
the rocker cover.
9. If damaged, remove and discard the gasket.
Figure 178.
B
C
E D A
A CCV filter
B Capscrews
C Oil filler cap
D Gasket
E Rocker cover
Install
step.
2. Tighten the capscrews to the correct torque
value.

Item Nm
B 7
15 - 58 9813/6500-1 15 - 58
15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ........................................................................................................................... 15-61
15 - 59 9813/6500-1 15 - 59
Notes:
15 - 60 9813/6500-1 15 - 60
15 - Engine
63 - Mount
00 - General
Introduction .................................................... 15-61 Engine mounts support the engine and in some
Remove and Install ....................................... 15-62 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 - 61 9813/6500-1 15 - 61
15 - Engine
63 - Mount
00 - General
Remove and Install
Consumables 2. Make sure that the engine is safe to work on. If

Description Part No. Size the engine has been running, let it cool before
Waxoyl 4004/0501A 0.4L you start the service work.
4004/0502 5L 3. Support the engine with suitable lifting
4004/0505 200L equipment.
4. Remove the engine front mount from the
Remove machine as follows:
Figure 179.
W V
A X
E
B
X
V
Y F
C
A Engine B Bolt 1 (x6)

C Mounting bracket (x2) D Chassis
E Mount (x2) F Locknut 1 (x4)
V Washer 1 (x4) W Bolt 2 (x2)
X Washer 2 (x4) Y Locknut 2 (x2)
4.1. Remove the bolt 1 (x6). 4.4. Remove the engine mount from the
chassis.
4.2. Remove the locknut 1 (x4) and washer 1
(x4) from the engine mount. 5. Remove the engine rear mount from the machine
4.3. Remove the bolt 2 (x2), locknut 2 (x2) and as follows:
washer (x4).
15 - 62 9813/6500-1 15 - 62
15 - Engine
63 - Mount
00 - General
Figure 180.
L U
S
R
J
P
H N
Q
T
G Rear mount plate H Resilient mount

J Locking plate (x2) K Bolt 3 (x2)
L Washer 3 (x2) M Locknut 3 (x2)
N Bolt 4 (x4) P Washer 4 (x4)
Q Locknut 4 (x8) R Setscrew (x8)
S Overload washer T Rebound washer
U Boss
5.1. Remove the setscrews (x8) and locknut 4 5.5. Remove the rebound washer, resilient
(x8). mount and overload washer.
5.2. Lift the engine and transmission assembly 5.6. Remove the bolt 4 (x4), washers 4 (x4) and
away from the machine. Refer to (PIL locking plate (x2).
15-00).
5.7. Collect the boss (x4).
5.3. Use a suitable stand to support the engine
5.8. Remove the rear mount plate from the
and transmission assembly.
transmission.
5.4. Remove the bolt 3 (x2), locknut 3 (x2) and
washers 3 (x2).
15 - 63 9813/6500-1 15 - 63
15 - Engine
63 - Mount
00 - General
Install
step.
2. Apply locking fluid to the bolt 3 before installation.
Consumable: Waxoyl
3. Tighten the nuts to the correct torque value.
4. Apply Waxoyl to the bolt 4 after you tighten it.

Item Nm
B 74
F 74
K 360
N 520
R 43
W 74
15 - 64 9813/6500-1 15 - 64
15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ........................................................................................................................... 15-67
15 - 65 9813/6500-1 15 - 65
Notes:
15 - 66 9813/6500-1 15 - 66
15 - Engine
72 - Alternator
00 - General
Introduction .................................................... 15-67 The alternator is a three phase generator having a
Health and Safety .......................................... 15-68 rotating field winding and static power windings.
Technical Data ............................................... 15-68
Component Identification ............................... 15-69 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Check (Condition) .......................................... 15-69 warning light to the field winding. This creates
Remove and Install ....................................... 15-71 a magnetic field which supplements the residual
magnetism in the rotor poles. As the engine is
started, the FEAD (Front End Accessory Drive)
belt drives the rotor and the alternating current is
generated in the power windings as they are cut by
the rotating magnetic field. Output is controlled by a
solid state regulator which varies the field current in
accordance with electrical demand.
15 - 67 9813/6500-1 15 - 67
15 - Engine
72 - Alternator
00 - General
Health and Safety Technical Data

• Ensure that the battery negative terminal is Refer to Electrical System- General, Technical Data
connected to the earthing cable. (PIL 33-00).
• Never make or break connections to the battery
or alternator, or any part of the charging circuit
whilst the engine is running. Disregarding this
instruction will result in damage to the regulator
or rectifying diodes.
• Main output cables are 'live' even when the
engine is not running. Take care not to earth
connectors in the moulded plug if it is removed
from the alternator.
• During arc welding on the machine, protect the
alternator by removing the moulded plug (or if
separate output cables installed, remove the
cables).
• If slave starting is necessary, connect the
second battery in parallel without disconnecting
the vehicle battery from the charging circuit.
The slave battery may then be safely removed
after a start has been obtained. Take care to
connect batteries positive to positive, negative
to negative.
15 - 68 9813/6500-1 15 - 68
15 - Engine
72 - Alternator
00 - General
Component Identification Check (Condition)

Figure 181.
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 182.
Check 2
The following checks should be made using an
analogue (moving pointer) type Multimeter.
15 - 69 9813/6500-1 15 - 69
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 183. 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. RH slider to DC (Direct Current) voltage.
voltage. 8.4. LH slider,Refer to Figure 184.
2.2. If the reading is zero, check the cables
9. AVO 2003
for continuity, particularly at the starter
terminals. 9.1. Red lead to amps socket (A) on the
Multimeter.
3. If the voltage is correct, check the alternator.
9.2. Black lead to negative on Multimeter.
Alternator Charging Test 9.3. RH slider to DC voltage
Figure 184. 9.4. LH slider to 200 Shunt
10. FLUKE 85
10.1. Red lead to volts socket (V ) on Multimeter.
10.2. Black lead to COM socket on Multimeter.
10.3. Set dial to mV.
11. Start the engine and run at maximum speed
(see Technical Data). Multimeter should show
maximum alternator output in Amps (see
Technical Data). The Multimeter reading should
be taken as soon as possible after starting the
engine, as the charging current will fall rapidly.
12. A zero reading indicates failure of the alternator
and may be caused by one of the following
conditions. These are listed in the order of
1. Make sure that all battery and alternator probability.
connections are in place, secure and making
good metal to metal contact, especially the earth 12.1. Defective suppression capacitor.
connections to chassis and engine.
12.2. Dirty slip rings or worn brushes.
2. Make sure that the alternator drive belt tension is 12.3. Defective regulator.
correctly adjusted.
12.4. Defective rectifier.
3. If the battery is in a fully charged condition, before
commencing the test switch on the working lights 12.5. Open or short circuited field (rotor)
for windings.
Duration: 3min 12.6. Open or short circuited power (stator)
windings.
15 - 70 9813/6500-1 15 - 70
15 - Engine
72 - Alternator
00 - General
13. To check for a fault, disconnect the capacitor and Remove and Install
repeat the charging test. Renew the capacitor if
necessary.
14. To check for faults with the slip rings, bushes or
Remove
regulator, remove the regulator and brush box 1. Make the machine safe with the lift arm lowered.
assembly. Check the condition of the brushes Refer to (PIL 01-03).
and, if necessary, clean the slip rings using extra-
fine glass paper. The regulator may only be 2. Make sure that the engine is safe to work on.
renewed. If the engine has been running, make sure the
engine has cooled sufficiently before you start
15. Faults with the rectifier, rotor and stator may be the removal.
checked only by removing and dismantling the
alternator for further testing. 3. Remove the ignition key.
4. Open the engine access cover. Refer to (PIL
06-06).
5. Disconnect the battery negative (-) lead followed
by the battery positive (+) lead. Refer to (PIL
33-03).
6. Remove the drive belt. Refer to (PIL 15-18).
7. Disconnect the electrical leads from the
alternator terminals. Label the leads to make
sure that they are installed in the correct positions
on assembly.
8. Remove the alternator link capscrew.
9. Remove the alternator mounting capscrew.
10. Remove the alternator from the machine.
11. If necessary, remove the bolt and lever.
Figure 185.
B
A
E
D
C
A Alternator
B Alternator mounting capscrew
C Alternator link capscrew
D Lever
E Bolt
Install
removal procedure.
2. Make sure to reconnect the electrical leads to the
alternator in the correct positions.
15 - 71 9813/6500-1 15 - 71
15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ........................................................................................................................... 15-73
15 - 72 9813/6500-1 15 - 72
15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................... 15-73 The electric starter motor is either a permanent-
Health and Safety .......................................... 15-74 magnet or a series-parallel wound direct current
Component Identification ............................... 15-74 electric motor with a starter solenoid mounted on to
Check (Condition) .......................................... 15-75 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Remove and Install ....................................... 15-77 the solenoid engages a lever that pushes out the
drive pinion on the starter driveshaft and meshes the
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 - 73 9813/6500-1 15 - 73
15 - Engine
75 - Starter Motor
00 - General

WARNING Make the machine safe before
working on it. Park the machine on level ground Figure 186.
and lower the loader arm. Stop the engine and
remove the ignition key. Make sure the park brake 1
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. 2
Notice: Do not isolate the machine electrics
when the engine is running, this may cause
damage to the machine electrics.
1 Solenoid
2 Brush gear
3 Tie bolts
15 - 74 9813/6500-1 15 - 74
15 - Engine
75 - Starter Motor
00 - General
Check (Condition) Figure 188.
Before carrying out the multimeter tests, check

the battery condition and make sure that all the
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.
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 A Starter main terminal
start position (HS) and the controls set to enable B Commutator end bracket (Starter earth
the starter motor. The readings are shown for both connection)
12V and 24V systems. The highest values are for
machines with 24V systems. Identify the applicable 2.1. Minimum permissible reading in start
system before carrying out the tests. position
Do not operate the starter motor for more than 20s at Voltage: 9V
one time. Let the starter motor cool for at least 2min Voltage: 17V
between starts. 2.2. If the reading is within this limit, continue to
3. If the reading is outside the limit, proceed
1. Connect the multimeter across the battery to 4.
terminals.
3. Connect the multimeter between the solenoid
Figure 187. terminal and a good earth. Minimum permissible
reading in start position
Voltage: 8V
Voltage: 16V
Figure 189.
1.1. Reading in start position approximately

Voltage: 10V
Voltage: 20V
1.2. Minimum permissible reading in start C Solenoid terminal
position
4. If the reading is less than specified, connect
Voltage: 9.5V
the multimeter between the start relay switched
Voltage: 18V
output and earth. A fault is indicated with the
1.3. A low reading probably indicates a fault in wiring from the start relay to the solenoid if the
the starter motor. reading increases to
2. Connect the multimeter between the starter main Voltage: 8V
terminal and the commutator end bracket. In the Voltage: 16V
start position, the reading should not be below
the reading obtained in 1 by any more than
Voltage: 0.5V
Voltage: 1V
15 - 75 9813/6500-1 15 - 75
15 - Engine
75 - Starter Motor
00 - General
Figure 190. 5.1. If the reading is above the maximum

permissible voltage, a high resistance in the
earth lead or connections is indicated.
6. Connect the voltmeter between battery positive
and the starter main terminal. With the starter
switch off, the voltmeter should indicate battery
voltage, but it should fall to practically zero when
the switch is turned to the on position, maximum
permissible reading
Voltage: 0.25V
Figure 192.
A Starter main terminal

B Starter earth connection
C Solenoid terminal
D Start relay feed
E Start relay switched output
H Battery positive and solenoid connection
4.1. If the reading is less than specified, connect
the multimeter between the start relay feed
and earth.
4.2. A faulty start relay or a fault in the feed to
the relay solenoid is indicated if the voltage A Starter main terminal
increases to
Voltage: 8V 7. If the reading is above the maximum permissible
Voltage: 16V voltage, a high resistance is present in the
insulated lead or in the solenoid. Connect the
4.3. Check also the solenoid earth connection. multimeter between the battery positive and
The fault must be in either the starter switch solenoid connection. If the multimeter now reads
or in the wiring between the solenoid, starter zero with the switch closed, the fault is in the
switch, and the start relay, if the reading solenoid.
between terminal and earth is less than
Figure 193.
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 191.
H Battery positive and solenoid connection

8. Finally install the engine stop fuse.
B Starter earth connection
15 - 76 9813/6500-1 15 - 76
15 - Engine
75 - Starter Motor
00 - General
Remove and Install
Remove
4. Open the engine compartment access cover.
5. Disconnect the electrical harnesses from the
starter motor.
6. Put a label on the electrical harnesses to help
installation.
7. Support the starter motor.
8. Remove the capscrews (x3).
9. If installed, remove the spacers.
10. Remove the stater motor from the engine.
Figure 194.
A
A Starter motor
B Capscrews (x3)
Install
procedure. Additionally do the following step.
2. Tighten the capscrews to the correct torque
value.

Item Description Nm
B Capscrews 43
15 - 77 9813/6500-1 15 - 77
Notes:
15 - 78 9813/6500-1 15 - 78
Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-03 Tank
18-03-00 General ........................................................................................................................... 18-11
18-04 Auxiliary Tank
18-04-00 General ........................................................................................................................... 18-13
18-09 Filter
18-09-00 General ........................................................................................................................... 18-17
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-21
18-12-04 Water in Fuel Sensor ..................................................................................................... 18-23
18-18 Injection
18-18-00 General ........................................................................................................................... 18-27
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-29
18-30 Selective Catalytic Reduction (SCR)
18-30-00 General ........................................................................................................................... 18-33
18-30-03 Tank ................................................................................................................................ 18-45
18-30-06 Filter ............................................................................................................................... 18-50
9813/6500-1
2017-01-13
Acronyms Glossary
CAN Controller Area Network

DOC Diesel Oxidation Catalyst
DRT Decomposition Reaction Tube
EAT Exhaust After Treatment
HP High Pressure
HPV High Pressure Valve
IMV Inlet Metering Valve
NOx Nitrogen Oxide
9813/6500-1
2017-01-13
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3
18 - 1 9813/6500-1 18 - 1
Notes:
18 - 2 9813/6500-1 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
Fault-Finding .................................................... 18-6 requirements refer to Consumable Products (PIL
Clean ............................................................... 18-8 75-00), Technical Data, Fuel, Acceptable and
Unacceptable Fuels and Cleanliness Requirements.
For information about the fuel injection system, refer

to (PIL 18-18).
Common Rail Fuel Injection

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

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

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

inject fuel when supplied with electrical signals from
the ECM (Engine Control Module).
18 - 3 9813/6500-1 18 - 3
00 - General

Fuel Table 74.
Fuel is flammable, keep naked flames away from the
Description Data
fuel system. Stop the engine immediately if a fuel
leak is suspected. Do not smoke while refuelling or QSB 6.7 Tier 4i QSB 6.7 Tier 4f
working on the fuel system. Do not refuel with the Injection pump Bosch HP (High Bosch HP Com-
engine running. Completely wipe off any spilt fuel type Pressure) Com- mon Rail
which could cause a fire. There could be a fire and mon Rail
injury if you do not follow these precautions. Governing Electronic Electronic
Fluid Under Pressure ISO Setting N/A N/A
code
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under Injection timing Electronic Electronic
pressure and wear personal protective equipment. Maximum fuel 0.0013bar 0.0013bar
Hold a piece of cardboard close to suspected inlet restrictions (0.0psi) (0.0psi)
leaks and then examine the cardboard for signs of Fuel rail pres- 250–2,200bar 250–2,200bar
fluid. If fluid penetrates your skin, get medical help sure operating (3,623.2– (3,623.2–
immediately. range 31,883.9psi) 31,883.9psi)
WARNING! Do not open the high pressure fuel Maximum 0.81bar 0.81bar
system with the engine running. Engine operation pressure drop (11.7psi) (11.7psi)
causes high fuel pressure. High pressure fuel spray across fuel filter
can cause serious injury or death. Maximum fu- 0.19bar (2.8psi) 0.19bar (2.8psi)
Notice: Do not allow dirt to enter the fuel system. el drain line re-
Before disconnecting any part of the fuel system, strictions
thoroughly clean around the connection. When a Maximum fuel 80°C (175.9°F) 80°C (175.9°F)
component has been disconnected, for example inlet tempera-
a fuel pipe, always install protective caps and tures
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.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
waste disposal sites.
18 - 4 9813/6500-1 18 - 4
00 - General
Figure 195.
H A
G
D
C
F
B
A Chassis B Engine
C Fuel pump D Water separator
E Drain tap F Fuel hose (Pump to tank)
G Fuel hose (Filter to pump) H Fuel hose (Tank to filter)
18 - 5 9813/6500-1 18 - 5
00 - General
Fault-Finding
Fault
Fuel Consumption Excessive Table 75. Page 18-6
Fuel/Oil- Leaking from Exhaust Manifold Table 76. Page 18-6
General Fuel System Faults Table 77. Page 18-7
Exhaust Gas Recirculation Table 78. Page 18-7
Table 75. 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 76. 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 - 6 9813/6500-1 18 - 6
00 - General
Table 77. 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 78. 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 - 7 9813/6500-1 18 - 7
00 - General
Clean These contaminants can appear during

manufacture, assembly, operation and maintenance.
Cleanliness Requirements The main filter is rated at 2 micron = 0.002 mm

(0.0007874 in). The pre-filter is rated at 5 micron.
Important: Additional cleaning must be carried out Listed are a few typical comparisons of micron size:
prior to working on the high pressure fuel system.
It is extremely important the high pressure fuel Figure 196.
components and the adjacent parts of the engine
are meticulously cleaned before any components are
removed. Refer to:-Effects of Contamination.
Before starting work on the high pressure fuel

system, make sure that the working environment
is suitable. Refer to:-Maintenance Environment, C
Common Rail Fuel Injection. B
1. Refer to: Fuel - Health and Safety (PIL 18-00).
2. Clean the machine, prior to completing any A
maintenance work.
3. Clean the engine, refer to: Engine - Clean (PIL A 8 Microns
15-00). B 70 Microns
C 100 Microns
4. Remove the hoses, electrical harnesses and
ancillaries to improve access and expose any • Red Blood Cell = 8 microns (0.008 mm,
remaining trapped dirt close to the relevant high 0.000315 in).
pressure components. • Human Hair = 70 microns (0.07 mm, 0.00275
in).
5. Wash away any remaining dirt or debris and then • Grain of Salt = 100 microns (0.1 mm, 0.00394
dry the area using a compressed air jet. When in).
the area is dry use a soft clean brush to remove • The smallest particle visible to the naked eye is
sand or grit particles that remain. 40 microns (0.00157in) approximately.
Effects of Contamination The main filter and pre-filter must be changed in

accordance with the applicable service schedule
Whist the requirement for a good level of cleanliness and procedures. The water in fuel sensor must be
is well known and common practice, the introduction maintained to ensure correct operation at all times.
of high pressure common rail fuel injection
necessitates working to new levels of cleanliness. The potential for engine damage due to fuel
contamination is much greater when using common
Once inside the system, fuel circuit contaminants rail injection technology than with mechanical
greatly affect the performance and life of the fuel injection systems. This is because common rail
injection equipment. For example, contaminants in requires components with smaller manufacturing
the fuel pump will develop internal wear to cause tolerances, especially the fuel injectors. In addition,
internal leakage and hence lower discharges. Use common rail operates at much higher fuel pressures,
of poor quality fuels and poor maintenance could over five times that of mechanical systems.
also lead to contaminants entering the fuel injectors.
There is a possibility of catastrophic equipment Similar pressures are used by commercial water
failure if debris should prevent the injectors from fully jet cutting machines to cut metal. Fortunately clean
closing. The main contaminants can be classified as diesel fuel has lubricating qualities that prevents
follows: erosion of components but it is obvious that
contaminated fuel will cause serious damage at such
• Solid Particles - sand, fibres, metallic particles, high pressures.
welding scale, sealing materials and wear
particles etc. Maintenance Environment, Common
• Liquid - usually water and incompatible oils and
greases.
Rail Fuel Injection
• Gases - Air, sulphur dioxide etc. which can Depending on circumstances engine maintenance
create corrosive compounds if dissolved in the may be required in various working environments.
fluid. Obviously procedures are best carried out in a
18 - 8 9813/6500-1 18 - 8
00 - General
dedicated workshop equipped with a suitable clean site. Make sure that the replacement parts are
room, but in practice this is not always possible. still sealed inside their packaging.
• Cap all exposed ports and orifices immediately.
Maintenance procedures requiring removal or Do not leave them open.
replacement of fuel system components, particularly • High pressure fuel pipes MUST BE RENEWED
high pressure components, require special if any pipe joint is loosened or disconnected. DO
precautions to make the working environment NOT re-use the original pipe.
suitable, reducing the risk of contamination to an
absolute minimum. Vehicle Maintenance Workshop
Use the following guidelines to make sure you reduce Unless the workshop has a dedicated `sealable
the chances of fuel system contamination when clean room' work bay, precautions must still be taken.
working in different environments:
• Clean the engine, refer to (PIL 15-00). Clean the
Worksite - Open to weather engine in the dedicated area and then move it
to the workshop.
This repair site is not an acceptable location. Only • Clean the floor area around the machine.
in extreme circumstances should a machine be • Erect clean plastic sheeting to shelter the
repaired on an open site. Use the guidelines below: engine from any wind and the possibility of
debris such as dirt and dust falling from above.
• Clean the engine, refer to (PIL 15-00). If the • Ensure that workshop doors to the outside are
machine is on hard standing, clean away the kept closed. A gust of wind through an open
material washed from the engine. door will easily blow sand particles into the air.
• Place suitable clean boards on the ground
around the machine. • Make sure your work wear is clean, non-flocking
• Erect clean plastic sheeting to shelter the and lint free. If in doubt wear a new disposable
engine from wind and rain. environmental type suit.
• Wear a new disposable environmental type suit • Use clean latex gloves (non-powdered).
when working on the fuel system. If the suit
becomes contaminated with mud, move away • Before you start work make sure that all the
from the engine and change into a new suit. required replacement parts and tools are on
• Use clean latex gloves (non-powdered). site. Make sure that the replacement parts are
• Before you start work make sure that all the still sealed inside their packaging
required replacement parts and tools are on • Cap all exposed ports and orifices immediately.
site. Make sure that the replacement parts are Do not leave them open.
still sealed inside their packaging. • High pressure fuel pipes MUST BE RENEWED
• Cap all exposed ports and orifices immediately. if any pipe joint is loosened or disconnected. DO
Do not leave them open. NOT re-use the original pipe.
• High pressure fuel pipes MUST BE RENEWED
if any pipe joint is loosened or disconnected. DO
NOT re-use the original pipe.
Worksite - Closed to weather from above

This repair site is the least acceptable condition,
if possible move the machine to a more suitable
environment. Use the guidelines below:
• Clean the engine, refer to (PIL 15-00). Clean the

floor of all material washed from the engine.
• Place suitable clean boards on the ground
around the machine.
• Erect clean plastic sheeting to shelter the
engine from the wind and the possibility of
debris such as dirt and dust falling from above.
• Wear a new disposable environmental type suit
when working on the fuel system. If it becomes
contaminated with mud, move away from the
engine and change into a new suit.
• Use clean latex gloves (non-powdered).
• Before you start work make sure that all the
required replacement parts and tools are on
18 - 9 9813/6500-1 18 - 9
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-11
18 - 10 9813/6500-1 18 - 10
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 - 11 9813/6500-1 18 - 11
04 - Auxiliary Tank
04 - Auxiliary Tank
Contents Page No.
18-04-00 General ........................................................................................................................... 18-13
18 - 12 9813/6500-1 18 - 12
04 - Auxiliary Tank
00 - General
Introduction .................................................... 18-13 This machine is installed with an auxiliary fuel tank to
Component Identification ............................... 18-14 increase the fuel carrying capacity of the machine.
The auxiliary fuel tank is a separate assembly with

toolbox and steps. The total capacity of the auxiliary
fuel tank is 110L. The total usable fuel from the
auxiliary fuel tank is 105.5L.
The auxiliary fuel tank is connected to the main fuel

tank through a fuel hose and breather hose. There is
no separate filter for this tank.
18 - 13 9813/6500-1 18 - 13
04 - Auxiliary Tank
00 - General
Figure 197.
E
D
A Auxiliary fuel tank B Tank hose

C Fuel breather hose D Breather
E Bulkhead F Chassis
18 - 14 9813/6500-1 18 - 14
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-17
18 - 15 9813/6500-1 18 - 15
Notes:
18 - 16 9813/6500-1 18 - 16
09 - Filter
00 - General
Introduction .................................................... 18-17 The fuel filter consists of a paper element folded in
Remove and Install ....................................... 18-18 such a way as to give a very large surface area. It is
most important that the fuel filter is changed regularly
in accordance with the machine maintenance
schedule. Use only the correct specification filters.
18 - 17 9813/6500-1 18 - 17
09 - Filter
00 - General
Remove and Install
Remove
(PIL 06-06).
3. Remove the water separator. Refer to (PIL
18-12).
4. Remove the filter cap.
6. Be careful, the filter will be full of fuel.
7. Remove and discard the O-ring.
Figure 198.
A Filter cap
Install
steps.
2. Do not fill the new filter element with fuel before
installation.
3. Install the new O-ring.
4. Tighten the filter cap to the correct torque value.
5. Prime the fuel system.
6. Check the fuel system for leaks.

Item Description Nm
A Filter cap 38
18 - 18 9813/6500-1 18 - 18
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-21

18-12-04 Water in Fuel Sensor ..................................................................................................... 18-23
18 - 19 9813/6500-1 18 - 19
Notes:
18 - 20 9813/6500-1 18 - 20
00 - General
Introduction .................................................... 18-21 The water separator is used to separate any water
Drain and Fill ................................................. 18-22 from the fuel. It is installed downstream of the main
Remove and Install ....................................... 18-22 fuel filter.
The filter element in the water separator is a

chemically treated paper of 30 micron size. It is
designed to be used with the main fuel filter. It will
extend the service intervals and ensure optimum
protection of the fuel injection system.
18 - 21 9813/6500-1 18 - 21
00 - General
Drain and Fill Remove and Install

1. Obey all the fuel system health and safety
information. Refer to (PIL 18-00).
Remove
Refer to (PIL 01-03). 2. Open the engine compartment cover. Refer to
(PIL 06-06).
(PIL 06-06). 3. Drain the water separator. Refer to (PIL 18-12).
4. Turn the drain tap anticlockwise. 4. Remove the water in fuel sensor. Refer to (PIL
18-12).
5. Allow the fluid to drain until there is clear fuel is
visible. 5. Remove the filter cap.
6. Push the valve upwards and turn clockwise until 6. Remove the filter element.
it closes.
7. Be careful, the filter will be full of fuel.
7. Do not overtighten the drain cap.
(PIL 06-06). Figure 200.
Figure 199.
A
B
A
A Water separator
B Water in fuel sensor
A Drain tap
B Water separator
Install
step.
2. Fill the filter element with fuel.
18 - 22 9813/6500-1 18 - 22
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor Introduction

Introduction .................................................... 18-23 The water in fuel sensor is installed in the fuel
Remove and Install ....................................... 18-24 filter water bowl. A warning light will illuminate in
the instrument panel to indicate that water has
accumulated in the fuel filter water bowl and must be
drained.
18 - 23 9813/6500-1 18 - 23
04 - Water in Fuel Sensor
Remove and Install
Remove
(PIL 06-06).
4. Remove the screw from the water in fuel sensor.
5. Remove the water in fuel sensor.
Figure 201.
A Water separator
B Water in fuel sensor
Install
removal procedure.
18 - 24 9813/6500-1 18 - 24
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-27
18 - 25 9813/6500-1 18 - 25
Notes:
18 - 26 9813/6500-1 18 - 26
18 - Injection
00 - General
00 - General
Introduction
Fuel at rail pressure is continuously supplied to the

injectors via high pressure fuel pipes.
The high pressure fuel injector fuel pipes consist

of thick walled, seamless steel tubing. The ends of
the tubes are formed with conical nipples for sealing
in the sealing cones on the common rail and on
the injector at port. It is essential that the tubes
are maintained and installed correctly for safe and
effective engine operation.
Important: If the high pressure fuel pipes are

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

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

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

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

initiates several separate injections of fuel during the
compression stroke. The timing of the fuel injections
is also varied by the ECM depending on engine
operating parameters.
18 - 27 9813/6500-1 18 - 27
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-29
18 - 28 9813/6500-1 18 - 28
24 - Exhaust
00 - General
Introduction .................................................... 18-29 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-30 away from the controlled combustion inside the
Check (Condition) .......................................... 18-30 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 - 29 9813/6500-1 18 - 29
24 - Exhaust
00 - General

Exhaust Gases Excessive smoke from the exhaust stack combined
Machine exhaust gases can harm and possibly kill with a complaint of low power could be as a result of:
you or bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure • Dirt or dust (unfiltered air) ingested directly into
there is good ventilation. If possible, install an the engine, resulting in damage to the cylinder
exhaust extractor. If you begin to feel drowsy, stop bores, there will also be a possible increase in
the machine at once and get into fresh air. oil consumption.
• Air leaks from the air hose connections.
Sparks • Exhaust manifold leaks.
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
engine cover open.
18 - 30 9813/6500-1 18 - 30
30 - Selective Catalytic Reduction (SCR)
Contents Page No.
18-30-00 General ........................................................................................................................... 18-33

18-30-03 Tank ................................................................................................................................ 18-45
18-30-06 Filter ............................................................................................................................... 18-50
18 - 31 9813/6500-1 18 - 31
Notes:
18 - 32 9813/6500-1 18 - 32
00 - General
Introduction .................................................... 18-33 To meet Tier 4 emission standards, this machine has
Health and Safety .......................................... 18-34 EAT (Exhaust After Treatment) using SCR (Selective
Technical Data ............................................... 18-35 Catalytic Reduction) technology. In SCR technology
Component Identification ............................... 18-36 a liquid called DEF (Diesel Exhaust Fluid) is injected
into the exhaust gases.
Operation ....................................................... 18-37
Diagram ......................................................... 18-40 DEF is specified in standards DIN 70070 and ISO
Clean ............................................................. 18-41 22241. Most commonly known trademarks of DEF
Remove and Install ....................................... 18-42 are:
• AdBlue
• Air1
• Greenox
The SCR system consists of the engine control

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

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

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

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

ISO 22241 certified). Do not dilute DEF or mix it with
other substances, it may damage the catalyst.
When filling theDEF tank, make sure that you use

the DEF filler and not the fuel filler. Even small
amounts of DEF in the fuel tank may damage the
system. If there is any possibility that fuel has been
contaminated with DEF, the engine must not be
started before emptying and cleaning the fuel tank.
Supplementary admixtures or additives are not

allowed. Do not dilute DEF or mix it with other
substances as it may damage the catalyst. If the DEF
quality sensor detects a problem, it will cause the
engine to run at reduced power.
Be careful when handling DEF. It is aggressive to

some materials and corrosive to some metals. DEF
18 - 33 9813/6500-1 18 - 33
00 - General
becomes crystalline when in contact with air. In case Health and Safety
of a spillage, rinse with plenty of water and dry with
a clean cloth.
Diesel Exhaust Fluid (DEF)
If large quantities of DEF have been swallowed
a doctor should be called immediately. Do not
induce vomiting unless directed to do so by medical
personnel. Never give anything by mouth to an
unconscious person. Avoid prolonged or repeated
skin contact. After contact with skin wash thoroughly
with plenty of soap and water. If irritation develops
seek medical advice. Avoid contact with eyes,
skin and clothing. Wear chemical resistant gloves,
overalls and safety goggles complying with an
approved standard. If in contact with eyes, rinse
immediately with plenty of clean water. If irritation
occurs seek medical attention. Always wash hands
and arms thoroughly after handling before eating,
drinking, smoking or using the lavatory. DEF is
corrosive to some metals such as copper and
its alloys. Use only recommended storage and
dispensing systems. DEF solution is very polluting
to surface water and groundwater. DEF may not
be removed by oil separators so it is important to
isolate drainage from the dispensing area to prevent
pollution in the event of a spill. Store below 30
degrees C in a segregated, approved and labelled
area. Keep container closed.
Notice: No warranty liability whatsoever will be
accepted for failure of the emissions control system
where the failure is attributed to the quality and grade
of the diesel exhaust fluid (DEF) used.
Notice: No warranty liability whatsoever will be
accepted for failure of the emissions control system
where the failure is attributed to contamination of the
diesel exhaust fluid (DEF).
18 - 34 9813/6500-1 18 - 34
00 - General
Technical Data
Refer to Consumable Products, General, Technical

Data (PIL 75-00).
18 - 35 9813/6500-1 18 - 35
00 - General
Figure 202.
G
K
M L
G H N
E
A
J
C
F
B
A SCR (Selective Catalytic Reduction) control B ECM (Engine Control Module)

module
C Drive CAN (Controller Area Network) D Pump module
E SCR feed pump F DEF (Diesel Exhaust Fluid) tank
G DEF metering equipment H DEF precessing reactor
J DEF fill level / temperature sensor K DEF return line
L DEF delivery line M DEF intake line
N EAT (Exhaust After Treatment) module
18 - 36 9813/6500-1 18 - 36
00 - General
Operation
The ECM (Engine Control Module) and SCR operational readiness of the EAT system. Once the
(Selective Catalytic Reduction) control module system is released, the SCR feed pump, which is an
together control and regulate the basic function of integral part in the pump module, gets engaged. This
the SCR technology used in the EAT (Exhaust After SCR feed pump takes in the DEF (Diesel Exhaust
Treatment) system. Fluid) from the DEF tank and pumps it to the DEF
metering equipment through the DEF feed line.
After you switch on the engine, the ECM starts
an automatic background test routine to check the
Figure 203.
G
K
M L
G H N
E
A
J
C
F
B
A SCR control module B ECM

C Drive CAN (Controller Area Network) D Pump Module
E SCR feed pump F DEF tank
G DEF metering equipment H DEF processing reactor
J DEF fill level / temperature sensor K DEF return line
L DEF delivery line M DEF intake line
N EAT module
The DEF injection into the exhaust flow is not a accordingly. The DEF metering equipment injects
constant process, so the DEF flows through the DEF the DEF into the hydrolysis segment in the DEF
return line back to the DEF tank. This circulation processing reactor.
takes place continuously, irrespective of whether
DEF is actually injected. This results in circulation The DEF mixes with the exhaust and in the first
cooling, which protects the DEF metering equipment stage of the process, decomposes to form ammonia
installed directly on the DEF processing reactor from (NH3). Together with the nitrogen oxide molecules
damage due to overheating. NOx (Nitrogen Oxide) generated during combustion,
the ammonia (NH3) created continues as part of
Reduction of NOx the exhaust flow to the SCR catalytic converter.
The honeycomb in the latter consists of titanium
The SCRcontrol module determines the amount and dioxide (TiO2), tungsten oxide (WO3) and vanadium
time of the injection of the DEF into the exhaust pentoxide (V2O5). This honeycomb structure acts
flow and activates the DEF metering equipment as a catalyst and converts the NH3 NOx and into
harmless nitrogen (N2) and water vapour (H2O).
18 - 37 9813/6500-1 18 - 37
00 - General
Figure 204.
R
P Q S
P Exhaust gas from engine Q Hydrolysis section

R SCR catalyst S Exhaust gas after reduction
18 - 38 9813/6500-1 18 - 38
00 - General
Operational Monitoring
The number of diagnostics routines continuously
monitor the system. If necessary, diagnostic trouble
codes are issued and operational restrictions are
activated.
Heater
In order to ensure operational safety even in the
event of frost, the DEF lines and the components are
combined with heaters.
Run-on
Depending on the installed position, operating
conditions and ambient temperature, system run-
on may be necessary to ensure cooling. The SCR
control module determines the duration for the
cooling. The supply of power must be safeguarded
throughout the entire run-on period. Do not isolate
the system until the run-on period is complete. Make
sure the LED (Light Emitting Diode) next to the
isolator key has gone out before you isolate the
machine.
18 - 39 9813/6500-1 18 - 39
00 - General
Diagram
Figure 205.
A
B
G
H
M J N K
E C D
F L
A Exhaust gas B NOx (Nitrogen Oxide)

C Water D Nitrogen
E Ammonia F DEF (Diesel Exhaust Fluid) (AdBlue)
G NOx sensor upstream of SCR (Selective H Temperature sensor, exhaust gas upstream of
Catalytic Reduction) catalyst urea metering unit
J Temperature sensor upstream of SCR catalyst K Temperature sensor downstream of SCR
catalyst
L NOx sensor downstream of SCR catalyst M Urea metering unit
N Catalytic converter
18 - 40 9813/6500-1 18 - 40
00 - General
Clean
1. Inspect the aftertreatment SCR (Selective
Catalytic Reduction) catalyst around the weld
areas for cracks or any damage. If necessary,
replace it.
2. Inspect the aftertreatment SCR catalyst inlet for
DEF (Diesel Exhaust Fluid) deposits. If any build-
ups are present, carefully scrape the build-up
with a non-metallic object to clean the build-up
from the catalyst.
2.1. Do not use a mechanical device to remove
DEF deposits from the aftertreatment SCR
catalyst.
2.2. Do not use a pressure washer to remove
DEF deposits from the aftertreatment SCR
catalyst.
2.3. If crystallization build-up was present after
installation, complete a stationary SCR/
exhaust system cleaning. Make sure that
any of the remaining DEF crystallization
is removed from the aftertreatment SCR
catalyst.
3. Inspect the exhaust flanges for corrosion or other
damage.
4. Use a putty knife to remove any residual gasket
material from the flanges on the aftertreatment
SCR catalyst.
4.1. Avoid dropping fragments of gasket
material into the aftertreatment SCR
catalyst.
5. Do not grind on the flange surface, as this can
damage the flange and cause the connection to
leak.
6. Inspect the V-band clamps and mounting straps
for signs of over extension.
7. Make sure that the V-band is not bent or
damaged.
8. Inspect the V-band clamp and mounting strap
threads for damage. If necessary, replace them.
18 - 41 9813/6500-1 18 - 41
00 - General
Remove and Install
Remove 3. Open the engine compartment cover. Refer to

(PIL 06-06).
4. Disconnect all the hoses and electrical
2. Make sure that the engine is safe to work on. If connectors from the aftertreatment units.
the engine has been running, make sure that the
engine has cooled sufficiently before you start 5. Put a label on the hoses to help installation.
the removal procedure.
contamination.
Figure 206.
C
A
A SCR (Selective Catalytic Reduction) unit B DRT (Decomposition Reaction Tube) unit
C DOC (Diesel Oxidation Catalyst) unit
7. Remove the SCR unit as follows: 8.2. Remove the clamp 2 (x2) from the DRT unit.
7.1. Support the SCR unit. 8.3. Disconnect the DRT unit from the exhaust
pipework.
7.2. Remove the clamp 1 (x2) from the SCR unit.
8.4. Discard the gaskets.
7.3. Disconnect the SCR unit from the exhaust
pipework. 8.5. Loosen the nut from the U-clamp.
7.4. Discard the gaskets. 8.6. Remove the U-clamp.
7.5. Loosen the nut from the bolt clamp 1. 8.7. Remove the DRT unit from the engine.
7.6. Remove the bolt clamp 1. 9. Remove the DOC unit as follows:
7.7. Remove the SCR unit from the engine. 9.1. Support the DOC unit.
8. Remove the DRT unit as follows: 9.2. Remove the clamp 2 (x2) from the DOC
unit.
8.1. Support the DRT unit.
18 - 42 9813/6500-1 18 - 42
00 - General
9.3. Disconnect the DOC unit from the exhaust 9.5. Loosen the nut from the bolt clamp 2.
pipework.
9.6. Remove the bolt clamp 2.
9.4. Discard the gaskets.
9.7. Remove the DOC unit from the engine.
Figure 207.
G B
F H F
D
A E
F J
C
K
A SCR unit B DRT unit

C DOC unit D Clamp 1
E Bolt clamp 1 F Exhaust pipework
G Clamp 2 H U-clamp
J Clamp 3 K Bolt clamp 2
18 - 43 9813/6500-1 18 - 43
00 - General
Install
step.
Torque: 17N·m
18 - 44 9813/6500-1 18 - 44
03 - Tank
03 - Tank Introduction
Introduction .................................................... 18-45 The DEF (Diesel Exhaust Fluid) tank stores the
Drain and Fill ................................................. 18-46 DEF. It is very important that only clean DEF is
Remove and Install ....................................... 18-47 used. Use of any other fluid will contaminate and
potentially cause damage to the SCR (Selective
Catalytic Reduction) system.
18 - 45 9813/6500-1 18 - 45
03 - Tank
Drain and Fill Fill

1. Make sure that the area around the filler is clean
The SCR (Selective Catalytic Reduction) tank level to prevent SCR system contamination.
must be checked and filled every time the main diesel
tank is filled. The machine must not be run with the 2. Remove the DEF tank filler cap.
tank empty.
3. Fill the tank with clean DEF.
The tank must never be filled with anything other than 4. Install the DEF tank filler cap.
the DEF (Diesel Exhaust Fluid) specified in Technical
Data. Refer to (PIL 18-30).
Drain
Figure 208.
1 DEF tank
2 Drain plug (hidden)
1. Get access to the drain plug.
2. Position a container of suitable size under the
drain plug
3. Remove the drain plug and let the DEF drain out.
4. Dispose of any unused DEF according to local
regulations.
5. Install the drain plug. Tighten to the correct
torque value. Refer to the relevant machine
service manual for the correct torque value.
18 - 46 9813/6500-1 18 - 46
03 - Tank
Remove and Install
Remove 7. Put a label on the hoses to help installation.
1. Make the machine safe. Refer to (PIL 01-03). 8. Plug all the open ports and hoses to prevent
contamination.
2. Remove the undershield. Refer to (PIL 06-06).
9. Remove the clamp from the DEF tank filler hose
3. Drain the DEF (Diesel Exhaust Fluid) tank. and breather hose.
3.1. Put a suitable container under the DEF 10. Disconnect the DEF filler hose and breather hose
tank. from the DEF tank.
3.2. Remove the drain plug. 11. Remove the button clips (x4).
3.3. Remove and discard the O-ring.
12. Remove the DEF tank insulation cover.
3.4. Allow all the DEF to drain.
13. Remove the bolt (x2) and washer (x2) from the
3.5. Clean the drain plug. lower clamp.
3.6. Install the new O-ring.
14. Remove the lower clamp from the machine.
3.7. Install the drain plug.
15. Support the DEF tank.
16. Loosen the nut from the J-bolt.
5. Disconnect the DEF hoses.
17. Remove the upper clamp.
6. Disconnect the coolant hoses.
18. Remove the DEF tank from the machine.
Figure 209.
K
F J
L
N
E
M D
G
P
C H
A DEF tank B Filler hose
18 - 47 9813/6500-1 18 - 47
03 - Tank
C Breather hose D DEF module

E DEF hoses F Coolant hoses
G Lower clamp H Setscrew (x2)
J Upper clamp K Nut (x2)
L J-bolt (x2) M DEF level sender
N Button clips (x4) P DEF tank insulation cover
18 - 48 9813/6500-1 18 - 48
03 - Tank
Install
removal procedure.
18 - 49 9813/6500-1 18 - 49
06 - Filter
06 - Filter Introduction
Introduction .................................................... 18-50 The DEF (Diesel Exhaust Fluid) filter is located in the
Remove and Install ....................................... 18-51 pump supply module. It is designed to filter all the
contamination that is generated through use to the
required level of cleanliness.
It is important that the filter is changed in accordance

with the machine maintenance schedule. Use only
the correct specification filters.
18 - 50 9813/6500-1 18 - 50
06 - Filter
Remove and Install
Remove Figure 210.
1. Make the machine safe. Refer to (PIL 01-03). A
2. Make sure that the engine is safe to work on.

If the engine has been running, make sure the
the removal.
D B
3. Open the engine compartment cover. Refer to C
(PIL 06-06). E
4. Remove the filter cap from the DEF (Diesel
Exhaust Fluid) module.
4.1. If necessary, use the specified wrench to
remove the filter cap. A DEF module
B Filter element
Dimension: 27mm C Filter cap
D Filter equalizing element
5. Remove and discard the filter equalizing
E Service tool
element.
6. Remove and discard the filter element.
6.1. Use the appropriate end of the service tool,
depending on the color of the plastic on the
filter.
6.2. A disposable service tool is supplied with
the filter to aid in filter removal.
6.3. When you insert the tool, a 'click' sound is
heard which indicates proper engagement
with the filter.
18 - 51 9813/6500-1 18 - 51
06 - Filter
Figure 211.
A DEF module B Filter element

C Filter cap
18 - 52 9813/6500-1 18 - 52
06 - Filter
Install
step.
2. Tighten the filter cap to the correct torque value.

Item Nm
C 20
18 - 53 9813/6500-1 18 - 53
Notes:
18 - 54 9813/6500-1 18 - 54
21 - Cooling System
Contents Page No.
21-00 Cooling System

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ........................................................................................................................... 21-13
21-03-15 Fan ................................................................................................................................. 21-16
21-05 Fan Motor
21-05-00 General ........................................................................................................................... 21-21
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-35
21-09 Pump
21-09-00 General ........................................................................................................................... 21-39
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-43
21-93 Hose
21-93-00 General ........................................................................................................................... 21-47
9813/6500-1
2017-01-25
Acronyms Glossary
CAC Charge Air Cooler

LP Low Pressure
PTFE Polytetrafluoroethylene
9813/6500-1
2017-01-25
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9813/6500-1 21 - 1
Notes:
21 - 2 9813/6500-1 21 - 2
21 - Cooling System
00 - Cooling System
00 - General
Introduction ...................................................... 21-3 During the working cycle of the engine a great deal
Health and Safety ........................................... 21-4 of heat is generated. It is important that the engine is
Technical Data ................................................. 21-4 kept at its normal operating temperature to achieve
Component Identification ................................. 21-5 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Fault-Finding .................................................... 21-7 quickly and then maintain it.
Drain and Fill ................................................... 21-9
Check (Level) ................................................ 21-10
21 - 3 9813/6500-1 21 - 3
21 - Cooling System
00 - Cooling System
00 - General

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the Table 81.
cap, hot coolant can spray out and burn you. Description Data
Make sure that the engine is cool before you work
on the cooling system. Coolant pressure cap 15bar (217.4psi)
setting
CAUTION Antifreeze can be harmful. Obey the Coolant temperature 82–110°C (179.5–
manufacturer's instructions when handling full (normal) 229.8°F)
strength or diluted antifreeze.
Thermostat opens at 88°C (190.3°F)
Thermostat fully opens 97°C (206.5°F)
at
Capacity 35L
21 - 4 9813/6500-1 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Figure 212.
P B
E
C
G
D
H F
J
A
A Cooling pack B Cooling fan guard

C Expansion tank D Breather hose (Cooler to tank)
E Expansion tank filler point F Expansion tank mounting bracket
G Water hose (Inlet) H CAC (Charge Air Cooler) pipe (Cooler to inlet)
J Breather hose (Engine) K CAC pipe (Outlet to cooler)
L Water hose (Outlet) M Engine
N Chassis P Rear bulkhead
21 - 5 9813/6500-1 21 - 5
21 - Cooling System
00 - Cooling System
00 - General
Figure 213.
Q Cooling fan (Behind the fan guard) R Fan motor mounting

S Fan motor
21 - 6 9813/6500-1 21 - 6
21 - Cooling System
00 - Cooling System
00 - General
Fault-Finding
Fault
Coolant - Loss. Table 82. Page 21-7
Coolant - Over Temperature. Table 83. Page 21-7
Coolant - Under Temperature. Table 84. Page 21-8
Coolant - Contaminated. Table 85. Page 21-8
Table 82. 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 83. 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 83. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 82. 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 - 7 9813/6500-1 21 - 7
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 84. 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 85. 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 82. Coolant - Loss.
gasket, cylinder head and crankcase.
SCR system leak.
(2)
See Also: Table 82. Coolant - Loss.
(2) If installed
21 - 8 9813/6500-1 21 - 8
21 - Cooling System
00 - Cooling System
00 - General
Drain and Fill Figure 214.

A
Make a note that the illustration shows a typical
C
expansion tank. The actual expansion tank installed
on the machine may look different.

2. Stop the engine.
(PIL 06-06). B
5. Carefully loosen the cap just enough to let any A Cap
pressure escape. B Bottom radiator hose
C Expansion tank
6. Remove the cap when all pressure is released.
7. Disconnect the bottom radiator hose.
8. Allow the coolant to drain into a suitable
container.
9. Pour clean water into the filler port to flush the
system.
10. Reconnect the radiator hose.
11. Fill the expansion tank, use the correct anti-
freeze solution, to the level indicated.
12. Run the engine for a while to raise the coolant to
working temperature and pressure.
14. Check the cooling system for leaks.
15. Check the level in the expansion tank. If
necessary, fill the expansion again.
21 - 9 9813/6500-1 21 - 9
21 - Cooling System
00 - Cooling System
00 - General
Check (Level) 3.9. Check the cooling system for leaks. Refer
to (PIL 21-00).
Note: Never use a sealing additive to stop a leak in Note: When the machine is operated on slopes
the cooling system. The additive can cause problems greater than 35%, make sure that the coolant is at its
with the cooling system and cause the engine to maximum level. The header tank low level warning
overheat. may appear if the machine is operated on slopes
greater than 35% for a prolonged period of time.
Note: The machine must be level when the coolant
is checked to make sure that the measurement is
correct.

(PIL 06-06).
3. Check the level of coolant in the coolant
expansion tank. If necessary, fill the coolant tank
as follows:
Figure 215.
A Coolant expansion tank

B Coolant filler cap
3.1. Use a work platform to get safe access to
the filler cap of the coolant expansion tank.
3.2. Slowly turn the filler cap to the first notch
to release any pressure from the cooling
system.
3.3. Remove the filler cap.
3.4. Do not add coolant to a hot engine.
3.5. Fill the coolant system with the
recommended fluid to the correct level.
3.6. Install the filler cap and make sure it is tight.
3.7. Run the engine until the coolant is at its
operating temperature and pressure.
3.8. Stop the engine.
21 - 10 9813/6500-1 21 - 10
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ........................................................................................................................... 21-13

21-03-15 Fan ................................................................................................................................. 21-16
21 - 11 9813/6500-1 21 - 11
Notes:
21 - 12 9813/6500-1 21 - 12
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction .................................................... 21-13 The cooling pack can contain sections for charge
Clean ............................................................. 21-14 air cooling, engine coolant, transmission fluid and
Remove and Install ....................................... 21-14 hydraulic oil cooling.
The different sections can be replaced individually

when you remove the bolts from their top and bottom
mounting plates, though in order for a section to be
replaced, the whole cooling pack will need to be
removed from the machine.
21 - 13 9813/6500-1 21 - 13
21 - Cooling System
03 - Cooling Pack
00 - General
Clean Remove and Install

CAUTION If you use compressed air for cleaning CAUTION This component is heavy. It must only
the equipment, do so with extreme caution. Take be removed or handled using a suitable lifting
care not to blow debris at yourself or other method and device.
persons or into machinery. Use eye protection.

Remove
1. Observe all the HVAC (Heating Ventilation
Air Conditioning) system health and safety
(PIL 06-06).
information. Refer to (PIL 12-00).
3. Pull the cable to release the Antiluce fastener.
2. Remove the engine compartment cover. Refer to
4. Move the condenser away from the cooling pack. (PIL 06-06).
Figure 216. 3. Disconnect the all the cooling system hoses.

D
4. If necessary, remove the air filter from the
B machine. Refer to (PIL 15-24).
C
5. Remove the condenser from the cooling pack.
A
6. Remove the expansion tank from the machine.
7. Support the cooling pack with suitable lifting
equipment.
8. Remove the bolt (x4) and washers (x4) from the
mounting.
9. Remove the cooling pack from the machine.
A Condenser
B Cooling pack
C Cable
D Antiluce fastener
5. Use a soft brush to remove debris from both
sides of the cooling pack.
6. Use a LP (Low Pressure) air line with maximum
specified air value to clean debris from the
cooling pack fins.
Pressure: 1bar (14.5psi)
7. Make sure that you keep the air nozzle at a
minimum specified distance from the cooling
pack.
Distance: 300mm
21 - 14 9813/6500-1 21 - 14
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 217.
E
D
A Cooling pack
B Bolt (x4)
C Washer (x4)
D Mounting
Install
removal procedure.
21 - 15 9813/6500-1 21 - 15
21 - Cooling System
03 - Cooling Pack
15 - Fan
15 - Fan Introduction
Introduction .................................................... 21-16 The engine cooling fan is a key component of the
Health and Safety .......................................... 21-17 engine’s cooling system. The cooling fan circulates
Adjust ............................................................ 21-17 air through the radiator to dissipate excess engine
Remove and Install ....................................... 21-19 heat.
21 - 16 9813/6500-1 21 - 16
21 - Cooling System
03 - Cooling Pack
15 - Fan
Health and Safety Adjust

Special Tools
Turning the Engine
Do not try to turn the engine by pulling the fan or fan Pressure Gauge (0-400 892/00279 1
belt. This could cause injury or premature component Bar)
failure.
Uni-Directional Fan
Speed check
1. Install the specified pressure gauge to the test
point on the engine driven fan drive pump to
measure the fan motor pressure. Refer to Figure
218.
Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
1)
2. Attach tacho reflective tape to the fan hub. Do not
attach it to the fan blades.
3. Warm up the hydraulic system until the hydraulic
temperature gauge shows a reading.
4. Hold the engine at maximum specified RPM
(Revolutions Per Minute). Refer to Engine-
Technical Data (PIL 15-00).
5. Check the fan reaches its recommended
operating speed (1300 RPM).
Speed adjustment
The Uni-directional fan motors will have inverse
proportional relief valve on the motor body.
1. Open the rear grille and get access to the fan

motor.
2. Loosen the locknut on the fan motor.
21 - 17 9813/6500-1 21 - 17
21 - Cooling System
03 - Cooling Pack
15 - Fan

D
D
A
D Test point
3. Attach tacho reflective tape to the fan hub. Do not
attach it to the fan blades.
4. Warm up the hydraulic system until the hydraulic
A Fan motor temperature gauge shows a reading.
B Inverse proportional relief valve 5. Hold the engine at maximum specified RPM.
C Locknut
D Test point 6. Measure the fan speed and record.
3. Adjust the fan speed as required. Tighten the 7. Measure the feed pressure to the fan for normal
locknut to increase the fan speed and loosen to direction of rotation and record.
decrease.
8. Set the fan to the reverse direction of rotation
4. If the fan exceeds the required speed, reduce the and measure the pressure. Record the pressure
speed to at least 100 RPM below the requirement obtained.
then increase slowly to obtain the correct speed.
The maximum fan motor pressure in both the
5. When you adjust the fan speed, make sure that direction of rotation should not be more than 160bar
the pressure should not exceed the specified (2,318.8psi). It is normal for the reverse rotation fan
value. RPM not to match the forward rotation RPM.
Pressure: 160bar (2,318.8psi)
Speed adjustment
6. Tighten the locknut and check the fan speed
again. In the bi-directional fan motor, there are two adjusters
on the fan motor.
Bi-Directional Fan
• The inverse proportional valve controls the
Speed check speed of the fam motor..
• The directional control valve controls the
1. Turn the adjusters on the fan motor fully in a direction of rotation.
clockwise direction and tighten the locknuts.
2. Install the specified pressure gauge to the test
point on the engine driven fan drive pump to
measure the fan motor pressure.
1)
21 - 18 9813/6500-1 21 - 18
21 - Cooling System
03 - Cooling Pack
15 - Fan
Figure 220. Remove and Install
The Cooling Fan, remove and install procedure

is given in the Fan Motor, remove and install
procedure. Refer to Fan Motor, remove and install
E (PIL 21-03-27).
F
E Direction control valve
F Inverse proportional relief valve
G Locknut
1. Open the rear grille and get access to the fan
motor.
2. Loosen the locknut on the inverse proportinal
valve and adjust the speed simultaneously.
3. Adjust the fan speed as required. Tighten the
locknut to increase the fan speed and loosen to
decrease.
4. When you adjust the fan speed, make sure that
the pressure should not exceed the specified
value.
Pressure: 160bar (2,318.8psi)
5. Tighten the locknut and check the fan speed
again.
6. If the fan exceeds the required speed, reduce the
speed to at least 100 RPM below the requirement
then increase slowly to obtain the correct speed.
7. Adjust the direction control valve to control the
forward and reverse rotation of the fam motor.
21 - 19 9813/6500-1 21 - 19
21 - Cooling System
05 - Fan Motor
05 - Fan Motor
Contents Page No.
21-05-00 General ........................................................................................................................... 21-21
21 - 20 9813/6500-1 21 - 20
21 - Cooling System
05 - Fan Motor
00 - General
Introduction .................................................... 21-21 Two different types of motors can be installed in the
Health and Safety .......................................... 21-22 cooling fan.
Component Identification ............................... 21-22
Check (Condition) .......................................... 21-23 • Uni-directional.
• Bi-directional.
Disassemble and Assemble .......................... 21-27 The uni-directional motor rotates in clockwise
direction.
The direction of rotation of bi-directional motor can be

reversed thorough the electrically operated direction
control valve.
21 - 21 9813/6500-1 21 - 21
21 - Cooling System
05 - Fan Motor
00 - General

Hydraulic Pressure Figure 221.
Before connecting or removing any hydraulic hose, A
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 C B
D
penetrates your skin, get medical help immediately.
A Fan
B Drive coupling
C Fan motor
D Direction control valve
21 - 22 9813/6500-1 21 - 22
21 - Cooling System
05 - Fan Motor
00 - General
Check (Condition) there is no sign of scoring on it. Loading against

the gear side faces of the bushes can cause
bright polished areas on them. These areas are
1. You must thoroughly clean, carefully examine more likely on the low pressure side.
and check each component of the fan motor is in
good condition. 2. Check if there is a half-moon shaped witness
mark on the bushing where the tip of the
2. If any of the components are not suitable for use opposing gears wipe an overlap. There must be
then replace the complete fan motor. no noticeable wear step as it is critical that the
bush side face is completely flat on the gear side
3. When you disassemble the motor, always face.
replace all of the seals.
3. The bush bearing liners are acceptable for use
4. Use only genuine JCB parts. if they have no scores. If they have a bronze
5. Use the following guidelines to check the appearance through the grey surface or show
condition of the components of the fan motor. any prominent signs of wear then they must be
replaced.
Body
Gears
1. Inspect the body bore cut-in on the inlet side
where the gears wipe the body. The body can 1. Inspect the gear side faces for brushing or
only be re-used if the cut-in is bright and polished scoring. The operation of the motor with
in appearance and the depth does not exceed contaminated fluid, shows the scoring between
the specified. the root of the gear and the journal, which leaves
a wear step.
Dimension: 0.08mm
2. If a wear step can be felt coincident with the
2. Make sure that the there are no scores or 'matt' root diameter by drawing a fingernail across the
appearance on the body of the fan motor. surface from the journal outwards to the tip of the
gear, then the gear must be replaced.
3. During operation the tip of the gears may have
dug in or torn away surface material. Make sure 3. Carefully examine the gear teeth and make sure
that the there are no signs of damage. that there are no signs of scuffing or pitting on the
involute face.
4. Make sure that there is no superficial damage on
the body. This can adversely affect performance 4. Make sure that the journal bearing surfaces
or sealing. are completely free from scoring or bruising.
The surface should appear highly polished and
5. Carefully examine the port threads and body O- smooth to the touch.
ring seal recesses for damage.
5. Inspect the area where the shaft seal lips run on
Mounting Flange and End Cover the driveshaft, this shows up as a polished ring or
rings. If a noticeable groove can be felt or there
1. Do an inspection of the inner surfaces of the is scoring the shaft must be replaced.
mounting flange and end cover.
6. The gears can be reused if the driveshaft has not
2. Make sure that there is no unusual wear or been damaged from the drive coupling and the
scoring in the body O-rings and bush seals gears are not damaged.
contact areas. This could result in external
leakage.
3. Check the shaft seal recess for scoring or
damage that could result in oil leakage around
the outer diameter of the shaft seal.
4. If necessary, install the replacement shaft seals
with Loctite hydraulic sealant to overcome slight
damage in shaft seal areas.
Bushes
1. Make sure that the side faces of the bushes that
are in contact with the gears are perfectly flat and
21 - 23 9813/6500-1 21 - 23
21 - Cooling System
05 - Fan Motor
00 - General
Remove and Install
Remove 8. Remove the fan motor mounting with the fan and
fan guard.
9. Support the fan motor assembly.
(PIL 06-06). 10. Remove the screws 2 (x6) and washers 2 (x6)
that attach the fan to the fan drive coupling.
3. Disconnect the electrical connections from the
motor. 11. Remove the fan from the coupling.
4. Disconnect the hydraulic hoses from the fan 12. Remove the coupling nut.
motor.
13. Remove the fan drive coupling.
14. Remove the screws 3 (x2) that attach the motor
6. Plug all the open ports and hoses to prevent to the fan guard.
contamination.
15. Remove the motor from the machine.
7. Remove the screws 1 (x6) and washers 1 (x6).
Figure 222.
F
D
A
E
A
B
H
J
21 - 24 9813/6500-1 21 - 24
21 - Cooling System
05 - Fan Motor
00 - General
A Screws 1 B Washers 1
C Fan motor mounting D Screw 2
E Washer 2 F Fan
G Coupling nut H Coupling
J Screws 3 K Fan guard
L Motor M Hoses
21 - 25 9813/6500-1 21 - 25
21 - Cooling System
05 - Fan Motor
00 - General
Install
step.

Item Nm
D 43
J 43
21 - 26 9813/6500-1 21 - 26
21 - Cooling System
05 - Fan Motor
00 - General
Disassemble and Assemble
Consumables 2. Mark the gear housing, front housing and rear

Description Part No. Size housing to make sure of correct alignment when
Surface Cleaning Fluid 4103/1204 1L you assemble the fan motor.
3. Hold the fan motor in a vice on the housing, with
1. Before you remove or disassemble the motor, the driveshaft pointing downwards. Use the vice
make sure that its performance is as specified soft-jaws to protect the housing.
in technical data. If necessary replace the fan
motor. 4. Loosen the bolts (x4) and remove the fan motor
Refer to: General (Page 21-21). from the vice.
2. If any of the components are not suitable for use 5. Remove the bolts (x4), washers (x4) and the rear
then replace the complete fan motor. housing.
3. If the output of the fan motor is satisfactory 6. Remove the gear housing carefully and keep on
but there is an evidence of external leakage, a clean work bench.
disassemble the fan motor and replace the seals.
7. Remove the rear bearing block, idler shaft and
4. Make sure that the external body of the fan motor the driveshaft gear.
and the work area is thoroughly cleaned and free
8. Remove the front bearing block.
from contamination.
9. Turn the housing over, with the shaft seal
5. Put a plug on all the ports and wash the exterior
upwards, and remove the retaining circlip and the
of the fan motor with a proper cleaning solvent
shaft seal.
before you disassemble the fan motor.
Consumable: Surface Cleaning Fluid 10. If necessary, remove the proportional relief valve
cartridge.
Uni-Directional Motor 11. Clean all of the sealant from the mating surfaces.
Refer to Figure 223. Consumable: Surface Cleaning Fluid
Disassemble 12. Discard all the seals and O-rings.
1. Remove the port plugs and drain the oil from the
motor.
21 - 27 9813/6500-1 21 - 27
21 - Cooling System
05 - Fan Motor
00 - General
Figure 223. Uni-Directional Motor

C
D
E
F
A
B G
R
N
K T
E
M D P
S
Q
V
A Circlip B Seal
C Front housing D Back-up ring
E E-seal F Front bearing block
G O-ring1 H Locating dowels
J Gear housing K O-ring2
L Idler gear M Driveshaft gear
N Rear bearing block P Rear housing
Q Proportional relief valve cartridge R Measuring coupling
S Spring T Ball
U Valve seat V Washer
W Bolt
21 - 28 9813/6500-1 21 - 28
21 - Cooling System
05 - Fan Motor
00 - General
Inspection 5. Apply a layer of petroleum jelly to the grooves

in the bearing blocks, E-seals (x2) and back-up
1. Clean and dry all the parts before you do an seals (x2). This will keep the seals in place.
inspection.
6. Keep the E-seals, flat side outwards, into the
2. Inspect all O-ring grooves and shaft seal front and rear bearing blocks. Carefully put the
recesses and make sure that there are no burrs. backup seals with the flat side outwards, in the
respective groove made by the E-seal and the
3. Inspect the driveshaft for damage. Check for groove in the bearing block.
marks or grooves on the driveshaft in the area
of the seal. Slight discolouration of the shaft is 7. Make sure that the notches in the back-up seals
permitted. and E-seals are lined up, so that the back-up seal
sits flush with the E-seal.
4. Inspect the faces of the gears for scoring or
excessive wear. If the face of the gear is sharp, 8. Keep the front housing, with the seal side facing
it can damage the bearing block. If you find any downwards on a clean flat surface.
signs of wear, replace the parts.
9. Apply a thin layer of petroleum jelly to the
5. Inspect the bearing blocks for excessive wear or exposed face of the front bearing block.
scoring on the surfaces that are in contact with
the gears. 10. Insert the drive end of the driveshaft through the
front bearing block with the seal side down, and
6. Inspect the bearing for excessive wear or the open side of the E-seal pointing to the intake
damage. side of the motor.
7. Inspect the area inside the gear housings. It is 11. Install a sleeve over the driveshaft threads
normal for the surface inside the gear housing to protect the shaft seal. Slide the driveshaft
to show a clean “wipe” on the surface of the carefully through the seal and then remove the
intake side. There should not be excessive wear sleeve from the driveshaft.
or scoring.
12. Install the idler gear shaft into the remaining
8. Replace the fan motor, if you find any of the position in the bearing block.
following defects:
13. Apply a thin layer of clean hydraulic oil to the face
8.1. The gear cut-in track on the low pressure of the driveshaft and idler gears.
side of the body is deeper than the specified
or has a scarred and matt appearance. 14. Keep the rear bearing block on the driveshaft and
idler gear shafts with the seals facing upwards
Dimension: 0.08mm and the open ends of the E-seals facing the
8.2. The PTFE (Polytetrafluoroethylene) coated intake side of the motor.
bearings in the body or flanges are worn
through so that the bronze base is visible. 15. Make sure that the dowel pins are in place in
the gear housing. On later housings there are
8.3. The gear side faces or bearing blocks are two long dowels through the housing that locate
scarred. in the front mounting flange and the rear cover.
8.4. The driveshaft has a wear groove where the These replace the four short dowels.
shaft seal lips run. 16. Apply a layer of petroleum jelly to the seal
grooves in both sides of the gear housing.
Assemble
17. Apply a thin layer of petroleum jelly on the O-
1. Wash all the components in a suitable ring1 and O-ring2 and install them in the gear
aromatic solvent. When dry apply hydraulic fluid housing.
immediately to prevent moisture collecting.
18. Move the gear housing downward over the rear
2. Install a new shaft seal into the front housing, bearing block until the dowel pins come in contact
with the part number of the seal facing outwards. with their respective bores in the front housing.
Press the new seal into its bore until it fully seats.
19. Press the housing together with your hands. Do
3. Install the circlip into its groove in the front not force or use any tool.
housing.
20. Make sure that the intake port in the housing is
4. Keep the front and rear bearing blocks on a on the same side as the open end of the rear E-
clean work bench with the E-seal grooves facing seal and that the marks made on the housing are
upwards. aligned.
21 - 29 9813/6500-1 21 - 29
21 - Cooling System
05 - Fan Motor
00 - General
21. The surface of the rear bearing block should be Bi-Directional Motor
slightly below the face of the gear housing. If
the bearing block sits higher than the rear face Refer to Figure 224.
of the housing then the E-seal or O-ring may
have become detached from its seat and maybe Disassemble
trapped. Remove the housing and check the
seals for correct installation. 1. Remove the port plugs and drain the oil from the
motor.
22. Install the rear housing onto the dowels in the
housing. Make sure that the marks made on 2. Mark the solenoid operated control valve, gear
the housing are aligned and press the housing housing and front housing to make sure of correct
together with hand pressure only. alignment when you assemble the fan motor.
23. Install the bolts (x4) and washers (x4). 3. Hold the fan motor in the vice on the housing,
with the driveshaft pointing downwards. Use a
24. Hold the fan motor in the vice on the housing, with soft jaw vice to protect the housing.
the driveshaft pointing downwards. Use a soft-
jaw vice to protect the housing. 4. Loosen the bolts (x4) and remove the fan motor
from the vice.
Refer to Table 87. 5. Remove the bolts (x4), washers (x4) and the
solenoid operated control valve.
26. Remove the fan motor from the vice.
6. Remove the gear housing carefully and keep on
27. Put a small amount of clean hydraulic oil in the a clean work bench.
inlet of the motors and rotate the driveshaft away
from the inlet by one revolution. If the driveshaft 7. Remove the rear bearing block, idler shaft and
binds, disassemble the motor and check for the driveshaft gear.
assembly problems. Rectify the problems and
assemble the motor again. 8. Remove the front bearing block.
28. If removed, install the proportional relief valve 9. Turn the housing over, with the shaft seal
cartridge. Tighten it to the correct torque valve. upwards, and remove the retaining circlip and the
Refer to Table 87. shaft seal.
10. If necessary, remove the proportional relief valve
Table 87. Torque Values cartridge.
Item Description N·m 11. Clean all sealant from the mating surfaces.
Q Proportional re- 40 Consumable: Surface Cleaning Fluid
lief valve car-
tridge 12. Discard the seals and O-rings.
W Bolt 56
21 - 30 9813/6500-1 21 - 30
21 - Cooling System
05 - Fan Motor
00 - General
Figure 224. Bi-Directional Motor
C
D
E
A
B F
P
M
J D
L
R
Q
A Circlip B Shaft seal

C Front housing D Seal
E Front bearing block F O-ring1
G Gear housing H Locating dowels
J O-ring2 K Idler gear
L Driveshaft gear M Rear bearing block
N Solenoid operated control valve P Proportional relief valve cartridge
Q Bolt R Washer
21 - 31 9813/6500-1 21 - 31
21 - Cooling System
05 - Fan Motor
00 - General
Inspection 4. Keep the front and rear bearing blocks on a

clean work bench with the seal grooves facing
1. Clean and dry all the parts before you do an upwards.
inspection.
5. Apply a layer of petroleum jelly to the grooves in
2. Inspect all O-ring grooves and shaft seal the bearing blocks and seals (x2). This will keep
recesses and make sure that there are no burrs. the seals in place.
3. Inspect the driveshaft for damage. Check for 6. Position the seals, flat side outwards, into the
marks or grooves on the driveshaft in the area front and rear bearing blocks.
of the seal. Slight discolouration of the shaft is
permitted. 7. Position the front housing, with the seal side
facing downwards on a clean flat surface.
4. Inspect the faces of the gears for scoring or
excessive wear. If the face of the gear is sharp, 8. Apply a thin layer of petroleum jelly to the
it can damage the bearing block. If you find the exposed face of the front bearing block.
wear, replace the parts.
9. Insert the drive end of the driveshaft through the
5. Inspect the bearing blocks for excessive wear or front bearing block with the seal side down.
scoring on the surfaces that are in contact with
the gears. 10. Install a sleeve over the driveshaft threads
to protect the shaft seal. Slide the driveshaft
6. Inspect the bearing for excessive wear or carefully through the seal and then remove the
damage. sleeve from the driveshaft.
7. Inspect the area inside the gear housings. It is 11. Install the idler gear shaft into the remaining
normal for the surface inside the gear housing position in the bearing block.
to show a clean “wipe” on the surface of the
intake side. There should not be excessive wear 12. Apply a thin layer of clean hydraulic oil to the face
or scoring. of the driveshaft and idler gears.
8. Replace the fan motor, if you find any of the 13. Position the rear bearing block on the driveshaft
following defects: and idler gear shafts with the seals facing
upwards and the open ends of the E-seals facing
8.1. The gear cut-in track in the low pressure the intake side of the motor.
side of the body is deeper than the specified
or has a scarred and matt appearance. 14. Make sure that the dowel pins are in place in
the gear housing. On later housings there are
Dimension: 0.08mm two long dowels through the housing that locate
8.2. The PTFE coated bearings in the body or in the front mounting flange and the rear cover.
flanges are worn through so that the bronze These replace the four short dowels.
base is visible.
15. Apply a layer of petroleum jelly to the seal
8.3. The gear side faces or bearing blocks are grooves in both sides of the gear housing.
scarred.
16. Apply a thin layer of petroleum jelly on the O-
8.4. The driveshaft has a wear groove where the ring1 and O-ring2 and install them in the gear
shaft seal lips run. housing.
Assemble 17. Move the gear housing downward over the rear
bearing block until the dowel pins come into
1. Wash all the components in a suitable solvent. contact with their respective bores in the front
When dry apply hydraulic fluid immediately to housing.
prevent moisture collecting.
18. Press the housing together with your hands. Do
Consumable: Surface Cleaning Fluid not force or use any tool.
2. Install a new shaft seal into the front housing, 19. Make sure that the intake port in the housing is
with the part number of the seal facing outwards. on the same side as the open end of the rear E-
Press the new seal into its bore until it fully seats seal and that the marks made on the housing are
in. aligned.
3. Install the circlip into its groove in the front 20. The surface of the rear bearing block should
housing. be slightly below the face of the gear housing.
If the bearing block sits higher than the rear
21 - 32 9813/6500-1 21 - 32
21 - Cooling System
05 - Fan Motor
00 - General
face of the housing then the seal or O-ring may

have become detached from its seat and maybe
trapped. Remove the housing and check the
seals for correct installation.
21. Install the solenoid operated control valve onto
the dowels in the housing. Make sure that the
marks made on the housing are aligned and
press the housing together with hand pressure
only.
22. Install the bolts (x4) and washers (x4).
23. Hold the fan motor in the vice on the housing,
with the driveshaft pointing downwards. Use a
soft jaws vice to protect the housing.
Refer to Table 88.
25. Remove the fan motor from the vice
26. Put a small amount of clean hydraulic oil in the
inlet of the motors and rotate the driveshaft away
from the inlet by one revolution. If the driveshaft
binds, disassemble the motor and check for
assembly problems. Rectify the problems and
assemble the motor again.
27. If removed, install the proportional relief valve
cartridge. Tighten it to the correct torque valve.
Refer to Table 88.

Item Description N·m
P Proportional re- 40
lief valve car-
tridge
Q Bolt 56
21 - 33 9813/6500-1 21 - 33
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-35
21 - 34 9813/6500-1 21 - 34
21 - Cooling System
06 - Expansion Tank
00 - General
Introduction .................................................... 21-35 The expansion tank retains coolant that has been
Component Identification ............................... 21-36 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 - 35 9813/6500-1 21 - 35
21 - Cooling System
06 - Expansion Tank
00 - General
Component Identification Remove and Install

Figure 225.
Remove
A B G 1. Make the machine safe. Refer to (PIL 01-03).
C 2. Make sure that the engine is safe to work on. If

D
E (PIL 06-06).
F 4. Drain the cooling system. Refer to (PIL 21-00).
5. Remove the hoses from the coolant expansion
tank. (PIL 21-93).
6. Disconnect the electrical connection from the
coolant level sensor.
A Expansion tank 7. Remove the clips (x2) from the coolant level
B Filler cap hoses.
C Level indicator
D Level tube 8. Disconnect the coolant level hose 1 and hose 2
E Level sensor from the expansion tank.
F Mounting bracket
G Rear bulkhead 9. Put a label on the hoses to help installation.
contamination.
11. Remove the coolant level sensor from the
coolant level tube.
13. Remove the coolant level tube with coolant level
hoses.
15. Remove the expansion tank from the machine.
21 - 36 9813/6500-1 21 - 36
21 - Cooling System
06 - Expansion Tank
00 - General
Figure 226. Table 89. Torque Values

Item Nm
A E 3
B
F,G C
J,K H
D
A Expansion tank
B Clips (x2)
C Coolant level hose 1
D Coolant level hose 2
E Coolant level sensor
F Screws 1 (x2)
G Washers 1 (x2)
H Coolant level tube
J Screws 2 (x3)
K Washers 2 (x3)
Install
steps.
2. Make a note of the following when you install the
coolant level sensor.
2.1. Check the condition of the coolant level
sensor for terminal build up. If necessary,
replace it.
2.2. Hand tighten the coolant level sensor.
2.3. Tighten the coolant level sensor to the
2.4. Make sure that the pin connector is in a
vertical position with the connector pins
facing upwards.
2.5. If necessary, further tighten the coolant level
sensor through the specified angle to bring
pin connector in a vertical position.
Angle: 180–270°
3. Check the coolant level and top up to the correct
level. Refer to (PIL 21-00).
21 - 37 9813/6500-1 21 - 37
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-39
21 - 38 9813/6500-1 21 - 38
21 - Cooling System
09 - Pump
00 - General
Introduction .................................................... 21-39 The coolant pump is a centrifugal type located in the
Operation ....................................................... 21-40 front of the crankcase, driven by the engine drive belt.
The impeller rotates to circulate the coolant through
the cooling system. The pump shaft bearing and seal
are not renewable.
21 - 39 9813/6500-1 21 - 39
21 - Cooling System
09 - Pump
00 - General
Operation Remove and Install
The coolant pump is driven via a pulley and front end Remove
accessory drive belt, the pump draws coolant from
the pump cavity. The coolant is pumped through the 1. Make the machine safe. Refer to (PIL 01-03).
outlet gallery to the oil cooler cavity in the left-hand
side of the crankcase. As the coolant flows past the 2. Make sure that the engine is safe to work on. If
oil cooler matrix, heat is exchanged from the oil to the the engine has been running, make sure that the
coolant. This enables the oil to function as a coolant engine has cooled sufficiently before you start
as well as a lubricant. the removal.
For cooling system operation. Refer to (PIL 21-00). 3. Remove the engine drive belt. Refer to (PIL
15-18).
4. Support the cooling pump.
5. Remove the screws (x2).
6. Remove the cooling pump from the engine.
7. Remove and discard the seal.
Figure 227.
A Cooling pump
B Screws (x2)
Install
step.

Item Nm
B 30
21 - 40 9813/6500-1 21 - 40
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-43
21 - 41 9813/6500-1 21 - 41
Notes:
21 - 42 9813/6500-1 21 - 42
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-43 The thermostat is located between the engine and
Check (Condition) .......................................... 21-44 the radiator. The function of the thermostat is to block
Remove and Install ....................................... 21-44 the flow of coolant to the radiator until the engine has
warmed up to a sufficient temperature.
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 - 43 9813/6500-1 21 - 43
21 - Cooling System
12 - Thermostat
00 - General

1. If the thermostat is suspected of being faulty,
perform a thermostat test, refer to Thermostat
Remove
- Check Operation (PIL 21-12) to confirm its 1. Make the machine safe. Refer to (PIL 01-03).
serviceability. Note that the thermostat is a non-
serviceable item. If the thermostat is faulty or 2. Make sure that the engine is safe to work on.
damaged it must be renewed. If the engine has been running, make sure the
2. Inspect the seal for damage or splits. If necessary the removal.
renew the seal. Make sure that the seal is
correctly located. 3. Isolate the battery. Refer to (PIL 33-03).
(PIL 06-06).
5. Drain the coolant. Refer to (PIL 21-00).
6. Disconnect the upper radiator hose. Refer to (PIL
21-03).
8. Remove the coolant outlet connection.
9. Remove the thermostat from the engine.
Figure 228.
C B
A Thermostat
B Coolant outlet connection
C Capscrew
Install
step.
2. Tighten the capscrew to the correct torque value.
3. Fill the cooling system. Refer to (PIL 21-00).
4. Run the engine and check for leaks.

Item Nm
C 10
21 - 44 9813/6500-1 21 - 44
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-47
21 - 45 9813/6500-1 21 - 45
Notes:
21 - 46 9813/6500-1 21 - 46
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-47 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-48 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-48 between the engine and the radiator/cooling pack.
21 - 47 9813/6500-1 21 - 47
21 - Cooling System
93 - Hose
00 - General

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the 1. Visually inspect the engine and related cooling
cap, hot coolant can spray out and burn you. components for:
Make sure that the engine is cool before you work
on the cooling system. 1.1. Leaks.
1.2. Cracked, burnt or perished hoses.
1.3. Hose clips are in good condition and
tightened to the correct torque value.
21 - 48 9813/6500-1 21 - 48
21 - Cooling System
93 - Hose
00 - General
Remove and Install
Remove 3. Drain the cooling system. Refer to (PIL 21-00).
1. Make the machine safe. Refer to (PIL 01-03). 4. Open the engine compartment cover. Refer to
(PIL 06-06).
the engine has been running, make sure that the 5. Remove the water hoses as follows:
the removal.
Figure 229. Water Hoses

A
C
L
D
R F
H,J,K,X
H,J,K
M,N,P
E
A Cooling pack B Engine

C Expansion tank D Water inlet hose
E Water outlet hose F Breather hose - cooler to tank
G Breather hose - engine H Setscrew 1 (x2)
J Washer 1 (x2) K P-clip (x2)
L Spring clamp 1 (x4) M Setscrew 2 (x2)
N Washer (x2) P Hose clip (x2)
Q Spring clamp (x4) R Support clamp
X Nut (x1)
5.1. Remove the setscrew 1 (x2), washer 1 5.4. Remove the setscrew 2 (x2), washer 2
(x2), nut (x1) and the P-clips (x2) from the (x2) and the hose clips (x2) from the water
breather hoses (x2). hoses.
5.2. Loosen the spring clamps 1 (x4). 5.5. Loosen the spring clamps 2 (x4).
5.3. Disconnect the breather hoses (x2). 5.6. Loosen and remove the support clamp.
5.7. Disconnect the water hoses.
21 - 49 9813/6500-1 21 - 49
21 - Cooling System
93 - Hose
00 - General
6. Remove the CAC (Charge Air Cooler) hoses as

follows:
Figure 230. CAC Hoses
T A
W
U
V
A Cooling pack S Spring clamps 3 (x8)

T CAC outlet pipe U CAC inlet pipe
V Moulded hose W U-clamp
6.1. Loosen the spring clamps 3 (x8).

6.2. Disconnect the CAC outlet hose.
6.3. Remove the U-clamp.
6.4. Disconnect the CAC inlet pipe from the
moulded hoses.
6.5. Remove the moulded hoses.
Install
step.
2. Tighten the clamps to the correct torque value.

Item Nm
L 5
Q 10
V 5
21 - 50 9813/6500-1 21 - 50
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-03 Service Brake
24-03-00 General ............................................................................................................................. 24-9
24-03-09 Brake Valve .................................................................................................................... 24-10
24-18 Park Brake
24-18-00 General ........................................................................................................................... 24-17
24-18-15 Pad ................................................................................................................................. 24-27
24-18-18 Caliper ............................................................................................................................ 24-30
9813/6500-1
2017-01-27
Acronyms Glossary
9813/6500-1
2017-01-27
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9813/6500-1 24 - 1
Notes:
24 - 2 9813/6500-1 24 - 2
24 - Brake System
00 - Brake System
00 - General
Introduction ...................................................... 24-3 The brake system is a full hydraulic system with
Health and Safety ........................................... 24-4 compact valve and pressure accumulators. These
Technical Data ................................................. 24-5 operate an integral axle mounted, oil immersed
Component Identification ................................. 24-6 service brakes and a single transmission park brake.
The hydraulic supply is from a transmission driven
Diagram ........................................................... 24-7 gear type hydraulic pump.
Bleed ............................................................... 24-7
The standard park brake installed on this machine
is mechanical type. Some machines can be installed
with electrical park brake option.
The park brake is hydraulically released and is a fail

safe design. It operates on the transmission propeller
shaft. An operating warning system is available
to indicate the brake position with the machine
unattended.
24 - 3 9813/6500-1 24 - 3
24 - Brake System
00 - Brake System
00 - General
Health and Safety the test has been completed, make sure all brake
system components are installed and the system is
operating correctly.
Brake Fluid
WARNING! Before testing the park brake make sure
Use of incorrect brake fluid will cause serious
the area around the machine is clear of people.
damage to the seals of the braking system. This will
result in brake failure. WARNING! If the machine starts to move during the
park brake test, immediately apply the foot brake and
Service Brake Bleeding
reduce the engine speed.
Before bleeding the service brake system, park on
WARNING! If the machine starts to move during the
level ground and set the park brake to on. Put blocks
service brake test, immediately reduce the engine
on both sides of the wheels on one axle to prevent
speed and apply the park brake.
the machine rolling. Stop the engine and disconnect
the battery so that the engine cannot be started. If WARNING! Do not use a machine with a faulty park
you do not take these precautions the machine could brake.
run over you. WARNING! Non approved modifications to drive
Park Brake Maintenance ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels WARNING! Oil on the brake disc will reduce brake
to prevent the machine rolling. Stop the engine and effectiveness. Keep oil away from the brake disc.
disconnect the battery so that the engine cannot be Remove any oil from the disc with a suitable solvent.
started. If you do not take these precautions the Read and understand the solvent manufacturer's
machine could run over you. safety instructions. If the pads are oily, install with the
new pads.
Working Under the Machine
WARNING! Faulty brakes can kill. If you have to
top up the brake reservoir frequently, get the brake
system checked by your JCB Dealer. Do not use the
machine until the fault has been put right.
has wheels use blocks to prevent unintentional WARNING! The park brake must not be used to
movement. slow the machine from travelling speed, except in an
emergency, otherwise the efficiency of the brake will
Brake Dust
be reduced. Whenever the park brake has been used
Brake pads generate dust, which if inhaled may in an emergency the brake friction components must
endanger health. Wash off the caliper assemblies be renewed and the other components inspected.
before commencing work. Clean hands thoroughly
Notice: Over adjustment or failure to disengage the
after completing the work.
park brake properly will cause excessive wear of the
Brake Dust park brake mechanism.
Brake shoes generate dust, which if inhaled
may endanger health. Make sure that dust is
removed correctly, particularly before installing
new components. Clean hands thoroughly after
completing the work.
Springs
Always wear personal protective equipment when
dismantling assemblies containing components
under pressure from springs. This will protect against
eye injury from components accidentally flying out.
Notice: Using incorrect fluid could damage the
system. See Fluids, Capacities and Lubricants for
the correct fluid. The fluid can harm your skin. Wear
rubber gloves. Cover cuts or grazes.
WARNING! Before working on the brake system,
make sure that the machine is on solid level ground.
Put blocks on all wheels to prevent the machine
rolling.
WARNING! Do not use the machine with any part of
its brake system disconnected or inoperative. When
24 - 4 9813/6500-1 24 - 4
24 - Brake System
00 - Brake System
00 - General
Technical Data
Table 93.
Brake modulation valve
Type LT07 Dual brake modulation valve
Make Rexroth
Output pressure 60bar (869.6psi)
Maximum input pressure 200bar (2,898.5psi)
Maximum flowrate 60L/min
Brake valve pressure regulator settings
Cut-in pressure 117–129bar (1,695.6–1,869.6psi)
Cut-out pressure 160–180bar (2,318.8–2,608.7psi)
Service brake operating pressure 55–65bar (797.1–942.0psi)
Pressure switch operating pressure
Low pressure warning 105bar (1,521.7psi)
Park brake warning OFF 3bar (43.5psi)
Stop lamp ON 64bar (927.5psi)
24 - 5 9813/6500-1 24 - 5
24 - Brake System
00 - Brake System
00 - General
Figure 231.
A
D
C F
C
A Brake pedal B Brake valve

C Test points D Accumulator
E Charge valve F Hoses
24 - 6 9813/6500-1 24 - 6
24 - Brake System
00 - Brake System
00 - General
Diagram Bleed
WARNING Before proceeding with the bleed
Refer to Hydraulic Schematic (PIL 30-00). procedure it is important to make sure that the
park brake is engaged and that one pair of wheels
is chocked on both sides.
The brake systems are fed from the engine driven

brake pump and incorporate brake accumulators.
These allow approximately nine applications of the
brakes with the engine stopped.
Bleed each hub separately as follows:
1. Attach a tube to the brake bleed screw, located

at the wheel hub.
2. Make sure that the free end of the tube
is immersed in fluid contained in a suitable
container.
3. Open the brake bleed screw and fully depress
the brake pedal.
4. Hold the pedal fully depressed until air free fluid
flows from the bleed screw.
5. Close the brake bleed screw with the pedal fully
depressed.
6. Repeat the procedure for the other hubs.
7. Check the hydraulic fluid level. Refer to (PIL
30-00).
24 - 7 9813/6500-1 24 - 7
24 - Brake System
03 - Service Brake
03 - Service Brake
Contents Page No.
24-03-00 General ............................................................................................................................. 24-9

24-03-09 Brake Valve .................................................................................................................... 24-10
24 - 8 9813/6500-1 24 - 8
24 - Brake System
03 - Service Brake
00 - General
00 - General
Check (Operation)
WARNING Do not use a machine with a faulty
park brake.
Accumulators back-up the foot brakes on this

machine. If there is an accumulator failure, the foot
brakes will not operate when the engine is stopped.
Check the operation of the accumulators as follows:
1. Park the machine on hard level ground, then

lower the attachments to the ground.
2. Engage the park brake, then stop the engine.
3. Operate the foot brake repeatedly, until all of the
system pressure is released.
4. Start the engine and run it at a high RPM
(Revolutions Per Minute) for specified duration.
Duration: 1min
5. Stop the engine.
6. Push the foot brake pedal repeatedly. Count the
number of operations of the brake pedal until all
of the system pressure is released.
7. One or more of the accumulators may have failed
and need immediate replacement, if:
7.1. The number of foot brake operations is less
than six.
7.2. The brake system pressure low failure
warning light illuminates immediately.
24 - 9 9813/6500-1 24 - 9
24 - Brake System
03 - Service Brake
09 - Brake Valve
09 - Brake Valve Introduction

Introduction .................................................... 24-10 The brake valve uses the vehicle's main hydraulic
Component Identification ............................... 24-11 system. When the brake pedal is actuated, the
Remove and Install ....................................... 24-13 hydraulic pump reduces the flow rate from the travel
drive. Braking then takes place using the engine’s
support torque. Only if the pedal is pressed harder
does the brake valve ensure that the brake linings
make contact.
24 - 10 9813/6500-1 24 - 10
24 - Brake System
03 - Service Brake
09 - Brake Valve
Figure 232.
G
A F
R
E
T
S
B L
K
J
N
M
D
P Q
U
W V
V U
A Pedal B Pedal mountings

C Pedal boot D Brake modulation valve
E Bearing F Spring
G Screws H Bolts
J Gasket K Nut
L Pivot tube M Adaptor 1
N Adaptor 2 P Adaptor 2
Q Pressure sensor (0–80bar (0.0–1,159.4psi)) R Bolt
S Locknut T Screws
U Test couplings V Test points
W Pressure regulator
24 - 11 9813/6500-1 24 - 11
24 - Brake System
03 - Service Brake
09 - Brake Valve
Figure 233.
B A
F D
C
E
F
A Port T to the hydraulic tank

B Port BR1 to the front brake actuators
C Port SP1 to the accumulator 1
D Port BR2 to the rear brake actuators
E Port SP2 to the accumulator 2
F Test points
24 - 12 9813/6500-1 24 - 12
24 - Brake System
03 - Service Brake
09 - Brake Valve
Remove and Install
Remove 9. Disconnect the electrical connectors.
1. Make the machine safe with the lift arm lowered. 10. Remove the bolt 2 and locknut 2 to release the
Refer to (PIL 01-03). brake pedal return spring.
2. Discharge the hydraulic pressure. Refer to (PIL 11. Collect the washers and keep them safe.
30-00).
12. Remove the brake pedal.
3. Disconnect the batteries. Refer to (PIL 33-03).
13. If damaged, remove and discard the pedal boot.
4. Remove the unwanted materials from the cab
floor. 14. Replace the bearings if they are worn too much.
5. Remove the floor mats. Refer to (PIL 09-48). 15. Remove the screw 1 (x2) and screw 2 (x2).
6. Put a label on the hoses to help installation. 16. Remove the bolt 1 (x4).
7. Disconnect the hydraulic hoses. 17. Remove the brake valve from the machine.
8. Plug all the open ports and hoses to prevent 18. Remove the adaptors from the brake valve.
contamination.
24 - 13 9813/6500-1 24 - 13
24 - Brake System
03 - Service Brake
09 - Brake Valve
Figure 234.
G
A F
R
E
T
S
B L
K
J
N
M
D
P Q
U
W V
V U
A Pedal B Pedal mountings

C Pedal boot D Brake modulation valve
E Bearing F Spring
G Screw 1 H Bolt 1
J Gasket K Nut 1
L Pivot tube M Adaptor 1
N Adaptor 2 P Adaptor 2
Q Pressure sensor (0–80bar (0.0–1,159.4psi)) R Bolt 2
S Locknut 2 T Screw 2
U Test couplings V Test points
W Pressure regulator
24 - 14 9813/6500-1 24 - 14
24 - Brake System
03 - Service Brake
09 - Brake Valve
Install
The brake valve is very important component for the
safe machine operation.
The brake valve is not a serviceable component. If it

is damaged, you must replace it.

steps.
2. Install the new O-rings.
3. Install the adaptors and their Tee pieces into the
correct ports on the brake valve.
4. Attach the brake pedal to the mounting bracket.
Make sure to engage the tangs of the return
spring in the anchor drilling.
5. Make sure that the bolt goes inside the bearings
through the spacer tube.
6. The brake pedal must pivot on the spacer tube.
The spacer tube is a sliding fit.
7. Make sure that the brake pedal does not pivot on
the bolt.
8. Make sure that the brake pedal moves freely
when the bolt is tightened.
9. Set the brake pedal accurately. Refer to (PIL
09-27-54).
24 - 15 9813/6500-1 24 - 15
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ........................................................................................................................... 24-17

24-18-15 Pad ................................................................................................................................. 24-27
24-18-18 Caliper ............................................................................................................................ 24-30
24 - 16 9813/6500-1 24 - 16
24 - Brake System
18 - Park Brake
00 - General
Introduction .................................................... 24-17 The parking brake assembly is mounted on the
Component Identification ............................... 24-18 propshaft and is the part of the gearbox unit. It is
Check (Operation) ......................................... 24-20 located below the machine and can be accessed
Bleed ............................................................. 24-21 from the front undershield access panel.
Remove and Install ....................................... 24-22 The parking brake can be operated from the cab.
Disassemble and Assemble .......................... 24-25
24 - 17 9813/6500-1 24 - 17
24 - Brake System
18 - Park Brake
00 - General
Figure 235.
L Brake unit M Brake disc
24 - 18 9813/6500-1 24 - 18
24 - Brake System
18 - Park Brake
00 - General
Figure 236.
M
A,B
K
E G J
F
H L
C,D
A Top guide pin B Top lock pin

C Bottom guide pin D Bottom lock pin
E Screw cap F Locknut
G Adjusting screw H Piston
J Nut K Set pin
N Brake pads
24 - 19 9813/6500-1 24 - 19
24 - Brake System
18 - Park Brake
00 - General
Check (Operation)
WARNING Before testing the park brake make
sure the area around the machine is clear of
people.
1. Test the brake on a level, dry surface only.

2. Fasten your seat belt.
3. Make sure that the lift arm is in the travel position.
4. Make sure that the park brake is fully engaged.
5. Set the ICCO switch to OFF.
6. Set the Auto/Manual switch to OFF.
7. Select third gear, but remain in neutral.
8. On the instrument panel, do the steps that follow:
8.1. Navigate to the service menu screen and
select the ‘Park Brake Test’ option.
8.2. Make sure that the park brake and speed
indications should be highlighted in green.
8.3. Select 'Start'.
8.4. Push down hard on the brake pedal and
select forward drive. The gear indication
should change to 'F3' and the highlight
colour should change from green to red.
8.5. Release the brake pedal.
8.6. Use the accelerator pedal to increase the
engine speed until the highlighted engine
speed turns green. The machine should
remain stationary.
8.7. After a few seconds, the instrument panel
will show a 'Passed' or 'Failed' result on the
screen.
9. Lower the attachments and stop the engine.
10. If the machine moved during this test, contact
your local JCB dealer for more information.
11. The push button park brake adjustment must be
done by a service engineer.
12. Do not use a machine with faulty brakes.
24 - 20 9813/6500-1 24 - 20
24 - Brake System
18 - Park Brake
00 - General
Bleed
1. Open the centre undershield from the rear 2. Loosen the service bleed nipple until air free fluid
chassis to get access to the park brake unit. flows from the nipple.
Figure 237.
A Service bleed nipple
3. Tighten the service bleed nipple.
24 - 21 9813/6500-1 24 - 21
24 - Brake System
18 - Park Brake
00 - General
Remove and Install
WARNING Oil on the brake disc will reduce 8. Operate the park brake switch for at least ten
brake effectiveness. Keep oil away from the times to drain the system pressure.
brake disc. Remove any oil from the disc with
a suitable solvent. Read and understand the 9. Open the service bleed nipple to make sure that
solvent manufacturer's safety instructions. If the all the pressure is dissipated.
pads are oily, install with the new pads.
10. Turn the ignition switch to OFF.
Removal 11. Remove the bottom lock pin then remove the
bottom guide pin.
1. Make sure that the disc is free of paint and oil
contamination. 12. Remove the brake pads (x2).
2. Run the engine for approximately one minute, to 13. Mark the position of the driveshaft to the flange.
charge the brake accumulators. 14. Remove the nuts and disconnect the driveshaft,
3. Stop the engine and turn the ignition switch to stow the driveshaft out of the way.
IGN. 15. Remove the set pins and remove the brake disc.
4. Release the park brake. 16. Support the brake unit and remove the top lock
5. Remove the screw cap. pin and the top guide pin.
6. Loosen the locknut with an Allen key. 17. Remove the brake unit.
7. Turn the adjusting screw anti-clockwise until the

adjusting screw protrudes outside of the piston to
the specified distance.
Distance: 27–30mm
Figure 238.
M
A,B
K
E G J
F
H L
C,D
A Top guide pin B Top lock pin
24 - 22 9813/6500-1 24 - 22
24 - Brake System
18 - Park Brake
00 - General
C Bottom guide pin D Bottom lock pin

E Screw cap F Locknut
G Adjusting screw H Piston
J Nut K Set pin
N Brake pads
24 - 23 9813/6500-1 24 - 23
24 - Brake System
18 - Park Brake
00 - General
Install
1. Keep the brake unit in position and install the top
guide pin and top lock pin.
2. Install the brake disc and secure with set pins.
3. Install the driveshaft and secure with nuts.
4. Tighten the set pin and nuts to the correct torque
value.
5. Install the brake pads. Install the bottom guide
pin and bottom lock pin.
6. Connect the brake hose.
7. Bleed the system. Refer to (PIL 24-18).
8. Adjust the brake pads. Refer to (PIL 24-18).
9. Check the park brake operation. Refer to (PIL
24-18).

Item Description Nm
J Nut 56
K Set pin 78
24 - 24 9813/6500-1 24 - 24
24 - Brake System
18 - Park Brake
00 - General
Consumables Description Part No. Size

Description Part No. Size 4002/0805 20L
JCB Hydraulic Fluid HP 4002/1001 5L 4002/0803 200L
32 4002/1025 20L
4002/1024 200L Disassemble
JCB Hydraulic Fluid HP 4002/0801 5L
46 Use the alphabetical sequence as a guide to
disassembly.Refer to Figure 239.
Figure 239.
A
E C
D
G
B
M J
P
X R
F
K H
L
N
T Q
V U
W
A Lock pin B Guide pin

C Screw cap D Seal 1
E Circlip F Spring retaining cup
G Seal 2 H Belleville washer
J Washer K Locknut
L Adjusting screw M Piston
N Seal 3 P Pressure bolt
Q Seal 4 R Seal 5
S Dust seal T Brake pads
U Magnet 1 V Magnet 2
W Brake unit X Service bleed nipple
24 - 25 9813/6500-1 24 - 25
24 - Brake System
18 - Park Brake
00 - General
Assemble
1. The assembly procedure is the opposite of the
disassembly procedure.
2. Use one of the below specified hydraulic fluid
only for cleaning and lubrication of the hydraulic
components.
Consumable: JCB Hydraulic Fluid HP 32
Consumable: JCB Hydraulic Fluid HP 46
3. Install the seal 2, seal 4 and seal 5 in the bore of
the brake unit.
4. Make sure that the seal 4 and seal 5 are installed
in the correct direction to avoid leaks.
5. Use a suitable seal installation tool with rounded
edges to prevent damage.
6. Make sure that the belleville washers are
installed correctly.
7. The dust seal may be removed by levering it out.
The new dust seal must be pressed into position.
24 - 26 9813/6500-1 24 - 26
24 - Brake System
18 - Park Brake
15 - Pad
15 - Pad Technical Data

Technical Data ............................................... 24-27 Table 95.
Check (Condition) .......................................... 24-28
Clearance between 0.5–1.5mm
Adjust ............................................................ 24-29 brake pad and disc
24 - 27 9813/6500-1 24 - 27
24 - Brake System
18 - Park Brake
15 - Pad
Check (Condition)
1. Park the machine on firm level ground and
engage the park brake.
2. Stop the engine.
3. Visually check the brake pad material thickness
of each brake pad. Make sure that the brake pad
thickness is not less than the specified.
Dimension: 1mm
4. If necessary, replace the worn brake pads. Refer
to (PIL 24-18).
24 - 28 9813/6500-1 24 - 28
24 - Brake System
18 - Park Brake
15 - Pad
Adjust
1. Make sure that the disc is free of paint and oil 4. Release the park brake.
contamination.
5. Remove the screw cap.
2. Run the engine for the specified duration to
charge the accumulator. 6. Loosen the locknut and turn the adjusting screw
clockwise until the two pads touch the brake disc.
Duration: 1min
3. Stop the engine and turn the ignition switch to
IGN.
Figure 240.
A C
B
A Screw cap B Locknut

C Adjusting screw D Brake pads
E Brake disc
7. Turn the adjusting screw anti-clockwise to set the

pad-disc clearance to the specified value.
Dimension: 0.5–1.5mm
7.1. Make a note that one half of a turn of the
adjusting screw changes the clearance by
the specified distance.
Distance: 1mm
8. Hold the adjusting screw in position with the Allen
key and tighten the locknut.
9. Install and hand tighten the screw cap.
10. Operate the park brake several times and check
the park brake operation. Refer to (PIL 24-18).
24 - 29 9813/6500-1 24 - 29
24 - Brake System
18 - Park Brake
18 - Caliper
18 - Caliper Figure 241.
Remove and Install

A
WARNING Oil on the brake disc will reduce
brake effectiveness. Keep oil away from the B
brake disc. Remove any oil from the disc with
a suitable solvent. Read and understand the
solvent manufacturer's safety instructions. If the
pads are oily, install with the new pads. G
E
Removal D
F
C
2. Release the park brake.
3. Disconnect the hydraulic pipework from the A
brake unit.
4. Remove the screw cap.
5. Loosen the nut 1 and nut 2.
6. Loosen the adjusting screw 1 and adjusting A Brake unit
screw 2. B Bolt 1
C Nut 1
7. Hold the nut 1 with a suitable spanner. D Adjusting screw 1
E Nut 2
8. Remove the bolt 1. F Adjusting screw 2
G Nut 3
9. Remove the brake unit from the machine.
Install
steps.
3. Bleed the brake system. Refer to (PIL 24-18).
4. Adjust the brake pads. Refer to (PIL 24-18).
5. Check the park brake operation. Refer to (PIL
24-18).

Item Nm
B 46
C 230
E 23
G 195
24 - 30 9813/6500-1 24 - 30
25 - Steering System
Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-01 Pump
25-01-00 General ........................................................................................................................... 25-11
25-03 Priority Valve
25-03-00 General ........................................................................................................................... 25-17
25-06 Steer Unit/Valve
25-06-00 General ........................................................................................................................... 25-19
25-12 Column
25-12-00 General ........................................................................................................................... 25-37
25-48 Manifold
25-48-00 General ........................................................................................................................... 25-45
9813/6500-1
2017-01-25
Acronyms Glossary
EMS Electronic Monitoring System

9813/6500-1
2017-01-25
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3
25 - 1 9813/6500-1 25 - 1
Notes:
25 - 2 9813/6500-1 25 - 2
00 - General
Introduction ...................................................... 25-3 The steering is controlled by the hydraulic system
Health and Safety ........................................... 25-4 and the main hydraulic pump. There are two steering
Technical Data ................................................. 25-5 rams, one either side of the central pivot articulation
Component Identification ................................. 25-6 joint. The rams articulate the front chassis in the
required direction.
Operation ......................................................... 25-7
Check (Pressure) ............................................ 25-8 A pressure relief valve is installed to guard against
shock steering loads.
A gearbox driven emergency steer pump may be

installed which provides pressure for steering in the
event of hydraulic pump or engine failure.
25 - 3 9813/6500-1 25 - 3
00 - General
Health and Safety

Engine/Steering Failure
If the engine or steering fails, stop the machine as
quickly as possible. Do not operate the machine until
the fault has been corrected.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear personal protective equipment.
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.
Hydraulic Pressure
Before connecting or removing any hydraulic hose,
25 - 4 9813/6500-1 25 - 4
00 - General
Technical Data
Table 97. Steer System

Steering control unit
Type Eaton Steering Control Unit ABV
System pressure 205bar (2,971.0psi)
Pump displacement 370 cm³/revolution (Standard option)
Steering ram
Bore 70mm
Rod diameter 40mm
Stroke 312 ± 1.6mm
Table 98. Secondary Steering Pump

Description Value
Motor 24V, 2kW, IP67 and
X9K
Pump 4.3 cm³
Relief valve pressure 40bar (579.7psi)
Operating temperature -25–80°C (-13.0–
175.9°F)
25 - 5 9813/6500-1 25 - 5
00 - General
Figure 242.
A B
A Steer valve B Steering hoses

C Steering ram
25 - 6 9813/6500-1 25 - 6
00 - General
Operation
Hydraulic oil is delivered from the hydraulic pump via

a steering priority valve to the steering valve. When
the steering wheel is turned the steering valve is
actuated and a pressure demand signal is sent to
the priority valve spool. The spool moves and directs
pressurised oil from the pump to the steering valve
and then to the steering rams.
Pressurised oil enters the ram cylinders (rod side first

ram and head side second ram) and causes the rams
to extend or retract to turn the machine in the required
direction.
25 - 7 9813/6500-1 25 - 7
00 - General
Check (Pressure)
Special Tools 2. Connect the specified pressure gauge to the test

Description Part No. Qty. point.
Pressure Gauge (0-40 892/00278 1 Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
Bar) 1)
Pressure Gauge (0-400 892/00279 1
Bar) 3. Turn on the ignition. Do not turn on the engine.
4. Let the EMS (Electronic Monitoring System)
WARNING Make sure the articulation lock is in carry out its self diagnostic test for the specified
the transport position before you transport the time.
the transport position if you are carrying out daily Duration: 4s
articulation danger zone. If the articulation lock is 5. Press and hold the emergency steer test switch
not in the transport position you could be crushed in the cab.
between the two parts of the chassis. 6. Record the pressure gauge reading.
7. Release the emergency steer test switch.
Pressure Check
8. Verify the pressure reading against the system
1. Observe all the health and safety information. maximum pressure. Refer to Steering system-
Refer to Steering System- Health and Safety (PIL Technical data (PIL 25-00).
25-00).
9. Remove the pressure gauge from the test point.
Figure 243.
A
D
C
A Test point B Nut

C Locknut D Adjuster
25 - 8 9813/6500-1 25 - 8
00 - General
Pressure Adjustment
It is only permitted to do the pressure adjustment if
the pressure is less than 50bar (724.6psi). When you
do the pressure adjustment, use a 40bar (579.7psi)
pressure gauge only. The 400bar (5,797.1psi)
analogue pressure gauge is not sensitive enough
to fine tune the output pressure. Alternatively you
can use the 400bar (5,797.1psi) calibrated digital
pressure gauge. The pressure adjuster is very
sensitive, make very small adjustments at the
adjusting screw.
1. Connect the specified pressure gauge to the test

point.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
2. Turn on the ignition. Do not turn on the engine.
3. Press and hold the emergency steer test switch
in the cab.
4. Release the emergency steer test switch.
5. It is not necessary to operate the pump when you
do the adjustment.
6. Hold the nut and release the locknut.
7. Insert the Allen key into the adjuster and turn it
as necessary to adjust the pressure.
8. After each small adjustment, tighten the locknut
and record the pressure as follows:
8.1. Turn on the ignition. Do not turn on the
engine.
8.2. Press and hold the emergency steer test
switch in the cab.
8.3. Record the pressure gauge reading.
8.4. Release the emergency steer test switch.
You must release the emergency steer
test switch before you do any further
adjustment.
9. If necessary, do the further adjustments to get the
correct specified reading. Refer to (PIL 25-00).
10. Tighten the locknut and again check the
pressure.
11. Remove the pressure gauge from the test point.
25 - 9 9813/6500-1 25 - 9
01 - Pump
01 - Pump
Contents Page No.
25-01-00 General ........................................................................................................................... 25-11
25 - 10 9813/6500-1 25 - 10
01 - Pump
00 - General
Introduction .................................................... 25-11 The secondary steering pump is an electronically
Component Identification ............................... 25-12 driven pump controlled by the EMS (Electronic
Remove and Install ....................................... 25-13 Monitoring System) system. If the EMS system
Disassemble and Assemble .......................... 25-15 detects a drop in the hydraulic pressure, at a preset
level, the EMS will switch on the secondary steering
pump. The system self tests every time the ignition
is turned on and will disable the machines starting
system if a fault is detected.
A switch is provided in the operator station for the

manual testing of the system. The pump and motor
are mounted on a bracket attached to the rear
chassis flange.
25 - 11 9813/6500-1 25 - 11
01 - Pump
00 - General
Figure 244.
A B
A Screw B Pump
C Motor
25 - 12 9813/6500-1 25 - 12
01 - Pump
00 - General
Remove and Install
CAUTION This component is heavy. It must only 5. Disconnect the hoses from the pump.
method and device. 6. Put a label on the hoses to help installation.
Remove contamination.
1. Make the machine safe with the lift arm lowered. 8. Support the weight of the pump and motor
Refer to (PIL 01-03). assembly.
2. Observe all the health and safety information. 9. Remove the locknut (x4), washers (x8) and
Refer to (PIL 25-00). setscrews (x4) from the clamp.
3. Isolate the battery. Refer to (PIL 33-03). 10. Remove the pump from the machine.
4. Remove the electrical leads from the motor.
Figure 245.
A
G
F H A
D
C
A Hoses B Electrical leads

C Locknut (x4) D Washers (x8)
E Setscrew (x4) F Clamps (x2)
G Pump H Motor
25 - 13 9813/6500-1 25 - 13
01 - Pump
00 - General
Install
step.
2. Check and adjust the system pressure. Refer to
(PIL 25-00).
25 - 14 9813/6500-1 25 - 14
01 - Pump
00 - General
Disassemble 3. Remove the screws (x4).
1. Put the pump/motor unit on a clean workbench. 4. Pull out the pump from the motor.
2. Make sure that the work area and all the tools
are thoroughly clean to prevent the unit from
contamination.
Figure 246.
A B
A Screws (x4) B Pump

C Motor
Assemble
following steps:
1.1. Clean all the parts thoroughly.
1.2. Tighten the screws to the correct torque
value.

Item Description Nm
A Screw 30
25 - 15 9813/6500-1 25 - 15
03 - Priority Valve
03 - Priority Valve
Contents Page No.
25-03-00 General ........................................................................................................................... 25-17
25 - 16 9813/6500-1 25 - 16
03 - Priority Valve
00 - General
00 - General
Remove and Install
The steer priority valve is installed on the lift arm

control valve block. Refer to Lift Arm Control Valve
Block, Disassemble and Assemble (PIL 30-51).
25 - 17 9813/6500-1 25 - 17
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ........................................................................................................................... 25-19
25 - 18 9813/6500-1 25 - 18
00 - General
Introduction .................................................... 25-19 The steer unit valve controls the amount of hydraulic
Component Identification ............................... 25-20 fluid flow in the steering system.
Operation ....................................................... 25-22
Check (Condition) .......................................... 25-26
25 - 19 9813/6500-1 25 - 19
00 - General
Figure 247.
K
G
M
H
L
F
N
P
Q
C
R
U
T E
W
D
V
X
B
Y
J A
AC AB
AA
AC
S
A Capscrew B End cap

C Meter D Seal 2
E Drive spacer F Drive
G Spacer plate H Seal 1
J Meter end seal K Retaining ring
L Gland bushing M Dust seal
N Teflon seal P O-ring 1
Q Back-up ring R Bearing race component
S Spool T Seal 3
U Setscrew V Check valve seat
25 - 20 9813/6500-1 25 - 20
00 - General
W O-ring 2 X O-ring 3
Y Check ball Z Lower check ball retainer
AA Pin AB Spring assembly
AC Sleeve
25 - 21 9813/6500-1 25 - 21
00 - General
Operation
The steering is hydraulically controlled. There are Operation 1

two steering rams installed on either side of a centre
pivot. These steer rams articulate the front chassis in The steering valve is installed as an extension of the
the required direction. steering column. The steering valve spool is installed
in the sleeve that is installed inside the housing.
The hydraulic oil is delivered from the pump through The metering unit is attached below the housing. A
the priority inlet section in the loader valve block to lobed rotor that is installed inside the metering unit
the steering valve. When the steering is turned, the is attached to the spool. The lobed rotor is driven by
steering valve is actuated and a pressure demand the spool inside the stator formed by the unit case.
signal sent to the priority inlet spool. The spool moves Refer to Figure 248.
and directs pressurised oil from the pump to the
steering valve. The pressurised oil is supplied to the steering valve
through the steering priority valve. The spring action
The pressurised oil enters the rod side of first ram of the stationary wheel holds the spool in a closed
and head side of second ram. This causes the rams centre position within the sleeve. Output from the
to extend or retract to turn the machine in the required pump is 'dead ended' and the load sensing port to
direction. the priority valve is connected to exhaust.
The PRV (Pressure Relief Valve) are installed to
guard against shock steering loads.
Figure 248.
G
C
A
E
A Steering valve B Housing

C Sleeve D Spool
E Metering unit F Lobed rotor
G Stator
When you actuate the steering column, the spool The electrically driven emergency pump supplies the
turns within the sleeve, the oil galleries get aligned steering hydraulic pressure, if the main pump is not
and the priority valve receives the demand pressure operating.
signal. The pressurised oil that goes to the steering
valve is passed through the sleeve, spool and then If the main hydraulic pump and the emergency
to the metering valve. The steering column also turns steering pump fails then the spring assisted non-
the rotor. When the rotor turns, interaction between return valve closes the supply line. When you turn
the rotor and the stator lobes pumps the oil out to the the steering wheel, it rotates the spool further until
steering rams to achieve the steering action. the sleeve gets mechanically engaged. When the
sleeve turns, oil goes to the metering unit, and this
pumps oil to the ram under manual pressure. The
oil that exhausts from the opposite side of the rams
25 - 22 9813/6500-1 25 - 22
00 - General
has sufficient pressure to lift the non-return valve. turns the steering column to take right turn, the
When the non-return valve lifts off, the pressure spool turns relative to the sleeve and a load sensing
and exhaust system gets cross connected and this signal is sent to the priority valve. The pressurised
supplements the manual operation of the steering oil is directed to the metering unit which pumps it to
system. the rod and piston sides of opposite steering rams.
Simultaneously the opposing piston and rod sides
Operation 2 - RH turn of the rams are connected to exhaust. When the
steering action stops, spring force brings the spool to
The illustration shows a flow through the steering its centre position.
valve in a right turn condition. When a operator
Figure 249.
H To priority valve
25 - 23 9813/6500-1 25 - 23
00 - General
Operation 3 - LH turn is sent to the priority valve. The pressurised oil

is directed to the metering unit which pumps it to
The illustration shows a flow through the steering the rod and piston sides of opposite steering rams.
valve in a left turn condition. When a operator turns Simultaneously the opposing piston and rod sides
the steering column to take left turn, the spool turns of the rams are connected to exhaust. When the
relative to the sleeve and a load sensing signal steering action stops, spring force brings the spool to
its centre position.
Figure 250.
H To priority valve
25 - 24 9813/6500-1 25 - 24
00 - General
Steering Shock Valve 240bar (3,478.2psi) shock relief valve senses the
pressure and holds the non-return valve 2 in closed
The steering shock valve is an integral part of the position.
steering valve. In normal operation, pressurised oil
from the pump enters the steering valve through a If an outside force generates the back pressure in
spring assisted non-return valve 1. the rams, shock relief valve opens to control the back
pressure. The oil is fed through non-return valve 3 to
The oil flow is directed to the steering rams as the opposite side of the rams preventing cavitation.
described in operation 1, 2 and 3. The steering relief
valve controls the maximum system pressure. The When the excess pressure drops, the spring action
closes the relief valve and rams revert to lock up.
Figure 251.
J
N
L
K
P A
L
K
J Non-return valve 1 K Shock valve

L Non-return valve 2 M Non-return valve 3
N Normal operation P Shock operation
25 - 25 9813/6500-1 25 - 25
00 - General
Check (Condition)
Consumables
1. Examine all contact surfaces and replace any

parts that have scratches, wear or other damage
that could cause leakage.
2. Do not use abrasive or try to file or grind the
surfaces.
3. Clean all metal parts with a solvent and blow dry
with an air line.
25 - 26 9813/6500-1 25 - 26
00 - General
Remove and Install
Remove 4. Remove the front plastic cover, wiper arm and

wiper motor.
Refer to (PIL 01-03). 5. Disconnect the hoses from the steer valve.
2. Install the articulation strut. Refer to (PIL 06-27). 6. Put a label on the hoses to help installation.
3. Access the steer valve from outside of the

operator station.
Figure 252.
B C
E
A D
A Hoses B Bolt 1
C Bolt 2 D Steer valve
E Flexible coupling
7. Remove the bolt 1 (x2). Refer to Figure 252. 1.2. Tighten the bolts to the correct torque value.
8. Remove the flexible coupling. Refer to Figure Table 100. Torque Values
252.
Item Description Nm
9. Support the steer valve. Refer to Figure 252. B Bolt 1 43
C Bolt 2 43
10. Remove the bolt 2 (x2). Refer to Figure 252.
11. Remove the steer valve from the machine.
Install
steps.
1.1. Make sure that the flexible coupling has
a specified end clearance, when it is
positioned within the splined socket of the
steer valve.
25 - 27 9813/6500-1 25 - 27
00 - General
Disassemble 2.3. Teflon seal.

2.4. O-ring 1.
1. Use the alphabetical sequence as a guide to
disassembly. Refer to Figure 253. 2.5. Back-up ring.
2. Before you remove the following items, rotate 2.6. Bearing race components.
the spool and sleeve assembly inside the valve
housing until the pin becomes horizontal. 3. Push the spool and sleeve assembly from the
valve housing just far enough to free the gland
2.1. Gland bushing. bushing.
2.2. Dust seal.
25 - 28 9813/6500-1 25 - 28
00 - General
Figure 253.
K
G
M
H
L
F
N
P
Q
C
R
U
T E
W
D
V
X
B
Y
J A
AC AB
AA
AC
S
A Capscrew B End cap

C Meter D Seal 2
E Drive spacer F Drive
G Spacer plate H Seal 1
J Meter end seal K Retaining ring
L Gland bushing M Dust seal
N Teflon seal P O-ring 1
Q Back-up ring R Bearing race component
S Spool T Seal 3
U Setscrew V Check valve seat
W O-ring 2 X O-ring 3
Y Check ball Z Lower check ball retainer
AA Pin AB Spring assembly
25 - 29 9813/6500-1 25 - 29
00 - General
AC Sleeve
25 - 30 9813/6500-1 25 - 30
00 - General
Assemble 3. Assemble the spool and sleeve as follows: Refer

to Figure 255.
1. Check the condition of all the components of the
steering valve. Refer to (PIL 25-06). 3.1. Slide the spool into the sleeve.
2. Assemble the check valve as follows: Refer to Figure 255.

Figure 254.
2.1. Put the lower check ball retainer into the AK
valve housing.
Figure 254.
U S
AC
W S Spool
V AC Sleeve
AK Spring slot
X
3.2. Rotate the spool to make sure it rotates
Y freely.
AE
3.3. Make sure that the spring slots in the spool
Z and the sleeve fully aligns.
4. Install the spring assembly on the sleeve and
spool as follows: Refer to Figure 256.
4.1. Insert the spring installation tool through the
aligned slots in the sleeve and spool.
Figure 256.
AJ
U Setscrew
AH
V Check valve seat
W O-ring 2 AF AF
X O-ring 3 AG AH
Y Check ball AJ
Z Lower check ball retainer
AE Valve housing
S
2.2. Make sure that the lower check ball retainer
is straight in the valve hole and not on its
edge.
2.3. Install the check ball into the valve housing.
AA
2.4. Lubricate the O-ring 2 and O-ring 3 and
AC
install them on the check valve seat.
2.5. Keep the check valve seat on the valve S Spool
housing open end and then push the seat AA Pin
fully into the valve housing. AC Sleeve
AF Low torque spring
2.6. Make sure that you do not twist or damage AG Spring installation tool
the O-ring 2 and O-ring 3. AH Spring spacer
2.7. Install the setscrew. Make sure that the top AJ Centering spring
of the setscrew is slightly below the valve
housing top surface. 4.2. Assemble a set of low torque springs,
extend edge downward, with a pair of spring
2.8. Tighten the setscrew to the correct torque spacers between two sets of centering
valve. springs.
25 - 31 9813/6500-1 25 - 31
00 - General
4.3. Insert one end of the assembled spring set 6.3. Install the seal 3 and bearing race
into the spring installation tool. components into the valve housing. Refer
to Figure 253.
4.4. Press the protruding end of the spring set
together and push it into the slot, at the 6.4. Install the Teflon seal, O-ring 1 and back-up
same time pull out the spring installation ring above the bearing race components.
tool. Refer to Figure 258.
4.5. Move the spring set to the centre of the Figure 258.
spool and sleeve assembly. Make sure
that the spring set pushes down evenly
and is flush with the upper surface of the
assembly.
4.6. Install the pin into the spool through the Q
sleeve. Make sure that the pin is flush with P
N
both sides of the sleeve.
5. Install the spool and sleeve assembly into the T
R
valve housing as follows: Refer to Figure 257.
5.1. Keep the spool and sleeve assembly in
position so that the splined end of the spool
enters the valve housing.
Figure 257.
S
AE AC
N Teflon tape
P O-ring 1
AD Q Back-up ring
R Bearing race components
AE T Seal 3
6.5. Install the dust seal, flat smooth side down,
into the gland bushing. Refer to Figure 259.
S Spool 6.6. Install the gland bushing and dust seal on

AC Sleeve the splined end of the spool. Refer to Figure
AD Insertion end face 259.
AE Valve housing
5.2. Push the assembly slowly into place with a
slight rotating action until the parts are flush
at the insertion end face.
5.3. Apply finger tip force to the spool splined
end to check the spool and sleeve assembly
for free rotation inside the housing.
5.4. Do not move the spool and sleeve assembly
beyond the flush position. If you do this,
the pin can drop into the housing discharge
groove. Refer to Figure 253.
6. Install the drive end seals as follows:
6.1. Keep the valve housing upright on the clean
lint free cloth.
6.2. Lubricate the seals.
25 - 32 9813/6500-1 25 - 32
00 - General

AM
K F
AC H
M
L
G
J
K AE
S AE
L AL
K Retaining ring
L Gland bushing
M Dust seal
S Spool F Drive
AC Sleeve G Spacer plate
AE Valve housing H Seal 1
J Meter end seal
6.7. Make sure that the gland bushing is flat AE Valve housing
against the bearing race. If necessary, tap AL Face line
the bushing with a soft faced hammer. AM Reference line 2
6.8. Install the retaining ring around the sleeve.
7.2. Install the spacer plate with seal1 on the
If necessary, press the retaining ring in
valve housing. Make sure that the bolt holes
position with a screwdriver blade. Refer to
in the valve housing are aligned with the
Figure 259.
holes in the spacer plate.
7. Install the meter end seal and the drive as 7.3. Rotate the spool and sleeve together until
follows: Refer to Figure 260. the pin becomes parallel to the face line of
the valve housing.
7.1. Insert the meter end seal into the valve
housing. 7.4. Install the drive on the pin. Make sure that
the drive is fully engaged with the pin. Refer
to Figure 253.
7.5. Mark the drive head to show the reference
line 2. Refer to Figure 260.
8. Install the meter as follows: Refer to Figure 261.
8.1. Install the seal 2 into the groove on the
meter.
25 - 33 9813/6500-1 25 - 33
00 - General

AN
D
6 4
C AM 1 2
F 3 7
AE AL 5
AP
AP
C Meter AP Face view

D Seal 2
F Drive Table 101. Torque Values
AE Valve housing
AL Face line Item Description Nm
AM Reference line 2 A Capscrew 31
AN Reference line 1 U Setscrew 11
8.2. Keep the meter in position so that the seal is
away from the valve housing and align the
meter valleys as shown at the reference line
1. Refer to Figure 261.
8.3. Make sure that the reference line 1,
reference line 2 and face line are parallel.
8.4. Install the meter on the drivehead. Align the
bolt holes and make sure that the drive does
not disengage.
9. Install the end cap as follows:
9.1. Install the drive spacer as necessary. Refer
to Figure 253.
9.2. Keep the end cap on the meter and align
the bolt holes.
9.3. Install the capscrews and pre-tighten to the
specified torque value.
Torque: 17N·m
9.4. Tighten the capscrews to the final torque
value in the given sequence viewed from
the face as shown. Refer to Figure 262.
25 - 34 9813/6500-1 25 - 34
12 - Column
12 - Column
Contents Page No.
25-12-00 General ........................................................................................................................... 25-37
25 - 35 9813/6500-1 25 - 35
Notes:
25 - 36 9813/6500-1 25 - 36
12 - Column
00 - General
Introduction .................................................... 25-37 The steering column connects the steering wheel to
Component Identification ............................... 25-38 the steering mechanism.
25 - 37 9813/6500-1 25 - 37
12 - Column
00 - General
Figure 263.
B
A
H
E
C
G
A Steering wheel B Steering column

C Park brake lever D Tilt adjust handle
E Upper front shroud F Upper rear shroud
G Lower front shroud H Lower rear shroud
J Column switches
25 - 38 9813/6500-1 25 - 38
12 - Column
00 - General
Remove and Install
Remove 6. Remove the park lever from the steering column.

Refer to (PIL 01-03). 7. Remove the button head bolts (x2) that attach the
upper front shroud. Refer to Figure 264.
8. Remove the upper front shroud from the steering
3. Remove the steering wheel. Refer to (PIL 09-36). column. Refer to Figure 264.
4. Remove the tilt lever from the steering column. 9. Remove the screws (x2) that attach the upper
Refer to Figure 264. rear shroud. Refer to Figure 264.
5. Remove the socket screw that attaches the park 10. Remove the upper rear shroud from the steering
adjust lever to the steering column. Refer to column. Refer to Figure 264.
Figure 264.
11. Remove the screws (x4) that attach the lower
5.1. The socket screw is installed behind the front and rear shrouds. Refer to Figure 264.
adjust lever.
25 - 39 9813/6500-1 25 - 39
12 - Column
00 - General
Figure 264.
B H
A
M
G
K
E
D
K
C
L
A Steering wheel B Steering column

C Tilt adjust lever D Socket screw
E Park lever F Button head bolts (x2)
G Upper front shroud H Screws (x2)
J Upper rear shroud K Screws (x4)
L Lower front shroud M Lower rear shroud
P Column switches
12. Remove the LH and RH column switches as

follows:
12.1. Disconnect the harness plugs. Refer to
Figure 265.
25 - 40 9813/6500-1 25 - 40
12 - Column
00 - General
P
Q
P Column switches
Q Capscrew (x2)
N 12.3. Remove the two column switches.

13. Remove the EMS (Electronic Monitoring System)
N Column switch harness connections from the front console. Refer to Figure 267.
12.2. Remove the capscrews (x2) that attach
the column switches to the steering
column. Refer to Figure 266.
Figure 267.
R EMS S Front console
14. Disconnect the electrical connectors from the 15. Remove the capscrews (x6) and washers (x4)
rear of the EMS unit. that attach the front console. Refer to Figure 268.
25 - 41 9813/6500-1 25 - 41
12 - Column
00 - General
Figure 268.
T
S
U
T
S Front console T Capscrew (x6)

U Washers (x4)
16. Carefully remove the front console from the cab. Figure 269.
17. Remove the electrical connectors installed to the
steering column.
18. Remove the steering shaft as follows: B
18.1. Mark the position of the steering column
with respect to the flexible coupling and
the steering column.
18.2. Remove the bolt and locknut that attach
the steering shaft to the flexible coupling.
X
B Steering column
V Steering shaft
W Locknut
X Bolt
18.3. Remove the bolt and locknut that attach
the steering shaft to the steering column.
25 - 42 9813/6500-1 25 - 42
12 - Column
00 - General
Figure 270. Install

procedure. Make sure that you obey the
instructions given below.
1.1. Make sure the position marks on the
steering shaft are aligned with the flexible
coupling and the steering column.
B
1.2. Connect the column switch harness to
the connector plugs and then install the
harness to the steering column.
Y Z 1.3. Make sure the position marks on the
steering wheel and the steering column are
aligned.
V 2. Tighten the bolts and screws to the correct torque

value.

Item Description Nm
D Socket screw 5.2
B Steering column F Button head bolt 5.2
V Steering shaft H Screw 1.3
Y Locknut
Z Bolt K Screw 1.3
T Capscrew 5
18.4. Remove the steering shaft. X Bolt 24
19. Remove the nuts (x2), washers (x4) and the Z Bolt 24
bolts (x2) that attach the steering column to the AA Bolt 24
mounting plate. Refer to Figure 271.
Figure 271.
AA, B
AB,
AC
AD
B Steering column
AA Bolt (x2)
AB Washer (x4)
AC Nut (x2)
AD Mounting bracket
20. Carefully remove the steering column away from
the cab.
25 - 43 9813/6500-1 25 - 43
48 - Manifold
48 - Manifold
Contents Page No.
25-48-00 General ........................................................................................................................... 25-45
25 - 44 9813/6500-1 25 - 44
48 - Manifold
00 - General
00 - General Component Identification

Figure 272.
B D
A C
A Port P B Port P1
C Port P2 D Port T
25 - 45 9813/6500-1 25 - 45
48 - Manifold
00 - General
Remove and Install
Remove 4.1. Put a label on the hoses to help installation.

4.2. Plug all the open ports and hoses to prevent
contamination.
2. Discharge the hydraulic pressure. Refer to (PIL
5. Remove the bolts (x2) and washers (x2).
30-00).
6. Remove the manifold with the mounting plate.
3. Get access to the manifold.
7. If required, remove the adaptors from the
4. Disconnect the hydraulic hoses from the
manifold.
manifold adaptors.
Figure 273.
C
A
A Manifold B Hoses
C Bolts (x2) D Mounting plate
E Adaptors
Install
step.
2. If removed, tighten the adaptors to the correct
torque value. Refer to (PIL 30-97).
25 - 46 9813/6500-1 25 - 46
27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-06 Semi-Automatic Gearbox
27-06-00 General ............................................................................................................................. 27-7
27-06-01 Clutch - 1st Speed ......................................................................................................... 27-16
27-06-02 Clutch - 2nd Speed ........................................................................................................ 27-22
27-06-03 Clutch - 3rd Speed ......................................................................................................... 27-24
27-06-04 Clutch - 4th Speed ......................................................................................................... 27-26
27-06-06 Clutch - Reverse ............................................................................................................ 27-31
27-06-11 Clutch - Forward (Input) ................................................................................................. 27-32
27-06-24 Oil Pump ........................................................................................................................ 27-38
27-06-36 Inductive Transmitter ...................................................................................................... 27-42
27-06-39 Filter ............................................................................................................................... 27-43
27-06-40 Suction Strainer .............................................................................................................. 27-45
27-06-52 Driveshaft ....................................................................................................................... 27-48
27-06-58 Output Shaft ................................................................................................................... 27-52
27-06-85 Oil Feed Pipe ................................................................................................................. 27-55
27-06-90 Front Case ..................................................................................................................... 27-58
27-06-91 Rear Case ...................................................................................................................... 27-59
27-06-94 Coupling Yoke ................................................................................................................ 27-62
27-14 Torque Converter
27-14-00 General ........................................................................................................................... 27-65
27-14-06 Control Valve .................................................................................................................. 27-72
27-14-09 Relief Valve .................................................................................................................... 27-74
27-20 Axle
27-20-00 General ........................................................................................................................... 27-77
27-20-03 Case ............................................................................................................................. 27-107
27-22 Drivehead
27-22-06 Crownwheel .................................................................................................................. 27-109
27-22-09 Pinion Gear .................................................................................................................. 27-112
27-24 Differential
27-24-00 General ......................................................................................................................... 27-115
27-27 Hub
27-27-00 General ......................................................................................................................... 27-133
27-27-18 Sun Gear ...................................................................................................................... 27-134
27-29 Wheel
27-29-00 General ......................................................................................................................... 27-137
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-143
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-147
27-51 Driveshaft
9813/6500-1
2017-02-02
27-51-00 General ......................................................................................................................... 27-155
9813/6500-1
2017-02-02
Acronyms Glossary
DTI Dial Test Indicator

LSD Limited Slip Differential
9813/6500-1
2017-02-02
Notes:
9813/6500-1
2017-02-02
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9813/6500-1 27 - 1
Notes:
27 - 2 9813/6500-1 27 - 2
27 - Driveline
00 - Driveline
00 - General
00 - General Health and Safety

Health and Safety ........................................... 27-3 Working Under the Machine
Technical Data ................................................. 27-4 Make the machine safe before getting beneath it.
movement.
WARNING! A raised and badly supported machine
can fall on you. Position the machine on a firm,
level surface before raising one end. Ensure the
other end is securely chocked. Do not rely solely
on the machine hydraulics or jacks to support the
machine when working under it. Disconnect the
battery, to prevent the engine being started while you
are beneath the machine.
WARNING! Before disconnecting any propshaft,
make sure you block both sides of all wheels to
prevent machine movement. The park brake will
become ineffective or may only operate on 2 wheels
(depending on machine specification).
WARNING! If a 4 wheel drive machine is to be
raised and the engine/transmission run, make sure
all four wheels are raised off the ground. Make sure
the machine is correctly supported by the correct
axle stands. If only one pair of wheels is raised, the
machine could move and fall off the stands.
WARNING! Under no circumstances must the
engine be run with the transmission in gear and only
one driving wheel jacked clear of the ground, since
the wheel on the ground will move the machine.
27 - 3 9813/6500-1 27 - 3
27 - Driveline
00 - Driveline
00 - General
Technical Data
Table 103.
Description Data
Gearbox type Semi Automatic Gear-
box
Gearbox model 6WG-160
Front axle model MT-L3075 II
Rear axle model MT-L3075 II
27 - 4 9813/6500-1 27 - 4
27 - Driveline
06 - Semi-Automatic Gearbox
Contents Page No.
27-06-00 General ............................................................................................................................. 27-7

27-06-01 Clutch - 1st Speed ......................................................................................................... 27-16
27-06-02 Clutch - 2nd Speed ........................................................................................................ 27-22
27-06-03 Clutch - 3rd Speed ......................................................................................................... 27-24
27-06-04 Clutch - 4th Speed ......................................................................................................... 27-26
27-06-06 Clutch - Reverse ............................................................................................................ 27-31
27-06-11 Clutch - Forward (Input) ................................................................................................. 27-32
27-06-24 Oil Pump ........................................................................................................................ 27-38
27-06-36 Inductive Transmitter ...................................................................................................... 27-42
27-06-39 Filter ............................................................................................................................... 27-43
27-06-52 Driveshaft ....................................................................................................................... 27-48
27-06-58 Output Shaft ................................................................................................................... 27-52
27-06-85 Oil Feed Pipe ................................................................................................................. 27-55
27-06-90 Front Case ..................................................................................................................... 27-58
27-06-91 Rear Case ...................................................................................................................... 27-59
27-06-94 Coupling Yoke ................................................................................................................ 27-62
27 - 5 9813/6500-1 27 - 5
Notes:
27 - 6 9813/6500-1 27 - 6
27 - Driveline
00 - General
Introduction ...................................................... 27-7 Semi-automatic gearboxes are a hybrid form of
Technical Data ................................................. 27-8 transmission where an integrated control system
Component Identification ................................. 27-9 handles manipulation of the clutch automatically,
Diagram ......................................................... 27-10 but the driver can still take manual control of gear
selection.
Check (Level) ................................................ 27-12
Calibrate ........................................................ 27-13 Many of these transmissions allow the driver to fully
Remove and Install ....................................... 27-14 delegate gear shifting choice to the control system,
Disassemble and Assemble .......................... 27-14 which then effectively acts as if it is an automatic
transmission. An automatic transmission uses a
torque converter instead of a straight friction clutch
to manage the connection between the transmission
gearing and the engine.
27 - 7 9813/6500-1 27 - 7
27 - Driveline
00 - General
Technical Data
(For: 6WG-160)
Table 104.
Description Data
Type 6WG-160
Torque convert- 340mm
er diameter
Drop centre dis- 500mm
tance
Stall ratio 2.38:1
Dry weight 372kg
Gear ratio Forward gear Reverse gear
1st 5.202:1 4.939:1
2nd 3.367:1 2.078:1
3rd 2.191:1 0.895:1
4th 1.418:1 Not Applicable
27 - 8 9813/6500-1 27 - 8
27 - Driveline
00 - General
(For: ZF Gearbox)
Make a note that the illustration shows a typical
semi-automatic gearbox. The actual semi-automatic
gearbox installed on the machine may look different.
Figure 274.
B
A C D
A N E N P
N
F
F
Q
G G
L H
K
J J
Item Description
Table 105. N Lifting lugs
Item Description P Hydraulic pump mount-
A Input drive plate ing
B Torque converter Q Electro-hydraulic control
unit
C Torque converter hous-
ing
D Breather
E Cover - gearbox case
F Filter head
G Filter
H Parking brake caliper
J Output drive flange
(brake disc to front axle)
K Magnetic oil drain plug
L Output drive flange to
rear axle
M Gearbox case
27 - 9 9813/6500-1 27 - 9
27 - Driveline
00 - General
Diagram
Figure 275.
Item Description
Table 106.
14 Proportional valve -
Item Description clutch K2
1 Oil sump 15 to 20 Pressure regulators
2 Transmission pump 21 Torque converter relief
3 Filter valve
4 System pressure valve 22 Torque converter
5 Pressure reducing valve 23 Torque converter back
6 Metering valve pressure valve
7 Oscillation damper 24 Oil cooler
8 Restrictor 25 Lubrication
9 Proportional valve - 26 Temperature sensors
clutch K4 27 Valve block control
10 Proportional valve - schematic
clutch KR 28 Main oil schematic
11 Proportional valve - 29 to 40 Test points
clutch K1 KV Clutch forward
12 Proportional valve - KR Clutch reverse
clutch K3
K1 Clutch 1st speed
13 Proportional valve -
K2 Clutch 2nd speed
clutch KV
27 - 10 9813/6500-1 27 - 10
27 - Driveline
00 - General
Item Description
K3 Clutch 3rd speed
K4 Clutch 4th speed
27 - 11 9813/6500-1 27 - 11
27 - Driveline
00 - General
Check (Level) Figure 276.
It is important to check the transmission oil level at

regular intervals. If the oil level is too low, it will cause B
malfunctions and damages to the gearbox. If the oil
level is too high, it will increase the power loss and
temperatures.
C
It is recommended to do weekly hot level check for
the gearbox oil. D
The oil level can be checked on the sight gauge
located near to the articulation joint at the left hand
side of the machine. A
1. Make sure that the machine safe. Refer to (PIL

01-03).
2. Make sure that the gear selector lever is in
neutral position.
A Sight gauge
4. Run the engine at idle RPM (Revolutions Per B Maximum hot level mark
Minute) for specified duration. C Minimum hot level mark
Duration: 3–5min D Cold level mark
4.1. With engine still running at idle, make sure

that the oil level is up to the cold level mark.
If necessary, top up to the cold level mark.
4.2. If the oil level at stage exceeds the cold level
mark, do not drain the oil.
4.3. The cold oil level check is done only to
ensure the safe operation of the gearbox
until the operating temperature is reached.
5. Make sure that the oil temperature reaches the
specified operating temperature.
Temperature: 80–90°C (175.9–193.9°F)
6. Allow the engine to run at idle for a further
specified duration.
Duration: 2min
7. With engine still running at idle, make sure that
the oil level is up to the hot level mark. If
necessary, top up or drain oil as required.
27 - 12 9813/6500-1 27 - 12
27 - Driveline
00 - General
Calibrate 2. Allow the torque converter temperature and

transmission oil temperature to increase.
You must calibrate the transmission clutch packs at: 3. Run the engine at idle.
• 1st 100h. 4. Apply the park brakes.

• Every oil change at 1,000h.
5. Make sure that each of the four boxes green.
• When the ZF controller or the transmission is
replaced. 6. Press the 'check' button on the display or use the
• If error codes P17C3-46 are displayed on the rotary encoder to start the AEB procedure.
EMS (Electronic Monitoring System).
6.1. The status of the AEB will be displayed
The calibration is carried out using a procedure during the process on the display screen.
called AEB.
6.2. When the procedure is complete, AEB
PASSED will be displayed.
Before AEB calibration
1. Navigate to the AEB option in the set-up menu
on the front or side display (if installed).
2. The AEB option screen shows the following
parameters on the display.
2.1. Torque converter temperature.
2.2. Transmission oil temperature.
2.3. Engine speed.
2.4. Park brake state.
Figure 277.
A C
B D
A Torque converter temperature

B Transmission oil temperature
C Engine speed
D Park brake state
3. Make sure that the all the parameters mentioned
in step 2 are displayed in green color.
3.1. The parameters in green color means the
value is in range.
3.2. The parameters in red color means the
value is out of range.
AEB Calibration Procedure

27 - 13 9813/6500-1 27 - 13
27 - Driveline
00 - General
Remove and Install Disassemble and Assemble
Refer to Engine- Remove and Install (PIL 15-00). (For: 6WG-160)

Remove the gearbox from the machine and make
sure that the oil is drained from the unit.
Support the gearbox assembly in an adjustable

turnover jig which allows the unit to be rotated as
necessary.
Disassembly
1. Remove the plug 1 and plug 2.
Figure 278.
B
A
A Plug 1
B Plug 2
2. Remove and discard the O-rings installed on the
two plugs.
3. Remove the screws 1 that attach the fill tube.
Figure 279.
C
D
C Fill tube
D Screw 1
4. Remove the oil level hose and its gasket.
5. Remove the two screws 2 that attach the cover
plate.
27 - 14 9813/6500-1 27 - 14
27 - Driveline
00 - General
Figure 280. 4. Install the front and rear case. (PIL 27-06-91).
5. Install the torque converter back pressure valve.
6. Install the oil pump. Refer to (PIL 27-06-24).
7. Install the torque converter with its housing. (PIL
27-14).
E 8. Install the inductive transmitters. Refer to (PIL

27-06-36).
9. Install the speed sensor. Refer to (PIL 33-84).
10. Install the torque converter safety valve. Refer to
F G (PIL 27-14).
E Cover plate
F Screw 2 11. Install the gear change control unit and the duct
G Magnetic drain plug plate to the gearbox. Refer to (PIL 33-45).
6. Remove the cover plate and its gasket. 12. Install new O-rings onto plug 1 and plug 2.
7. Remove the magnetic drain plug. 13. Install the plugs.
8. Remove the gear change control unit and the 14. Tighten the plugs to the correct torque value.
duct plate from the gearbox. Refer to (PIL 33-45). 15. Put the oil fill tube and its gasket in position.
9. Remove the torque converter safety valve. Refer 16. Attach the oil fill tube with the screws 1.
to (PIL 27-14).
17. Tighten the screws 1 to the correct torque value.
10. Remove the speed sensor. Refer to (PIL 33-84).
18. Put the cover plate and its gasket in position.
11. Remove the inductive transmitters. Refer to (PIL
27-06-36). 19. Attach the cover plate with the screws 2.
12. Remove the torque converter with its housing. 20. Tighten the screws 2 to the correct torque value.
21. Put a new O-ring onto the magnetic drain plug.
13. Remove the oil pump. Refer to (PIL 27-06-24).
21.1. Make sure that the drain plug is free from
14. Remove the torque converter back pressure any contamination.
valve. Refer to (PIL 27-14).
22. Install the drain plug.
15. Separate the front and rear case. Refer to (PIL
27-06-91). 23. Tighten the drain plug to the correct torque value.
16. Remove the output shaft. Refer to (PIL Table 107. Torque Values
27-06-58).
Item Nm
17. Remove the Input (drive) shaft, and the clutches. A 50
Refer to (PIL 27-06-57). B 80
18. Remove the oil pipes, studs, plugs and sealing D 34
cover. F 23
G 140
Assembly
1. Install the oil pipes, studs, plugs and sealing
cover.
2. Install the Input (drive) shaft, and the clutches.
(PIL 27-06-57).
3. Install the output shaft. (PIL 27-06-58).
27 - 15 9813/6500-1 27 - 15
27 - Driveline
01 - Clutch - 1st Speed
01 - Clutch - 1st Speed Component Identification

Figure 281.
E F
X C
S Z
V
W D
Q
A
P
M
AA L
Y H
U B
R
N
G J K
Item Description
Table 108. N Axial needle cage 2
P Axial bearing
Item Description
Q Snap ring 1
A Rectangular ring 1
R Shim plates
B Taper roller bearing 1
S Friction plates
C Clutch shaft
T Counter plates
D Stud
U Cup spring pack 1
E Rectangular ring 2
V Cup spring pack 2
F Taper roller bearing 2
W Snap ring 2
G Disc 1
X Plate carrier
H Axial needle cage 1
Y Piston
J Axial washer.
Z O-rings 1
K Idler gear
AA O-rings 2
L Needle bearing
M Disc 2
27 - 16 9813/6500-1 27 - 16
27 - Driveline
Remove and Install
The removal procedure of the 1st speed clutch is

similar to the Forward (Input) clutch. Refer to (PIL
27-06-11).
27 - 17 9813/6500-1 27 - 17
27 - Driveline
Special Tools Special Tool: Bearing Puller (Qty.: 1)

Description Part No. Qty. Special Tool: Bearing Puller (Qty.: 1)
Bearing Puller 892/01000 1 Special Tool: Bearing Tool (Qty.: 1)
Special Tool: Bearing Tool (Qty.: 1)
Spring Compressor 892/01002 1
Bearing Puller 892/01003 1 4. Remove the running disc 1, the axial needle cage
Bearing Tool 892/01004 1 1 and the axial washer 1, then remove the idler
gear.
Bearing Tool 892/01005 1
Heater 110 Volt 892/01006 1 5. Remove the needle bearings as well as the
running disc 2, the axial needle cage 2 and the
Consumables axial washer 2.
6. Remove the snap ring 1 and the plate packs.
JCB Threadlocker and 4101/0550 0.01L
Sealer (High Strength) 4101/0552 0.2L 7. Pre-load the cup spring pack 1 and spring pack
2 and remove the snap ring 2.
The disassemble-assemble procedure given below
Special Tool: Spring Compressor (Qty.: 1)
is for 3rd speed clutch. The procedure is similar for
the 1st speed and 2nd speed clutches. 8. Install the special tool circlip into the inner groove
of the plate carrier.
Disassemble
9. Use a suitable puller to remove the plate carrier
1. Remove the rectangular ring 1. from the clutch shaft.
2. Pull out the taper roller bearing 1 from the shaft. 10. Apply compressed air to the oil port on the
innermost bore of the plate carrier.
3. Remove the rectangular ring 2 and the taper
roller bearing 2 accordingly from the opposite 11. Remove the O-ring 1 and the O-ring 2 from the
side. piston.
27 - 18 9813/6500-1 27 - 18
27 - Driveline
Figure 282.
E F
X C
S Z
V
W D
Q
A
P
M
AA L
Y H
U B
R
N
G J K
A Rectangular ring 1 B Taper roller bearing 1

C Clutch shaft D Stud
E Rectangular ring 2 F Taper roller bearing 2
G Disc 1 H Axial needle cage 1
J Axial washer 1 K Idler gear
L Needle bearing M Disc 2
N Axial needle cage 2 P Axial washer 2
Q Snap ring 1 R Shim plates
S Friction plates T Counter plates
U Cup spring pack 1 V Cup spring pack 2
W Snap ring 2 X Plate carrier
Y Piston Z O-ring 1
AA O-ring 2
27 - 19 9813/6500-1 27 - 19
27 - Driveline
Assemble Figure 283.
1. Apply sealant to the threads of the stud and then

install the stud.
Q S S1
Consumable: JCB Threadlocker and Sealer
(High Strength)
2. Tighten the stud to the correct torque value. R
3. Install the plate carrier as follows: Y
3.1. Use a hot air blower to heat up the inner

diameter of the plate carrier.
T X
Special Tool: Heater 110 Volt (Qty.: 1)
3.2. Install the heated plate carrier onto the V
clutch shaft until contact is obtained.
Q Snap ring
4. Check the function of the purge valve in the R Shim plate
clutch piston. S Friction plates
S1 End friction plate
4.1. The ball must not stick, if necessary, clean T Counter plates
with compressed air. V Cup-spring pack
X Plate carrier
5. Install the O-ring 1 and O-ring 2 on the grooves Y Piston
of the piston.
10.2. 2nd speed and 3rd speed clutches
5.1. Make sure there is no twist in the O-rings. effective friction surfaces are 14.
5.2. Lubricate the O-rings with oil.
Figure 284.
6. Attach the piston into the piston plate.
6.1. Make sure that you attach the purge valve
side first. Q S S1
7. Install the cup spring pack and the guide ring.
Y
7.1. Make sure the cup springs are stacked R
properly. Refer step 9
8. Pre-load the cup spring pack and install it with
the snap ring. X
Special Tool: Spring Compressor (Qty.: 1) T
9. Assemble the friction plate and the counter plate, V

according to the gearbox model and the clutch Q Snap ring
identity. Refer to Figure 283. and Refer to Figure R Shim plate
284. . S Friction plates
9.1. Make sure that the uncoated side of the end S1 End friction plate
friction plate faces the piston. T Counter plates
V Cup-spring pack
10. The effective friction surfaces are as follows. X Plate carrier
Y Piston
10.1. 1st speed clutch effective friction surfaces
are 18. 11. Install the assembled plate pack without any oil
into the plate carrier.
12. Install the shim plate and a nominal thickness
snap ring.
13. Install a DTI (Dial Test Indicator) as shown.
27 - 20 9813/6500-1 27 - 20
27 - Driveline
Figure 285. 21. Install the idler gear until the counter plates are
all located.
AB 22. Install the axial washer 1, the axial needle cage
1 and the running disc 1 onto the clutch shaft.
22.1. Install the running disc 1 with the chamfer
facing towards the axial needle cage 1.
22.2. If the running disc1 does not fit over the
collar of the clutch shaft, the idler gear
is not fully engaged with all the counter
plates. Do the step21 again.
23. Push the taper roller bearing 1 against the
shoulder of the clutch shaft.
24. Push the taper roller bearing 2 against the
AB DTI shoulder of the clutch shaft.
14. Apply a pressure of 10kg to the shim plates and 25. Use compressed air to check the function of the
at the same time, set the DTI to zero. clutch.
15. Use a screwdriver to pull up the shim plates, until Figure 287.
they makes contact with the snap ring.
Figure 286.
AB
AC
26. If the clutch is assembled correctly then the

AB DTI closing and opening of the clutch shaft is clearly
AC Screwdriver audible.
16. The clearance reading on the DTI should be 27. Install the rectangular ring 1 and rectangular ring
within the limits for the relevant gearbox. Refer to 2.
Figure 283. and Refer to Figure 284. .
16.1. If the clearance is not within the limit, then
Item Description Nm
use correct thickness of snap ring to bring
the value to within the required limit. D Stud 17
17. Remove the original plate pack then put them into
oil and assemble again onto the plate carrier.
18. Secure the plate pack with the correct thickness
snap ring. Refer to step 16.1.
19. Install the running disc 2, the axial needle cage 2
and the axial washer 2 onto the clutch shaft.
20. Install the needle bearings.
27 - 21 9813/6500-1 27 - 21
27 - Driveline
02 - Clutch - 2nd Speed
02 - Clutch - 2nd Speed Remove and Install

Remove and Install ....................................... 27-22 The removal procedure of the 2nd speed clutch is
Disassemble and Assemble .......................... 27-23 similar to the forward (input) clutch. Refer to: Clutch
- Forward (Input) (Page 27-32).
27 - 22 9813/6500-1 27 - 22
27 - Driveline
02 - Clutch - 2nd Speed
Refer to Clutch-1st speed, Disassembly and

Assembly. Refer to: Clutch - 1st Speed
(Page 27-16).
27 - 23 9813/6500-1 27 - 23
27 - Driveline
03 - Clutch - 3rd Speed
03 - Clutch - 3rd Speed Remove and Install

Remove and Install ....................................... 27-24 The removal procedure of the 3rd speed clutch is
27 - 24 9813/6500-1 27 - 24
27 - Driveline
03 - Clutch - 3rd Speed
Refer to Clutch-1st speed, Disassembly and

Assembly. Refer to: Clutch - 1st Speed
(Page 27-16).
27 - 25 9813/6500-1 27 - 25
27 - Driveline
04 - Clutch - 4th Speed
04 - Clutch - 4th Speed Remove and Install

Remove and Install ....................................... 27-26 The removal procedure of the 4th speed clutch is
27 - 26 9813/6500-1 27 - 26
27 - Driveline
Special Tools Special Tool: Bearing Tool (Qty.: 1)

4. Remove the circlip.
Bearing Puller 892/01000 1
Bearing Tool 892/01001 1 5. Use a three leg puller to remove the plate carrier
Spring Compressor 892/01002 1 from the shaft.
Bearing Tool 892/01005 1 6. Remove the snap ring 1 and remove the plate
Heater 110 Volt 892/01006 1 packs.
Consumables 7. Pre-load the cup spring pack and guide ring then
Description Part No. Size remove the snap ring 2.
JCB Threadlocker and 4101/0550 0.01L 8. Apply compressed air to the oil port on the
Sealer (High Strength) 4101/0552 0.2L innermost bore of the plate carrier.
9. Remove the O-ring 1 and the O-ring 2 from the
Disassembly piston.
1. Remove the rectangular ring. 10. Remove the idler gear and then the running disc,
2. Pull out the taper roller bearing 1 from the shaft. needle cage 1, axial washer 1.
3. Remove the taper roller bearing 2 from the 11. Remove the needle bearings, the axial washer 2
opposite side. and axial washer 3.
Special Tool: Bearing Puller (Qty.: 1) 12. Remove the needle cage 2.
Special Tool: Bearing Tool (Qty.: 1)
27 - 27 9813/6500-1 27 - 27
27 - Driveline
Figure 288.
F
S
L Q
M
J
B
R G
V
T
N
P
Y
AA
H AB
E
U
W
X
A Z
C
D
Item Description
Table 110.
T Idler gear
Item Description
U Running disc (5mm
A Rectangular ring 1 thick)
B Taper roller bearing 1 V Needle cage 1
C Clutch shaft W Axial washer 1
D Rectangular ring 2 X Needle bearing
E Taper roller bearing 2 Y Axial washer 2
F Circlip Z Needle cage 2
G Plate carrier AA Axial washer 3
H Snap ring 1 AB Stud
J Shim plate
K Friction plates Assembly
L Counter plates
1. If previously disassembled, re-assemble the
M Guide ring
clutch shaft as follows.
N Cup spring pack
P Snap ring 2 1.1. Cool the shaft to the specified temperature.
Q Piston Temperature: -80°C (-111.9°F)
R O-ring 1
S O-ring 2
27 - 28 9813/6500-1 27 - 28
27 - Driveline
1.2. Heat up the gear to the specified Figure 290.

temperature.
Temperature: 120°C (247.8°F)
1.3. Install the gear onto the shaft against the K
shoulder and secure with a rectangular ring. H
2. Apply sealant to the screw-in thread and then Q

install the stud. J
(High Strength) G
3. Check the function of the purge valve in the

L
clutch piston.
3.1. The ball must not stick, if necessary, clean N
with compressed air.
G Plate carrier
Figure 289. H Snap ring 1
J Shim plate
K Friction plates
L Counter plates
N Cup spring pack
Q Piston
13. Install the assembled plate pack into the plate
carrier.
snap ring.
15. Install a DTI (Dial Test Indicator).
Figure 291.
4. Install the O-ring 1 and O-ring 2 on the grooves
of the piston. AC
5. Attach the piston with the piston plate.

6. Make sure that you attach the purge valve side
first.
7. Install the cup spring pack and the guide ring.
8. Carefully arrange the cup springs.
9. Secure the cup spring pack with the snap ring.
10. Assemble the friction plate and the counter plate, AC DTI
according to the gearbox model and the clutch
identity. 16. Apply a pressure of 10kg to the shim plates and
at the same time, set the DTI to zero.
11. Make sure that the you install the friction plate
with the uncoated side facing the piston. 17. Use a screwdriver to pull up the shim plates, until
they make contact with the snap ring.
12. For the clutch-4th speed effective friction
surfaces are 10.
27 - 29 9813/6500-1 27 - 29
27 - Driveline
Figure 292. 26. Use a hot air blower to heat up the inner diameter
AC of the plate carrier to the specified value.
27. Install the idler gear until all the counter plates
are located.
28. Secure the plate carrier with the circlip 1.
29. Use compressed air to check the function of the
clutch.
Figure 293.
AC DTI
18. The clearance reading on the DTI should be
within the limits for the relevant gearbox.
18.1. If the clearance is not within the limit, then
use the correct thickness of snap ring to
bring the value to within the required limit.
19. Remove the original plate pack then put them into
oil and assemble again onto the plate carrier.
20. Secure the plate pack with the correct thickness
snap ring. Refer to step 17.
21. Install the idler gear until all the counter plates
are located. 30. If the clutch is assembled correctly then the
closing and opening of the clutch shaft is clearly
21.1. This step makes the later assembly of the audible.
idler gear easier.
31. Push the taper roller bearing 1, the taper roller
21.2. Remove the idler gear. bearing 2 against the shoulder of the clutch shaft.
22. Install the axial washer 3, the axial washer 2 and keep them with the rectangular ring 2 and circlip
the needle cage 2. respectively.
22.1. Both the axial washer 2 and the axial Table 111. Torque Values
washer 3 are of the same specified Item Description Nm
thickness value. AB Stud 17
Dimension: 1mm
23. Install the needle bearings and the idler gear.
24. Install the running disc, the needle cage 1 and
the axial washer 1 onto the clutch shaft.
24.1. The axial washer 1 is of the same specified
thickness value.
Dimension: 1mm
24.2. The needle cage 1 is of the same specified
thickness value.
Dimension: 5mm
25. Make sure that the running disc chamfer is facing
towards the needle cage 1.
27 - 30 9813/6500-1 27 - 30
27 - Driveline
06 - Clutch - Reverse
06 - Clutch - Reverse
Refer to Clutch- Forward, Remove and Install. Refer

to: Clutch - Forward (Input) (Page 27-32).
27 - 31 9813/6500-1 27 - 31
27 - Driveline
11 - Clutch - Forward (Input)
11 - Clutch - Forward (Input) Remove and Install

Special Tools
Retainer 892/01014 6
Consumables
4003/2006 12.5kg
4003/2005 50kg
Before Removal
1. Remove the transmission rear case.
Refer to: Rear Case (Page 27-59).
2. Remove the output shaft.
Refer to: Output Shaft (Page 27-52).
Remove
1. Rotate the housing in the support jig so that the
clutch assemblies are on the top.
2. Remove the six clutch retainers.
3. Remove the clutches as follows:
3.1. This procedure requires two persons.
3.2. Slightly lift the 4th speed clutch from the
its bearing seat and lift out the 1st speed
clutch.
3.3. Put the 4th speed clutch in its bearing seat.
3.4. Remove the 2nd speed clutch and then
remove the 3rd speed clutch.
3.5. Slightly lift the forward and reverse clutches
with a pry bar and remove the 4the speed
clutch
3.6. Lift the forward, reverse and the input
(drive) shafts together, out from the housing
cover.
3.7. Remove the bearing outer races from the
housing after clutch/shaft removal but only
those for individual bearings, if any, which
are being replaced.
27 - 32 9813/6500-1 27 - 32
27 - Driveline
Figure 294.
F G
E
D
B
A C
A Clutch - 1st speed

B Clutch - 2nd speed
C Clutch - 3rd speed
D Clutch - 4th speed
E Clutch - forward
F Clutch - reverse
G Input (drive) shaft
Install
1. Put the outer races for the bearings being
replaced into the relevant bearing bores of the
housing cover.
2. Apply grease to the rectangular rings that retain
the taper bearings and align them centrally.
3. Put the reverse clutch, drive shaft and the
forward clutch together into the housing cover.
4. Raise the drive shaft and install the 4th speed
clutch.
5. Install the 3rd speed clutch followed by the 4th
speed clutch.
6. Raise the 4th speed clutch and install the 1st
speed clutch.
7. Attach the retainers to the threaded studs of the
six clutches protruding through the housing.
Special Tool: Retainer (Qty.: 6)
8. As an alternative to the retainers, install washers
and M10 nuts over each stud and tighten firmly.
After Installation
1. Install the output shaft.
Refer to: Output Shaft (Page 27-52).
2. Install the transmission case.
Refer to: Rear Case (Page 27-59).
27 - 33 9813/6500-1 27 - 33
27 - Driveline
Special Tools 5. Remove the tapered roller bearing 2 accordingly.

Description Part No. Qty. Special Tool: Bearing Tool (Qty.: 1)
Bearing Puller 892/01000 1 Special Tool: Bearing Tool (Qty.: 1)
Bearing Tool 892/01001 1 Special Tool: Bearing Puller (Qty.: 1)
Spring Compressor 892/01002 1 6. Remove the circlip 1 and the remove the plate
Bearing Tool 892/01005 1 carrier from the shaft.
Heater 110 Volt 892/01006 1
7. Remove the snap ring 1 and remove the plate
Consumables packs.
Description Part No. Size 8. Pre-load the compression spring, remove the
JCB Threadlocker and 4101/0550 0.01L snap ring 2.
Sealer (High Strength) 4101/0552 0.2L Special Tool: Spring Compressor (Qty.: 1)
The disassembly and assembly procedures for the 9. Force out the piston from its bore by applying
clutch-forward and clutch-reverse are the same. compressed air to the oil port on the innermost
bore of the plate carrier.
Disassembly
10. Remove the O-rings 1 and O-rings 2 from the
1. Make the machine safe. Refer to (PIL 01-03). piston.
2. Remove the gearbox from the machine. 11. Lift the idler gear slightly by means of pry bars.
3. Take out the rectangular ring. 12. Apply a suitable puller and separate the idler
gear from the clutch shaft.
4. Pull out the tapered roller bearing 1 from the
shaft. 13. Remove the circlip 2 and remove the ball bearing.
27 - 34 9813/6500-1 27 - 34
27 - Driveline
Figure 295.
G
H
T
N
M Q
K B
U
S
P X
R
Y
J D
E
W
A
V
F
C
Item Description
Table 112. U O-rings 2
Item Description V Idler gear
A Rectangular ring 1 W Circlip 2
B Tapered roller bearing 1 X Ball bearing
C Clutch shaft Y Needle bearing
D Stud
E Rectangular ring 2 Assembly
F Tapered roller bearing 2 1. Check the function of the purge valve in the
G Circlip 1 clutch piston.
H Plate carrier
2. The ball must not stick, if necessary, clean with
J Snap ring 1
compressed air.
K Shim plate
L Friction plates
M Counter plates
N Disc
P Compression spring
Q Guide ring
R Snap ring 2
S Piston
T O-rings 1
27 - 35 9813/6500-1 27 - 35
27 - Driveline
Figure 296. 11. Install the assembled plate pack, free of oil, into
the plate carrier.
snap ring.
13. Install a DTI (Dial Test Indicator).
Figure 298.
Z
3. Install O-ring 1 and O-ring 2 onto the grooves of

the clutch piston.
4. Attach the clutch piston on to the plate carrier.
5. Make sure that you attach the purge valve side
first.
6. Install the disc, spring and the guide ring. Z DTI
7. Use a spring compressor to compress the spring 14. Apply a pressure of approximately 10kg to the
and secure it with the snap ring. shim plates and at the same time set the DTI to
zero.
15. Use a screw driver to pull up the shim plate until
8. Assemble the friction plate and the counter it touches the snap ring.
plates.
Figure 299.
9. Install the friction plate with the uncoated side
Z
facing towards the piston.
Figure 297.
J L
S
K
H Z DTI
M 16. Note the clearance reading on the DTI.

17. The reading should be within the limits for the
relevant gearbox.
H Plate carrier 18. If the clearance is not as indicated, this can
J Snap ring 1 be corrected by fitment of a suitable alternative
K Shim plate thickness snap ring.
L Friction plates (coated both sides)
M Counter plates 19. Remove the original plate pack.
S Piston
20. Put the plates into the oil and then again
10. Effective friction surfaces for the clutch-forward assemble them into the plate carrier.
and clutch-reverse are 20.
21. Secure with the correct thickness snap ring
mentioned in the step18.
27 - 36 9813/6500-1 27 - 36
27 - Driveline
22. Install the idler gear after all the counter plates Table 113. Torque Values
are located. This step makes the later assembly
Item Description Nm
of the idler gear easier.
D Stud 17
23. Remove the Idler gear.
24. Install the stud.
25. Apply sealant to the threads.
(High Strength)
26. Install the bolt and then tighten the bolt to the
specified torque value.
Torque: 17N·m
27. Install the bearing onto the idler gear and then
secure with the circlip.
28. Install the needle bearing.
29. Push the idler gear onto the clutch shaft.
30. Use a hot air blower to heat the inner diameter of
the plate carrier to the specified value.
31. Install the pre-assembled plate carrier over the
idler gear and secure with the circlip.
32. Use compressed air to check the function of the
clutch.
Figure 300.
33. If the clutch is assembled correctly then the

closing and opening of the clutch shaft is clearly
audible.
34. Push the tapered roller bearing 1 and the tapered
roller bearing 2 against the shoulder of the clutch
shaft.
35. Install rectangular ring 1 and rectangular ring 2.
27 - 37 9813/6500-1 27 - 37
27 - Driveline
24 - Oil Pump
24 - Oil Pump Component Identification

Component Identification ............................... 27-38 Figure 301.
D
B
A
E
A Screw
B Washer
C Pump
D Control disc
E Stator rotor
27 - 38 9813/6500-1 27 - 38
27 - Driveline
24 - Oil Pump
Remove and Install
Remove 6. Separate the control disc from the pump rotor.

1. Remove the torque converter and converter
housing. Refer to (PIL 27-14). 7. If the original pump is to be used again then:
2. Remove the screws and washers that attach 7.1. Put the control disc on top of the pump rotor.
the pump to the transmission housing. Refer to 7.2. Secure with two grooved pins through the
Figure 304. holes as shown. Refer to Figure 303.
3. Clamp the exposed portion of the pump stator Figure 303.
shaft with a suitable separator tool. Refer to
Figure 302.
C
Figure 302.
E P
C Pump
D Control disc
E Stator rotor
N Grooved pins
P Holes for grooved pins installation
4. Carefully pull the pump stator shaft out of the 8. Remove the socket head screw 1, socket head
housing bore with the two leg puller. Refer to screw 2, socket head screw 3 and hexagonal
Figure 302. screw (x2). Refer to Figure 304.
5. Separate the pump and the control disc away 9. Remove the oil feed housing and gasket from the
from the stator shaft. Refer to Figure 303. transmission housing. Refer to Figure 304.
27 - 39 9813/6500-1 27 - 39
27 - Driveline
24 - Oil Pump
Figure 304.
M
B
A
L
K
H
A Screw B Washer
C Pump D Control disc
E Stator rotor F Socket head screw 1
G Socket head screw 2 H Socket head screw 3
J Hexagonal screw (x2) K Oil feed housing
L Gasket M Transmission housing
27 - 40 9813/6500-1 27 - 40
27 - Driveline
24 - Oil Pump
Install Figure 306.

R
1. Install two alignment dowels (M8) at the position
shown. Refer to Figure 305.
Figure 305.
R Lifting ring

Q Alignment dowels (M8) Item Nm
2. Install the gasket. Refer to Figure 304. A 46
F-H 23
3. Install the oil feed housing with the socket head J 46
screw 1, socket head screw 2 and socket head
screw 3. Refer to Figure 304.
3.1. Do not tighten the screws at this stage.
4. Install the alignment dowels (M10) into the
gearbox housing through the centre hole of the
oil feed housing.
5. Install the stator shaft until a contact is obtained.
5.1. Pay attention to the overlapping of the
bores.
6. Install an O-ring into the annular groove of the oil
pump and lubricate the O-ring.
7. Put the pump over the stator shaft and position it
evenly against the shoulder with screws (without
O-rings). Refer to Figure 304.
8. Remove the screws and install the new greased
O-rings on the screws.
9. Attach the pump with the screws.
value.
10. Attach the oil feed housing with the socket head
screw 1, socket head screw 2, socket head screw
3 and hexagonal screw (x2). Refer to Figure 304.
value.
11. Note: Pay attention to the position of the lifting
ring.
27 - 41 9813/6500-1 27 - 41
27 - Driveline
36 - Inductive Transmitter
36 - Inductive Transmitter
Remove and Install
There are three inductive transmitters installed on the

gearbox.
Remove
1. Get access to the inductive transmitters installed
on the gearbox case.
2. Remove the electrical connections from the
inductive transmitters.
3. Remove the engine RPM (Revolutions Per
Minute) inductive transmitter from the torque
converter housing.
4. Remove the turbine RPM and central gear train
RPM inductive transmitters from the gearbox
housing.
5. Remove and discard the O-rings from the
Figure 307.
C B
A
A Inductive transmitter - engine RPM
B Inductive transmitter - turbine RPM
C Inductive transmitter - central geartrain RPM
Install
1. Apply grease on the O-rings and install onto the
2. Install the three inductive transmitters.
3. Tighten the transmitters to the correct torque
value.
4. Connect the electrical connectors to the inductive
transmitters.

Item Nm
A-C 30
27 - 42 9813/6500-1 27 - 42
27 - Driveline
39 - Filter
39 - Filter Introduction
Introduction .................................................... 27-43 The transmission filter is designed to filter all the
Remove and Install ....................................... 27-44 contamination that is generated through use to
the required level of cleanliness. The filter must
be serviced to the requirements of the machine
maintenance schedules.
27 - 43 9813/6500-1 27 - 43
27 - Driveline
39 - Filter
Remove and Install
Working Under the Machine Remove

the ignition key, disconnect the battery. If the machine 2. Install the articulation strut. Refer to (PIL 06-27).
movement. 3. Place a suitable container under the gearbox.
4. Open the oil filler cap.
Figure 308.
D
C
A Filler cap B Sight gauge

C Filter D Drain plug
5. Remove the drain plug.

6. Drain the oil.
7. Clean and install the drain plug.
8. Remove and discard the filter.
Install
1. Clean the mounting face and lubricate the seal
on the new filter with clean torque converter fluid.
2. Install the new filter.
3. Tighten the filter by hand.
4. Fill the system with new oil at the filler point.
5. Make sure that the oil does not cross the top level
mark.
27 - 44 9813/6500-1 27 - 44
27 - Driveline
40 - Suction Strainer
40 - Suction Strainer Introduction

Introduction .................................................... 27-45 The suction strainer is a component used for trapping
Remove and Install ....................................... 27-46 large and coarse particles entering the transmission
system.
27 - 45 9813/6500-1 27 - 45
27 - Driveline
Remove and Install
Working Under the Machine 3. Drain the transmission oil. Refer to (PIL 27-06).
Make the machine safe before getting beneath it. 4. Disconnect the transmission hoses.
correctly attached. Engage the park brake, remove 5. Put a label on the hoses to help installation.
has wheels use blocks to prevent unintentional 6. Plug all the open ports and hoses to prevent
movement. contamination.
7. Remove the setscrew (x2), washer (x4) and
Remove locknut (x2).
1. Make the machine safe. Refer to (PIL 01-03). 8. Remove the suction strainer.
2. Open the undershield cover. Refer to (PIL 06-06).
Figure 309.
E
G F
A Gearbox B Suction strainer

C Screw D Hoses
E Setscrew (x2) F Washer (x4)
G Locknut (x2)
27 - 46 9813/6500-1 27 - 46
27 - Driveline
Removal
removal procedure.
27 - 47 9813/6500-1 27 - 47
27 - Driveline
52 - Driveshaft
52 - Driveshaft Introduction
Introduction .................................................... 27-48 The driveshaft is a mechanical component for
Remove and Install ....................................... 27-49 transmitting torque and rotation, it is used to connect
Disassemble and Assemble .......................... 27-50 other components of the driveline that cannot be
connected directly because of the distance or the
need to allow for relative movement between them.
27 - 48 9813/6500-1 27 - 48
27 - Driveline
52 - Driveshaft
Remove and Install
The removal procedure of the driveshaft is similar to

the forward clutch. Refer to (PIL 27-06-11).
27 - 49 9813/6500-1 27 - 49
27 - Driveline
52 - Driveshaft
Disassemble 4. Remove the circlip and remove the gear.
1. Remove the rectangular ring. 5. If necessary, push the turbine shaft off the
driveshaft.
2. Pull off the tapered roller bearing 1 from the shaft.
5.1. The turbine shaft is axially attached with the
3. Remove the taper roller bearing 2 from the snap ring which will be deformed when you
opposite side. pull it out.
Figure 310.
F E D
C
B
A
H
G
A Rectangular ring B Taper roller bearing 1

C Drive shaft D Taper roller bearing 2
E Circlip F Gear
G Turbine shaft H Snap ring
27 - 50 9813/6500-1 27 - 50
27 - Driveline
52 - Driveshaft
Assemble
CAUTION: Protective gloves must be worn when
handling extremely hot or cold components.
1. Cool the driveshaft to the specified temperature.

Temperature: -80°C (-111.9°F)
2. Heat the gear to the specified temperature.
3. Install the gear onto the shaft until contact is
obtained.
4. Secure the gear axially with the circlip.
5. If removed, install a new snap ring into the groove
of the turbine shaft.
6. Install the turbine shaft until the snap ring
is positioned properly in the groove of the
driveshaft.
6.1. This axially secures the turbine shaft.
7. Install the tapered roller bearing 1 against the
shoulder of the driveshaft.
8. Install the rectangular ring into the groove of the
driveshaft.
9. Install the tapered roller bearing 2 against the
shoulder of the driveshaft.
27 - 51 9813/6500-1 27 - 51
27 - Driveline
58 - Output Shaft
58 - Output Shaft Introduction

Introduction .................................................... 27-52 In the gearbox, the input and output shafts lie along
Remove and Install ....................................... 27-53 the same line, and are sometimes combined into a
single shaft within the gearbox. This single shaft is
called the main shaft.
The input and output ends of this combined shaft

rotate independently, at different speeds, which is
possible because one piece slides into a hollow bore
in the other piece, where it is supported by a bearing.
Sometimes the term main shaft refers to just the input
shaft or just the output shaft, rather than the entire
assembly.
In many gearboxes the input and output components

of the main shaft can be locked together to create a
1:1 gear ratio, causing the power flow to bypass the
layshaft. The main shaft then behaves like a single,
solid shaft: a situation referred to as direct drive.
27 - 52 9813/6500-1 27 - 52
27 - Driveline
58 - Output Shaft
Remove and Install
Special Tools 2. Remove the socket head screws and remove

Description Part No. Qty. the complete output shaft assembly from the
Bearing Puller 892/01003 1 housing.
Bearing Tool 892/01004 1 3. Remove the taper roller bearing 1 and taper roller
bearing 2 from the output shaft.
Before Removal Special Tool: Bearing Tool (Qty.: 1)
Special Tool: Bearing Puller (Qty.: 1)
Remove the transmission assembly from the
machine and support on a suitable jig. 4. Separate the oil collecting plate 1 and oil
collecting plate 2 from the output shaft.
1. Remove the transmission rear case.
Remove
1. Install the housing cover onto an assembly jig.
Figure 311.
D
F
E
A
B
C
A Socket head screw B Output shaft

C Taper roller bearing 1 D Taper roller bearing 2
E Oil collecting plate 1 F Oil collecting plate 2
27 - 53 9813/6500-1 27 - 53
27 - Driveline
58 - Output Shaft
Install
1. Install the oil collecting plate 2 over the output
shaft.
2. Apply heat to the tapered roller bearing 1 and
tapered roller bearing 2 and then install onto the
shaft.
3. Put the outer races for the bearings being
replaced into the relevant bearing bores of the
housing cover.
4. Install a new O-ring in every bore.
5. Put the oil collecting plate in position over the
output shaft bore.
6. Install the output shaft assembly.
7. Attach the oil collecting plates with the socket
head screws.

Item Nm
A 23
27 - 54 9813/6500-1 27 - 54
27 - Driveline
85 - Oil Feed Pipe
85 - Oil Feed Pipe Figure 312.

E
B E C
Remove and Install
Special Tools
Description Part No. Qty. D
Pipe Swaging Tool 892/01007 1
E
Consumables E
Sealer (High Strength) 4101/0552 0.2L
Remove
E
Studs, Plugs and Sealing Cover
1. Remove the sealing cover. Remove any traces A
of the sealing compound.
A Suction pipe
2. Remove the plugs. B Pressure pipe 1
C Pressure pipe 2
3. Remove and discard the O-rings installed on the D Pressure lubrication pipe
plugs. E Socket head screw
4. Remove the studs. 2. Secure the suction and pressure pipes with the
socket head screws.
Oil tubes
3. Tighten the socket head screws to the correct
1. Remove the oil tubes 1. torque value.
2. Remove the screw plugs. 4. Tilt the gearbox housing by the specified angle.
3. Remove and discard the O-rings installed on the Angle: 180°
screw plugs.
5. Roll the suction and pressure pipes into the
4. Remove the oil tubes 2. housing apertures as shown with the swaging
tool. Refer to Figure 313.
5. Remove the socket head screws that secure the
Special Tool: Pipe Swaging Tool (Qty.: 1)
suction pipe, pressure pipes and the pressure
lubrication pipe.
6. Remove the suction pipe, pressure pipes and the
pressure lubrication pipe from the housing bores.
Install
Oil Tubes
1. Put the suction pipe, pressure pipes and the
pressure lubrication pipe into the housing bores.
27 - 55 9813/6500-1 27 - 55
27 - Driveline
85 - Oil Feed Pipe
Figure 313. 8.1. Tighten the screw plug to the correct torque
value.
F 9. Install both the oil tubes 1 into the housing cover.

Figure 316.
K
K
F Housing apertures
5.1. Note: The rolled pipe ends must not K Oil tube1
protrude beyond the level of the mating
flange of the housing. If necessary adjust 10. Tilt the gearbox housing by the specified angle
the individual pipes to suit. and roll the oil tubes 1 into the housing bores.
Angle: 180°
6. Put the O-rings into the annular grooves of the
two oil tubes 2. Refer to Figure 314. 10.1. Note: The rolled pipe ends must not
protrude beyond the level of the mating
6.1. Lubricate the O-rings. flange of the housing. If necessary adjust
the individual pipes to suit.
Figure 314.
10.2. If necessary equalise the projection of the
H G H
tubes.
Studs, Plugs and Sealing Cover

1. Apply the sealant to the threads of the studs and
G Oil tube 2 then install the studs.
H O-rings
7. Assemble the two oil tubes 2 until contact is (High Strength)
obtained.
1.1. Tighten the studs to the correct torque
Figure 315. value.
J Figure 317.
M
L
L
G
G L M
L
H Oil tube 2 L Studs

J Screw plug M Plugs
8. Put a new O-ring onto the screw plug and then 2. Install new O-rings onto the plugs and then install
install the screw plug. the plugs.
27 - 56 9813/6500-1 27 - 56
27 - Driveline
85 - Oil Feed Pipe
2.1. Tighten the plugs to the correct torque

value.
3. Apply sealant onto the mounting face of the
sealing cover.
Figure 318.
N Sealing cover
4. Install the sealing cover. Makes sure the recess
points upwards.

Item Description Nm
E Socket head screw 23
J Screw plug 140
L Studs 9
M Plug (M16 x 1.5) 40
M Plug (M18 x 1.5) 50
M Plug (M26 x 1.5) 80
27 - 57 9813/6500-1 27 - 57
27 - Driveline
90 - Front Case
90 - Front Case
Remove and Install
The procedure to remove the front case is similar to

the removal procedure for the rear case. Refer to:
Rear Case (Page 27-59).
27 - 58 9813/6500-1 27 - 58
27 - Driveline
91 - Rear Case
91 - Rear Case Figure 319.

G
K
Remove and Install F
Special Tools
Description Part No. Qty. H A
J B
Eye Bolt 892/01013 1 E
Retainer 892/01014 6
Eye Bolt 892/01015 2
Consumables D C
JCB Multi-Gasket 4102/1212 0.05L
M
Before Removal
Remove the transmission assembly from the
machine and support in a suitable jig before you do
this procedure. L
1. Remove the gear change control unit. Refer to
(PIL 33-45).
2. Remove the torque converter. Refer to (PIL A Nut 1
27-14). B Washer 1
C Cover 1
3. Remove the oil pump. Refer to (PIL 27-06-24).
D Seal 1
4. Remove the speed sensor. Refer to (PIL 33-84). E Stud 1
F Nut 2
5. Remove the inductive transmitters. Refer to (PIL G Washer 2
27-06-36). H Cover 2
J Seal 2
6. Remove the output drive flanges. K Stud 2
L Screw 1
Remove M Rear case
1. Remove the nuts and washers. Refer to Figure 5. Remove the cylindrical pins (x2) from the
319. locations shown. Refer to Figure 320.
2. Remove the cover 1 and seal 1. Refer to Figure Figure 320.

319.
3. Do the steps 1 to 2 for the cover 2 assembly.
4. Remove the screws. Refer to Figure 319.
6. To separate the rear case from the transmission

gearbox housing do the steps that follow: Refer
to Figure 321.
6.1. Attach M20 eye bolts (x2) and M16 eye bolt
(x1) to the housing cover.
Special Tool: Eye Bolt (Qty.: 2)
27 - 59 9813/6500-1 27 - 59
27 - Driveline
91 - Rear Case
U
V
N N Q
P
R
S
W T
X
N M20 Eye bolt

P M16 Eye bolt
Q Retainer
R Screw 2
6.2. Attach retainers to the threaded studs of S Retaining plate
the clutches (x6) protruding through the T Gasket
housing. U Circlip
Special Tool: Retainer (Qty.: 6) V Ball bearing
W Pump shaft
6.3. As an alternative to the retainers, install X Ring
washers and M10 nuts over each stud and
tighten firmly.
Install
6.4. Lift the housing cover along with the
clutches from the gearbox housing with a 1. If removed, install the clutch assemblies.
suitable lifting device.
2. Attach the M20 eye bolts and the M16 eye bolt to
6.5. Install the housing cover onto an assembly the housing cover. Refer to Figure 321.
jig.
7. If required remove the clutch assemblies. Special Tool: Eye Bolt (Qty.: 1)
8. Remove the pump driveshaft as follows: Refer to 3. Apply grease on the O-rings of the oil tubes (x2).
Figure 322. Refer to Figure 323.
8.1. Tilt the housing cover to the specified angle. Figure 323.
Angle: 90°
8.2. Remove the screw 2, retaining plate and the
gasket.
8.3. Remove the circlip. Y Y
8.4. Remove the complete pump shaft
assembly.
8.5. Remove the ring, and ball bearing from the
pump shaft.
Y Oil tubes
3.1. Apply sealing compound on the mounting
surface.
Consumable: JCB Multi-Gasket
4. Put the pre-assembled housing cover in position
against the gearbox housing with a suitable lifting
device.
27 - 60 9813/6500-1 27 - 60
27 - Driveline
91 - Rear Case
5. Make sure that the oil tubes are aligned with the
bores in the housing cover.
6. Remove the clutch retainers (x6).
7. Install the cylindrical pins centrally to the housing
face at the positions shown. Refer to Figure 320.
8. Attach the housing cover with the screws. Refer
to Figure 319.
10. Pay attention to the position of the lifting ring.
11. Install the ball bearing.
12. Install the rectangular snap ring.
13. Apply grease onto the rectangular ring and align
it centrally.
14. Put the pump shaft into the housing cover. Refer
to Figure 322.
15. Attach the pump shaft with the circlip.
16. Install the gasket and retaining plate and attach
with the screws 2.
17. Install the seals 1 and seal 2 into the annular
grooves of the oil feed cover 1 and cover 2
respectively. Refer to Figure 319.
18. Attach the cover 1 with the nut 1 and washer 1.
19. Install the cover 2 with the nut 2 and washer 2.
After Installation
1. Install the output drive flanges.
2. Install the inductive transmitters. Refer to (PIL
27-06-36).
3. Install the speed sensor. Refer to (PIL 33-84).
4. Install the oil pump. Refer to (PIL 27-06-24).
5. Install the torque converter. Refer to (PIL 27-14).
6. Install the gear change control unit. Refer to (PIL
33-45).

Item Nm
A 23
F 23
L 46
27 - 61 9813/6500-1 27 - 61
27 - Driveline
94 - Coupling Yoke
94 - Coupling Yoke
Remove and Install
Consumables 2. Remove the O-ring 1.

3. Remove the output drive flange 1 from the shaft.
4003/2006 12.5kg 4. Remove the seal 1 out of the housing bore.
4003/2005 50kg
5. Do the steps 1 to 4 for the output drive flange 2.
Remove
1. Remove the lock plate 1, screws 1, and retainer
disc 1.
Figure 324.
H
K
L
M
F G
E J
C
B
D
A
A Lock plate 1 B Screw 1

C Retaining plate 1 D O-ring 1
E Output drive flange 1 (for rear axle) F Seal 1
G Lock plate 2 H Screw 2
J Retaining plate 2 K O-ring 2
L Output drive flange 2 (for front axle) M Seal 2
27 - 62 9813/6500-1 27 - 62
27 - Driveline
94 - Coupling Yoke
Install
1. Install seal 2 with the sealing lip facing the oil
chamber.
1.1. Clean the rubber coated outer diameter of
the seal 2.
1.2. Apply grease to the sealing lip of the seal1.
2. Install the output drive flange 2 onto the shaft.
3. Install the O-ring 2 into the gap between the drive
flange and the shaft.
4. Attach the output flange 2 with the retaining disc
2 and the screw 2.
5. Tighten the screw 2 to the correct torque value.
6. Secure the screw 2 with the lock plate 2.
7. Do the steps 1 to 6 for output drive flange1.

Item Nm
B 46
H 46
27 - 63 9813/6500-1 27 - 63
27 - Driveline
14 - Torque Converter
Contents Page No.
27-14-00 General ........................................................................................................................... 27-65

27-14-06 Control Valve .................................................................................................................. 27-72
27-14-09 Relief Valve .................................................................................................................... 27-74
27 - 64 9813/6500-1 27 - 64
27 - Driveline
00 - General
Introduction .................................................... 27-65 The torque converter is a type of fluid coupling that
Operation ....................................................... 27-66 is used to transfer rotating power from the engine to
Remove and Install ....................................... 27-67 a rotating driven load.
The torque converter normally takes the place of

a mechanical clutch in a vehicle with an automatic
transmission, allowing the load to be separated from
the power source.
It is usually located between the engine flywheel and

the transmission.
The key characteristic of a torque converter is its

ability to multiply torque when there is a substantial
difference between input and output rotational
speed, thus providing the equivalent of a reduction
gear. Some torque converters are equipped with a
temporary locking mechanism which rigidly locks the
engine to the transmission when their speeds are
nearly equal, to avoid slippage and a resulting loss
of efficiency.
27 - 65 9813/6500-1 27 - 65
27 - Driveline
00 - General
Operation
The Torque converter lock up function (if installed)

can be selected to be on or off (by console switch
in cab). There is also a switch on the side of the
lift arm which controls whether the torque converter
will engage or not, i.e. lock up is prevented from
engaging if the lift arm is above the switch position.
When it is selected on, the transmission will lock

directly to the engine when certain criteria are met
(controlled by the gearbox ECU (Electronic Control
Unit)) Once the transmission is locked up a light will
appear on the instrument panel.
27 - 66 9813/6500-1 27 - 66
27 - Driveline
00 - General
Remove and Install
Consumables 10. Remove the disc and then move the drive flange
Description Part No. Size off the shaft. Refer to Figure 327.
JCB Threadlocker and 4101/0550 0.01L 11. Mark the radial installation position of the housing
Sealer (High Strength) 4101/0552 0.2L cover and the bell housing. Refer to Figure 327.
Disassembly 12. Remove the screws 4 and the nuts 2. Refer to

Figure 327.
Remove the gearbox assembly and put in a suitable 13. Use a suitable lifting tool to remove the torque
adjustable jig which allows the unit to be rotated as converter along with the housing cover from the
necessary. housing. Refer to Figure 327.
1. Make the machine safe. Refer to (PIL 01-03). 14. Press the driveshaft torque converter out of the
housing cover. Refer to Figure 327.
2. Remove the socket head screws 1 (x2) from the
top and bottom. Refer to Figure 327. 15. Remove the circlip and remove the ball bearing
from the housing cover. Refer to Figure 327.
3. Install threaded dowels in place of the socket
head screws, to prevent hidden components 16. Remove the screws 5 (x4) then remove the
from falling out at the time of disassembly. diaphragm along with the driveshaft from the
torque converter. Refer to Figure 327.
4. Remove the remaining socket head screws 1 and
then remove the control module from the duct 17. Remove the screws 6 and then remove the
plate. Refer to Figure 327. driveshaft from the diaphragm. Refer to Figure
327.
5. Remove the gasket 1, gasket 2 and then remove
the intermediate plate. Refer to Figure 327. 18. Remove the engine inductive transmitter from
the gearbox assembly. Refer to Figure 326.
6. Remove the socket head screws 2 along with the
nuts 1 and the washer. Refer to Figure 327. Figure 326.
7. Remove the duct plate from the gearbox housing. B
Then remove the gasket 3. Refer to Figure 327.
8. Use the correct tool to pull out the safety valves
from the gearbox bore. Refer to Figure 325.
Figure 325.
B Engine inductive transmitter

19. Remove the screws 7 and remove the converter
A housing from the gearbox. Refer to Figure 327.
20. Mark the radial installation position of the
A Safety valve converter housing and the gearbox housing.
9. Remove the two screws 3 and remove the lock
plate. Refer to Figure 327.
27 - 67 9813/6500-1 27 - 67
27 - Driveline
00 - General
Figure 327.
L K
J
D
A
F
H G
E
M
T Y
V U
Q
AG P
S
AA
X AB
N AC
Table 120. Item Description

Item Description Q Drive flange
C Socket head screws 1 R Screws 4
D Control module S Nuts 2
E Duct plate T Housing cover
F Gasket 1 U Circlip
G Intermediate plate V Ball bearing
H Gasket 2 W Screws 5
J Socket head screws 2 X Diaphragm
K Nuts 1 Y Driveshaft
L Washer Z Screws 7
M Gasket 3 AA Housing
N Screws 3 AB Torque converter
P Disc
27 - 68 9813/6500-1 27 - 68
27 - Driveline
00 - General
Item Description 8. Install the ball bearing on to the cover and secure
AC Screws 6 it with the circlip. Refer to Figure 330.
AG Lock plate 9. Loosely install the cover on the housing. Align the
match marks made at the time of disassembly.
Assembly Refer to Figure 330.
1. Install the torque converter housing on the 10. Install the drive flange, the disc and then secure
gearbox assembly. Apply sealant to the screw them with the screws 3. Refer to Figure 330.
threads and then secure it screws 7. Refer to
Figure 330. 11. Tighten the screws 3 to the correct torque value.
(High Strength) 12. Install the lock plates to secure the screws 3.
2. Make sure that you align the match mark made
at the time of disassembly. Refer to Figure 330. 13. Secure the housing cover to the housing with the
screws 4 and nuts 2. Refer to Figure 330.
3. Tighten the screws 7 to the correct torque value.
Refer to Figure 330. 14. Tighten the screws 4 to the correct torque value.
4. Attach the driveshaft on the diaphragm and
secure it with the screws 6. Tighten the screws 6 15. Mount the gasket 4 and secure the cover 2 with
to the correct torque value. Refer to Figure 330. the screws 8. Refer to Figure 330.
5. Fasten the diaphragm to the torque converter 16. Tighten the screws 8 to the correct torque value.
with the screws 5. Refer to Figure 330. Refer to Figure 330.
6. Tighten the screws 5 to the correct torque value. Figure 329.

7. The disc of the torque converter must be
positioned axially to the bore of the inductive
transmitter. Refer to Figure 328.
Figure 328.
A Safety valve
17. Install the torque converter safety valve into the
housing bore. Refer to Figure 329.
27 - 69 9813/6500-1 27 - 69
27 - Driveline
00 - General
Figure 330.
T Y
V U
Q
AG P
S
AA
X AB
N AC
AD
AF AE
Table 121. Item Description

Item Description AA Housing
N Screws 3 AB Torque converter
P Disc AC Screws 6
Q Drive flange AD Gasket 4
R Screws 4 AE Cover 2
S Nuts 2 AF Screws 8
T Housing cover AG Lock plate
U Circlip
V Ball bearing
W Screws 5
X Diaphragm
Y Driveshaft
Z Screws 7
27 - 70 9813/6500-1 27 - 70
27 - Driveline
00 - General

Item Description Nm
Z Screws 7 (M10/10.9) 68
AC Screws 6 (M10/10.9) 115
W Screws 5 (M10/10.9) 115
N Screws 3 (M8/10.9) 34
R Screws 4 (M10/8.8) 46
AF Screws 8 (M8/8.8) 23
27 - 71 9813/6500-1 27 - 71
27 - Driveline
06 - Control Valve
06 - Control Valve
Remove and Install
Remove 2. Remove the pressure plate, compression spring

and the piston from the oil feed housing.
1. Pre-load the compression springs and remove
the lock plate. 3. Remove the plug and the O-ring. Discard the O-
ring.
Figure 331.
E
D C A
A Lock plate B Plug

C Pressure plate D Compression spring
E Piston F Oil feed housing
27 - 72 9813/6500-1 27 - 72
27 - Driveline
06 - Control Valve
Install
1. Put the piston, compression spring and the
pressure plate into the oil feed housing.
2. Pre-load the springs and secure with the lock
plate.
2.1. Make sure the spigot of the pressure plate
faces the lock plate.
3. Put the new O-ring onto the plug.
4. Install the plug.
5. Tighten the plug to the correct torque value.

Item Nm
B 25
27 - 73 9813/6500-1 27 - 73
27 - Driveline
09 - Relief Valve
09 - Relief Valve Introduction

Introduction .................................................... 27-74 The pressure relief valve is a type of valve used to
Remove and Install ....................................... 27-75 control or limit the pressure which can build up due
to a fault in the system.
The pressure is relieved by allowing the pressurised

fluid to flow from an auxiliary passage out of the
system. The relief valve is designed to open at
a predetermined set pressure to protect pressure
vessels from being subjected to pressures that
exceed their design limits.
27 - 74 9813/6500-1 27 - 74
27 - Driveline
09 - Relief Valve
Remove and Install
Remove
1. Remove the gear change control module and the
duct plate. Refer to (PIL 33-45).
2. Use the correct tool to pull out the safety valves
from the gearbox bore.
Figure 332.
A Converter safety valve
Install
1. Install the converter safety valve into the housing
bore.
2. Install the gear change control module and the
duct plate.
27 - 75 9813/6500-1 27 - 75
27 - Driveline
20 - Axle
20 - Axle
Contents Page No.
27-20-00 General ........................................................................................................................... 27-77

27-20-03 Case ............................................................................................................................. 27-107
27 - 76 9813/6500-1 27 - 76
27 - Driveline
20 - Axle
00 - General
Introduction .................................................... 27-77 Axles are an integral component of a wheeled
Health and Safety .......................................... 27-78 vehicle. The axle transmits a driving torque to the
Technical Data ............................................... 27-78 wheel, as well as maintaining the position of the
Component Identification ............................... 27-79 wheels relative to each other and to the vehicle body.
Drain and Fill ................................................. 27-80
Check (Level) ................................................ 27-82
Check (Pressure) .......................................... 27-82
27 - 77 9813/6500-1 27 - 77
27 - Driveline
20 - Axle
00 - General

Lifting the Machine Table 124. For 40kph machines
Under no circumstances must the engine be run with
Description Data
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the Axle weight 780kg
ground will move the machine. Axle ratio 21.53:1
WARNING! A machine can roll off jacks and crush Bias ratio 30%
you unless the wheels have been blocked. Always
block the wheels at the opposite end of the machine Table 125. For 48kph machines
that is to be jacked. Do not work underneath a Description Data
machine supported only by jacks. Always support a Axle weight 780kg
jacked-up machine on axle stands before working
underneath it. Axle ratio 18.667:1
Bias ratio 30%
CAUTION! This component is heavy. It must only be
removed or handled using a suitable lifting method
and device.
Notice: It is not recommended that the machine be
driven with the axle partially filled with oil.
Notice: The oil level must be checked with the
machine level, otherwise a false indication of the
amount of oil will be given.
27 - 78 9813/6500-1 27 - 78
27 - Driveline
20 - Axle
00 - General
Figure 333.
A B A
D D
A Drain plug 1 B Drain plug 2

C Oil fill and check plug D Breather
27 - 79 9813/6500-1 27 - 79
27 - Driveline
20 - Axle
00 - General
Drain and Fill
Drain 4. Position a suitable container below the drain

points to collect the oil.
5. Loosen one of the drain plugs (x4).
6. Allow oil to drain from the axle.
3. Gain access to the axle from underneath the
machine. 7. Remove and discard the O-rings.
Figure 334.
D
C
A Dipstick B Drain plug - Output

C Drain plug D Drain plug (Optional)
27 - 80 9813/6500-1 27 - 80
27 - Driveline
20 - Axle
00 - General
Fill
1. Clean the drain plugs (x4).
2. Install new O-rings on the drain plugs.
3. Install the drain plugs (x4).
4. Tighten the drain plugs to the correct torque
value.
5. Remove the dipstick.
6. Pour clean oil into the axle up to the MAX mark
on the dipstick.
7. Check the oil level after a few minutes and fill
up to the specified level, until the level remains
constant.
8. Install the dipstick.
9. Tighten the dipstick to the correct torque value.

Item Nm
A 50
B 50
C 50
D 50
27 - 81 9813/6500-1 27 - 81
27 - Driveline
20 - Axle
00 - General
Check (Level) Check (Pressure)

Notice: The oil level must be checked with the
machine level, otherwise a false indication of the Check the Brake Hydraulics for Leakage
amount of oil will be given.
Notice: It is not recommended that the machine Before you start the test, completely release the
be driven with the axle partially filled with oil. brake hydraulic pressure. Temporarily pressurise the
brakes (5x) with 100bar (1,449.3psi) maximum.
1. Stop the machine on hard and level ground.
High Pressure Test
Increase the test pressure to 100bar (1,449.3psi)
3. Install the articulation lock. Refer to (PIL 06-27). maximum then use the shut-off valve to close the
connection to the HP pump.
4. Wait for a few minutes for the oil to settle.
A maximum of 2% pressure decrease is allowed
5. Clean the area around the dipstick.
during a 5min test time.
6. Remove and clean the dipstick.
Low Pressure Test
7. Check the oil level. It should be between MIN and
MAX mark on the dipstick. Decrease the test pressure to 5bar (72.5psi) then
close the shut-off valve. No decrease in pressure is
Figure 335. allowed during a 5min test time.
Figure 336.
A
MAX
MIN
A Dipstick
8. If necessary, add the recommended oil to the
system through the hole.
9. Clean and install the dipstick.
10. Tighten the dipstick to the correct torque value.

Item Nm
A 50
B 50
27 - 82 9813/6500-1 27 - 82
27 - Driveline
20 - Axle
00 - General
Remove and Install
WARNING A raised and badly supported 4.6. Support the axle on a trolley jack at the point
machine can fall on you. Position the machine of balance.
on a firm, level surface before raising one end.
4.7. Remove the nuts (x8), washers (x16),
Ensure the other end is securely chocked. Do
spacer (x8) and the bolts (x8) from the front
not rely solely on the machine hydraulics or jacks
axle.
to support the machine when working under it.
Disconnect the battery, to prevent the engine 4.8. Remove the front axle from the machine.
being started while you are beneath the machine.
5. Remove the rear axle as follows:
Remove 5.1. Raise and support the rear chassis of the

machine.
Make a note that the illustration shows a typical 5.2. Remove the rear wheels. Refer to (PIL
machine chassis. The actual chassis of the machine 27-29).
may look different.
5.3. Disconnect the grease hoses from the axle.
1. Make the machine safe with the lift arm raised.
Refer to (PIL 01-03). 5.4. Plug all the open ports and hoses to prevent
contamination.
2. Install the safety strut on the lift arm. Refer to (PIL 5.5. Disconnect the rear propshaft from the axle
06-69). yoke. Refer to (PIL 27-47).
3. Install the articulation lock. 5.6. Remove the capscrews 1 (x10).
Refer to: Articulated Joint (Page 06-39). 5.7. Remove the front trunnion.
4. Remove the front axle as follows: 5.8. Remove the capscrews 2 (x14).
4.1. Raise and support the front chassis of the 5.9. Remove the capscrews 3 (x10).
machine. 5.10. Remove the rear trunnion.
4.2. Remove the front wheels. 5.11. If necessary, remove the dowels.
Refer to: Wheel (Page 27-135). 5.12. Support the axle on a trolley jack at the
4.3. Disconnect the grease hoses from the axle. point of balance.
4.4. Plug all the open ports and hoses to prevent 5.13. Remove the nuts (x8), washers (x16),
contamination. spacer (x8) and the bolts (x8) from the rear
axle.
4.5. Disconnect the front propshaft from the axle
yoke. 5.14. Remove the rear axle from the machine.
Refer to: Propshaft (Page 27-146).
27 - 83 9813/6500-1 27 - 83
27 - Driveline
20 - Axle
00 - General
Figure 337.
D
J
K
A G
A Front axle B Rear axle

C Front chassis D Rear chassis
E Bolts (x16) F Washers (x32)
G Spacer (x16) H Nut (x16)
J Capscrews 1 (x10) K Front trunnion
L Capscrews 2 (x14) M Rear trunnion
N Capscrews 3 (x10)
27 - 84 9813/6500-1 27 - 84
27 - Driveline
20 - Axle
00 - General
Install
1. Replacement is the opposite of the removal
procedure.
3. Bleed the brake system. Refer to (PIL 24-00).
4. Make sure that the axle and hubs are filled to the
correct level with the appropriate oil.

Item Nm
E 874
J 259
L 311
N 259
27 - 85 9813/6500-1 27 - 85
27 - Driveline
20 - Axle
00 - General
Consumables
4003/2006 12.5kg
4003/2005 50kg
Disassemble
Output Shaft and Brake
1. Put the axle on a suitable work platform and B
make sure it is secure. Refer to Figure 338. B Drain plug
Figure 338. 4. If installed, remove the brake tube. Refer to
Figure 341.
Figure 341.
A
A Axle
2. Position a suitable container to collect the oil from
the axle. C Brake tube
3. Loosen the plugs (X3), then let the oil drain from 5. Support the output assembly with suitable lifting
the axle. Refer to Figure 339. and Refer to Figure equipment.
340.
5.1. Use a wheel nut to secure the lifting device
Figure 339. in position.
6. Remove the screws 1. Refer to Figure 342.
Figure 342.
E
D
D Hexagon screw 1
E Output assembly
27 - 86 9813/6500-1 27 - 86
27 - Driveline
20 - Axle
00 - General
7. Separate the output assembly from the axle Figure 345.

housing. Be careful when you release the end-
plate and the multi disks.
8. Remove the stub shaft and the sun gear shaft.
Be careful, this can release the shims. Refer to
Figure 343.
Figure 343.
G
L Cover 1
F
12. Remove the locking screws.
13. Remove the cover 2. Refer to Figure 346.
Figure 346.
F Stub shaft
G Sun gear shaft
9. Attach the output assembly to the work platform. N
10. Remove the end plate, brake breather valve and
screw neck. Refer to Figure 344.
Figure 344.
H M
M Locking screws
N Cover 2
J K 14. Use a lifting device to remove the planetary
carrier from the brake housing. Refer to Figure
347.
Figure 347.
H End plate
J Brake breather valve
K Screw neck
11. Use a lever to remove the cover 1 from the output
shaft. Refer to Figure 345.
14.1. For MT-L3065 II axles, there are three

planetary gears.
27 - 87 9813/6500-1 27 - 87
27 - Driveline
20 - Axle
00 - General
14.2. For MT-L3075 II axles, there are four 18. Remove the disc package from the brake
planetary gears. housing. Refer to Figure 351.
15. Disengage the retaining ring. Refer to Figure Figure 351.
348.
Figure 348.
R
P
R Disc package
19. Remove the hexagon screws 2.
P Retaining ring
20. Remove the releasing cover, cup spring and
16. Remove the planetary gear. Refer to Figure 349. washer. Refer to Figure 352.
S
T
U
Q
Q Planetary gear S Releasing cover
T Cup spring
17. Remove the tapered roller bearing from the
U Washer
planetary carrier. Refer to Figure 350.
21. Remove the piston with a suitable lever. Refer to
Figure 350.
Figure 352.
Figure 353.
27 - 88 9813/6500-1 27 - 88
27 - Driveline
20 - Axle
00 - General
22. If necessary, remove the guide ring, back-up Figure 356.

rings and the grooved rings from the annular
grooves in the brake housing. Refer to Figure
354.
Figure 354.
V
W
X
Y Brake housing
24. Use a lever to remove the shaft seal from the
brake housing. Refer to Figure 357.
V Guide ring Figure 357.
W Back-up rings (x2)
X Grooved rings (x2)
Figure 355.
V
Y
W Z
X
Z Shaft seal
X W 25. If necessary, remove both of the bearing outer

rings.
26. Remove the tapered roller bearing from the
output shaft. Refer to Figure 358.
Figure 358.
V Guide ring
Y Brake housing
23. Use a lifting device to remove the brake housing
from the output shaft. Refer to Figure 356.
27. Check the condition of the screening plate for

wear.
27 - 89 9813/6500-1 27 - 89
27 - Driveline
20 - Axle
00 - General
28. If necessary, remove the screening plate from the Figure 361.
Figure 359.
AG
AF
AF Bearing outer ring
AG O-ring
8. If installed, remove the piston from the axle
housing.
Axle Housing
9. Loosen the threaded connections.
1. Attach the lifting device to the axle housing.
10. Remove the releasing brake tube.
2. Remove the hexagon screws 3. Refer to Figure
360. 11. Loosen the screw neck.

AC AA
AB AD AE AD
AB Axle housing AA Screw neck

AC Hexagon screw 3 AD Threaded connections
AE Releasing brake tube
3. Carefully separate the axle housing from the axle
drive housing. Bearing Bush
4. Support the axle with a suitable stand. 1. For an axle with an above centre pivot bearing
do as follows:
5. Remove the bearing outer ring.
1.1. If necessary, make a groove.
6. Remove the shim from behind.
7. Remove the O-ring. Refer to Figure 361.
27 - 90 9813/6500-1 27 - 90
27 - Driveline
20 - Axle
00 - General
AK AL
1.2. Force the bearing bush from the hole.

1.3. Discard the bush.
Figure 364. AK Differential assembly
AL Axle drive housing
2. Remove the bearing outer ring.
3. Remove the shim from behind it. Refer to Figure
367.
Figure 367.
AH
AH Groove
Bearing Flange
1. Loosen the bolts. AM
2. Remove the bearing flange.
Figure 365. AM Bearing outer ring
AJ 4. Use a hot air blower to heat the hexagon nut 1.
5. Make a note that the hexagon nut 1 is installed
with Loctite sealant.
Figure 368.
AJ Bearing flange
Input Pinion
1. Use a lifting device to lift the differential from the
axle drive housing. Refer to Figure 366.
27 - 91 9813/6500-1 27 - 91
27 - Driveline
20 - Axle
00 - General
6. Remove the hexagon nut 1. Figure 371.

7. Remove the shim from behind it. Refer to Figure
369.
Figure 369.
AQ
AN
AQ Input pinion
11. Remove the tapered roller bearing from the axle
drive housing.
AN Hexagon nut 1 12. Remove the spacer ring.
8. Remove the input flange from the input pinion. 13. Remove the tapered roller bearing from the input
Refer to Figure 370. pinion. Refer to Figure 372.
AP
AP Input flange
9. Use a lever to remove the shaft seal from behind 14. If necessary, remove both bearing outer rings
the axle drive housing. from the axle drive housing. Refer to Figure 373.
10. Remove the input pinion from the axle drive Figure 373.
housing. Refer to Figure 371.
AR
AR Bearing outer rings
27 - 92 9813/6500-1 27 - 92
27 - Driveline
20 - Axle
00 - General
Differential Figure 375.
1. If necessary, disassemble the differential

assembly. Refer to (PIL 27-24).
Assemble
Differential
1. If disassembled, assemble the differential AT
assembly. Refer to (PIL 27-24).
Input Pinion
If the crownwheel or the input pinion are damaged,
AT Dimension-2
you must replace both components. When there is
a new installation of a complete set of bevel-gears, 1.3. Calculate the bearing width (dimension3).
make a record of the mating numbers of the input Refer to Figure 376.
pinion and the crownwheel.
Figure 376.
The calculation of the shim thickness must be done
accurately. An inaccurate measurement can cause
an incorrect contact pattern, which will require an
additional disassemble and assemble procedure of
the input pinion and the differential.
1. Calculate the thickness of the shims as follows:

1.1. Read the value in the axle drive housing
(dimension-1). Refer to Figure 374.
Figure 374.
1.4. Calculate the shim thickness (dimension-1,

dimension-2, dimension-3).
2. Install the shims of calculated thickness (refer to
step 1) in position in the axle drive housing. Refer
AS to Figure 377.
Figure 377.
AS Dimension-1
1.2. Read the value on the pinion (dimension-2).
AU
AU Shims
3. Let the internal bearing outer ring cool.
27 - 93 9813/6500-1 27 - 93
27 - Driveline
20 - Axle
00 - General
4. Install the internal bearing outer ring in the hole Setting the Rolling Torque of the Input Pinion
in the housing. Refer to Figure 378.
1. Set the rolling torque of the input pinion bearing.
Figure 378.
2. Install the spacer. Refer to Figure 381.
Figure 381.
AW
5. Let the external bearing outer ring cool.

AW Spacer
6. Install the external bearing outer ring in the hole
in the housing. Refer to Figure 378. 2.1. To get the correct rolling torque, use the
spacer removed during disassembly. You
Figure 379. must check the rolling torque again.
3. Put the input pinion into the axle drive housing.
4. Install the heated tapered roller bearing in its
correct position. Refer to Figure 382.
Figure 382.
7. Heat the tapered roller bearing, then put it into

position in the input pinion. Refer to Figure 380.
AX
Figure 380.
AX Tapered roller bearing

5. Install the protection plate on the input flange.
AV
AV Tapered roller bearing
27 - 94 9813/6500-1 27 - 94
27 - Driveline
20 - Axle
00 - General
Figure 383. Setting Bearing Rolling Torque and the Backlash

1. Calculate the correct shim thickness. Refer to
Figure 385.
Figure 385.
AY
AY Tapered roller bearing

6. Do not install the shaft seal, before you check the BA BB
correct contact pattern. Refer to (PIL 27-22).
7. Temporarily install the hexagon-nut without BA Test dimension
Loctite. BB Deviation
8. Install the input flange with the disc and hexagon Figure 386.
nut. Refer to Figure 384.
9. Tighten the hexagon nut to the correct torque BC BE
value.
10. When you tighten the hexagon nut, you must turn
the input pinion several times in both directions.
Figure 384.
AZ
BF
BD
BC Axle housing
BD Shim 1 (Crownwheel side)
BE Shim 2 (Differential carrier side)
BF Axle housing
AZ Tapered roller bearing 1.1. The test dimension is stamped into the rear
crownwheel side.
11. Make sure that the rolling torque without the
shaft seal is as specified. If necessary, adjust the 1.2. If there is no +ve or –ve deviation shown,
rolling torque as follows: the deviation corresponds to the value 0 in
the table. Refer to Table 129.
Torque: 1–5N·m
2. Put the shim 1 of the calculated thickness into the
11.1. If the rolling torque is less than the
hole in the axle-housing.
specified, install the thinner spacer.
11.2. If the rolling torque is more than the 3. Adjust the bearing outer ring until there is contact.
specified, install the thicker spacer. Refer to Figure 387.
11.3. Make a note that when you install the new
bearings, you must try to get the upper
value of rolling torque.
27 - 95 9813/6500-1 27 - 95
27 - Driveline
20 - Axle
00 - General
BG
BG Shim 1
7. Put the shim 2 of the calculated thickness into the
4. Put a thin layer of marking ink on the drive and hole in the axle-housing.
coast flanks of the crownwheel.
8. Adjust the bearing outer ring until there is contact.
5. Put the assembled differential into the axle drive Refer to Figure 387.
Figure 391.
Figure 388.
AT
BH
BK
BK Shim 2
9. Use a suitable lifting device to move the axle
AT Axle drive housing
housing into position with the axle drive housing.
BH Differential housing
10. Install the hexagon screws. Refer to Figure 392.
6. If necessary, do the following:
11. Tighten the hexagon screws to the correct torque
6.1. Apply grease to the O-rings.
value.
6.2. Put the O-rings into the annular grooves in
the piston. Refer to Figure 389. Figure 392.
Figure 389. AT
BL
BJ
BJ O-rings
6.3. Put the piston in position in the bearing AT Axle drive housing
housing. Refer to Figure 390. BL Hexagon screws
27 - 96 9813/6500-1 27 - 96
27 - Driveline
20 - Axle
00 - General
12. Check the correct lock as follows: Figure 395.

12.1. Pressurise the lock.
12.2. Close the shut-off valve.
12.3. Remove the air line.
12.4. Make a note that no noticeable pressure
loss is allowed to occur within the specified
duration.
Duration: 10s
Figure 393.
AP
AP Input flange
19. Wet the outer diameter of the shaft seal with
white spirits.
20. Fill the space between the seal and the dust lip
with grease.
21. Install the shaft seal with the seal lip facing the
oil chamber.
22. Apply a layer of Loctite on the thread of the
hexagon nut 1.
13. Turn the input flange to roll the crownwheel over
the input pinion in both directions several times. 23. Install the input flange.
14. Remove the axle housing. 24. Install the hexagon nut 1.
15. Remove the differential from the axle drive 25. Tighten the hexagon nut 1 to the correct torque
housing. value.
16. Check the contact pattern. Refer to (PIL 27-22). 26. After a good contact pattern check, install the
differential assembly again into the axle drive
16.1. If there is a deviation from the correct housing. Refer to Figure 396.
contact pattern, a measuring error was
made when the shim thickness was Figure 396.
calculated. Do the calculation again.
17. Remove the hexagon nut 1. Refer to Figure 394.
Figure 394.
AK AL
AN
AK Differential assembly
AL Axle drive housing
27. Apply grease to the axial roller cage.
AN Hexagon nut 1 28. Install axial roller cage in the sliding sleeve.
18. Remove the input flange from the input pinion.
27 - 97 9813/6500-1 27 - 97
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20 - Axle
00 - General
Figure 397. 3. Install the fitting.

4. Tighten the fitting to the correct torque value.
5. Install the brake tube with the threaded
connection and nut.
6. Tighten the nut to the correct torque value.
Figure 399.
CB
CD CC
C
CH
CH Axial roller cage
Table 129. Shims for the Differential D/DZ

and DHL-1200 in ZF axles MT-L 3065/3075
Descrip- Data
tion
C Brake tube
Crown- 20 10 10 CB Fitting
wheel CC Nut
marking CD Threaded connection
Devia- .2 0.1 0 0.1
tion 7. Apply the specified grease to the O-ring. Refer to
Shim 0.7 0.8 0.9 1.0 Figure 400.
thick- Consumable: Special HP Grease
ness
(Crown- Figure 400.
wheel AB
side)
Shim 1.3 1.2 1.1 1.0
thick-
ness
(Differ-
ential CE
carrier
side)
Axle housing
1. Apply the specified grease to the O-ring. Refer to
Figure 398.
Consumable: Special HP Grease AB Axle housing
CE O-ring
Figure 398.
8. Instal the O-ring into the axle housing.
CA
9. Use a suitable lifting device to move the axle
housing into position with the axle drive housing.
10. Install the hexagon screws. Refer to Figure 401.
C 11. Tighten the hexagon screws to the correct torque

value.
C Brake tube
CAO-ring
2. Instal the O-ring into the annular groove of the
brake tube.
27 - 98 9813/6500-1 27 - 98
27 - Driveline
20 - Axle
00 - General
AT
BL
BG
BG Taper roller bearing
AT Axle drive housing 3. For axles with slide ring seal:
BL Hexagon screws
3.1. Apply a lubricant on the O-ring of the slide
Output Shaft and Brake ring seal and the locating hole.
1. Use the wheel stud puller to pull the wheel stud 3.2. Install a new slide ring seal 2 into the output
into the output shaft. shaft. Refer to Figure 398.
1.1. Only use a wheel stud puller when the Figure 404.
individual wheel studs are replaced on an
installed output shaft. When a new output
shaft is used, use a press to install the
wheel studs. Refer to Figure 402.
Figure 402.
BE
AA
AA Slide ring seal 2

3.3. Install a new slide ring seal 1 into the brake
Figure 405.
BF
BE Wheel stud
BF Wheel stud puller
2. Heat the taper roller bearing, then put it into the
output shaft until there is contact. Refer to Figure
403.
Z Slide ring seal 1

3.4. Also Refer to Figure 412. for the installation
position of the seal.
3.5. Ensure the surface area of the slide ring
seal does not have any grooves, scratches
or other types of damage.
27 - 99 9813/6500-1 27 - 99
27 - Driveline
20 - Axle
00 - General
3.6. Make sure that the sealing surface is Figure 408.

parallel to the housing face.
3.7. Be careful, the metal rings have very sharp
edges, you must wear protective gloves.
BN
3.8. Install the O-rings evenly into the locating
holes, they must not protrude out of the
locating hole.
3.9. Install the two bearing outer rings into
position into the brake housing. Refer to
Figure 400.
Figure 406.
BN Pressure ring
BH
4.5. Apply a lubricant on the outer diameter of
the shaft seal.
4.6. Put the shaft seal into the brake housing.
Figure 409.
BH Bearing outer rings

4. For axles with combination seals:
4.1. Refer to Figure 401. for the installation
position of the combination seal.
Figure 407.
BJ Y
BK
BL 4.7. Make sure that all of the components have

been assembled correctly. Refer to Figure
401.
BM 5. Use a suitable lifting device to move the brake
housing over to its installation position over the
Y Brake housing
BJ Output shaft 5.1. Before the slide seal rings are clamped,
BK Combination seal clean the sliding surfaces and apply a layer
BL Shaft seal of oil. For example, use a leather cloth
BM Screening plate soaked with oil.
4.2. The combination seal consists of a shaft

seal and a screening plate.Refer to Figure
401.
4.3. Heat the slide bushing, then position it on
the collar of the output shaft.
4.4. Use a pressure ring to move the slide
bushing to its correct position.Refer to
Figure 408.
27 - 100 9813/6500-1 27 - 100

27 - Driveline
20 - Axle
00 - General

Y
V
W
X
Y
X
W
AA
Y Brake housing
6. Put the back-up rings and grooved rings into the
annular grooves of the brake housing. Refer to
Figure 411.
Figure 411.
V
W BJ
V Guide ring
X W Back-up rings (x2)
Y Brake housing
Z-AA Slide ring seal
BJ Output shaft
8. Clean the annular grooves of the brake housing.
9. Put the guide ring into the annular groove and
secure it with Loctite at its extremities. Refer to
V Guide ring Figure 413.
X Grooved rings (x2) 9.1. The full circumference of the guide ring
must be in the correct contact position.
7. Make sure that the components are installed Refer to Figure 412.
correctly. Refer to Figure 412.
9.2. When installed, the orifice in the guide ring
must face up (12 o'clock position).
Figure 413.
V Guide ring
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27 - Driveline
20 - Axle
00 - General
10. Install the slotted pins into the holes in the piston. Figure 416.
Refer to Figure 414. BT
10.1. Make sure that the slotted pins are
BS
installed flush.
Figure 414.
BQ
BP
BS Disc
BT Cup spring
14. Put the cover 3 into position and secure with the
hexagon screws 2. Refer to Figure 417.
BP Slotted pin
Figure 417.
BQ Piston
11. Put the piston into the brake housing, then use S
a suitable lifting device to carefully install it in its
correct position. Refer to Figure 415. T
Figure 415.
Y BQ
BR
S Hexagon screw 2
T Cover 3
15. Tighten the hexagon screws 2 to the correct
torque value.
16. Install the outer and inner discs. Refer to Figure
Y Brake housing
418.
BQ Piston
BR Lifting device Figure 418.
12. Use enough oil to seal the surfaces of the piston, R
back-up rings, grooved rings, and guide ring. BU
13. Put the disc and the cup spring (with the convex
side at the top) into position. Refer to Figure 416.
R Outer disc
BUInner disc
27 - 102 9813/6500-1 27 - 102

27 - Driveline
20 - Axle
00 - General
17. Install the end plate. Refer to Figure 419. 20. Heat the inner bearing rings, then put the
planetary gears (with the large radius facing the
Figure 419. planetary carrier (downwards)) in position. Refer
to Figure 422.
Q 21. If necessary, adjust the bearing inner rings when
they have cooled.
22. Use the retaining rings to secure the planetary
gears. Refer to Figure 422.
Figure 422.
Q End plate
18. Push the stop bolt into the planetary carrier until
there is contact. Refer to Figure 420.
Figure 420.
N
BV
N Retaining ring
23. Heat the tapered roller bearing then put it in
position on the planetary carrier. Refer to Figure
423.
M Figure 423.
M Planetary carrier
BVStop bolt
19. Push the cylindrical roller bearing through the
packaging sleeve until the snap ring engages into
the annular groove of the planetary gear. Refer
to Figure 421.
BZ
Figure 421.
M
BX BW
BZ Taper roller bearing
BY
P 24. Apply an anti-corrosive agent on the front face
(contact face of the bearing inner ring) and the
profile teeth in the output shaft. Refer to Figure
424.
P Planetary gear
BW Cylindrical roller bearing
BX Packaging sleeve
BY Snap ring
27 - 103 9813/6500-1 27 - 103

27 - Driveline
20 - Axle
00 - General
CA CB L
K
CA Contact face of the bearing inner ring L Cover 2
CB Teeth of the output shaft K Locking screws
25. Align the disc package centrally and radially. 30. When the cover 2 with an offset of specified value
is used, the groove must be visible when the
26. Use the suitable lifting device to move the cover is installed. Refer to Figure 425.
planetary carrier onto the teeth of the output
shaft. Length/Dimension/Distance: 0.07mm
27. Set the width of the gap between the output shaft 31. Tighten the locking screws in sequence to the
and the planetary gear. correct torque value in two stages:
28. Select the cover 2 (optional) based on the 31.1. Stage 1: 200Nm.
calculation done in step 27. Refer to Figure 425. 31.2. Stage 2: 500Nm
Figure 425. 32. Attach the O-ring to the cover 1. Refer to Figure
427.
L CC Figure 427.
CD
J Cover 1
CDO-ring
L Cover 2
CCOffset identification groove 33. Apply Terostat MS9360 on the mating face of the
cover 1.
29. Put the cover 2 with the offset facing the
planetary carrier, then tighten with new locking 33.1. Note: the Terostat curing period is more
screws. Refer to Figure 426. than the specified duration.
Duration: 24h
34. Put the cover 1 into position on the output shaft.
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27 - Driveline
20 - Axle
00 - General
Figure 428. 38. Apply grease, then install the O-ring into the
countersink of the brake housing. Refer to Figure
431.
Figure 431.
CF
J
J Cover1
35. Calculate the axial play of the sun gear shaft.
CF O-ring
36. Put the sun gear shaft into the planetary carrier.
Refer to Figure 429. 39. Apply grease, then install the O-ring into the axle
Figure 429.
Figure 432.
CG
G
G Sun gear-shaft
CG O-ring
37. Apply grease, then install the correct shim (refer
step 35) into the sun gear shaft. Refer to Figure 40. Put the two adjusting screws in position, then use
430. the lifting device to move the output shaft into
position with the axle housing.
Figure 430.
41. Use the hexagon screws 1 to secure the output
CE shaft.
41.1. Use a wheel stud to secure the lifting
device.
CE Shim
27 - 105 9813/6500-1 27 - 105

27 - Driveline
20 - Axle
00 - General
Figure 433.
D Output assembly
E Hexagon-screws 1
42. Install the breather valve.
Figure 434.
C Breather valve

Item Nm
S 34
AC 560
AE 36
AL 1,200
BC 100
BD 50
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27 - Driveline
20 - Axle
03 - Case
03 - Case
Remove and Install
For the removal of the axle case refer to the

disassembly procedure of the axle. Refer to: Axle
(Page 27-76).
27 - 107 9813/6500-1 27 - 107

27 - Driveline
22 - Drivehead
22 - Drivehead
Contents Page No.
27-22-06 Crownwheel .................................................................................................................. 27-109

27-22-09 Pinion Gear .................................................................................................................. 27-112
27 - 108 9813/6500-1 27 - 108

27 - Driveline
22 - Drivehead
06 - Crownwheel
06 - Crownwheel Introduction
Introduction .................................................. 27-109 A crown wheel is a rotating gear wheel with teeth set
Check (Condition) ........................................ 27-110 at right angles to its plane, it is usually matched with a
pinion gear that meshes with the crown wheel. They
are mainly used in vehicles to maintain a forward
movement.
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27 - Driveline
22 - Drivehead
06 - Crownwheel
Check (Condition) Dedendum Tooth Position

The contact pattern on the convex and concave
The condition of the crownwheel is determined from flanks is too far in the root section, although more
the contact pattern on the flanks of the crownwheel. than 50% of the flank in the h direction is covered.
Make sure that the contact pattern on the flanks of Refer to Figure 436.
the crownwheel are acceptable as mentioned in the
below steps. Figure 436. Contact Pattern Unacceptable
C
Contact Pattern Setting
The contact patterns are shown on the flanks of the
crownwheel. Refer to Figure 435.
Figure 435. Contact Pattern Acceptable

A
D
E C
H
F C Convex
D Concave
G
E
On the convex flank, the contact pattern has an
D impression at the toe / root and on the concave flank
on the heel/root. Refer to Figure 436.
B
A Pinion shimming Adjustment: Add a smaller shim to the pinion.

B Middle of the tooth
C Convex The contact pattern is in the flank and a minimum
D Concave 50% of the flank in the h direction is covered. Refer
E Root of the tooth to Figure 437.
F Top of the tooth
G Toe Figure 437. Contact Pattern Acceptable
H Heel
C
The contact pattern must be at a tangent to the centre

of the tooth flank (middle of the tooth). If not, the
contact pattern will be too close to the top of the tooth
or to the root of the tooth sections.
D
The contact pattern size should be a minimum 50%
of the flank in the h direction. Refer to Figure 435.
• Convex flank = Drive side C Convex

• Concave flank = Coast side D Concave
• Toe = Crownwheel: inner side
• Heel = Crownwheel: outer side The contact pattern in the example is relatively
small. But, the contact pattern has an impression on
General the middle of the tooth and would cover the flank
optimally with a greater load. Refer to Figure 437.
When the pinion distance changes, the position of
the contact pattern changes as follows: Refer to Addendum Tooth Position
Figure 435.
• Shimming in ‘+’ = decrease the thickness of the flanks is too far in the top section. Refer to Figure
pinion shim (the contact pattern moves to the 438.
top)
• Shimming out ‘-’ = increase the thickness of the
pinion shim (the contact pattern moves to the
root)
27 - 110 9813/6500-1 27 - 110

27 - Driveline
22 - Drivehead
06 - Crownwheel
Figure 438. Contact Pattern Unacceptable Adjustment: Add a thicker shim to the pinion.
C The convex contact pattern must have an impression

at the tooth middle line. A minimum of 50% of the
tooth depth (flank) is covered. Refer to Figure 441.
Figure 441. Contact Pattern Acceptable

C
D
C Convex
D Concave
The contact pattern is too small and is not at a

tangent to the flank middle line. Refer to Figure 438.
D
Adjustment: Add a thicker shim to the pinion.
C Convex
The convex contact pattern must be visible in the D Concave
direction of the tooth centre depth. Refer to Figure
The edge on the root of the tooth of the crownwheel
439.
is permitted. This edge is caused by the shot peening
Figure 439. Contact Pattern Acceptable process. Refer to Figure 442.
Figure 442.
C
C Convex
D Concave
J Edge
A minimum 50% of the flank in the direction of the
tooth depth is covered. Refer to Figure 439.
Line Contact Pattern

flanks is too far up on the crownwheel. The contact
pattern is also too small and is not at a tangent to the
middle line of the flank. Refer to Figure 440.
Figure 440. Contact Pattern Unacceptable

C
C Convex
D Concave
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27 - Driveline
22 - Drivehead
09 - Pinion Gear
09 - Pinion Gear
Introduction
A pinion gear is a small gear that meshes with a

larger crownwheel. They are mainly used in vehicles
to maintain a forward movement.
27 - 112 9813/6500-1 27 - 112

27 - Driveline
24 - Differential
24 - Differential
Contents Page No.
27-24-00 General ......................................................................................................................... 27-115
27 - 113 9813/6500-1 27 - 113

Notes:
27 - 114 9813/6500-1 27 - 114

27 - Driveline
24 - Differential
00 - General
Introduction .................................................. 27-115 A differential is a particular type of simple planetary
Remove and Install ..................................... 27-116 gear train.
Disassemble and Assemble ........................ 27-117
The differential couples the drive shaft to half-shafts
that connect to the rear driving wheels. The purpose
of the differential is to allow a speed differential
between the inner and outer wheel while being driven
by the input shaft. In its most common form, the
differential consists of a pinion and ring and planetary
bevel gears to connect the output shafts.
The axle can have the following type of differentials.
1. Open Differential.
2. LSD (Limited Slip Differential).
Open Differential
A standard differential, or what is referred to as an
open carrier. A conventional open differential always
supplies close to equal (because of limited internal
friction) torque to each side. The differential gearing
allows the outer drive wheel to rotate faster than the
inner drive wheel during a turn. This is necessary
when the vehicle turns, making the wheel that is
travelling around the outside of the turning curve roll
farther and faster than the other.
In a standard [open type] differential, the rotational

velocity of the input shaft is the average of the
rotational velocity of the output shafts under normal
traction conditions. Therefore, increasing the speed
of one output shaft will decrease the speed of the
other output shaft.
The problem is an open differential always tries to

balance the torque. It means that if the spider gears
are pushing on both drive gears and one of them
offers lots of resistance and the other side offers no
resistance then it will try to find a balance where both
sides are receiving almost no torque at all. All the
rotational energy is guided to the side with the least
resistance. In the end, that side spins very fast and
the pressure on each drive gear is the same. Almost
no torque is needed to spin one wheel, and since
the open differential always sends the same amount
of torque to both output shafts, almost no torque is
going to the other side as well.
Limited Slip Differential (LSD)

In the most basic sense, a LSD equalizes the
difference in either speed between output shafts or
applied torque between output shafts to maintain
traction in adverse or performance conditions. The
benefits of installing an LSD are:
1. Enhanced traction in snow, gravel, and sand.
27 - 115 9813/6500-1 27 - 115

27 - Driveline
24 - Differential
00 - General
2. More predictable handling at the limits of grip. Remove and Install

This type behaves as an open differential unless one
wheel begins to spin and exceeds that threshold. For the removal and installation of the differential
The LSD will remain open unless enough torque is assembly refer to the disassembly and assembly
applied to cause one wheel to lose traction and spin, procedure of the axle. Refer to: Axle (Page 27-76).
at which point it will engage.
An LSD can use clutches when engaged, or may

also be a solid mechanical connection like a locker
or spool. It is called limited slip because it does just
that; it limits the amount that one wheel can slip.
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27 - Driveline
24 - Differential
00 - General
Consumables
JCB Autogrease 4003/2305 0.5kg B
D
Multi Disc Differential Lock (DHL-1200) E
Disassembly
1. Remove the tapered roller bearings (x2) from the
differential. Refer to Figure 443. A
Figure 443.
C
A Lid
B Cylindrical pins
C Cage
D Pressure piece
E Lever
5. Use a press to pre-load the housing cover
compression spring.
6. Remove the retaining ring.
7. Remove the sliding sleeve and compression
spring from the housing cover.
Figure 446.
2. Use a press to pre-load the differential.

3. Loosen the hexagon screws. Refer to Figure 444.
Figure 444.
8. Remove the disc package and disc carrier. Refer

to Figure 447.
4. Remove the lid, cylindrical pins, cage, pressure

piece and the lever. Refer to Figure 445.
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27 - Driveline
24 - Differential
00 - General
Figure 447. 11. Separate both halves of the spider shaft in the
direction of the arrows.
12. Disassemble the differential housing. Refer to
Figure 450.
F Figure 450.
G
K
R
N
S P
F Disc package
9. Remove the crownwheel, axle bevel gear, thrust
washer and the spacer. Refer to Figure 448.
J Q L M
Figure 448. T
G Differential housing
L Slotted pin 1 (x2)
G M Slotted pin 2 (x2)
N Split spider shaft
H T One-piece spider shaft
P Spider gear (x4)
R Thrust washer (x4)
K Axle bevel gear
S Spacer
Q Outer disc
J Thrust washer
L K Assembly
J
G Differential housing 1. Install the spacer into the differential housing.
H Crownwheel Refer to Figure 451.
L Spacer
J Thrust washer Figure 451.
K Axle bevel gear
10. Remove the slotted pins from each half of the
spider shaft. Refer to Figure 449. A
Figure 449.
A Spacer
2. Install the outer disc and the thrust washer in the
differential housing. Refer to Figure 452.
2.1. Make sure that the outer disc and the thrust
L Slotted pins washer are installed correctly.
27 - 118 9813/6500-1 27 - 118

27 - Driveline
24 - Differential
00 - General

C J
B K
H
E F
E Long one piece spider shaft

B Outer disc F Spider gear (x4)
C Thrust washer G Thrust washer (x4)
H Short spilt model spider shaft
3. Install the axle bevel gear in the differential K Slotted-pin (x2)
housing. Refer to Figure 453. J Slotted-pin (x2)
Figure 453. 5. Install the spider gears and the thrust washers
into the differential housing.
D 6. Secure the spider gears and the thrust washers

in position with either long spider shaft or short
spider shaft. Refer to Figure 455.
6.1. Install the tabs of the thrust washers into the
recesses in the differential housing.
Figure 455.
G
F
D Axle bevel gear

4. Assemble the differential spider components.
Refer to Figure 454. E
E Long spider shaft

F Spider gears
G Thrust washer
6.2. The securing holes in the spider shafts.
27 - 119 9813/6500-1 27 - 119

27 - Driveline
24 - Differential
00 - General
Figure 456. 9. Install the thrust washer and the spacer into the
G
F 9.1. Make sure that the thrust washer and the
spacer are installed correctly.
Figure 459.
H
A
H Short spider shaft

7. Secure the spider shafts in position with the
slotted pins. Refer to Figure 457.
7.1. Make sure that the slotted pins are installed.
A Spacer
7.2. Make sure that the slotted pin openings are
C Thrust washer
offset to each other at the specified angle.
Angle: 180° 10. Install the locating pins (x2) in position.
Figure 457. 11. Press the crownwheel into position on the

Figure 460.
L
L
L Slotted pins
8. Install the axle bevel gear 2. Refer to Figure 458.
P Locating pins
Figure 458. L Crownwheel
12. Install the compression spring onto the sliding
sleeve. Refer to Figure 461.
K
Figure 461.
K Axle bevel gear 2

M Compression spring
27 - 120 9813/6500-1 27 - 120

27 - Driveline
24 - Differential
00 - General
13. Install the assembled sliding sleeve into the 3.1. The locating grooves of the outer disc
housing cover. must be positioned over the cylindrical pins.
14. Use a press to pre load the compression spring.
Figure 464.
15. Install the retaining ring into the annular groove
in the sliding sleeve. C
16. Assemble the component. Refer to Figure 462.
16.1. Make sure that the lid is only supported
on the pressure piece, never on the sliding
sleeve.
Figure 462. B
P
Q
C Disc package
R B Housing cover
4. Install the snap ring into the annular groove in the
disc carrier. Refer to Figure 465.
N
Figure 465.
S
P Cage D
Q Lever (x12)
R Pressure piece 1
N Lid
S Pressure piece 2
Setting the Disc Package

1. Apply grease to the cylindrical pins.
Consumable: JCB Autogrease
2. Install the cylindrical pins into the housing cover. D Snap ring
5. Install the assembled disc carrier, so that all of
Figure 463. the inner discs are in their correct positions.
6. Pre-load the disc package.
A 6.1. Use the specified axial force.
Force: 50 -0/+30kN
7. Measure the setting dimension 1.
B 7.1. Setting dimension = From the collar of the
housing cover to the plane face of the outer
disc.
7.2. Use the outer discs to correct any
measured deviation from the specified
setting dimension 1.
A Cylindrical pins
B Housing cover
3. Install the disc package into the housing cover.
27 - 121 9813/6500-1 27 - 121

27 - Driveline
24 - Differential
00 - General
36
11. Secure the housing cover in position with the new

locking screws. Refer to Figure 469.
7.3. Make sure that the housing cover is only
supported on the pressure piece 1, never 12. Tighten the new locking screws to the correct
on the sliding sleeve. torque value.
7.4. Make sure that pressure piece is seated on Torque: 400N·m
the disc package, never on the disc carrier. Figure 469.
Figure 467.
F 27
26
E
J
K
13. Heat the tapered roller bearings (x2).

G 14. Move the tapered roller bearings into position.
22 Figure 470.
H
E Setting dimension 1
G Housing cover
H Sliding sleeve
K Disc package
J Disc carrier
K
8. Use the lifting device to put the differential onto
the housing cover.
9. Use new locking screws to temporarily secure
the housing cover in position.
10. Use a press and a pressure piece to pre-load the
differential. K Tapered roller bearings
15. If necessary, adjust the tapered roller bearings in
position.
27 - 122 9813/6500-1 27 - 122

27 - Driveline
24 - Differential
00 - General
Differential (D-1200) Figure 473.
Disassembly
1. Remove the tapered roller bearings (x2) from the
differential. Refer to Figure 471. H
Figure 471.
G
H Differential housing
G Crownwheel
7. Disassemble the crownwheel components.
Figure 474.
2. Use a press to pre load the differential.

H
3. Loosen the locking screws.

4. Remove the housing cover. Refer to Figure 472.
Figure 472.
L K
J
H Crownwheel
L Spacer
J Thrust washer
A K Axle bevel gear
8. Remove the slotted pins from each half of the
spider shaft (split model). Refer to Figure 475.
Figure 475.
A Locking screws
5. Install some of the locking screws and the
pressure plate in position. L
6. Press the differential housing from the

crownwheel. Refer to Figure 473.
L Slotted pins
27 - 123 9813/6500-1 27 - 123

27 - Driveline
24 - Differential
00 - General
9. Separate the spider shaft halves. Refer to Figure Figure 478.

475. C
10. Remove the components from the differential
housing. Refer to Figure 476. B
Figure 476.
G
K
R
N
S P
B Outer disc
C Thrust washer
J Q L M 3. Install the axle bevel gear. Refer to Figure 479.
T
G Differential housing Figure 479.
L Slotted pin 1 (x2)
M Slotted pin 2 (x2)
N Spilt spider shaft D
T One piece spider shaft
P Spider gear (x4)
R Thrust washer (x4)
K Axle bevel gear
S Spacer
Q Outer disc
J Thrust washer
Assembly
1. Install the spacer into differential housing. Refer
to Figure 477. D Axle bevel gear
Figure 477. 4. Assemble the differential spider components.
Figure 480.
A
J
K
H
E F
A Spacer
G
2. Install the outer disc and the thrust washer in the
2.1. Make sure the outer disc and the thrust 5. Install the spider gears and the thrust washers
washer are installed correctly. into the differential housing.
6. Secure them in position with either long spider
shaft or short spider shafts. Refer to Figure 481.
27 - 124 9813/6500-1 27 - 124

27 - Driveline
24 - Differential
00 - General
6.1. Install the tabs of the thrust washers into the Figure 483.
recesses in the differential housing.
Figure 481.
G
F
E L
8. Install the axle bevel gear 2. Refer to Figure 484.

E Long spider shaft
Figure 484.
F Spider gear
G Thrust washer
6.2. The securing holes in the spider shafts. K
Figure 482.
G
F
K Axle bevel gear 2

9. Install the thrust washer and the spacer into the
9.1. Make sure that the thrust washer and
H Short spider shaft
spacer are installed correctly.
7. Secure the spider shafts in position with the
Figure 485.
slotted pins. Refer to Figure 483.
A
7.1. Make sure that the slotted pins are installed.
7.2. Make sure that the slotted pin openings are C
offset to each other at the specified angle.
Angle: 180°
A Spacer
C Thrust washer
10. Install the locating pins (x2) in position. Refer to
Figure 486.
27 - 125 9813/6500-1 27 - 125

27 - Driveline
24 - Differential
00 - General
11. Press the crownwheel into position on the Figure 488.

Figure 486.
M
L
M Tapered roller bearings
P Locating pins
Multi-Disc Differential Lock (DZ-1200)
N Crownwheel
Disassembly
12. Install the housing cover in position on the
crownwheel. 1. Remove the tapered roller bearings from the
differential.
Figure 489.
14. Secure the housing cover in position with new
locking screws. Refer to Figure 487.
15. Tighten the new locking screws to the correct
torque value.
Torque: 400N·m
Figure 487.

3. Loosen the locking screws.
16. Heat the tapered roller bearings (x2). 4. Remove the housing cover.
17. Move the tapered roller bearings into position.

17.1. If necessary, adjust the tapered roller
bearings in position.
27 - 126 9813/6500-1 27 - 126

27 - Driveline
24 - Differential
00 - General

F
J
A Locking screw
5. Install some of the locking screws and the F Disc package
pressure plate in position. J Thrust washer
K Axle bevel gear
6. Press the differential housing away from the
crownwheel. 8. Remove the slotted pins from each half of the
spider shaft (split model).
Figure 491.
9. Separate the spider shaft halves. Refer to Figure
493.
Figure 493.
H
G
L
H Crownwheel
7. Remove the disc package, thrust washer and the
axle bevel gear. L Slotted pins
10. Remove the components from the differential
housing.
27 - 127 9813/6500-1 27 - 127

27 - Driveline
24 - Differential
00 - General

M B
L D
C
N E F
G
A
S P
I H
R
S Long one piece spider shaft

P Spider gear
R Thrust washer
N Short spilt model spider shaft
L Slotted pin (x2) J
M Slotted pin (x2)
11. Remove the axle bevel gear, thrust washer and
the disc package.
K
Figure 495. A Housing cover
K B Crownwheel
C Short split model spider shaft
J D Slotted pins
E Spider gear
F F Axle bevel gear
H Disc package
I Disc package
J Installation dimension (18.6mm)
K Installation dimension (16.7mm)
2. Install the disc package and a thrust washer into
the differential housing.
2.1. Make sure the disc package and a thrust
K Axle bevel gear washer are installed correctly.
J Thrust washer
F Disc package Figure 497.
Assembly M
1. Use outer discs with different thicknesses, to get L

a disc package with the installation dimension.
Note the installation position.
M Thrust washer
L Disc package
27 - 128 9813/6500-1 27 - 128

27 - Driveline
24 - Differential
00 - General
3. Install the axle bevel gear into the differential Figure 500.
housing.
E
Figure 498. M
F
N
E Spider gear
M Thrust washer
N Long spider shaft
F Axle bevel gear
Figure 501.
4. Assemble the differential spider components.
E
Figure 499. M
F
D C
C
N E
C Short spider shaft
M
6.1. Put the tabs of the thrust washers into the
recesses in the differential housing
N long one piece spider shaft
E Spider gear (x4) 7. Secure the spider shafts in position with the
M Thrust washer (x4) slotted pins.
C Short spilt model spider shaft
D Slotted pin (x2) 7.1. Make sure that the slotted pins (x2) are
F Slotted pin (x2) installed.
7.2. Make sure that the slotted pin openings are
5. Install the spider gears and the thrust washers offset to each other at specified angle.
Angle: 180°
6. Secure the spider gears and the thrust washers
in position with either long spider shaft or short
spider shaft.
27 - 129 9813/6500-1 27 - 129

27 - Driveline
24 - Differential
00 - General
Figure 502. 11. Press the crownwheel into position on the

differential housing.
Figure 505.
P
D
D Slotted pins
8. Install the axle bevel gear 2.
P Crownwheel
Figure 503.
12. Install the housing cover in position on the
crownwheel.
F 13. Use a press to pre-load the differential.
14. Secure the housing cover with new locking
screws.
15. Tighten the new locking screws to the correct
torque value.
Torque: 400N·m
Figure 506.
F Axle bevel gear 2

9. Install the thrust washer and the disc package
9.1. Use outer discs with different thicknesses,
to get a disc package of the installation
dimension.
Figure 504.
L
M 16. Heat the tapered roller bearings (x2).
17. Move the tapered roller bearings into position.
17.1. If necessary, adjust the tapered roller
bearings in position.
L Thrust washer
M Disc package
10. Install the locating pins (x2) into position.
27 - 130 9813/6500-1 27 - 130

27 - Driveline
24 - Differential
00 - General
Figure 507.
Q Tapered roller bearings
27 - 131 9813/6500-1 27 - 131

27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ......................................................................................................................... 27-133

27-27-18 Sun Gear ...................................................................................................................... 27-134
27 - 132 9813/6500-1 27 - 132

27 - Driveline
27 - Hub
00 - General
00 - General
Introduction
The hub is the part of the axle where the wheel

is mounted and where the axle shaft (if installed)
passes through.
Some hubs are not driven and rotate due to motion

of the machine and some driven hubs may also have
reduction gearing installed.
The hub may also be designed to allow steering of

the wheels and/or incorporate brakes.
27 - 133 9813/6500-1 27 - 133

27 - Driveline
27 - Hub
18 - Sun Gear
18 - Sun Gear Figure 510.
Calibrate
B
The calibration of the sun gear includes the
adjustment of the axial play. The permitted axial play
between the sun gear and shaft is 0.5–2mm.
1. Measure the dimension1 and dimension2 as

follows:
1.1. Use gauge blocks and a straight edge
to calculate the dimension1, from the
mounting face of the brake housing to the B Sun gear shaft
front face of the stop bolt. Refer to Figure
508. 1.5. Use a straight edge to measure the
dimension2, from the front face of the sun
Figure 508. gear shaft to the mounting surface of the
axle housing. Refer to Figure 511.
Figure 511.
1.2. Put the stub-shaft into the teeth of the axle

bevel gear until there is contact. Refer to
Figure 509.
2. Calculate the shim required as follows (shown as
Figure 509. an example):
• Dimension1 = 19.75mm
A • Dimension2 = -17.15mm
• Difference = 2.6mm
• Required axial play = 1mm
• Then, required shim = 1.6mm
A Stub shaft
1.3. Make sure that you position the stub shaft
with the long teeth facing the differential.
1.4. Put the sun gear shaft into position. Refer
to Figure 510.
27 - 134 9813/6500-1 27 - 134

27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ......................................................................................................................... 27-137
27 - 135 9813/6500-1 27 - 135

Notes:
27 - 136 9813/6500-1 27 - 136

27 - Driveline
29 - Wheel
00 - General
Introduction .................................................. 27-137 On new machines, and whenever a wheel has been
Health and Safety ........................................ 27-138 removed, check the wheel nut torques every two
Remove and Install ..................................... 27-139 hours until they stay correct. Every day, before
starting work, check that the wheel nuts are tight.
Tighten the wheel nuts (in a diagonal sequence) to
the correct torque value, refer to Technical Data.
27 - 137 9813/6500-1 27 - 137

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 - 138 9813/6500-1 27 - 138

27 - Driveline
29 - Wheel
00 - General
Remove and Install
CAUTION You can be injured if you use incorrect 2. Install the articulation strut. Refer to (PIL 06-27).
or faulty lifting equipment. You must identify the
weight of the item to be lifted then choose lifting 3. Put chocks against the wheels.
equipment that is strong enough and suitable for
the job. Make sure that lifting equipment is in good 4. Loosen the nuts in the sequence shown on the
condition and complies with all local regulations. wheel to be exchanged. Refer to Figure 512.
5. Use suitable lifting equipment to lift the machine,
Important: The wheel and tyre assembly is heavy. then use a stand to support its axle.
Get the help of one more person to remove and
replace a wheel. 6. Remove the nuts in the sequence shown from
the wheel. Refer to Figure 512.
Remove 7. Move the wheel away from the machine.
Figure 512.
1
9 5
12 7
3 4
8 11
6 10
2
27 - 139 9813/6500-1 27 - 139

27 - Driveline
29 - Wheel
00 - General
A Nut
27 - 140 9813/6500-1 27 - 140

27 - Driveline
29 - Wheel
00 - General
Install
removal procedure.
2. Tighten the nuts by hand, then tighten to the
correct torque value in the sequence shown.

Item Nm
A 620
27 - 141 9813/6500-1 27 - 141

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-143
27 - 142 9813/6500-1 27 - 142

27 - Driveline
33 - Tyre
00 - General
Introduction .................................................. 27-143 Tyres provide a flexible cushion that absorb shocks,
Health and Safety ........................................ 27-144 while keeping the wheel in close contact with the
Check (Condition) ........................................ 27-144 ground.
Tyre materials are usually synthetic rubber, natural

rubber, fabric and wire, along with other compound
chemicals. They consist of a tread and a body.
The tread provides traction while the body ensures
support.
Make sure that the tyres are kept in good condition.

Refer to Health and Safety and Check Condition (PIL
27-33).
27 - 143 9813/6500-1 27 - 143

27 - Driveline
33 - Tyre
00 - General

DANGER Make sure that all tyres are inflated
to the correct pressure. Refer to the machine Always drive with consideration for the condition
operator manual. of the tyres. Incorrect tyre pressures will affect the
stability of the machine. Check the tyres daily for
WARNING An exploding tyre can kill. Inflated the correct tyre pressure and signs of damage. For
tyres can explode if over-heated or over-inflated. example:
Follow the instructions given when inflating the
tyres. Do not cut or weld the rims. Use a tyre/ • Signs of distortion (bulges).
wheel specialist for all repair work. • Cuts or wear.
WARNING Wheels and tyres are heavy. Take • Embedded objects (nails, etc.).
care when lifting or moving them. Store with care
to ensure that they cannot fall and cause injury. Install the valve caps firmly to prevent dirt from
entering the valve. Inspect for leaks when you check
WARNING Do not use the machine with the tyre pressures.
damaged, incorrectly installed, incorrectly inflated
or excessively worn tyres. Recognise the speed Inspect the tyre valve for leaks, when you check the
limitation of the tyres installed and do not operate tyre pressures.
at more than their recommended maximum
speed.
Tyre Inflation
WARNING Running tyres outside recommended
guidelines may result in failure of the tyres which Always try to maintain the tyre pressure to the
at high speeds may endanger life. recommended settings. Using a machine with under-
WARNING Deflate the tyre you wish to change inflated tyres means:
before removing the wheel from the machine.
• Decreasing the machines stability.
Air pressure in the tyres can cause the tyre and
• Higher tyre temperatures.
rim sections to explode causing serious injury or
• Excessive strain of the tyre fabric.
death. Never loosen the nuts that hold the inner
• Causes bulging of the sidewalls.
and outer wheel halves together when there is air
• Shortens the tyres life.
pressure in the tyre. Always wear safety glasses.
WARNING Do not install pneumatic tyres on a Using the machine with over-inflated tyres is
wheel made for a solid tyre. Do not install a solid dangerous:
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for • It causes excessive tensile loads in the fabric:
your machine, contact your local JCB dealer or a this makes a tyre more susceptible to cuts and
trained specialist. punctures.
WARNING When ordering tyres, you must Do not cut or weld on the rim of an inflated tyre.
specify not only the tyre size but also the speed
designation. The correct tyres for the machine are After checking or amending the tyre pressure always
shown in the Operator's Manual. On no account replace and secure the valve cap.
should you use tyres of other designations
without first gaining approval from the machine Always deflate the tyre before removing foreign
manufacturer. obstacles from the tread.
WARNING Remove the valve core to make sure
the tyre is fully deflated. If the tyre is not fully Procedure
deflated, unseen damage to the wheel and / or
tyre could cause the assembly to explode. These instructions are for adding air to a tyre which is
already inflated. If the tyre has lost all its air pressure,
call in a qualified tyre mechanic. The tyre mechanic
should use a tyre inflation cage and the correct
equipment to do the job.
1. Prepare the wheel. Before you add air to the tyre,

make sure it is correctly installed on the machine
or installed in a tyre inflation cage.
27 - 144 9813/6500-1 27 - 144

27 - Driveline
33 - Tyre
00 - General
Figure 513.
2. Prepare the equipment.

2.1. Use only an air supply system which
includes a pressure regulator. Set the
regulator no higher than 1.38 bar (20 psi)
above the recommended tyre pressure.
2.2. Use an air hose fitted with a self-locking air
chuck and remote shut-off valve.
3. Add the air.
3.1. Make sure that the air hose is correctly
connected to the tyre valve. Clear other
people from the area. Stand behind the
tread of the tyre while adding the air.
3.2. Inflate the tyre to the recommended
pressure. Do not over-inflate.
27 - 145 9813/6500-1 27 - 145

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-147
27 - 146 9813/6500-1 27 - 146

27 - Driveline
47 - Propshaft
00 - General
Introduction .................................................. 27-147 The propeller shaft or propshaft is usually the shaft
Lubricate ...................................................... 27-148 that connects the gearbox to the differential or
Remove and Install ..................................... 27-149 drivehead.
The propshaft is a mechanical component for

transmitting torque and rotation, usually used to
connect components of a drive train that cannot be
connected directly because of distance or the need
to allow for relative movement between them.
27 - 147 9813/6500-1 27 - 147

27 - Driveline
47 - Propshaft
00 - General
Lubricate
5 grease points.
Figure 514.
1 2 3 5
27 - 148 9813/6500-1 27 - 148

27 - Driveline
47 - Propshaft
00 - General
Remove and Install
For: Front ................................ Page 27-149 2. Install the articulation strut. Refer to (PIL 06-27).
For: Rear ................................. Page 27-150
3. Put the chocks against the wheels.
For: Intermediate ..................... Page 27-150
4. Get access to the front and intermediate
(For: Front) propshaft joint between the front and rear
chassis.
WARNING A machine can roll off jacks and
crush you unless the wheels have been blocked. 5. Put marks on the front and intermediate
Always block the wheels at the opposite end of propshaft joints. This will help in the installation.
the machine that is to be jacked. Do not work
underneath a machine supported only by jacks. 6. Remove the screws 1 (x4) and the bearing straps
Always support a jacked-up machine on axle that attach the intermediate propshaft to the front
stands before working underneath it. propshaft.
7. Remove the nuts, washers, and bolts.
Remove
Figure 515.
G
B
A
F
F
C
E
A Intermediate propshaft B Screw 1

C Bearing strap D Front propshaft
E Nut F Washer
G Bolt
8. Get access to the front axle and front propshaft 11. Remove the front propshaft carefully from the
joint from the bottom of the machine. machine.
9. Put marks on the front axle and front propshaft
joints. This will help in the installation.
Install
10. Remove the screws 2 (x4) that attach the front
procedure.
propshaft to the front axle.
27 - 149 9813/6500-1 27 - 149

27 - Driveline
47 - Propshaft
00 - General
2. Tighten the screws 1 and screws 2 to the correct Install

torque value.
Torque: 139–151N·m
procedure.
Torque: 61–81N·m
Torque: 139–155N·m
(For: Rear) (For: Intermediate)
Remove Remove
2. Remove the undershield covers. Refer to (PIL
3. Remove the centre undershield to get access to 06-06).
the gearbox and rear propshaft.
4. Put identification marks on the rear propshaft to
4. Put the chocks against the wheels.
the rear axle and the gearbox output shaft joints.
5. Support the intermediate propshaft.
5. Remove the screws that attach the rear propshaft
to the gearbox output shaft. 6. Put marks on the front and intermediate
propshaft joints to help installation.
6. Remove the screws that attach the rear propshaft
to the rear axle. 7. Disconnect the intermediate propshaft from the
front propshaft. Refer to (PIL 27-47).
7. Remove the rear propshaft.
8. Remove the nut (x10).
Figure 516.
9. Disconnect the intermediate propshaft from the
B transmission.
10. Remove the intermediate propshaft from the
machine.
A
A Screws (x8)
B Rear propshaft
27 - 150 9813/6500-1 27 - 150

27 - Driveline
47 - Propshaft
00 - General
Figure 517.
B
A
A Transmission B Intermediate propshaft

C Front propshaft D Nut (x10)
27 - 151 9813/6500-1 27 - 151

27 - Driveline
47 - Propshaft
00 - General
Install
removal procedure.
27 - 152 9813/6500-1 27 - 152

27 - Driveline
51 - Driveshaft
51 - Driveshaft
Contents Page No.
27-51-00 General ......................................................................................................................... 27-155
27 - 153 9813/6500-1 27 - 153

Notes:
27 - 154 9813/6500-1 27 - 154

27 - Driveline
51 - Driveshaft
00 - General
Introduction .................................................. 27-155 The driveshaft is a mechanical component for
Component Identification ............................. 27-156 transmitting torque and rotation, usually used to
Disassemble and Assemble ........................ 27-157 connect other components of the driveline that
cannot be connected directly because of distance
or the need to allow for relative movement between
them.
27 - 155 9813/6500-1 27 - 155

27 - Driveline
51 - Driveshaft
00 - General
Figure 518.
C
B
A
A Axle housing B Driveshaft

C Shim
27 - 156 9813/6500-1 27 - 156

27 - Driveline
51 - Driveshaft
00 - General
For instructions regarding the disassembly of the

driveshaft refer to the disassembly and assembly
procedure of the axle. Refer to (PIL 27-20).
27 - 157 9813/6500-1 27 - 157

Notes:
27 - 158 9813/6500-1 27 - 158

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-03 Smooth Ride System (SRS) .......................................................................................... 30-14
30-00-49 Schematic Symbols ........................................................................................................ 30-22
30-00-50 Schematic Circuit ........................................................................................................... 30-26
30-03 Tank
30-03-00 General ........................................................................................................................... 30-39
30-04 Filter
30-04-00 General ........................................................................................................................... 30-45
30-04-03 Main ................................................................................................................................ 30-47
30-04-09 Return Line .................................................................................................................... 30-50
30-11 Gear Pump
30-11-00 General ........................................................................................................................... 30-53
30-12 Variable Displacement Pump
30-12-00 General ........................................................................................................................... 30-67
30-12-46 Output Shaft Seal .......................................................................................................... 30-79
30-15 Cylinder Ram
30-15-00 General ........................................................................................................................... 30-81
30-15-03 Shovel Lift ...................................................................................................................... 30-88
30-15-06 Lift Arm ........................................................................................................................... 30-91
30-15-09 Lift Arm Quickhitch ......................................................................................................... 30-94
30-15-34 Steering .......................................................................................................................... 30-96
30-15-99 Seal Kit ........................................................................................................................... 30-98
30-18 Accumulator
30-18-00 General ......................................................................................................................... 30-103
30-18-06 Smooth Ride System (SRS) ........................................................................................ 30-107
30-18-12 Brake ............................................................................................................................ 30-113
30-51 Lift Arm Control Valve Block
30-51-00 General ......................................................................................................................... 30-117
30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-128
30-60 Flow Control Valve
30-60-00 General ......................................................................................................................... 30-131
30-60-90 Flow Regulator ............................................................................................................. 30-133
30-93 Hose
30-93-00 General ......................................................................................................................... 30-135
30-97 Connectors
30-97-00 General ......................................................................................................................... 30-139
30-97-03 Quick Release Coupling .............................................................................................. 30-142
30-97-09 Adaptor ......................................................................................................................... 30-144
9813/6500-1
2017-02-22
Acronyms Glossary
ARV Auxiliary Relief Valve

LS Load Sense
LSRV Load Sense Relief Valve
MRV Main Relief Valve
SAE Society of Automotive Engineers
SRS Smooth Ride System
9813/6500-1
2017-02-22
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-03 Smooth Ride System (SRS) .......................................................................................... 30-14
30-00-49 Schematic Symbols ........................................................................................................ 30-22
30-00-50 Schematic Circuit ........................................................................................................... 30-26
30 - 1 9813/6500-1 30 - 1
Notes:
30 - 2 9813/6500-1 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.
Operation ......................................................... 30-6
To help you trace specific hydraulic problems to
Diagram ........................................................... 30-6 a faulty unit (valve, actuator, ram etc.), refer to
Fault-Finding .................................................... 30-7 Fault finding (PIL 30-00). Once you have traced the
Discharge and Pressurise ............................. 30-10 faulty unit, refer to the relevant section for removal,
Clean ............................................................. 30-10 disassembly and checking instructions.
Check (Leaks) ............................................... 30-11 To help identify circuits, valves, rams etc. mentioned
Check (Level) ................................................ 30-12 in the fault finding procedures. Refer to the hydraulic
Check (Operation) ......................................... 30-12 schematic diagrams (PIL 30-00-50).
Check (Pressure) .......................................... 30-13
• 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, 122 °F).
• Whatever the fault, check the condition of the
hydraulic fluid. Drain and replace if necessary.
Refer to Hydraulic fluid quality in this procedure
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 9813/6500-1 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
These contaminants can appear during
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: Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component
has been disconnected, always install protective
caps and plugs to prevent dirt ingress.Failure to
follow these instructions will lead to dirt entering the
system. Dirt in the system will seriously damage
the systems components and could be expensive to
repair.
CAUTION! The temperature of the hydraulic oil will
be high soon after stopping the machine. Wait until it
cools before beginning maintenance.
30 - 4 9813/6500-1 30 - 4
00 - General
00 - General
Technical Data Description Data

Filtration size 10 micron
Table 132. Pump Maximum working pres- 36bar (521.7psi)
sure
Description Data
Rated maximum flow 360L/min
Make Rexroth
Suction strainer size 140 micron
Model L A10VO
Type Variable displacement
Standby pressure 21bar (304.3psi)
Maximum rotational 2100 RPM (Revolutions
speed Per Minute)
Maximum loop pressure 245bar (3,550.7psi)
Maximum rated flow 210L/min
Direction of shaft rota- Clockwise
tion
Operating temperature -20–106°C (-4.0–
222.7°F)
Table 133. Lift arm valve

Description Data
Type Closed centre, directional control
Service Operated
4 Spool 3 Spool
Spool 1 Lift arm Lift arm
Spool 2 Shovel Shovel
Spool 3 Quickhitch (Op- Auxiliary (Op-
tional) tional)
Spool 4 Auxiliary (Op- Not applicable
tional)
Table 134. Relief Valve Operating Pressures

Description Data
System PRV (Pressure 260bar (3,768.1psi)
Relief Valve)
LSRV (Load Sense Re- 230bar (3,333.3psi)
lief Valve)
Steer relief valve 205 ± 5bar
(2,971.0 ± 72.5psi)
Priority valve pressure 7.9bar (114.5psi)
(Neutral)
Priority valve pressure 12.2bar (176.8psi)
(Fully selected)
ARV (Auxiliary Relief Valve)
Lift ram, head side 350bar (5,072.4psi)
Shovel ram, head side 115bar (1,666.7psi)
Shovel ram, rod side 250bar (3,623.2psi)
Servo 30bar (434.8psi)
Brake (non adjustable) 60bar (869.6psi)
Table 135.
Description Data
Oil cooler bypass pres- 3bar (43.5psi)
sure
Filter bypass pressure 3.5bar (50.7psi)
30 - 5 9813/6500-1 30 - 5
00 - General
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Operation Diagram
The main components of the hydraulic system are: Hydraulic State Colour Codes
• The combined hydraulic pumps. Some diagrams in this section use colours to
• Lift arm valve block. represent the different hydraulic system states. Refer
• Servo valve. to Figure 519.
• Steering valve.
• Emergency steer valve. Figure 519.
• Brake valve.
• Hydraulic tank.
• Ram.
• Filters.
1 2 3 4 5 6 7
For descriptions of the steering (PIL 25-00) and 1 Lock up
brake valves (PIL 24-00), refer to the relevant 2 Cavitation
sections. 3 Exhaust
4 Neutral
The primary pump and secondary pump are driven 5 Servo
by the engine to supply pressurised oil to the 6 Pressure
hydraulic system. The primary pump supplies oil to 7 Maximum pressure
the complete hydraulic system, the secondary pump
supplies oil to the lift arm valve block spools.
When there is no pressure requirement from the lift

arm circuits, the secondary pump returns to standby
mode. The priority valve makes sure that the pump
pressure serves the requirement of the steering
circuit first.
A pressure regulated output from the priority valve is

routed to the servo valve, which in turn is redirected
to the lift arm valve block spools as control inputs.
When the servo control valve is operated, it causes
the selected service valve spool in the lift arm valve
block to direct pressurised oil from the pumps to
the selected service ram. Pressurised oil forces the
piston along the bore to cause a service movement.
As the piston moves, oil is pushed from the opposite
end of the ram and returns to tank by way of a
hydraulic filter.
Relief valves in the system prevent undue pressure

increases through the internal and external sources.
When you assemble the MP22 valve blocks make

sure that the tie-rods are tightened within the
specified torque limits. 74.6–81.4N·m
30 - 6 9813/6500-1 30 - 6
00 - General
00 - General
Fault-Finding
Fault
Lack of power in all loader functions Table 136. Page 30-7
All hydraulic rams slow to operate Table 137. Page 30-7
One hydraulic service fails to operate or is slow to operate Table 138. Page 30-7
Engine tends to stall when hydraulics are under load Table 139. Page 30-8
Valve spool sticking Table 140. Page 30-8
Ram creep Table 141. Page 30-8
Hydraulic oil becomes too hot Table 142. Page 30-8
Boom judders when used while machine is moving Table 143. Page 30-9
Table 136. 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 137. 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 138. 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 - 7 9813/6500-1 30 - 7
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 139. 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 140. 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 141. 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 142. 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 - 8 9813/6500-1 30 - 8
00 - General
00 - General
Table 143. 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 - 9 9813/6500-1 30 - 9
00 - General
00 - General
Discharge and Pressurise Clean

Special Tools
Observe all the health and safety information. Refer Description Part No. Qty.
to Hydraulic System- Health and Safety (PIL 30-00). Hydraulic Flushing Rig 892/01255 1
Discharge
Cleaning Operation
Refer to (PIL 01-03). The purpose of cleaning oil is to remove
contaminants of all types and sludge by filtering
2. Apply the park brake. hydraulic fluid through a cleaning unit.
3. Set the transmission to neutral. Procedure

4. Turn the ignition key to the ON position. Do not 1. Connect the Hydraulic flushing rig in place of the
start the engine. hydraulic filter.
5. Make sure that the loader isolator switch is ON. Special Tool: Hydraulic Flushing Rig (Qty.: 1)
The switch will be illuminated when ON.
2. Run the system for sufficient time to pump all the
6. Operate the push button controls repeatedly to hydraulic fluid through the unit.
release the hydraulic pressure in the loader
arms. 3. Disconnect the cleaning unit and reconnect the
filter.
7. Operate the controls for the loader arms, shovel
and the auxiliaries at least 10 times to release 4. Top up the system with clean hydraulic fluid as
all of the pilot and any trapped pressure in the required.
service lines.
Figure 520.
8. Turn the ignition key to the OFF position.
9. Make sure that you release the pressure in
the service hose lines before you connect or
disconnect the hoses.
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 9813/6500-1 30 - 10
00 - General
00 - General
• Red Blood Cell = 8 microns (0.008 mm, Check (Leaks)

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. Install the articulation strut. Refer to (PIL 06-27).
3. Open the access covers as required. Refer to
The smallest particle visible to the naked eye is (PIL 06-06).
40 microns (0.00157) approximately. Standards will
often be quoted to ISO (International Standards 4. Check the areas around the hydraulic
Organisation) for which literature can be obtained. components and hoses for traces of hydraulic oil.
5. Check the chassis and undershield for any traces
of hydraulic oil.
6. Check all the hoses, connectors and fittings for
any leaks.
7. If a leak is found, do the following.
7.1. Clean the area around the leaking
component, hose or fittings.
7.2. Tighten the connectors to the correct torque
value. Refer to (PIL 30-97).
7.3. If the leak is still not correct, disassemble
the component to replace the O-rings and
seals as applicable.
30 - 11 9813/6500-1 30 - 11
00 - General
00 - General
Check (Level) Check (Operation)

Notice: If the fluid is cloudy, then water or air
has contaminated the system. This could damage Hot test setting
the hydraulic pump. Contact your JCB dealer
immediately. You must warm the machine before you start, check
that:
Refer to (PIL 01-03). • The coolant temperature is above 80°C
(175.9°F)
2. Make a note that the machine must be level when • The hydraulic oil temperature is between 45–
you check the fluid level to make sure that the 55°C (112.9–130.9°F)
measurement is correct.
For a stall speed test with the transmission engaged,
3. Make sure that the fluid is visible in the sight take a reading just before it enters the red band.
gauge.
To show the actual temperatures for the
4. If necessary, add the hydraulic fluid. Refer to (PIL transmission, coolant and the hydraulic fluids
30-03). (instead of using a gauge).
Figure 521.
• Before you check the stall speed, all of the
electrics must be off (air conditioning, lights,
heater blower, etc).
• Make sure that the HVAC (Heating Ventilation
Air Conditioning) switch and transmission
disconnect switch are off. Select 3rd gear.
• Excessive or continual adjustment should be
B reported to the person concerned who will
A
report to the supplier.
A Chassis For the hot test setting values refer to Hydraulic

B Sight gauge System, General, Technical data. Refer to (PIL
30-00).
30 - 12 9813/6500-1 30 - 12
00 - General
00 - General
Check (Pressure) Figure 524.

2. Connect the pressure line to the test points on
the step.
Figure 522.
5. Check and set the pressure under the operator

station.
5.1. Loosen the nut.
5.2. Adjust the adjusting screw with Allen key.
Figure 525.
3. Disconnect the hose from valve block.

Figure 523.
6. Make a note of the pressure values.

7. Connect the hoses.
Figure 526.

contamination.
30 - 13 9813/6500-1 30 - 13
00 - General
03 - Smooth Ride System (SRS)
03 - Smooth Ride System (SRS) Introduction

Introduction .................................................... 30-14 The SRS (Smooth Ride System) is a hydraulic
Operation ....................................................... 30-15 suspension system that is designed to enable a
Diagram ......................................................... 30-19 “cushion” effect for the loader lift rams, so that the
Discharge and Pressurise ............................. 30-20 ride will be smoother when you travel over rough
terrain. The system is fully effective under all load
conditions, from full payload to an empty shovel.
Nitrogen accumulators act through a stabilisation

module valve to balance the oil displacement across
the lift rams as the machine travels across rough
terrain. The accumulators use hydraulic pressure on
one side of a diaphragm, working against nitrogen
gas pressure on the other, to damp out the forces felt
in the loader lift arms, so keeping the machine steady
at all times.
The stabilisation valve is solenoid activated through

a speed sensing switch, and operates automatically
when yo go over the 7km/h (4.3mph) speed limit.
A manual override switch allows the system to be

switched off if not necessary. The accumulators
retain their charge at all times so that there is no
possibility of the loader lift arm collapsing when the
system is activated again.
Figure 527.
30 - 14 9813/6500-1 30 - 14
00 - General
Operation
When the driving speed exceeds 7km/h (4.3mph) the Circuit descriptions
solenoid inside the stabilisation module is activated.
This connects the head side of the lift rams to the Make a note that the illustration shown is for the
hydraulic accumulators. purpose of explanation only. For the actual hydraulic
schematic, refer to (PIL 30-00).
During the lifting process, the solenoid is switched
off so that the accumulators can be loaded up to a System charging
maximum value of the set pressure during the lifting
operation. If the pressure on the head side of the With the engine ON, regardless of whether the
lifting rams is lower than the peak pressure in the cab system activation switch is set to ON or OFF,
accumulator, the two way cartridge valve 1 closes. whenever loader operations are carried out, the SRS
The accumulators are not subjected to continuous (Smooth Ride System) circuit will be charged as
pressure variation. follows.
The sequence valve and the pressure relief valve When the lift service is operated, pressurised oil
in the stabilisation module limit the maximum flows from the loader valve spool out of port 2 to
accumulator pressure. As the pressure in the the head end of the loader lift rams causing them to
accumulator is always equal to or greater than the rise. At the same time, oil flows from a connection in
pressure in the lift rams, the shovel will be slightly this feed line to the SRS valve. The pressurised oil
raised when the stabilisation system cuts in. enter the SRS valve at port1, and flows on through
the one way valve to the accumulators where it acts
The piston side of the lift rams are connected through upon one side of the accumulator pistons, against
a two way cartridge valve 2 to the tank. When the accumulators stored gas charge pressure, as a
the system is activated both cartridge valves are result the hydraulic pressure increases.
operated simultaneously via the solenoid valve 1
this ensures cavitation free oscillation of the lift ram The hydraulic pressure increase will be in correlation
pistons. to the pressure generated by the lift circuit, is that
the heavier the load lifted, the greater the pressure
generated.
Figure 528.
F
C T
E
B A
A Port 1 B Port 2
C SRS valve D Loader valve spool
E Lift arms F Valve block
30 - 15 9813/6500-1 30 - 15
00 - General
System fully charged causing it to move to the left. The internal pilot supply
to the left side of the spool is through the double
With the engine ON and regardless of the status check valve and the solenoid spool, supplied with a
of the system’s cab activation switch, should the pathway to tank, so it cannot damage the operation
loading operations being carried out cause the of the spool. With the spool in this position, flow
hydraulic pressure stored in the SRS valve to rise too between the loader lift rams and the accumulators
high the following will happen. is dead ended by the operating spool preventing the
loader operations charging the system further.
When the charge pressure of the hydraulic oil
increases above a predetermined level, the level As the internal pressure is lowered by the relief valve,
being set by the pressure relief valve, the relief valve the pilot pressure on the right side of the operating
will be forced off its seat by the generated internal spool is also reduced, allowing the spring pressures
pilot pressure, allowing the excess pressure to bleed to centre the spool to the charging position, ready for
to tank. the cycle to begin again.
At the same time, a second internal pilot pressure At this stage the system is charged but not active.
acts upon the right side of the operating spool
Figure 529.
B A
A Port 1 B Port 2
30 - 16 9813/6500-1 30 - 16
00 - General
System operating and pilot pressure to the right of the operating spool
causing the spool to move to the right.
With the engine ON, the cab system activation
switch in the ON position and the machines road With the spool in this position, oil from the head end
speed above the speed required to activate the SRS of the lift rams is connected to the accumulators,
system, the status of the SRS opening valve will be thereby allowing the variations in the oil pressure
as follows. caused by the machine travelling over the uneven
ground to be dampened by the action of the stored
With the system activation switch turned ON, and gas pressure acting on the opposing side of the
the speed above the required activation speed, the accumulator pistons.
solenoid in the SRS valve is switched ON, closing
the path to tank of the oil in the pilot line to the With the loader valve lift spool in the closed position,
left of the operating spool, and opening a pilot line the oil from the rod end of the lift rams path to
from the accumulator charged internal pressure to tank has been dead ended by the spool. However, a
the left hand side of the spool through the double connection has been opened by the SRS operating
check valve. This pilot pressure in conjunction with spool to tank allowing the rod end of the lift rams to
the spring pressure overcomes the combined spring take in or take out oil as required.
Figure 530.
F
C
B A
A Port 1 B Port 2
30 - 17 9813/6500-1 30 - 17
00 - General
System pressure equalisation the stored accumulator oil pressure and the pressure
in the lift arms.
With the system activating cab switch turned ON and
the machine carrying out loading operations, there The effect of this pressure differential causes the
is a sequence of events that could potentially allow combined spring and pilot pressure acting on the
the stored accumulator pressure to be greater than right side of the SRS operating spool to move it fully
the pressure in the loader arm circuit. This, when to the left.
the system activates, would cause a sudden and
possibly violent rise of the lift arms. To stop this from With the spool in this position, the high pressure oil
happening, the SRS valve operating spool has an from the accumulators is allowed to bleed to tank,
additional position that operates as follows. thereby reducing the internal pressures, while dead
ending the connections from the lift rams.
The machine travelling with a loaded shovel, and with
the SRS system operating, stops and empties the Once the pressure differential equalises, the
load from the shovel. On resumption of road travel, combined spring and pilot pressure acting on the left
when the predetermined speed at which the SRS side of the operating spool overcome those forces
valve’s solenoid is activated to switch the system on, applied to the right side, moving the spool to the right,
the valve senses the pressure differential between thereby providing the required dampening effect to
the lift rams.
Figure 531.
F
C
BB A
A
A Port 1 B Port 2
30 - 18 9813/6500-1 30 - 18
00 - General
Diagram
Figure 532.
T C
B A
A Lift ram port - Head side

B Lift ram port - Rod side
C Accumulator port
D Drain port
T Tank return port
30 - 19 9813/6500-1 30 - 19
00 - General
Discharge and Pressurise
Observe all the health and safety information. Refer 2. Fully lower the lift arm to the ground or put it on
to Hydraulic System- Health and Safety (PIL 30-00). props with the shovel supported or fully dumped.
The SRS (Smooth Ride System) control valve is
located at the inside of the front chassis, towards the 3. Remove the blanking plug, located behind the
rear in the centre articulated joint area on the left hose, from the SRS control valve with the
hand side of the machine. specified Allen key.
Dimension: 4mm
Discharge
Figure 533.
A SRS control valve B Hose

C Blanking plug
4. Loosen the grub screw, located below the full turns to remove the grub screw fully. If you
blanking plug, with the specified Allen key. fully remove the grub screw, pressurised oil can
be forced out of the hole.
Dimension: 3mm
5. Do not remove the grub screw fully from the SRS
control valve. It only requires a maximum of two
30 - 20 9813/6500-1 30 - 20
00 - General
6. Make sure that the pressure is released before

you start any other work. Let the system drain the
pressure for the specified time period.
Duration: 1min
7. When you complete the work on the SRS system,
reverse the above steps.
8. Make sure that the grub screw and the blanking
plug are fully tightened.
30 - 21 9813/6500-1 30 - 21
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-22 Complex hydraulic components and circuits can
Diagram ......................................................... 30-23 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 - 22 9813/6500-1 30 - 22
00 - General
Diagram Table 147. Control valves

Symbol Description
Used to enclose sever-
Table 144. 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 pilot operated
Indication of rotation 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 145. 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 146. 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 - 23 9813/6500-1 30 - 23
00 - General
Table 148. 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 149. 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 - 24 9813/6500-1 30 - 24
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 - 25 9813/6500-1 30 - 25
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-26 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-27 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 - 26 9813/6500-1 30 - 26
00 - General
Diagram
30 - 27 9813/6500-1 30 - 27
Notes:
30 - 28 9813/6500-1 30 - 28
00 - General
Page 30-30 Figure 534. Variable Flow Hydraulic

Circuit 335/H1014- Issue 5 (sheet 1 of 2) Page 30-31
30 - 29 9813/6500-1 30 - 29
00 - General
Figure 534. (Part 1 of 2) Page Page
30-30 30-31
Page 30-31
30 - 30 9813/6500-1 30 - 30
00 - General
30-30 30-31
Page 30-30
30 - 31 9813/6500-1 30 - 31
00 - General
30 - 32 9813/6500-1 30 - 32
00 - General
Page 30-34 Figure 535. Variable Flow Hydraulic

Circuit 335/H1014- Issue 5 (sheet 2 of 2) Page 30-35
A E
D
F H
30 - 33 9813/6500-1 30 - 33
00 - General
30-34 30-35
A
D
Page 30-35
F
30 - 34 9813/6500-1 30 - 34
00 - General
30-34 30-35
E
Page 30-34
F H
30 - 35 9813/6500-1 30 - 35
00 - General
A Trailer brake (Option) B Electric brake (Option)

C Electric brake - German (Option) D SRS (Smooth Ride System) (Option)
E Tow hitch (Option) F Reverse fan motor
G Proportional fan motor H Auxiliary dump valve (Option)
J Quickhitch (Option)
Item Description
Table 150. Component key 23a Cooling fan motor - relief valve
24 Hydraulic oil tank
Item Description
25 Suction strainer
1 Pump 1
26 Main return filter
1a P1 Stand-by PRV (Pressure Relief
Valve) 27 Breather
1b P1 System PRV 28 Accumulator
1c P1 Pump control piston 30 Restrictor check valve - LS
1d P1 Stroking piston 31 Loader valve
2 Pump 2 31.1 Counter pressure valve
2a P2 Stand-by PRV 31.2 Spool bucket service
2b P2 System PRV 31.3 Sequence valve A1
2c P2 Pump control piston 31.4 Load check valve - A1
2d P2 Stroking piston 31.5 Port relief - valve A1
3 Pressure switch 31.6 Load check valve - B1
4 Priority valve 31.7 Sequence valve B1
5 Shuttle valve - LS (Load Sense) 31.8 Port relief - valve B1
6 Check valve 31.9 Shuttle valve - LS
7 Emergency steer pump 31.10 Spool boom service
7a Pump 31.11 Float position device
7b Electric motor 31.12 Sequence valve B2
7c Relief valve 31.13 Load check valve - B2
8 Pressure sensor - Emergency steer 31.14 Sequence spool load position
pump 31.15 Restrictor, priority
9 Steer control unit (SCU) 31.16 Port relief valve - B2
9a SCU anti-cavitation valves 31.17 Load check valve - B2
9b SCU LS relief 31.18 Sequence valve - A2
9c SCU spool and sleeve 31.19 Port relief valve - A2
9d SCU gerotor 31.20 Section 3
9e SCU cylinder reliefs 31.21 Section 4
10 Steer ram 31.22 Port relief valve (optional)
11 Brake pump and charge valve 31.23 Pressure reducing valve - Pilot
12 Brake charge pressure sensor 32 Bucket ram
13 Test point - Fan 33 Boom ram
14 Test point - Brake charge 34 Quick-hitch (Auxiliary option)
15 Brake accumulators 34a Quick-hitch locking valve
16 Brake modulation valve 34b Quick-hitch ram
17 Front brake actuator 34c Attachment ram
18 Rear brake actuator 34d Optional quick release couplings
19 Park brake actuator and check valve 35 Test point - Pilot pressure
(Germany and USA only) 36 Test point - Pump 1
20 Parking brake valve 37 Test point - Pump 2
21 Parking brake caliper 38 Test point - SLS
22 Oil cooler 39 Check valve
23 Cooling fan motor
30 - 36 9813/6500-1 30 - 36
00 - General
Item Description
50 SRS valve (Option)
51 SRS accumulator
60 Cooling fan reversing motor (Option)
61 Loader control valve isolator and reduc-
er
61.1 Pressure reducing valve
61.2 Loader control valve isolator
30 - 37 9813/6500-1 30 - 37
03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ........................................................................................................................... 30-39

30 - 38 9813/6500-1 30 - 38
03 - Tank
00 - General
Introduction .................................................... 30-39 The hydraulic tank holds excess hydraulic oil to
Component Identification ............................... 30-40 accommodate volume changes due to the following.
Drain and Fill ................................................. 30-41
Remove and Install ....................................... 30-41 • 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 - 39 9813/6500-1 30 - 39
03 - Tank
00 - General
Figure 536.
D
B
A Rear chassis B Hydraulic tank access panel

C Suction strainer D Sight gauge
E Filler cap F Hydraulic tank filter
30 - 40 9813/6500-1 30 - 40
03 - Tank
00 - General
Drain and Fill Remove and Install

1. Make the machine safe with the lift arm lowered. This part is a none serviceable component, if the tank
Refer to (PIL 01-03). is faulty replace the complete rear chassis assembly.
(PIL 06-06).
5. Remove the filler cap from the hydraulic tank.
5.1. Make sure that no foreign objects or
contamination can enter the hydraulic tank.
6. Put a large suitable container below the drain
plug of the hydraulic tank.
Figure 537.
A Hydraulic oil filler cap

B Drain plug
7. Remove the drain plug.
8. When the hydraulic tank is empty, check the drain
plug.
8.1. Clean the drain plug.
8.2. Install the drain plug.
8.3. If the drain plug is damaged, replace it.
9. Fill the hydraulic tank with clean fluid through the
filler neck.
10. Check the hydraulic oil level. Refer to (PIL
30-00).
11. Install the filler cap.
30 - 41 9813/6500-1 30 - 41
03 - Tank
12 - Suction Strainer Introduction

Introduction .................................................... 30-42 The suction strainer is a component used for trapping
Remove and Install ....................................... 30-43 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 - 42 9813/6500-1 30 - 42
03 - Tank
Remove and Install
Remove 2. Drain the tank. Refer to (PIL 30-03).
1. Make the machine safe with the lift arm lowered. 3. Remove the hydraulic tank access panel.
Figure 538.
B
D
C
A Suction strainer B Hydraulic tank access panel

C Bolt D Washer
4. Remove the bolt and washer from the suction

strainer.
5. Remove the suction strainer from the machine.
6. Check the strainer for damage. If necessary,
replace the strainer.
7. Flush the suction strainer with clean hydraulic
fluid.
Install
removal procedure.
30 - 43 9813/6500-1 30 - 43
04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ........................................................................................................................... 30-45

30-04-03 Main ................................................................................................................................ 30-47
30-04-09 Return Line .................................................................................................................... 30-50
30 - 44 9813/6500-1 30 - 44
04 - Filter
00 - General
Introduction .................................................... 30-45 Hydraulic filters are an important part of the
Technical Data ............................................... 30-46 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 - 45 9813/6500-1 30 - 45
04 - Filter
00 - General
Technical Data
Table 151. Filter

Description Value
Filtration size 10 micron
Bypass setting 3.5bar (50.7psi)
Maximum working pres- 36bar (521.7psi)
sure
Maximum rated flow 360L/min
30 - 46 9813/6500-1 30 - 46
04 - Filter
03 - Main
03 - Main Introduction
Introduction .................................................... 30-47 The main hydraulic filter is usually located in the main
Remove and Install ....................................... 30-48 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 - 47 9813/6500-1 30 - 47
04 - Filter
03 - Main
Consumables
JCB JCB Hydraulic 4002/1605 20L C
Fluid EP 46 4002/1603 200L
Remove
2. Discharge the hydraulic pressure. Refer to (PIL D
30-00).
3. Open the rear chassis cover to get access to the
filter. Refer to (PIL 06-06).
4. Remove the hydraulic tank filler cap.
5. Remove the screws (x4).
Figure 539.
B
A
A Screws (x4)
B Hydraulic filter
6. Remove and discard the O-rings.
7. Remove the filter cover which secures the filter C Filter cover
element. D Filter element
8. Take out the filter element and turn it over to
remove the seal.
9. Check the condition of the components. Replace,
if necessary.
Install
steps.
2. Replace the element and the seal with a new
one.
30 - 48 9813/6500-1 30 - 48
04 - Filter
03 - Main
4. Top up the system to the correct level with the

recommended hydraulic fluid.
Consumable: JCB JCB Hydraulic Fluid EP 46
30 - 49 9813/6500-1 30 - 49
04 - Filter
09 - Return Line
09 - Return Line
Introduction
The cleanliness of this component is critical and

must conform to JCB standard 9993/0003. Refer to
Hydraulic System - Introduction (PIL 3000).
30 - 50 9813/6500-1 30 - 50
11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ........................................................................................................................... 30-53
30 - 51 9813/6500-1 30 - 51
Notes:
30 - 52 9813/6500-1 30 - 52
11 - Gear Pump
00 - General
Introduction .................................................... 30-53 The gear pump consists of an end cover, a body,
Technical Data ............................................... 30-54 housing a matched gear pair, bushes and a mounting
Component Identification ............................... 30-55 flange fixed together with bolts. The gear journals are
Check (Condition) .......................................... 30-56 supported in plain bearings within pressure balanced
bushes to give high volumetric and mechanical
Remove and Install ....................................... 30-57 efficiencies.
The direction of rotation of the pump is indicated by
an arrow on the body near to the driveshaft.
30 - 53 9813/6500-1 30 - 53
11 - Gear Pump
00 - General
Technical Data
Refer to Hydraulic System- General, Technical Data

(PIL 30-00).
30 - 54 9813/6500-1 30 - 54
11 - Gear Pump
00 - General
Figure 541.
K
L
N
N
E G L
K
A
Q
P
F
H M
A Flange B Body
C Drive gear shaft D Drive gear
E Screw driven F Hexagonal nut
G Name plate H Snap ring
J Stud K Pump seal energiser
L Pump seal element M Lip seal
N Balance plate P Washer
Q Section seal
30 - 55 9813/6500-1 30 - 55
11 - Gear Pump
00 - General
Check (Condition) shows scoring between the root of the gear and
the journal, which leaves a wear step. If a wear
step can be felt coincident with the root diameter
Each component should be thoroughly cleaned, by drawing a fingernail across the surface from the
carefully checked and assessed for possible re-use journal outwards to the tip of the gear, then the gear
again. Use the guide below to check the various is unserviceable.
components and if any component is unserviceable,
replace the complete pump assembly. The gear teeth must be carefully checked to make
sure that there are no signs of scuffing or pitting on
Body the involute face.
Check the body bore cut-in on the inlet side where The journal bearing surfaces should be completely
the gears touch the body. The body can only be re- free from scoring or bruising. The surface should
used if the cut-in is bright and polished in appearance appear highly polished and smooth to the touch.
and the depth does not exceed 0.08mm. The body
should not be scored, have a ‘matt’ appearance or Make sure that the area where the shaft seal lips run
show signs that the tip of the gears have dug in and on the driveshaft, this shows up as a polished ring
torn away the surface material. or rings. If a noticeable groove can be felt or there is
scoring the shaft is unserviceable.
The body must be checked to make sure that there
is no superficial damage, which may badly affect If the driveshaft is not damaged from the drive
performance or sealing. Give particular attention to coupling and the gears have not been harmed as
the port threads and the body O-ring seal recesses. described above, then the gears can be used again.
When pumps are disassembled, all the seals must

Mounting flange and end cover be replaced. It is most important that genuine JCB
parts are used.
The inner surfaces must be checked to make sure
that there is no unusual wear or scoring in the area
where the body O-rings and bush seals contact,
which could result in external leakage.
Check the shaft seal recess for scoring or damage

that could result in oil leakage around the outer
diameter of the shaft seal. Shaft seals can be re-used
with Loctite hydraulic sealant to overcome small
damage in this area.
Bushes
The side faces, which abut the gears, should be
perfectly flat, should not have any signs of scoring.
Characteristically there are bright polished areas on
this surface caused by loading against the gear side
faces and is often more pronounced on the low
pressure side.
Often there is a witness mark where the tips of the

opposing gears have wiped an overlap resembling
a half moon shape. There must be no noticeable
wear step as it is critical that the bush side face is
completely flat on the gear side face.
The bush bearing liners are acceptable for use

unless they are not scored, have bronze appearing
through the grey surface or show any prominent
signs of wear.
Gears
The gear side faces should be checked for bruising
or scoring. Often operation on contaminated fluid
30 - 56 9813/6500-1 30 - 56
11 - Gear Pump
00 - General
Remove and Install
Remove 5. Disconnect the hydraulic hoses from the

hydraulic ports on the pump. Cap the open ports
1. Make the machine safe. Refer to (PIL 01-03). to prevent contamination.
2. Open the engine compartment cover. Refer to 6. Disconnect the electrical connection to the pump.
(PIL 06-06).
7. Remove the two screws that attach the pump to
3. Release the hydraulic pressure from the system. the engine.
8. Remove the gear pump.
4. Get access to the gear pump. It is installed on the
flywheel side of the engine.
Figure 542.
A Gear pump B Hydraulic ports

C Electrical connection D Screws
30 - 57 9813/6500-1 30 - 57
11 - Gear Pump
00 - General
Install
procedure.
30 - 58 9813/6500-1 30 - 58
11 - Gear Pump
00 - General
Consumables
Disassemble
Take extreme care not to damage the machined
surfaces when you remove sections. Excessive force
while prying can result in misalignment and seriously
damage to parts.
If parts are difficult to install during assembly, tap

gently with a soft hammer (never use an iron
hammer).
Gears are closely matched, therefore they must be 4. Lift off the flange. If the prying is necessary, be
kept together as sets when removed from a unit. careful not to damage the machined surfaces.
Handle the gears with care to avoid damage to the
journals or teeth. Avoid touching the gear journals. Figure 545.
Never hammer the bushings into bores. Use a

suitable press.
Do not grip on or near any machined surfaces during

assembly or disassembly.
1. Place the pump in a vice with the drive shaft

pointing up.
2. Put match mark on all the sections. Make sure to
align these marks when you assemble.
Figure 543.
5. Remove the balance plate. Examine and replace

if necessary.
Figure 546.
3. Use a wrench to remove the capscrews (x4) on

a single unit or the hexagon nuts (x4), studs and
washers of the multiple units.
30 - 59 9813/6500-1 30 - 59
11 - Gear Pump
00 - General
6. Remove the drive and driven gears. Avoid Figure 549.

tapping the gear teeth together or against other
hardened surfaces. Keep these gears together
because they are a matched set.
Figure 547.
9. Push out the shaft seal.

Figure 550.
7. Remove the balance plate from the bottom of the
body. Examine and replace if necessary.
Figure 548.
10. Inspect all the bushings for scoring or

discolouration and replace if necessary. The
bushing cannot be easily removed with a puller.
8. Remove the snap ring (located in front of the Replace it with a new flange or body with
shaft seal ring). bushings already installed.
30 - 60 9813/6500-1 30 - 60
11 - Gear Pump
00 - General
11. Clean all faces of the body and mounting flange 3. Replace and install the bushings removed from
from sealant and dirt. the flange and the body in the drive bores with the
groove to the top of unit (at 12 o’clock position).
Figure 552.
4. Install the bushings in the driven bores with the
groove to the bottom of the unit (at 6 o’clock
position).
Figure 554.
Assemble
1. If the bushings have been removed, deburr the
bushing bores with an emery cloth.
5. Press the bushings into the bore one at a time
2. Rinse parts in a suitable solvent. Air blast all the using the special installation tool and a suitable
parts and wipe with a clean, lint less cloth before press. Make sure that the grooves are positioned
you start the assembly. as per step 3 and step 4.
Consumable: Surface Cleaning Fluid 6. Press the bushings into the bores flush with the
casting face. Make sure to support the castings
so that they are square and level.
30 - 61 9813/6500-1 30 - 61
11 - Gear Pump
00 - General
7. Pack the shaft seal with grease before you install 9. Install the snap ring. A new snap ring should be
it in the bore. used if supplied in the seal kit.
7.1. Apply Loctite to the outside of the can for

the shaft seals with metal outer diameter. 10. Check the section seal. Use of a new one is
recommended in each case. Put grease on the
8. Press in the shaft seal to the bottom of the shaft NES section seal to hold it in the groove.
seal bore.
Figure 559.
30 - 62 9813/6500-1 30 - 62
11 - Gear Pump
00 - General
11. Put a circle of Loctite 518 sealant outside the 14. Motor balance the plate and the seals.
interlock track on the body. Refer to (PIL 75-16).
Figure 563.
Figure 560.
15. Install the lower balance plate into the body,

sealing parts can be fixed with grease. The
12. Check the balance plates and the sealing parts. position is rotation sensitive.
13. Install new sealing parts. Install the rubber seal

first and the plastic seal on top (Pump plate and 16. Install the gears into the body. Lubricate the
seals). journals and other contact faces with clean
Figure 562. hydraulic fluid.
30 - 63 9813/6500-1 30 - 63
11 - Gear Pump
00 - General
Figure 565. 19. Install the mounting flange carefully from top
down to the body. Install the interlocking
correctly.
Figure 568.
17. Install the upper balance plate on top of the gear

set. The position is rotation sensitive.
Figure 566.
20. Install the screws into the body and tighten

alternately.
21. Tighten the screws diagonally to the correct
torque value.
Figure 569.
18. Slide the steel shaft seal sleeve over the

drive shaft. Lubricate the sleeve with grease to
lubricate the shaft seal during assembly.
Figure 567.
30 - 64 9813/6500-1 30 - 64
12 - Variable Displacement Pump
Contents Page No.
30-12-00 General ........................................................................................................................... 30-67

30-12-46 Output Shaft Seal .......................................................................................................... 30-79
30 - 65 9813/6500-1 30 - 65
Notes:
30 - 66 9813/6500-1 30 - 66
00 - General
Introduction .................................................... 30-67 The most common variable displacement pump used
Technical Data ............................................... 30-68 in vehicle technology is the axial piston pump. This
Component Identification ............................... 30-69 pump has several pistons in cylinders arranged
Operation ....................................................... 30-70 parallel to each other and rotating around a central
shaft. A swashplate at one end is connected to the
Check (Condition) .......................................... 30-72 pistons. As the pistons rotate, the angle of the plate
Check (Pressure) .......................................... 30-72 causes them to move in and out of their cylinders.
Disassemble and Assemble .......................... 30-78 A rotary valve at the opposite end from the
swashplate alternately connects each cylinder to
the fluid supply and delivery lines. By changing the
angle of the swashplate, the stroke of the pistons
can be varied continuously. If the swashplate is
perpendicular to the axis of rotation, no fluid will flow.
If it is at a sharp angle, a large volume of fluid will be
pumped.
Some pumps allow the swashplate to be moved in

both directions from the zero position, pumping fluid
in either direction without reversing the rotation of the
pump.
Piston pumps can be made variable-displacement

by inserting springs inline with the pistons. The
displacement is not positively controlled, but
decreases as the back-pressure increases.
30 - 67 9813/6500-1 30 - 67
00 - General
Technical Data
Refer to Hydraulic System- General, Technical Data

(PIL 30-00).
30 - 68 9813/6500-1 30 - 68
00 - General
Figure 570.
D
X
B
A
B
S
S D
A Control Valve B Pressure port

D LS (Load Sense) port S Suction port
X Drain port
Do not adjust the control valve. Any adjustment

to control valve changes the characteristics of the
horsepower control of the pump.
30 - 69 9813/6500-1 30 - 69
00 - General
Operation
The hydraulic system is powered by two pumps, a The stroke length of the pistons and consequently
primary pump and a secondary pump. the output of fluid is directly related to the swashplate
angle. The swashplate is normally held in its
The pumps are of the variable displacement axial maximum displacement angle by the stroking piston
piston type. Displacement of oil is achieved by the spring and system pressure inside the stroking
continuous operation of nine pistons. Pump fluid piston.
output is controlled by a tilting cam (swashplate),
the angle of which is regulated to make sure that Pump Pressure/Flow Regulator Valves
only the amount of fluid necessary to satisfy load
conditions is delivered. If a load condition is such that Refer to Figure 571.
no flow is required, only sufficient fluid for cooling and
lubrication is provided. Start Up
Main components of the pump are. The Start Up Valve (SUV) is energised, opening
chamber setting spring, to exhaust. This allows the
• Cylinder barrel splined to a drive shaft which is
spool1 to move up against the chamber setting
held against a kidney plate.
spring. Oil from the pump signal port is able to flow
• Axial pistons located in the cylinder barrel, each
across the spool and into the pump control piston.
having an articulated shoe that is in held contact
The control piston moves the swashplate to the
with the swash plate by an attachment plate.
minimum flow position.
• Stroking piston and a control piston which help
in tilting action of the swash plate. Later the
tilting action is fed by servo pressure. Hydraulic Service Operated
• The valve block housing and the pressure/flow
The SUV is de-energised, opening chamber setting
regulators are installed on the pump exterior
spring, to loader valve signal circuit. A signal from
that provide servo control.
loader valve moves spool down onto its stop. Oil in
Rotation of the cylinder barrel causes linear control piston is open to exhaust through restrictor
movement of the axial pistons and fluid from the allowing the swash plate to be moved by control
suction port is drawn into the pump through the spring to maximum flow position.
kidney plate to fill a developing vacuum behind
the piston. As the cylinder barrel rotates the fluid Minimum Flow/Maximum Pressure
is carried from an elongated suction kidney to an
elongated pressure kidney where linear movement The SUV is de-energised, opening chamber setting
starts to return the piston into the cylinder barrel. spring, to loader valve signal circuit. System pressure
Fluid is forced from the pump through the pressure acts on spool2 moving it against spring. Oil is then
port. diverted to control piston moving the swashplate to
the minimum flow position. Minimal flow is allowed
across restrictor to stabilize pump.
30 - 70 9813/6500-1 30 - 70
00 - General
Figure 571.
C C C
F F F
D D D
G G G
E E E
A A A
B B B
P P P
A Control piston B Valve block

C Spring D Spool 2
E Restrictor F Chamber setting spring
G Spool 1
30 - 71 9813/6500-1 30 - 71
00 - General
Check (Condition) Check (Pressure)

Special Tools
1. Check the hydraulic pumps for signs of damage Description Part No. Qty.
or wear.
Pressure Gauge (0-40 892/00278 1
2. Make sure that the O-ring grooves, the seal Bar)
recess of the mounting flange and all the seal Pressure Gauge (0-400 892/00279 1
faces are free from burrs and scores. Bar)
3. Make a note that the burrs and scores can Raised Equipment
damage the seals. The damaged seals can
cause hydraulic oil leakage. 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.
Hydraulic Pressure
Before connecting or removing any hydraulic hose,
WARNING! Make sure the articulation lock is in the
transport position before you transport the machine.
The articulation lock must also be in the transport
position if you are carrying out daily checks or doing
any maintenance work in the articulation danger
zone. If the articulation lock is not in the transport
position you could be crushed between the two parts
of the chassis.
Standby Pressure
Important: Due to ambient temperature variations
worldwide, it is recommended that initial checks of
the Standby pressure are taken using a 400bar
(5,797.1psi) gauge.
1. Connect a specified pressure gauge to the main

pump test point.
1)
Figure 572.
A Main pump test point
30 - 72 9813/6500-1 30 - 72
00 - General
2. Start the engine, run the engine at low idle. Figure 573.
C
2.1. Based on the ambient temperature the D
pressure should be within the specified
value.
Pressure: 29–32bar (420.3–463.8psi)
E
2.2. Do not perform any adjustment at this
stage.
3. Stop the engine.
4. Remove the LS (Load Sense) hose from the
pump and put a plug at the open end of the hose.
5. Keep the pump connection open to the
atmosphere.
6. Replace the 400 bar pressure gauge with a 40
bar pressure gauge.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
C Locknut
7. Start the engine and see the pressure value on D Adjusting screw
the gauge. E LS hose
8. Make sure that the pressure value is within the 10. Install the LS hose to the pump.
specified limit.
11. Remove the pressure gauge.
9. If necessary, adjust the standby pressure as
follows: Main Pressure
9.1. Hold the lock nut with a 17mm spanner and 1. Connect a specified pressure gauge to the main
remove the domed nut. pump test point.
9.2. A sealing washer is installed in a recess in Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
the domed nut. Make sure that you keep it 1)
for installation.
1.1. Make sure that the LS hose has been
9.3. Put a 3mm hexagon key into the threaded connected after checking the standby
section and loosen the lock nut. Adjust as pressure.
required.
9.4. This adjustment is very sensitive. Figure 574.
9.5. Tighten the locknut and install the domed A

nut.
9.6. Make sure that the pressure has not
changed.
A Main pump test point

3. Operate the controls to crowd the bucket with
the lift arms down and hold the controls at this
position to read the maximum operating pressure
for the main pump.
4. Make sure that the pressure value is within the
specified limit.
5. If necessary, adjust the standby pressure as
follows:
30 - 73 9813/6500-1 30 - 73
00 - General
5.1. Hold the lock nut with a 17mm spanner and Figure 576.
remove the domed nut.
B
5.2. A sealing washer is installed in a recess in
the domed nut. Make sure that you keep it
for installation.
5.3. Put a 3mm hexagon key into the threaded
section and loosen the lock nut. Adjust as
required.
5.4. This adjustment is very sensitive. B Servo test point
5.5. Tighten the lock nut and install the domed 3. Start the engine. The pressure should rise to the
nut. specified range.
5.6. Make sure that the pressure has not
changed. No adjustment is normally required, however, it is
possible to increase the pressure by installing a shim
Figure 575. beneath the cap on the servo regulator slice. Do not
C do this if the Standby Pressure has been verified as
D correct.
C Locknut
D Adjusting screw
E LS hose
6. Put the shovel on the ground and remove the test
gauge.
7. Install the dust covers on the test points.
Servo Pressure
1. Operate the servo lever a minimum of 10 times
to vent the pressure from the servo system.
2. Connect a pressure gauge of the specified value
to the servo test point.
30 - 74 9813/6500-1 30 - 74
00 - General
Remove and Install
Consumables 8. Remove and discard the O-rings.

Sealer (High Strength) 4101/0552 0.2L 10. Remove the pressure pipe from the pump.
11. Remove the flange bolts.
Remove
12. Remove the outlet hose from the pump body.
13. Disconnect the LS (Load Sense) hose from the
2. Make sure that the exterior of the pump and pump.
working area is thoroughly cleaned and free of
possible sources of contamination. 14. Disconnect the case drain hose from the pump.
3. Discharge the hydraulic pressure. Refer to (PIL 15. Plug all the open ports and hoses to prevent
30-00). contamination.
4. Drain the hydraulic tank. Refer to (PIL 30-00). 16. Put a label on the hoses to help installation.
5. Remove the electrical connector from the pump. 17. Support the pump with suitable lifting equipment.
6. Loosen the clamp. 18. Remove the mounting bolts.
7. Remove the suction hose from the pump. 19. Carefully remove the pump from the machine.
30 - 75 9813/6500-1 30 - 75
00 - General
Figure 577.
B
A
C
A Pump B Mounting bolts

C Outlet pipe D Capscrews
E Electrical connector F Clamp
G Suction hose H LS hose
30 - 76 9813/6500-1 30 - 76
00 - General
Install
steps.
2. Make sure that the pump flanges and the mating
faces are clean.
3. Lubricate the O-rings with clean hydraulic fluid.
4. Apply the specified sealant to the mounting bolts,
suction pipe bolts and flange bolts.
(High Strength)
6. Fill the pump case with clean hydraulic fluid
through the case drain hose port.
7. Check the hydraulic oil level and top up to the
correct level. Refer to (PIL 30-00).

Item Nm
B 74
D 119
30 - 77 9813/6500-1 30 - 77
00 - General
This is not a serviceable component. If the

component is damaged, you must replace it.
30 - 78 9813/6500-1 30 - 78
46 - Output Shaft Seal
46 - Output Shaft Seal Consumable: Special MPL-EP Grease
Remove and Install

Consumables
Special MPL-EP 4003/1501 0.4kg
Grease 4003/1506 12.5kg
4003/1510 50kg
Remove
2. Remove the pump from the machine. Refer to
(PIL 30-12).
3. Remove the retaining ring.
4. Remove the output shaft seal.
5. Make a note of the position of the seal grooved
face.
Figure 578.
C A
A Output shaft seal

B Pump
C Retaining ring
D O-ring
Install
step.
2. Lubricate the new output shaft seal with the
specified grease.
30 - 79 9813/6500-1 30 - 79
15 - Cylinder Ram
15 - Cylinder Ram
Contents Page No.
30-15-00 General ........................................................................................................................... 30-81

30-15-03 Shovel Lift ...................................................................................................................... 30-88
30-15-06 Lift Arm ........................................................................................................................... 30-91
30-15-09 Lift Arm Quickhitch ......................................................................................................... 30-94
30-15-34 Steering .......................................................................................................................... 30-96
30-15-99 Seal Kit ........................................................................................................................... 30-98
30 - 80 9813/6500-1 30 - 80
15 - Cylinder Ram
00 - General
Introduction .................................................... 30-81 A hydraulic cylinder ram is a mechanical actuator
Health and Safety .......................................... 30-82 that is used to give a unidirectional force through a
Technical Data ............................................... 30-83 unidirectional stroke. It is used in many applications,
Component Identification ............................... 30-84 the cylinder gets the power from pressurised
hydraulic oil. The hydraulic cylinder consists of a
Disassemble and Assemble .......................... 30-85 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 - 81 9813/6500-1 30 - 81
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 2.1. In cold conditions the rod seals may
other end is securely chocked. Do not rely solely be frozen, so if the ram is operated at
on the machine hydraulics or jacks to support the maximum pressure and maximum speed,
machine when working under it. Disconnect the the seals will be damaged.
battery, to prevent the engine being started while you
2.2. There is a large amount of air in a new
are beneath the machine.
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 - 82 9813/6500-1 30 - 82
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
exposed part of the ram piston rod. Table 153.
2. Use genuine JCB parts when replacing parts. Cylinder Dimension

ram Bore Rod diame- Stroke
2.1. If parts other than genuine JCB parts ter
are used, the desired results may not be Shovel ram 90mm 60mm 927 ± 1.6mm
obtained. Use only genuine JCB parts.
Shovel ram 100mm 60mm 927 ± 1.6mm
3. Caution during dismantling and reassembly. (Option)
Lift ram 100mm 60mm 740 ± 1.6mm
3.1. Dismantling the ram while it is still installed
Steer ram 70mm 40mm 312 ± 1.6mm
on the machine can be dangerous as
unexpected movements of the machine can
occur. Remove the ram from the machine
and then dismantle.
3.2. If reassembled with dirty hands, foreign
matter can enter the ram causing a shorter
life span and also the other hydraulic
equipment may be damaged. Reassemble
in a clean state.
3.3. Follow the instructions in the diagrams
regarding torque tightening for screwed
parts. If the torque is too high or too low, it
can cause damage.
30 - 83 9813/6500-1 30 - 83
15 - Cylinder Ram
00 - General
Figure 579.
B B
A Shovel lift cylinder ram
B Lift arm cylinder ram
30 - 84 9813/6500-1 30 - 84
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 580. 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 - 85 9813/6500-1 30 - 85
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 581.
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 - 86 9813/6500-1 30 - 86
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 - 87 9813/6500-1 30 - 87
15 - Cylinder Ram
03 - Shovel Lift
03 - Shovel Lift
Remove and Install
Consumables 6. Support the shovel ram with suitable lifting

Description Part No. Size equipment.
JCB Threadlocker 4101/0250 0.01L 7. Remove the grease nipples from the pivot pins.
and Sealer (Medium 4101/0251 0.05L
Strength) 8. Remove the bolt (x2), washers 1 (x4) and locknut
Special Slew Pinion 4003/1619 0.4kg (x2).
Grease
1 (x2). Refer to (PIL 06-30).
Remove
10. Collect the shims 1, seals and bearings.
Refer to (PIL 01-03). 11. Remove the setscrew (x2), washers 2 (x2) and
keep plate spacers (x2).
3. Disconnect the battery cables. Refer to (PIL 2 (x2). Refer to (PIL 06-30).
33-03).
13. Collect the shims 2.
30-00). 14. Make a note of the positions of the seals and
shims to help installation.
5. Disconnect the ram hoses.
15. Remove the shovel ram from the machine.
Figure 582.
A B
E P
D A Q
C K
N
M
L
J
G
F
K
H
30 - 88 9813/6500-1 30 - 88
15 - Cylinder Ram
03 - Shovel Lift
A Shovel ram B Ram hoses

C Bolt (x2) D Washers 1 (x4)
E Locknut (x2) F Pivot pin 1 (x2)
G Shims 1 H Seals
J Bearings K Grease nipples
L Setscrew (x2) M Washers 2 (x2)
N Keep plate spacer (x2) P Shims 2
Q Pivot pin 2 (x2)
30 - 89 9813/6500-1 30 - 89
15 - Cylinder Ram
03 - Shovel Lift
Install
steps.
2. Apply specified threadlocker to the bolts and
setscrews.
(Medium Strength)
3. Apply the specified grease to the pivot pins.
Consumable: Special Slew Pinion Grease
30 - 90 9813/6500-1 30 - 90
15 - Cylinder Ram
06 - Lift Arm
06 - Lift Arm
Remove and Install
Consumables 8. Support the lift ram with suitable lifting

Description Part No. Size equipment.
JCB Threadlocker 4101/0250 0.01L 9. Remove the grease nipples from the pivot pins.
and Sealer (Medium 4101/0251 0.05L
Strength) 10. Remove the bolt (x2), washers 1 (x4) and locknut
Special Slew Pinion 4003/1619 0.4kg (x2).
Grease
1 (x2). Refer to (PIL 06-30).
Remove
12. Collect the shims 1, seals and bearings.
13. Remove the setscrew (x2), washers 2 (x2) and
2. Install the articulation strut. Refer to (PIL 06-27). keep plate spacers (x2).
3. Raise the lift ram. 14. Use the slide hammer kit to remove the pivot pin
4. Install the maintenance strut. Refer to (PIL 2 (x2). Refer to (PIL 06-30).
06-69). 15. Collect the shims 2.
5. Disconnect the battery cables. Refer to (PIL 16. Make a note of the positions of the seals and
33-03). shims to help installation.
6. Discharge the hydraulic pressure. Refer to (PIL 17. Remove the lift ram from the machine.
30-00).
7. Disconnect the ram hoses.
30 - 91 9813/6500-1 30 - 91
15 - Cylinder Ram
06 - Lift Arm
Figure 583.
D A
B
E P
Q
K
N
B
M L
J
G
F
K
H
A Lift ram B Ram hoses

C Bolt (x2) D Washers 1 (x4)
E Locknut (x2) F Pivot pin 1 (x2)
G Shims 1 H Seals
J Bearings K Grease nipples
L Setscrew (x2) M Washers 2 (x2)
N Keep plate spacer (x2) P Shims 2
Q Pivot pin 2 (x2)
30 - 92 9813/6500-1 30 - 92
15 - Cylinder Ram
06 - Lift Arm
Install
steps.
2. Apply the specified threadlocker to the bolts and
setscrews.
(Medium Strength)
3. Apply the specified grease to the pivot pins.
Consumable: Special Slew Pinion Grease
30 - 93 9813/6500-1 30 - 93
15 - Cylinder Ram
Remove and Install
Remove 7. Put a label on the hoses to help installation.
1. Make the machine safe with lift arm lowered. 8. Disconnect the hydraulic hoses.
2. Install the articulation strut. Refer to (PIL 06-27). contamination.
3. Remove the attached as required. Refer to (PIL 10. Use the slide hammer kit to remove the pivot pin.
03-00). Refer to (PIL 06-30).
4. Remove the bolts (x8). 11. Remove the pivot pins from the locking pins and
the ram.
5. Remove the access cover with the indicator pins.
12. Remove the ram and locking pins from the
6. If necessary, remove the adaptor and grease quickhitch assembly.
nipple.
Figure 584.
F D
E
G H
A B
C C
A Cylinder ram B Locking pin (x2)

C Hydraulic hoses D Bolts (x8)
E Access cover F Indicator pins (x2)
G Adaptor (x2) H Grease nipple
30 - 94 9813/6500-1 30 - 94
15 - Cylinder Ram
Install
removal procedure.
30 - 95 9813/6500-1 30 - 95
15 - Cylinder Ram
34 - Steering
34 - Steering Lubricate
Lubricate ........................................................ 30-96 There are three grease points for the lubrication on
Remove and Install ....................................... 30-97 each steering ram Refer to Figure 585.
Figure 585.
30 - 96 9813/6500-1 30 - 96
15 - Cylinder Ram
34 - Steering
Remove and Install
Make a note that the illustration shows a typical 2. Install the articulation strut. Refer to (PIL 06-27).
steering ram. The actual steering ram installed on the
machine may look different. 3. When the pressure is released, do not operate
the ignition switch as this may pressurise the
steering system.
Remove
4. Tag and disconnect the hydraulic hoses. Refer to
Figure 586.
Figure 586.
C
D
E
B
A
C
D
E
A Hoses B Steering ram

C Bolt D Washer
E Pivot pin
5. Put a container below the steering ram to collect 11. Remove the steering ram from the machine.
the hydraulic fluid.
6. Put blanking caps on the open hoses to prevent
Install
contamination and excessive fluid loss. 1. Installation procedure is opposite of the removal
procedure. Additionally do the following steps:
7. Support the steering ram.
1.1. Examine the shims. Replace if worn or
8. Remove the bolt and washer from the front pivot
damaged.
pin. Refer to Figure 586.
1.2. Check the level of hydraulic oil. If necessary
9. Remove the pivot pin from the bottom. Make sure add more. Refer to (PIL 30-00).
that you keep the shims. Refer to Figure 586.
1.3. Check the steering ram and hoses for leaks.
10. Do the steps 7 to 9 at the rear of the steering ram.
30 - 97 9813/6500-1 30 - 97
15 - Cylinder Ram
99 - Seal Kit
99 - Seal Kit Figure 587.
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 588.
(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 589.
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 - 98 9813/6500-1 30 - 98
15 - Cylinder Ram
99 - Seal Kit
Figure 590. 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 592.
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 591.
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 593.
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 - 99 9813/6500-1 30 - 99
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 594.
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 - 100 9813/6500-1 30 - 100

18 - Accumulator
18 - Accumulator
Contents Page No.
30-18-00 General ......................................................................................................................... 30-103

30-18-06 Smooth Ride System (SRS) ........................................................................................ 30-107
30-18-12 Brake ............................................................................................................................ 30-113
30 - 101 9813/6500-1 30 - 101

Notes:
30 - 102 9813/6500-1 30 - 102

18 - Accumulator
00 - General
Introduction .................................................. 30-103 A hydraulic accumulator is a pressure storage
Health and Safety ........................................ 30-104 reservoir used to store hydraulic fluid, the non-
Technical Data ............................................. 30-104 compressible hydraulic fluid is held under pressure
Component Identification ............................. 30-105 by a compressed nitrogen gas. It is designed to
increase or relieve pressure in the hydraulic system.
Discharge and Pressurise ........................... 30-106
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 30-103).
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 - 103 9813/6500-1 30 - 103

18 - Accumulator
00 - General

DANGER Use only nitrogen gas to charge
accumulators. The use of any other gas can Table 154.
cause the accumulators to explode. Remember Description Data
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your Brake accumulator
workplace. Do not allow excessive quantities of Quantity 2
nitrogen to be discharged into the atmosphere. Capacity 2L each
CAUTION To reduce pressure use the Operating temperature -20–80°C (-4.0–175.9°F)
recommended charging tool or the charge valve range
could be damaged which may result in rapid Maximum working pres- 300bar (4,347.8psi)
discharge of the accumulator. sure
WARNING You must vent all the hydraulic Pre-charge pressure 57 -1/+2bar
pressure from the accumulators before (826.1 -14.5/+29.0psi)
disconnecting them from the hydraulic system. SRS (Smooth Ride System) accumulator
Quantity 1
Replacement accumulators will only be supplied in Capacity 4L
an uncharged, non pressurised condition to meet Operating temperature -20–100°C (-4.0–
Health and Safety, and Air freight hazardous goods range 211.9°F)
requirements.
Maximum working pres- 280bar (4,058.0psi)
sure
Pre-charge pressure 17 ± 1bar
(246.4 ± 14.5psi)
30 - 104 9813/6500-1 30 - 104

18 - Accumulator
00 - General
Figure 595.
A Diaphragm (sealed for life)-Non Rechargeable

B Diaphragm (with gas valve)-Rechargeable
C Piston Bladder-Rechargeable
30 - 105 9813/6500-1 30 - 105

18 - Accumulator
00 - General
Discharge and Pressurise
Special Tools Special Tool: Hand Pump Pressure Test (Qty.: 1)

6. Operate the hand pump.
Hand Pump Pressure 892/00223 1
Test 7. Watch the reading on the pressure gauge.
Pressure Gauge (0-400 892/00279 1
Bar) 7.1. If the accumulator is in good condition,
the pressure should rise steadily to the
1. Make the machine safe. Refer to (PIL 01-03). correct charge pressure and then much
more slowly for a duration before a further
2. Discharge the hydraulic pressure. Refer to (PIL increase. Refer to Accumulator - Technical
30-00). Data, (PIL 30-18).
3. Remove the accumulator from the machine. 7.2. If the pressure continues to rise steadily
Refer to (PIL 30-18). to well past the charge pressure, the
diaphragm is ruptured and you must
4. Install the accumulator into the adaptor block. replace the accumulator.
5. Connect a hand pump and specified pressure 8. Install the accumulator to the machine. Refer to
gauge. (PIL 30-18).
1)
Figure 596.
A
A Plug B Gas spring or accumulator

C Adaptor block D Hand pump
E Pressure gauge
30 - 106 9813/6500-1 30 - 106

18 - Accumulator
06 - Smooth Ride System (SRS) Discharge and Pressurise

Special Tools
Discharge and Pressurise ........................... 30-107
Check (Condition) ........................................ 30-110
Accumulator Charging 892/01042 1
Remove and Install ..................................... 30-111 Kit (Diaphragm)
Disassemble and Assemble ........................ 30-112 Accumulator Charging 892/01043 1
Adaptor
DANGER Use only nitrogen gas to charge

accumulators. The use of any other gas can
cause the accumulators to explode. Remember
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your
workplace. Do not allow excessive quantities of
nitrogen to be discharged into the atmosphere.
The accumulators must be charged before

installation.
Diaphragm Type
1. Remove the plastic cap from the top of the

accumulator.
2. Connect the nitrogen charging tool kit and
connector to the accumulator.
Special Tool: Accumulator Charging Kit
(Diaphragm) (Qty.: 1)
Special Tool: Accumulator Charging Adaptor
(Qty.: 1)
2.1. Note: The charging tool kit (892/00239)
used in the brake section can be used as
an alternative.
3. Open the filler plug by three turns with the
charging device.
4. Open the discharge valve of the charging device.
4.1. Carefully open the nitrogen gas bottle valve
and make sure that the nitrogen gas flows
freely.
4.2. Close the gas bottle valve and the
discharge valve of the charging device.
30 - 107 9813/6500-1 30 - 107

18 - Accumulator
5. Carefully open the gas bottle valve and, let 4. Make sure not to loop or twist the hose and
nitrogen to flow until the pressure reading of the connect the nitrogen charging tool kit to the
specified value is shown on the pressure gauge. accumulator.
Pressure: 20bar (289.9psi) Special Tool: Accumulator Charging Kit
(Diaphragm) (Qty.: 1)
6. Close the gas bottle valve.
5. Turn the handle clockwise, this will depress the
7. Adjust the pressure in the accumulator by core in the gas valve.
carefully opening and closing the discharge valve
of the charging device to the applicable value. 6. Carefully open the nitrogen gas bottle valve, let
Refer to: General (Page 30-103). nitrogen flow until the pressure reading of the
specified value is shown on the pressure gauge.
8. Close the filler plug with the charging device. Pressure: 20bar (289.9psi)
8.1. Tighten the filler plug to the correct torque 7. Close the gas bottle valve.
value.
8. Adjust the pressure in the accumulator by
Torque: 20N·m
9. Open the discharge valve to release the pressure of the charging device to the applicable value.
from the gas bottle hose. Refer to: General (Page 30-103).
10. Disconnect the charging device from the 9. Turn the handle counterclockwise and then open
accumulator. the discharge valve to release the pressure from
the hose.
11. Do a leak test of the accumulator by pouring
soapy water around the filler plug. 10. Hold the gas valve to prevent it from turning and
loosen the nut.
12. Install the plastic cap.
11. Disconnect the charging device from the
Figure 597. accumulator.
12. Install the brass valve cap and valve guard.
Figure 598.
C
B
A
A
B
D
C F
A Charging tool kit
B Filler plug
C Nitrogen gas bottle valve
Piston Type 1
1. Remove the gas valve guard and the gas valve A Gas valve guard
cap. B Gas valve cap
2. Turn the handle counterclockwise before you C Handle
attach the charging tool to the accumulator gas D Discharge valve
valve. E Nitrogen gas bottle valve
F Nut
3. Close the discharge valve.
30 - 108 9813/6500-1 30 - 108

18 - Accumulator
Piston Bladder Type 2 Figure 599.

B
Refer to Figure 599. A
1. Remove the steel cap from the charge valve of
the accumulator.
2. Connect the nitrogen charging tool kit and the D
connector to the accumulator.
Special Tool: Accumulator Charging Kit
(Diaphragm) (Qty.: 1) E
Special Tool: Accumulator Charging Adaptor
(Qty.: 1) C F
3. Make sure not to loop or twist the hose and

connect the nitrogen charging tool to a bottle
of compressed nitrogen gas installed with a
regulator set to minimum pressure.
4. Open the charge valve plug by three turns with
the charging device.
A Steel cap
5. Open the discharge valve of the charging device.
B Charge valve
5.1. Carefully open the nitrogen gas bottle valve C Charge valve plug
and make sure that the nitrogen gas flows D Discharge valve
freely. E Nitrogen gas bottle valve
5.2. Close the gas bottle valve and the
discharge valve of the charging the device.
6. Carefully open the gas bottle valve and, let
nitrogen to flow until the pressure reading of the
specified value is shown on the pressure gauge.
7. Close the gas bottle valve.
8. Adjust the pressure in the accumulator by
of the charging device to the applicable value.
9. Close the charge valve with the charging device.
9.1. Tighten the charge valve to the correct
torque value.
Torque: 20N·m
10. Open the discharge valve to release the pressure
from the gas bottle hose.
11. Disconnect the charging device from the
accumulator.
12. Do a leak test of the accumulator by pouring
soapy water around the charge valve plug.
13. Install the steel cap.
30 - 109 9813/6500-1 30 - 109

18 - Accumulator
Check (Condition)
1. Disassemble the piston (Type 1) accumulators
only. Refer to (PIL 30-18).
2. Inspect the piston for cracks, burrs around the O-
ring grooves for damage.
3. Check the body bore for scratches or scoring
using a light.
4. Inspect the end caps for damaged threads or
burrs on the O-ring grooves.
5. Remove any minor nicks, scratches or light
scoring of the body bore with a very fine abrasive
paper. Rub the bore until all the apparent
imperfections have been removed.
6. Discard all old seals and O-rings.
7. Install new seals and O-rings.
8. Assemble the piston (Type 1) accumulators.
30 - 110 9813/6500-1 30 - 110

18 - Accumulator
Remove and Install
Remove 8. Loosen the nuts from the U-clamp.
1. Make the machine safe with the lift arm lowered. 9. Remove the accumulator from the machine.
Install
3. Release the SRS (Smooth Ride System) removal procedure. Additionally do the following
pressure. step.
4. Put labels on the accumulator hoses. 2. Make sure that you install the pre-charged
accumulator.
5. Put a suitable container below the accumulators
to collect the hydraulic fluid. 3. Check the hydraulic oil level. Refer to (PIL
30-00).
6. Disconnect the hoses.
4. Do a leak test on the accumulators.
contamination and excessive fluid loss.
Figure 600.
D
A
A Accumulator B U-clamp
C Nut D Hose
30 - 111 9813/6500-1 30 - 111

18 - Accumulator
The SRS (Smooth Ride System) accumulators are

sealed for life and cannot be disassembled. If the
accumulators are found damaged and/or not holding
their gas charge they must be replaced.
30 - 112 9813/6500-1 30 - 112

18 - Accumulator
12 - Brake
12 - Brake
Remove and Install
Remove 7. Disconnect the hydraulic hoses 1 (x2) and hoses

2 (x2).
2. Install the articulation lock. Refer to (PIL 06-27). contamination.
3. Isolate the battery. Refer to (PIL 33-03). 9. Support the accumulator and remove the nuts
(x8), bolts (x4) and washers.
30-00). 10. Remove the accumulator from below the
machine.
5. Remove the undershield. Refer to (PIL 06-06).
Figure 601.
F
E
B C,D
A Hoses 1 B Hoses 2
C Nuts D Washers
E Bolts F Accumulator
30 - 113 9813/6500-1 30 - 113

18 - Accumulator
12 - Brake
Install
step.
2. Tighten the bolt and hoses to the correct torque
value.

Item Nm
B 41
C 22
30 - 114 9813/6500-1 30 - 114

51 - Lift Arm Control Valve Block
Contents Page No.
30-51-00 General ......................................................................................................................... 30-117

30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-128
30 - 115 9813/6500-1 30 - 115

Notes:
30 - 116 9813/6500-1 30 - 116

00 - General
Introduction .................................................. 30-117 The lift arm control valve block controls all
Technical Data ............................................. 30-118 hydraulic functional elements of the lift arm such
Component Identification ............................. 30-119 as direction, pressure, flow and check functions. It
Diagram ....................................................... 30-122 is complemented by integrated electronic sensors,
controls and control elements.
Remove and Install ..................................... 30-124
Disassemble and Assemble ........................ 30-125
30 - 117 9813/6500-1 30 - 117

00 - General
Technical Data
Table 156.
Service port flow (Max) 325L/min
Service port pressure 325bar (4,710.1psi)
(Max)
Tank pressure (Max) 20bar (289.9psi)
MRV (Main Relief Valve) 280bar (4,058.0psi)
pressure
ARV (Auxiliary Relief 350bar (5,072.4psi)
Valve) pressure
Pilot supply flow 10L/min
Solenoid connection PS25/24V
30 - 118 9813/6500-1 30 - 118

00 - General
Figure 602. 3 Spool Valve Block

B A
C D
E
M F
L G
K H
A Outlet port B LS (Load Sense) port

C Sump port D Pilot supply port
E PPC supply port F Auxiliary
G Crowd H Lift arm - Raise
J Steer supply port K Lift arm - Lower
L Lift arm - Dump M Auxiliary
30 - 119 9813/6500-1 30 - 119

00 - General
N Inlet port P Inlet gauge port

Q Outlet port

A
B
D
C
E
R S
M
F
L G
K H
A Outlet port B LS port

C Sump port D Pilot supply port
E PPC supply port F Auxiliary
G Crowd H Lift arm - Raise
J Steer supply port K Lift arm - Lower
L Lift arm - Dump M Auxiliary
N Inlet port P Inlet gauge port
30 - 120 9813/6500-1 30 - 120

00 - General
Q Outlet port R Auxiliary

S Auxiliary
30 - 121 9813/6500-1 30 - 121

00 - General
Diagram
B F
A C
D E G H
P
J
X
K
Q
N
R
M
L
S T U V W
A Steer LS (Load Sense) B Steer supply

C Sump D Pump
E Anti-cavitation F Pilot supply port
G Sump H PPC supply
J Tank K LS
L Pump gauge M Pump
N LS P Steer relief valve
Q LSRV (Load Sense Relief Valve) R PRV (Pressure Relief Valve)
S Inlet - priority steer T Lift arms
U Shovel V Auxiliary
W Outlet - PRV X Tank
Y Relief valve
30 - 122 9813/6500-1 30 - 122

00 - General
B
F
A
C
D E G H
P
J
X
K
Q
N
Y R
M
L
S T U V V W
A Steer LS B Steer supply

C Sump D Pump
E Anti-cavitation F Pilot supply port
G Sump H PPC supply
J Tank K LS
L Pump gauge M Pump
N LS P Steer relief valve
Q LSRV R PRV
S Inlet - priority steer T Lift arms
U Shovel V Auxiliary
W Outlet - PRV X Tank
Y Relief valve
30 - 123 9813/6500-1 30 - 123

00 - General
Remove
Refer to (PIL 01-03). H
H
2. Discharge the hydraulic system. Refer to (PIL
30-00).
4. Remove the bolt 1 (x4) and the washer 1 (x4) that
secure the valve cover plate.
H
H
Figure 606.
A
H
B H Hoses
C 8. Blank the hoses and fittings to prevent

contamination and excessive oil loss.
9. Support the valve with suitable lifting equipment.
Figure 608.
E
A Bolt 1
B Washer 1
C Valve cover plate
5. Remove the valve cover plate.
6. Label the hoses to help installation. D Valve
E Front chassis
7. Remove all the hose connections from the loader
lift arm valve. 10. Remove the valve retaining bolts.
11. Remove the valve from the machine.
Install
procedure.
30-00).
3. Operate the machine and check for leaks. Refer
to (PIL 30-00).
30 - 124 9813/6500-1 30 - 124

00 - General
Disassemble and pressure adjustment. Do not service

any part of ARV.
1. Remove the valve block from the machine. Refer
2.4. Take care not to damage the seals.
to (PIL 30-51).
3. Support the valve block in a suitable vice.
2. Make a note of the following, when you
disassemble the valve block: 4. Remove the nut from the tie rod.
2.1. You must disassemble the valve block in a 5. Remove the outlet housing.
clean environment.
2.2. After you disassemble, you must clean 6. Remove the seals carefully.
between the valve sections. 7. Remove each valve spool carefully.
2.3. The ARV (Auxiliary Relief Valve) may be
disassembled only for cleaning, inspection
30 - 125 9813/6500-1 30 - 125

00 - General
Figure 609.
A Valve spool B Outlet housing

C Inlet housing D Tie rod
E Nut F Seals
30 - 126 9813/6500-1 30 - 126

00 - General
Assemble
following steps.
2. You must assemble the valve block on a clean
flat surface.
3. Make sure that the intersection seals are
installed in their grooves.
4.1. You must tighten the nuts evenly while the
valve is lying on a flat surface with the
ports facing upwards. This allows the spool
sections to assume their correct positions.

Item Nm
E 90.8
30 - 127 9813/6500-1 30 - 127

06 - Auxiliary Relief Valve (ARV)
Check (Pressure)
Special Tools Special Tool: Test Block for Loader Valve ARV
Description Part No. Qty. (Qty.: 1)
Hand Pump Pressure 892/00223 1 3. Connect the specified hand pump to the test
Test block.
Pressure Gauge (0-400 892/00279 1
Bar) Special Tool: Hand Pump Pressure Test (Qty.: 1)
Test Block for Loader 892/00923 1 4. Install the specified pressure gauge to the hand
Valve ARV pump.
Removed ARV 1)
You can test the ARV (Auxiliary Relief Valve) when 5. Pressurise the hand pump until oil begins to
removed from the valve block with the use of a test escape from the drain hole. At this point the
block and the hand pump. The advantage of using gauge will indicate the crack pressure of the
this method are as follows: ARV.
• This method is more accurate. 6. Check the pressure gauge reading. Make sure
• No need to disconnect the hoses from the valve that the gauge reading is as specified in
block. Technical Data. Refer to (PIL 30-00).
• No need to connect gauges and install the caps.
7. If necessary, adjust the ARV as follows.
1. Remove the required ARV from the valve block.
Refer to (PIL 30-51). 7.1. If installed, remove the dome nut.
7.2. Loosen the locknut and turn the cap in or
2. Install the ARV into the specified test block.
out as required.
Figure 610.
A
B
A Locknut B Cap
30 - 128 9813/6500-1 30 - 128

Installed ARV
If the test block or the hand pump are not available
then the ARV can be tested as installed.
The ARV's which are set below the MRV (Main Relief
Valve) pressure can be tested simply by operating
the relevant service. For the tilt ram ARV which are
set above the MRV pressure, the MRV should be
temporarily set at 260bar (3,768.1psi).
1. Operate the machine to normal operating

temperature before you do the following steps.
1.1. With the pressure gauge connected to the
test point, run the engine at idle and operate
the service to full travel.
1.2. The engine must not be run at maximum
speed as a significant increase in pressure
will be recorded.
1.3. Hold the service at full travel and check the
maximum gauge reading.
1.4. Make sure that the gauge reading is equal
to the ARV operating pressure.
1.5. Stop the engine.
1.6. Turn the ignition key to the ON position.
1.7. Discharge the hydraulic system pressure.
1.8. Adjust the ARV as required.
1.9. Check the MRV pressure again.

Item Description Nm
A Locknut 6.8
C Dome nut (If installed) 6.8
30 - 129 9813/6500-1 30 - 129

60 - Flow Control Valve
Contents Page No.
30-60-00 General ......................................................................................................................... 30-131

30-60-90 Flow Regulator ............................................................................................................. 30-133
30 - 130 9813/6500-1 30 - 130

00 - General
00 - General
Introduction
Flow Control Valves Figure 614.
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 611.
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 612. 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 616.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 131 9813/6500-1 30 - 131

00 - General
Figure 617. 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 - 132 9813/6500-1 30 - 132

90 - Flow Regulator
90 - Flow Regulator
Remove and Install
Remove
2. Make sure that the exterior of the pump and
working area is thoroughly cleaned and free of
possible sources of contamination.
30-00).
4. Drain the hydraulic tank. Refer to (PIL 30-00).
5. Disconnect the hydraulic pipe.
6. Remove the capscrews (x4).
7. Remove and discard the O-rings.
8. Remove the flow regulator from the pump.
Figure 618.
A
B
C
A Flow regulator
B Capscrew (x4)
C Pump
Install
removal procedure.
30 - 133 9813/6500-1 30 - 133

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-135
30 - 134 9813/6500-1 30 - 134

93 - Hose
00 - General
Introduction .................................................. 30-135 Hydraulic hoses are used to connect different
Disconnect and Connect ............................. 30-136 components in the hydraulic circuit. The hoses
Check (Condition) ........................................ 30-137 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 - 135 9813/6500-1 30 - 135

93 - Hose
00 - General
Disconnect and Connect Figure 621.
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 engine.
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 engine then remove the ignition
Figure 619. key.
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
hot parts. High ambient temperatures can 4. Check the hoses and adaptors for damage.
cause the hose to fail.
5. If necessary, install the blanking caps.
4.3. Make sure that the hose does not touch
parts which can rub or cause abrasion. 6. Check for leaks:
4.4. Use the hose clamps (where possible) to
6.1. Start the engine.
support long hose runs and keep the hoses
away from moving parts, etc. 6.2. Operate the related controls to increase the
pressure in the hydraulic system.
Figure 620.
6.3. Stop the engine then remove the ignition
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 - 136 9813/6500-1 30 - 136

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 - 137 9813/6500-1 30 - 137

97 - Connectors
97 - Connectors
Contents Page No.
30-97-00 General ......................................................................................................................... 30-139

30-97-03 Quick Release Coupling .............................................................................................. 30-142
30-97-09 Adaptor ......................................................................................................................... 30-144
30 - 138 9813/6500-1 30 - 138

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 159. 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 161. 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 160. 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 - 139 9813/6500-1 30 - 139

97 - Connectors
00 - General
Hoses installed into Adaptors
Figure 622.
B
C
A B C
A
A Adaptor B Hose
C O-ring D Dimension will vary depending upon the torque
applied.
Hoses installed into adaptors seal onto an `O' ring

which is compressed into a 45° seat machined into
the face of the adaptor port.
Table 162. 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 163. 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 - 140 9813/6500-1 30 - 140

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 623.
B
C
A B C
A
A Adaptor B Hose
C O-ring D Shoulder
E Minimum dimension fixed by shoulder.
Torque-Stop hoses installed into adaptors seal onto the 'O' ring being damaged as a result of over
an `O' ring which is compressed into a 45° seat tightening, Torque-Stop hoses have an additional
machined into the face of the adaptor port. To prevent shoulder, which acts as a physical stop.
Table 164. 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 - 141 9813/6500-1 30 - 141

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-142 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-143 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 624.
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 - 142 9813/6500-1 30 - 142

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 625.
designed to do so.
C D E
C Ball
D Slot
E Sleeve
30 - 143 9813/6500-1 30 - 143

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-144 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-145 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 626.
A O-ring seal
B Locknut
C Washer
30 - 144 9813/6500-1 30 - 144

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 627.
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 - 145 9813/6500-1 30 - 145

Notes:
30 - 146 9813/6500-1 30 - 146

33 - Electrical System
Contents Page No.
33-00 Electrical System

33-00-00 General ............................................................................................................................. 33-3
33-00-50 Schematic Circuit ............................................................................................................. 33-6
33-00-90 Earth Point ..................................................................................................................... 33-82
33-03 Battery
33-03-00 General ........................................................................................................................... 33-85
33-03-03 Isolator Switch ................................................................................................................ 33-94
33-06 Battery Cable
33-06-00 General ........................................................................................................................... 33-97
33-09 Power Distribution
33-09-00 General ........................................................................................................................... 33-99
33-09-03 Fuse ............................................................................................................................. 33-101
33-09-06 Relay ............................................................................................................................ 33-104
33-12 Harness
33-12-00 General ......................................................................................................................... 33-107
33-12-04 Chassis ......................................................................................................................... 33-117
33-12-05 Rear Chassis ................................................................................................................ 33-126
33-12-09 Engine .......................................................................................................................... 33-135
33-12-11 Cooling Compartment ................................................................................................... 33-148
33-12-12 Operator Station ........................................................................................................... 33-153
33-12-25 Controls ........................................................................................................................ 33-186
33-12-27 Interior Roof ................................................................................................................. 33-190
33-12-34 Trailer Brake ................................................................................................................. 33-199
33-12-36 Work Lights .................................................................................................................. 33-202
33-12-48 LiveLink ........................................................................................................................ 33-203
33-12-57 Heating, Ventilating and Air-Conditioning (HVAC) ....................................................... 33-204
33-12-84 Instrument Panel .......................................................................................................... 33-221
33-12-89 Speakers ...................................................................................................................... 33-223
33-12-93 Selective Catalytic Reduction (SCR) ........................................................................... 33-224
33-12-95 Cooling Fan .................................................................................................................. 33-229
33-24 Instruments
33-27 Interior Switch
33-33 Console Switch
33-33-00 General ......................................................................................................................... 33-243
33-39 Interior Light
33-39-03 Cab Roof ...................................................................................................................... 33-247
33-40 Bulb
33-40-00 General ......................................................................................................................... 33-251
33-42 Exterior Light
33-42-33 Number Plate Light ...................................................................................................... 33-253
9813/6500-1
2017-02-22
33-45 Control Module
33-45-00 General ......................................................................................................................... 33-257
33-45-06 Engine .......................................................................................................................... 33-260
33-45-09 Gearbox ........................................................................................................................ 33-262
33-45-10 Gear Change ................................................................................................................ 33-266
33-45-55 Interface ....................................................................................................................... 33-277
33-51 Beacon
33-51-00 General ......................................................................................................................... 33-281
33-54 Window Washer/Wipe
33-54-00 General ......................................................................................................................... 33-285
33-54-03 Tank .............................................................................................................................. 33-286
33-54-09 Front Motor ................................................................................................................... 33-287
33-54-15 Rear Window Wiper ..................................................................................................... 33-289
33-57 Electronic Diagnostic
33-57-00 General ......................................................................................................................... 33-293
33-57-03 Servicemaster .............................................................................................................. 33-295
33-57-90 Fault Codes .................................................................................................................. 33-315
33-84 Sensor
33-84-09 Speed Sensor .............................................................................................................. 33-345
9813/6500-1
2017-02-22
Acronyms Glossary
ABS Anti-lock Braking System

ATC Automatic Temperature Control
CAN Controller Area Network
DLA Data Link Adaptor
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
DTC Diagnostic Trouble Code
DVD Digital Versatile Disc
GPS Global Positioning System
LCD Liquid Crystal Display
MIL Malfunction Indicator Lamp
NOx Nitrogen Oxide
OEM Original Equipment Manufacturer
PTO Power Take-Off
PWM Pulse Width Modulation
SAE Society of Automotive Engineers
SPP Service Parts Pro
SRS Smooth Ride System
USB Universal Serial Bus
VGT Variable Geometry Turbocharger
9813/6500-1
2017-02-22
Notes:
9813/6500-1
2017-02-22
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-6
33-00-90 Earth Point ..................................................................................................................... 33-82
33 - 1 9813/6500-1 33 - 1
Notes:
33 - 2 9813/6500-1 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
Check (Condition) ............................................ 33-5 Make sure that all the health and safety warnings
in this section are followed. The machine must be
Check (Operation) ........................................... 33-5 safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.
33 - 3 9813/6500-1 33 - 3
00 - General

Arc Welding Table 166. System
To prevent the possibility of damage to electronic
Item Specification
components, disconnect the battery and the
alternator before arc-welding on the machine or Electrical System 24V, negative earth
attached implements.
Table 167. Battery
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control Item Specification
units (ECUs), monitor displays, etc., then disconnect Cold Crank Amps 900A
them before welding. Failure to disconnect the Capacity 100 AH
sensitive electrical equipment could result in Reserve Capacity (min- 180
irreparable damage to these components. utes) for 25A load
Parts of the machine are made from cast iron, welds
on cast iron can weaken the structure and break. Do Table 168. Alternator
not weld cast iron. Do not connect the welder cable
Item Specification
or apply any weld to any part of the engine.
Type DELCO 24SI
Always connect the welder earth (ground) cable to
Ampere 100A
the same component that is being welded to avoid
damage to pivot pins, bearings and bushes. Attach Voltage 28V
the welder earth (ground) cable a distance from the
part being welded no more than 0.6m. Table 169. Starter motor
Notice: Do not disconnect the battery while the Item Specification
engine is running, otherwise the electrical circuits Type Melco 90 P55
may be damaged. Voltage 24V
CAUTION! Understand the electrical circuit Power output 5.5kW
before connecting or disconnecting an electrical
component. A wrong connection can cause injury Table 170. Bulbs
and/or damage.
Item Specification (W)
Headlights- main 75
Headlights- dip 70
Side indicators 21
Indicator repeater 21
Instruments 1.2
Work lights (Halogen) 70
Number plate light 5
Tail lights 5
Front sidelights 5
Stop lights 21
Beacon (Halogen) 70
Rear fog light 21
For fuses and relays specification, Refer to (PIL

33-09).
33 - 4 9813/6500-1 33 - 4
00 - General
Check (Condition) Check (Operation)
Examine the electrical circuits regularly for: Make sure that all the electrical equipment listed
below operate correctly.
• Damaged connectors.
• Loose connections. • Switches
• Chafing on the wiring harnesses. • Warning lights
• Corrosion. • Beacon
• Missing insulation. • Alarms
• Incorrect routing of the wiring harnesses. • Horn
• Wipers
Do not use the machine if one or more of these faults • Hourmeter
are found. You must make sure that the electrical • Battery
circuit is repaired immediately. • Lights
All defective equipment must be repaired before the

machine is used.
33 - 5 9813/6500-1 33 - 5
50 - Schematic Circuit Introduction

Introduction ...................................................... 33-6 A schematic wiring diagram is a simplified pictorial
Diagram ........................................................... 33-9 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 - 6 9813/6500-1 33 - 6
Figure 629.
/7.B4 TO
0.50 mm² 1009A -S012
TO SWITCH:MAIN WIPER C116 #1996
C 7
-SW5
A 701/E0089
7219/0013 SWITCH: MAIN WIPER
FROM SPLICE:BACKLIGHTING S012 #1996
-C116 8 7
0.50 mm² 1009A 8/10 7/10
/3.D1 FROM
0.50 mm² 8100J B

-S011 1 D
F F 2/10 2
L H 3 3/10
4 4/10
-IC08_M -IC08_M
0.75 mm² 8006 21/21 21/21 0.75 mm² 8006 5/10 5
/9.B5 TO
#1783 6 6/10
TO MOTOR:WIPER-UPPER C058
D GD
K J
E
7236/0002
MOTOR:WIPER UPPER 9
-C058
6/6 6/6 RED 5/6 5/6 1.00 mm² 8006 5/20 5/20 0.75 mm² 8006 FROM
/7.B4
BLACK #1783 FROM SWITCH:MAIN WIPERS C116
2/6 2/6 GREEN
YELLOW
-B8 3/6 3/6
1/6 1/6 BROWN
WHITE 4/6 4/6
A Wire size (area) and number B Device harness connector code

C Device description D Connector pin number (wire location / total)
E Device internal schematic F Harness inter-connector codes
G Harness inter-connector symbol H Splice code and symbol
J Destination reference number K Destination (harness connector code)
L Destination (diagram sheet and grid)
To help locate a wire destination from other diagram Due to space limitations, the grid is sometimes
sheets use the grid reference. This identifies the omitted.
applicable location zone on the sheet in a similar way
to a map reference.
33 - 7 9813/6500-1 33 - 7
Figure 630. Grid reference example (D4)
1 2 3 4 5 6 7 8
F GROUND
RC012:6 /15.C5 FROM 1.00 mm² 601SP
F
GROUND 1.00 mm² 601AV
RC011:1 /13.A4 FROM
GROUND 1.00 mm² 601AX CAN SHLD

RC007:2 /13.B4 FROM
P006:5 /3.D2 FROM 0.75 mm² 601HB
GROUND 2.00 mm² 601AR 6.00 mm² 601RC1 CAN SHLD

RC009:1 /12.F6 FROM
P006:10 /3.D2 FROM 0.75 mm² 601EK

-SRC5
CAN SHLD 0.75 mm² 601HK
P007:10 /3.C2 FROM
GROUND 1.50 mm² 600WP CAN SHLD

RC18:2 /12.C6 FROM
P007:5 /3.C2 FROM 0.75 mm² 601HL
GROUND 2.00 mm² 601AW CAN SHLD

RC004:1 /12.E6 FROM
P008:10 /3.A2 FROM 0.75 mm² 601X
GROUND 2.00 mm² 601FK CAN SHLD

RC003:2 /14.F7 FROM
P008:5 /3.B2 FROM 0.75 mm² 601JJ
GROUND 2.00 mm² 601DG CAN SHLD -SP3

RC005:2 /13.C7 P101:10 1.00 mm² 601TS 3.00 mm² 601JC
E /8.D4
FROM
FROM
GROUND 2.00 mm² 601KG 6.00 mm² 601RC2 10.00 mm² 601RC CAN SHLD
E
RC008:2 /13.C7 FROM
P014:1 /13.F1 0.75 mm² 601LH

-RC06
FROM
-SRC6 -SRC7 M10
CAN SHLD 0.75 mm² 601SH

P014:5 /13.E1 FROM
HYD ECU SENSOR GND 0.75 mm² 699CE CAN SHLD

SP43 /30.E6 FROM
P058:4 /15.E2 FROM 1.00 mm² 601RD
HYD ECU SENSOR GND 1.00 mm² 699SK CAN SHLD CAN SHLD
SP44 /25.C5 FROM
P013:5 /8.C1 FROM 1.00 mm² 601LL P072:17 /9.C5 FROM 1.00 mm² 601DE
HYD ECU SENSOR GND 1.00 mm² 699CH CAN SHLD CAN SHLD
P095:3 /26.D1 FROM
P016:5 /11.E6 FROM 0.75 mm² 601SY P112:2 /14.C4 FROM 1.00 mm² 601HT
HYD ECU SENSOR GND 1.00 mm² 699SJ CAN SHLD CAN SHLD -SP11
P095:6 /26.D1 FROM
P016:10 /11.E6 FROM 0.75 mm² 601JB P020:7 /11.D3 FROM 0.75 mm² 601AD 3.00 mm² 601JE
HYD ECU SENSOR GND 0.75 mm² 699CB CAN SHLD CAN SHLD
P091:2 /29.E5 FROM
P010:5 /4.E2 FROM 0.75 mm² 601NS P063:7 /9.F7 FROM 1.00 mm² 601HP
HYD ECU SENSOR GND 0.75 mm² 699CC -SP42 1.50 mm² 699CA HYD ECU SENSOR GND CAN SHLD CAN SHLD
P092:2 /29.E5 FROM FROM
/22.B7 SC9 / P039:F7 P011:5 /10.F6 FROM 0.75 mm² 601BL P073:A /17.D1 FROM 1.00 mm² 601C
D
HYD ECU SENSOR GND 0.75 mm² 699CD CAN SHLD
P087:2 /21.B7 P036:7 /25.D2 1.00 mm² 601DZ
D
FROM
FROM
HYD ECU SENSOR GND 1.00 mm² 699CG

SP2 /27.E4 FROM
HYD ECU SENSOR GND 0.75 mm² 699CF

P111:2 /29.B6 FROM
CAN SHLD 1.00 mm² 601FV

P067:10 /14.D4 FROM
CAN SHLD 1.00 mm² 601KP -SP29 3.00 mm² 601JH -SP62 10.00 mm² 600 -P030 M10
P015:10 /14.D5 FROM
CAN SHLD 1.00 mm² 601V

P013:10 /10.B1 FROM
CAN SHLD 1.00 mm² 601AC

P015:5 /14.D3 FROM
CAN SHLD 2.00 mm² 601TR

P070:16 /21.C6 FROM
CAN SHLD
C CAN SHLD 1.50 mm² 606TR
P052:1 /14.E7 FROM 1.00 mm² 601DD
P070:15 /21.C6 FROM
C
CAN SHLD 1.00 mm² 601AC CAN SHLD 1.00 mm² 610ACF
CAN SHLD P017:7 /14.C5 FROM
P013:5 /14.E2 FROM
P055:1 /12.B6 FROM 2.00 mm² 600P 10.00 mm² 600

-SP61 -P035 M10 CAN SHLD
P062:7 /27.E4 FROM 1.00 mm² 601KK
CAN SHLD 2.00 mm² 601BU
P130:3 /13.D7 FROM
CAN SHLD 0.50 mm² 601P

CAN SHLD P40:10 /9.A3 FROM
P130:4 /13.D7 FROM 2.00 mm² 601AL

CAN SHLD 1.00 mm² Y
CAN SHLD P066:11 /8.B7 FROM
2.00 mm² SCR

SPMC12 /17.C3 FROM
CAN SHLD 0.75 mm² 601BF

CAN SHLD P024:7 /10.C1 FROM
2.00 mm² SCR

SVMC15 /17.D5 FROM
CAN SHLD 1.00 mm² 601DC -SP6 2.00 mm² 601JD

CAN SHLD P023:7 /10.F2 FROM
1.00 mm² 600H

P034:2 /7.C2 FROM
CAN SHLD 1.00 mm² 601AC

P026:7 /13.F3 FROM
CAN SHLD 1.00 mm² 601AY CAN SHLD 1.00 mm² 601BB
P028:7 /13.B2 FROM
P017:7 /25.E3 FROM
B P029:7 /13.E3
CAN SHLD 1.00 mm² 601KA P021:7 /12.F3
CAN SHLD 1.00 mm² 601BH
B
FROM FROM
CAN SHLD 1.00 mm² 601AL CAN SHLD 1.00 mm² 601DX 2.00 mm² 601JF
P061:7 /16.F2 FROM
P022:7 /12.E3 FROM
-SP28
CAN SHLD 1.00 mm² 601BL CAN SHLD 1.00 mm² 601KC
P052:7 /14.B5 FROM
P065:2 /15.B5 FROM
CAN SHLD 1.00 mm² 601N

P027:7 /21.B4 FROM
CAN SHLD 0.75 mm² 601AK

P042-A /28.E2 FROM
CAN SHLD 1.00 mm² 601EN

P018:7 /30.F2 FROM
A
A
1 2 3 4 5 6 7 8
33 - 8 9813/6500-1 33 - 8
Diagram
Table 171. Electrical Schematic (335/C0779)

Description Reference
Primary fuse, Ignition switch and Ignition relays Refer to Figure 631.
Instrument panels, J1939 connector and Immobiliser Refer to Figure 632.
Engine Management ECU (Electronic Control Unit) Refer to Figure 633.
Joystick (Option) Refer to Figure 634.
Multi lever (Option) Refer to Figure 635.
Gearbox ECU Refer to Figure 636.
Engine ECU Refer to Figure 637.
ATC (Automatic Temperature Control)
(1)
HVAC (Heating Ventilation Air Conditioning)
(1)
Front, Rear worklights and Beacon Refer to Figure 640.
Road Lighting Refer to Figure 641.
Radio, Heated Mirrors, Livelink, Seat, Auxiliary Power Feed and Refer to Figure 642.
Weigh load
Rear bonnet, Front wiper and Rear wiper Refer to Figure 643.
Earthing Refer to Figure 644.
CAN (Controller Area Network) Network (Page 1) Refer to Figure 645.
CAN Network (Page 2) Refer to Figure 646.
CAN Network (Page 3) Refer to Figure 647.
Trailer Electrics Refer to Figure 648.
(1) Note: Either HVAC or ATC may be installed.
33 - 9 9813/6500-1 33 - 9
Notes:
33 - 10 9813/6500-1 33 - 10
Page 33-12 Figure 631. Primary fuse, Ignition

switch and Ignition relays Page 33-13
1 2 3 4 5 6 7 8
MIDI FUSE BOX ALTERNATOR

7207/1213 7215/0018
716/30372 -B180 -TE_MIDI #888 TO SPLICE TE_SA1 TO ENGINE ECU
7219/0189 7219/0029 -TB1 MT3
1/1 4.00 mm² 320
/7.B6 -TE_JS
LIVELINK NEG FUSE
TO
-RC_PR -CB_PS 333/T7694 M5 -B186 3/5 1.00 mm² 133AIGNITION

-PF_LX 7.5A 7207/1203 /7.F3
F To LIVELINK TERMINAL BLOCK
TO
3.00 mm² LEAD 3.00 mm² 610 3.00 mm² 610R 3.00 mm² 611R 1.00 mm² 611 1/1 -MT1 16.00 mm² R #1189 TO GRID HEATER RELAY 3/5
1 2 J/16 J/16
-CB_S20 BAT NEG
TO
/12.D3
1
7208/1003
-SPB2 M5
TO
/7.E1 F
-RC_BF -RC_S21 1/1
7208/1120 7207/1203 7207/1405 L 2/5 1.00 mm² 418
7207/1203
2 -SPB2 16.00 mm² RED -MT1 1/1 1/1 -MT2 16.00 mm² 336 BAT POSTO EMRG STEER RELAY
25.00 mm² 136 -JS 1/1 B +VE 2/5
7207/1502 M5 MT1 MT2
M5
TO
/12.B2 M8
1/1
701/47400 -RC_BI M10 7208/1120
To Instrument Panel 812D
3 -SPB3
-BI 7208/1007 7208/1006 7208/1007 25.00 mm² 136
/2.E5 TO
BATTERY ISOLATOR 7208/1018 -C142 -C144 -C145 -BAT1 7208/1003 1/1

7208/1018 -VE -BAT1 -VE -BAT2
-C146 2 1 -C143 70.00 mm² BAT NEG 70.00 mm² BAT LINK 1/1 70.00 mm² BAT POS 4 STARTER MOTOR 7207/1606
332/W2503
LUG LUG LUG LUG
M10 -VE +VE -VE +VE -BAT2_+VE 7208/1003 7208/1018 1/1 -JV_B- 35.00 mm² EARTH BOND 3
M10 B -VE
+VE +VE 1/1 5 -SPB5 -JV_B+ M12
70.00 mm² START POS 1/1 B +VE
+VE +VE 1/1 M10 7207/1606
7207/1213 -B185 -E3-1 M12
70.00 mm² BAT NEG 6 4.00 mm² 003C -TE_JV 1/1 SOL
M5
STARTER EARTH BOND
7208/1018
-G2
-BI M10
25.00 mm² PRI -CB_GA -TE_XF
-R14
2.50 mm² 003B 2.50 mm² 003B
TO MAIN START -TE_S99
57/62 57/62 SPLICE_MAIN START
E -R7 -R8 6
-G6 STARTER -CB_GA -TE_XF
INTER START RLY LCKOUT RLY 4.00 mm² 310B 9 8 4.00 mm² 003 2.50 mm² 003A 2.50 mm² 003A E
4 9 -CB_S98 59/62 59/62
1.00 mm² 002 1 2 1.00 mm² 004 6 7 1.00 mm² 004A 5 7 1.00 mm² 630R GND TO EARTH SPLICE CB_S68
TO
/14.C1
16.00 mm² PRI2 1 3
-S53
3 5 8 10 2 4
-CB_GA -TE_XF
16.00 mm² PRI1
-FB8 5A IGN TO ECU CB_PX:22 125 TO ENGINE ECU

-SW2 0.50 mm² 002A
/3.C2 1.00 mm² 521A 1.00 mm² 521A
/7.F4
-CB_FK
TO TO
701/80184 -CB_CA -CB_CA 45/62 45/62

7241/0001 15 16
332/R3911
IGNITION SWITCH -CB_FA -FA1 3A 0.50 mm² 125 IGNITION To CB_S18 7241/0003 7241/0003
1.00 mm² 521 1.00 mm² 521B 125 TO GRID HEATER
TO
/2.F1 TO
/7.E1
III START
1 2
HEAT
-CB_S78 -CB_GA -TE_XF

PRE
0 OFF
-FA2 7.5A
I ON
7219/0189
7236/0003
1.00 mm² 9916 IGNITION To CB_S1 1.00 mm² 522 0.75 mm² 522 #1156 FROM ENGINE ECU
7219/0029 7234/0003 /6.F1 /7.F1
-CB_DB
TO FROM
-RC_PR -CB_PS 44/62 44/62

II
3 4
4.00 mm² 310 4.00 mm² 310 -CB_DA
4.00 mm² 310A 1 5 4.00 mm² 010
D/16 D/16 -FA3 5A IGNITION To Seat Belt GND TO SPLICE CB_S67
-CB_S2 1/4
2 6 5/6 1.00 mm² 1609 TO
/12.B2 0.50 mm² 600A TO
/14.B1
5 6
4.00 mm² 312 3 6/6
To SPLICE CB_S73
-FA4 3A IGNITION #892 FROM ECU CB_PX:27
4 0.50 mm² 101 0.75 mm² 1840
7207/1316 -RC_PR -CB_PS 7 8
TO
/13.D1 FROM
/3.D2
-DV1 4.00 mm² 312 8 -FA5 -R3
7232/0008 M6 7232/0009 E/16 TO SPLICE TE_S11
4.00 mm² 011
E/16 IGNITION
-RC_MB -PF1 -RC_MA 9 5A 1.00 mm² 133
/7.F1 332/W1815
-PF4 40A 1 30A -RC_PR -CB_PS 9 10
TO
To Seat CB_AB:7
4 2 RELAY IGNITION 1 100
D 4.00 mm² 315 4.00 mm² 315 7 1.00 mm² 001 2.00 mm² 872 TO
/12.C2
A/2
-PF3 30A -PF2 30A
A/2
-RC_PR
A/16 A/16
-CB_PS
7/6
5 7241/0001 D
5 3 4.00 mm² 313 4.00 mm² 313 4.00 mm² 315 8 2 4.00 mm² 830
-CB_FC -FC6 20A 2.00 mm² 119B 100 To Seat CB_AB:9
B/2 B/2 C/16 C/16 11 12
TO
/12.C2
-PF_FB5 -FA6 3A IGN To Immobiliser FROM IMMOBILISER IGN 0.50 mm² 132 6 4
-FC7 10A 100 To Autolube Plug
1.00 mm² 107 1.50 mm² 113C
716/30077 11 12
TO
/2.B4 /2.B4 FROM
13 14
TO
/18.C1
3 9
PRIMARY FUSEBOX 1 -FC8 10A
1 7 15 16 1.00 mm² 114 100 TO SPLICE AFT_S85
TO
/7.C6
-CB_FF
7241/0005
-R5 0.50 mm² 630H GND To Heated Screen Relay

TO
/10.C4
RELAY IGNITION 2
4
7241/0001
-FC1 10A To 24V Power Socket
4.00 mm² 312A 1 2 4.00 mm² 007 -CB_FC 2.00 mm² 124-24V 126
1 2
TO
/12.E5
-CB_S16 -FC2 5A
3 5 126 To Splice CB_S59
0.50 mm² 132C 0.50 mm² 630P 0.75 mm² 117
-FA7 15A
TO
/3.F1
4.00 mm² 318B 1.50 mm² 370 BATT TO SPLICE CB_S90 3 4
14
TO
/7.F1
13
-CB_FL
-FA8
C 10A
1.00 mm² 410 BATT TO DEF MODILE RELAY 7241/0003
IGN RELAY 2 & 3
/7.B1
C
TO
15 16
-FA9 5A BATT TO ENGINE BAY LAMP

17 18 2.00 mm² 1842
0.50 mm² 132A
TO
/13.C1 -R6
RELAY IGNITION 3 1.00 mm² 106-24V 117 TO 24/12V DROPPER
/12.E3
TO
9
7241/0001-FC3 5A To Splice CB_S49
4.00 mm² 312B 6 7 4.00 mm² 009 -CB_FC 1.00 mm² 106A-24V 117
6
/12.F1
TO
5
-FC4 15A To Splice CB_S34
4.00 mm² 313 8 10 0.50 mm² 630F 2.00 mm² 105 117
8
/13.F1
TO
7
-CB_FB -FB6 15A To Heated Rear Screen Relay -FC5 10A To Autolube Plug
16.00 mm² PRI2 4.00 mm² 318A 2.00 mm² 490 BATT -CB_FL 1.50 mm² 104 117
-CB_S37
TO
/10.D2 7241/0003 9 10
/12.A2
TO
11 12
-FB7 15A IGN RELAY 2 & 3
2.00 mm² 309-24V BATT TO 24-12V DROPPER
TO
/12.E1
13 14
0.50 mm² 630C

7207/1316
7232/0008 -DV2 M6 7232/0009 -R4
-RC_MP -PF8 30A -PF5 -RC_MN To I/O Module 1 333/S5959
4 1 2 -RC_PR -CB_PS BATT RELAY HVAC
40A 4.00 mm² 316B 4.00 mm² 316B
A/2 A/2 B/16 B/16
TO
/10.F1
4
B -PF7
5
40A -PF6
3 -RC_PR -CB_PS BATT
To I/O Module 2
1 2
7241/0001
-CB_FC-FC9 15A 112 To CB_DP_F :1
B/2
40A
B/2
4.00 mm² 317
F/16 F/16
4.00 mm² 317 TO
/11.F1 7241/0001-FB1 3A
To CB_S31
4.00 mm² 313 4.00 mm² 011
17 18
2.50 mm² 112 TO
/8.F1 B
-CB_FB 0.50 mm² 305 BATT
1 2
/12.D1
TO
To Earth Splice -FC10 5A To Compressor Relay

-PF_FB6 0.50 mm² 132B 3 5 0.50 mm² 630B GND 0.75 mm² 109 112
-FB2 5A To CB_S7 TO
/14.C1 20
TO
/8.B7
716/30077 1.00 mm² 301 BATT 19
PRIMARY FUSEBOX 2 /2.E1

TO
4.00 mm² 318

-RC_PR -CB_PS 4.00 mm² 318
3 4 -CB_FE
0.75 mm² 109A 112 To CB_DC_F:3
H/16 H/16 To CAN Connector 7241/0003 TO
/8.A1
0.50 mm² 301B BATT
/17.C7
TO
4.00 mm² 314

-RC_PR -CB_PS 4.00 mm² 314
G/16 G/16 -FB3 7.5A To ZF TCU CB_DW:68
1.00 mm² 9836 BATT
5 6
TO
/6.F3
BATT To ZF TCU CB_DW:23
1.00 mm² 9832 TO
/6.F3
-FB4 20A To Splice CB_S63
2.00 mm² 303 BATT
7
TO
/5.D2
8
-FB5 To Splice CB_S61
15A 2.00 mm² 302 BATT
9 10
TO
/3.C1
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 11 9813/6500-1 33 - 11
33-12 33-13
1 2 3 4
MIDI FUSE BOX

716/30372
-TB1 -B180 1/1
7219/0189 7219/0029 MT3
LIVELINK NEG FUSE
-PF_LX 7.5A -RC_PR -CB_PS 333/T7694
F 3.00 mm² LEAD 3.00 mm² 610 3.00 mm² 610R 3.00 mm² 611R 1.00 mm² 611
To LIVELINK TERMINAL BLOCK
1/1
1 2 J/16 J/16
TO
/12.D3 7208/1003
-CB_S20 BAT NEG 1 -SPB2
-RC_BF -RC_S21 1/1
7208/1120 7207/1203
2 -SPB2 16.00 mm² RED -MT1 1/1 MT2
1/1
7207/1502 M5 MT1
1/1
701/47400 -RC_BI M10 7208/1120
3 -SPB3
-BI 7208/1007 7208/1006 7208/1007 25.00 mm² 136
BATTERY ISOLATOR 7208/1018 -C142 -C144 -C145 -BAT1 7208/1003 1/1
7208/1018 -VE -BAT1 -VE -BAT2
-C146 2 1 -C143 70.00 mm² BAT NEG 70.00 mm² BAT LINK 1/1 70.00 mm² BAT POS 4
332/W2503
LUG LUG LUG LUG
M10 -VE +VE -VE +VE -BAT2_+VE

M10 7208/1003
+VE +VE 1/1 5 -SPB5 70.00 mm² START POS
+VE +VE 1/1
70.00 mm² BAT NEG 6
7208/1018
-BI M10
25.00 mm² PRI
E -G6
1.00 mm² 002

16.00 mm² PRI2 -S53
16.00 mm² PRI1
-FB8 5A IGN TO ECU CB_PX:22

-SW2 0.50 mm² 002A TO
/3.C2
701/80184 7241/0001 15 16
IGNITION SWITCH -CB_FA -FA1 3A 0.50 mm² 125 IGNITION To CB_S18
TO
/2.F1
III START
1 2
HEAT
PRE
0 OFF
-FA2 7.5A To CB_S1
I ON
7236/0003 IGNITION
7219/0189 7219/0029 1.00 mm² 9916
7234/0003 -CB_DB
TO
/6.F1
-RC_PR -CB_PS
II
3 4
4.00 mm² 310 4.00 mm² 310 -CB_DA
4.00 mm² 310A 1 5 4.00 mm² 010
D/16 D/16 -FA3 5A IGNITION To Seat Belt
-CB_S2 1/4
2 6 5/6 1.00 mm² 1609 TO
/12.B2
5 6
4.00 mm² 312 3 6/6
To SPLICE CB_S73
-FA4 3A IGNITION
4 0.50 mm² 101
7207/1316 -RC_PR -CB_PS 7 8
TO
/13.D1
-DV1 4.00 mm² 312 8 -FA5
7232/0008 M6 7232/0009 E/16 TO SPLICE TE_S11
4.00 mm² 011

E/16 IGNITION
-RC_MB -PF4 40A -PF1 30A -RC_MA -RC_PR -CB_PS
9 5A 1.00 mm² 133 TO
/7.F1
1 9 10
4 2
D A/2 A/2
4.00 mm² 315
A/16 A/16
4.00 mm² 315 7
7/6
1.00 mm² 001
-PF3 30A -PF2 30A -RC_PR -CB_PS

5 3 4.00 mm² 313 4.00 mm² 313
B/2 B/2 C/16 C/16
-PF_FB5 -FA6 3A IGN To Immobiliser

1.00 mm² 107
716/30077 11 12
TO
/2.B4
PRIMARY FUSEBOX 1
Page 33-13
-CB_S16
-FA7 15A BATT TO SPLICE CB_S90
4.00 mm² 318B 1.50 mm² 370
13 14
TO
/7.F1
-FA8
C 10A
1.00 mm² 410 BATT TO DEF MODILE RELAY
15 16
TO
/7.B1
-FA9 5A BATT TO ENGINE BAY LAMP
17 18 2.00 mm² 1842 TO
/13.C1
4.00 mm² 313
-CB_FB -FB6 15A BATT To Heated Rear Screen Relay

16.00 mm² PRI2 4.00 mm² 318A 2.00 mm² 490
-CB_S37
TO
/10.D2
11 12
-FB7 15A TO 24-12V DROPPER
2.00 mm² 309-24V BATT TO
/12.E1
13 14
7207/1316
7232/0008 -DV2 M6 7232/0009
-RC_MP -PF8 30A -PF5 -RC_MN To I/O Module 1
4 1 2 -RC_PR -CB_PS BATT
40A 4.00 mm² 316B 4.00 mm² 316B
A/2 A/2 B/16 B/16 /10.F1
TO
B -PF7
5
40A -PF6
3 -RC_PR -CB_PS BATT
To I/O Module 2
40A 4.00 mm² 317 4.00 mm² 317
/11.F1 7241/0001-FB1 3A
To CB_S31
TO
B/2 B/2 F/16 F/16

-CB_FB 0.50 mm² 305 BATT
1 2
/12.D1
TO
-PF_FB6
-FB2 5A To CB_S7
716/30077 1.00 mm² 301 BATT
PRIMARY FUSEBOX 2 /2.E1
TO
4.00 mm² 318

-RC_PR -CB_PS 4.00 mm² 318
3 4
H/16 H/16 To CAN Connector
0.50 mm² 301B BATT
/17.C7
TO
4.00 mm² 314

-RC_PR -CB_PS 4.00 mm² 314
G/16 G/16 -FB3 7.5A To ZF TCU CB_DW:68
1.00 mm² 9836 BATT
5 6
TO
/6.F3
1.00 mm² 9832 TO
/6.F3
-FB4 20A
2.00 mm² 303 BATT To Splice CB_S63
7 /5.D2
TO
8
-FB5 To Splice CB_S61
15A 2.00 mm² 302 BATT
9 10
TO
/3.C1
1 2 3 4
33 - 12 9813/6500-1 33 - 12
33-12 33-13
5 6 7 8
MIDI FUSE BOX ALTERNATOR

7207/1213 7215/0018
-B180 -TE_MIDI #888 TO SPLICE TE_SA1 TO ENGINE ECU
MT3
1/1 4.00 mm² 320 TO
/7.B6 -TE_JS
M5
7207/1203
-B186 3/5 1.00 mm² 133AIGNITION TO
/7.F3
1/1 -MT1 16.00 mm² R #1189 TO GRID HEATER RELAY 3/5
M5
TO
/7.E1 F
7207/1203 7207/1405 L 2/5 1.00 mm² 418
7207/1203
1/1 1/1 -MT2 16.00 mm² 336 BAT POSTO EMRG STEER RELAY
25.00 mm² 136 -JS 1/1 B +VE 2/5
MT1 MT2
M5
TO
/12.B2 M8
To Instrument Panel 812D
25.00 mm² 136
/2.E5 TO
STARTER MOTOR 7207/1606

7208/1018 1/1 -JV_B- 35.00 mm² EARTH BOND 3
B -VE M12
-JV_B+ 1/1 B +VE
M10 7207/1606
7207/1213 -B185 -E3-1 M12
4.00 mm² 003C -TE_JV 1/1 SOL
M5
STARTER EARTH BOND
-G2
-R14 -CB_GA -TE_XF

2.50 mm² 003B 2.50 mm² 003B
TO MAIN START -TE_S99
57/62 57/62 SPLICE_MAIN START
-R7 -R8 6
STARTER -CB_GA -TE_XF
INTER START RLY LCKOUT RLY 4.00 mm² 310B 9 8 4.00 mm² 003 2.50 mm² 003A 2.50 mm² 003A E
4 9 -CB_S98 59/62 59/62
1 2 1.00 mm² 004 6 7 1.00 mm² 004A 5 7 1.00 mm² 630R GND TO EARTH SPLICE CB_S68
TO
/14.C1
1 3
3 5 8 10 2 4
TO ECU CB_PX:22 -CB_GA -TE_XF
IGN 1.00 mm² 521A 1.00 mm² 521A 125 TO ENGINE ECU
TO
/3.C2 -CB_FK 45/62 45/62
TO
/7.F4
-CB_CA -CB_CA
7241/0003 7241/0003 332/R3911
IGNITION To CB_S18 1.00 mm² 521 1.00 mm² 521B 125 TO GRID HEATER
TO
/2.F1 TO
/7.E1
-CB_S78 -CB_GA -TE_XF
IGNITION To CB_S1 1.00 mm² 522 0.75 mm² 522 #1156 FROM ENGINE ECU
TO
/6.F1 44/62 44/62
FROM
/7.F1
IGNITION To Seat Belt GND TO SPLICE CB_S67
0.50 mm² 600A
TO
/12.B2 TO
/14.B1
To SPLICE CB_S73
IGNITION 0.75 mm² 1840 #892 FROM ECU CB_PX:27
TO
/13.D1 FROM
/3.D2
TO SPLICE TE_S11 -R3
IGNITION 332/W1815
TO
/7.F1 To Seat CB_AB:7
RELAY IGNITION 1 2.00 mm² 872 100 TO
/12.C2
5 7241/0001 D
4.00 mm² 315 8 2 4.00 mm² 830
-CB_FC -FC6 20A 2.00 mm² 119B 100 To Seat CB_AB:9
11 12
TO
/12.C2
IGN To Immobiliser FROM IMMOBILISER IGN 0.50 mm² 132 6 4
-FC7 10A 100 To Autolube Plug
1.50 mm² 113C
TO
/2.B4 /2.B4 FROM
13 14
TO
/18.C1
3 9
-FC8 10A
1 7 15 16 1.00 mm² 114 100 TO SPLICE AFT_S85
TO
/7.C6
-CB_FF
7241/0005
Page 33-12
-R5 0.50 mm² 630H GND To Heated Screen Relay

TO
/10.C4
RELAY IGNITION 2
4
7241/0001
-FC1 10A To 24V Power Socket
4.00 mm² 312A 1 2 4.00 mm² 007 -CB_FC 2.00 mm² 124-24V 126
1 2
TO
/12.E5
3 5
-FC2 5A 126 To Splice CB_S59
0.50 mm² 132C 0.50 mm² 630P 0.75 mm² 117 TO
/3.F1
BATT TO SPLICE CB_S90 3 4
TO
/7.F1
-CB_FL
BATT TO DEF MODILE RELAY 7241/0003
/7.B1 IGN RELAY 2 & 3
C
TO
BATT TO ENGINE BAY LAMP

0.50 mm² 132A
TO
/13.C1 -R6
RELAY IGNITION 3 1.00 mm² 106-24V 117 TO 24/12V DROPPER
/12.E3
TO
9
7241/0001-FC3 5A To Splice CB_S49
4.00 mm² 312B 6 7 4.00 mm² 009 -CB_FC 1.00 mm² 106A-24V 117
6
/12.F1
TO
5
-FC4 15A To Splice CB_S34
8 10 0.50 mm² 630F 2.00 mm² 105 117
8
/13.F1
TO
7
To Heated Rear Screen Relay -FC5 10A To Autolube Plug
BATT -CB_FL 1.50 mm² 104 117
TO
/10.D2 7241/0003 9 10
/12.A2
TO
IGN RELAY 2 & 3

BATT TO 24-12V DROPPER
TO
/12.E1
0.50 mm² 630C
-R4
333/S5959
RELAY HVAC
4
7241/0001
1 2 -CB_FC-FC9 15A 112 To CB_DP_F :1
BATT To CB_S31
4.00 mm² 313 4.00 mm² 011
17 18
2.50 mm² 112 TO
/8.F1 B
/12.D1 -FC10
GNDTo Earth Splice To Compressor Relay
5A
TO
0.50 mm² 132B 3 5 0.50 mm² 630B 0.75 mm² 109 112
To CB_S7 TO
/14.C1 19 20
TO
/8.B7
BATT
/2.E1
TO
-CB_FE
0.75 mm² 109A 112 To CB_DC_F:3
To CAN Connector 7241/0003 TO
/8.A1
BATT
/17.C7
TO

TO
/6.F3
TO
/6.F3
BATT To Splice CB_S63
/5.D2
TO
BATT To Splice CB_S61

TO
/3.C1
335-C0779-7
5 6 7 8
33 - 13 9813/6500-1 33 - 13
33 - 14 9813/6500-1 33 - 14
Page 33-16 Figure 632. Instrument panels,

J1939 connector and Immobiliser Page 33-17
1 2 3 4 5 6 7 8
0.50 mm² 125E

0.50 mm² 125D
To Earth Splice GND
0.50 mm² 125B 0.50 mm² 610U
/14.E1
F
TO
1.00 mm² 301N

-CB_GA -TE_XF 0.75 mm² 406
F
FromFuse A1 IGNITION CAMERA INPUT
0.50 mm² 125 0.50 mm² 125A 34/62 34/62
/1.E4 FROM
FRONT DISPLAY
0.50 mm² 125G -CB_S18 7216/0021 -B126
-CB_DIS2 ENGINE OIL 7213/0031 -CB_VID 4/6
0.50 mm² 125F 728/A1566 LEVEL -TE_ET 3/6 4/6
MED DISPLAY
0.75 mm² 406

A/3 3/6
To RH Column Sw 332/J7924
0.50 mm² 301G BATT C/3 -B3 A/3 -DIS1
0.50 mm² 125C
TO
/11.F1
IGNITION To Hazard Sw 332/E3213 C/3 B/3 333/A0895 0.50 mm² 480 1/6
/11.D1 J1-1 Digital Input Pin 2
To RH Column Sw (IND)
TO
0.50 mm² 301K BATT -CB_DJ B/3 1/6

TO
/11.D1 2/20
J1-2 Digital Input Pin 1
BATT To Hazard Sw J1-9 GND To Earth Splice S24

0.50 mm² 301L 3/20 332/E3213 0.50 mm² 610P
TO
/11.D1 J1-4 Digital Input Pin 4 5V REF J2-11 J1-1 DIGITAL INPUT 2 GROUND TO
/14.E1
From Fuse B2 -CB_DD 9/20
J1-2 DIGITAL INPUT 1
BATT To Earth Splice

#1438 2/20
1.00 mm² 301 1.00 mm² 301A 0.50 mm² 660F
/1.B4 FROM
10/20
J1-10 +VBATT Ground
J1-9 /14.F4
TO
J1-3 NOT USED
-CB_S7 9/20
J1-11 FREQ
-CB_GA -TE_XF J1-4 DIGITAL INPUT PIN 4
J1-12 Digital Input Pin 14 0.75 mm² 407 0.75 mm² 407
From Water In Fuel Sensor J2-4 J1-5 J2-1
Ground DIGITAL INPUT PIN 3 USB NEG
#539 0.75 mm² 429 4/20 42/62 42/62

/13.C1 FROM
J1-13 Digital Input Pin 13 J1-10 +VBATT USB POS
J2-2
E 332/V0520 J1-14 Digital Input Pin 12 J2-9 0.50 mm² 480
10/20
J1-11 VIDEO 1 USB VBUS
J2-3
332/W5209
E
Ground
7220/0058 7220/0061 9/20 TO EARTH SPLICE S24 GND 11/20
TO AIR FILTER -CBR_JR -AFT_JB -AFT_JN -TE_JM -TE_XF -CB_GA J1-15 Digital Input Pin 11 /14.E1 TO 0.50 mm² 610N J1-12 VIDEO GROUND 1 USB GROUND
J2-4
432 15/20 12/20
0.75 mm² 413 0.75 mm² 413 0.75 mm² 413 0.75 mm² 413 0.75 mm² 405
/7.E1 TO
31/62 31/62
J1-16 Digital Input Pin 10 HS Out 1 J2-19
19/20
J1-13 VIDEO 2 NOT USED
J2-5
16/20
R/23 R/23 24/31 24/31 J1-17 Digital Input Pin 9
-CB_GA -TE_XF J1-14 VIDEO GROUND 2 NOT USED
J2-6
J1-18 Digital Input Pin 8 HS Out 2 J2-20 0.75 mm² 405 0.75 mm² 405 J1-15 NOT USED NOT USED
J2-7
20/20 35/62 35/62
J1-16 NOT USED NOT USED
J2-8
J2-5 J1-17 NOT USED NOT USED
J2-9
FUEL LEVEL SEND
LS Out 1
J2-1 --- From Alternator D+ J1-18 NOT USED

J2-10
NOT USED
7212/0052
To Earth Splice 334/T9237 332/R4343 7219/0055 0.75 mm² 418-CB_GA -TE_XF 1.00 mm² 418812D
-RC_BD J2-2 --- LS Out 2 J2-13 /1.F8 FROM
J2-11
GND 0.75 mm² 650L 1/2 2/2 0.75 mm² 431 -RC_ML -CB_FZ 25/62 25/62
/14.C5 TO
1/2 2/2 21/31 21/31

J2-3 ---
J1-20 NOT USED
J2-12
NOT USED
J2-6 S/W Config 3 DIG/AN J2-13

NOT USED
J2-7 S/W Config 2 DIG/AN

To Earth Splice J2-14
NOT USED
0.50 mm² 660G #1438

J2-8 S/W Config 5 DIG/AN TO
/14.F4 J2-15
NOT USED
332/C8190
J2-10 ---
J2-16
NOT USED
0.50 mm² 431

-CB_DK
HYD OIL TEMP SEND J2-12 Analogue 1 J2-17
NOT USED
12/20
J2-14 S/W Config 4 DIG/AN GROUND
J2-18
7212/0052 333/U7228
To Earth Splice J2-15 J2-19
-RC_MC S/W Config 7 DIG/AN UART_RX
GND -RC_ML -CB_FZ

D /14.C5 TO 0.75 mm² 650M 2/2 -B6 1/2 0.75 mm² 401 0.50 mm² 401 J2-16 S/W Config 6 DIG/AN
J2-20
UART_TX
2/2 1/2 22/31 22/31 17/20

J2-17 S/W Config 1 DIG/AN D
J2-18 Analogue 2
CAN SHIELD
CAN HIGH
CAN LOW
J1-8
J1-7
J1-6
CAN Shield
CAN High
CAN Low
J1-6
J1-8
J1-7
ROTARY CONTROL
-SW3
728/A1568
C 7214/0078
To Earth Splice
0.50 mm² 125C-CB_AA 0.50 mm² 610S GND C
1/4
1 POWER GROUND 2
2/4 /14.E1
TO
CAN-H
4 CAN-L
3
MEMBRANE SW PAD #1
-SW7
333/D7363
7219/0023
7218/0071 IMMOBILISER
To Earth Splice -CB_EMA
0.50 mm² 301E-CB_CS 0.50 mm² 610C GND 9916E 0.50 mm² -B127
1/8
1 V_ Supply V_Ground
5
5/8
TO
/14.F1 728/E6334
Config Ground
6 1/12
11/12
2/12
8/12
7/12
1/12
Config Pin 2 7
Config Pin 1
8 2/12
11/12
7/12
8/12
1/12
2/12
7219/0019
-CB_EM
CAN S
CAN H
CAN L
4 3 2
B 0.50 mm² 125E
B
0.75 mm² 600G
0.50 mm² 301C
0.50 mm² 101C

1.00 mm² 107
0.50 mm² 132
MEMBRANE SW PAD #2
-SW6 IGN TO IGN RELAY
/1.D5
333/D7363
TO
7218/0071 To Earth Splice IGNITION TO SPLICE CB_S73 MEMBRANE SW PAD #3 ATC

/13.D1
-SW5
TO
0.50 mm² 125G-CB_CR 0.50 mm² 610B GND

5 /14.F1 From Fuse A6 To Earth Splice CB_S67 333/D7363
TO
1/8 5/8 IGN GND

Config Ground
6 /1.D4 FROM TO
/14.B1 7218/0071
6/8
Config Pin 2 7
-CB_CB To Earth Splice
0.50 mm² 500 0.50 mm² 610K GND
Config Pin 1
8
8/8
5 TO
/14.F1
1/8 5/8
Config Ground
6
6/8
CAN S
CAN H
CAN L
Config Pin 2 7 0.50 mm² 501

4 3 2 7/8
Config Pin 1
8
CAN S
CAN H
CAN L
4 3 2
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 15 9813/6500-1 33 - 15
33-16 33-17
1 2 3 4
0.50 mm² 125E

0.50 mm² 125D
0.50 mm² 125B
F 1.00 mm² 301N
-CB_GA -TE_XF 0.75 mm² 406
FromFuse A1 IGNITION
0.50 mm² 125 0.50 mm² 125A 34/62 34/62
/1.E4 FROM
FRONT DISPLAY
0.50 mm² 125G -CB_S18
-CB_DIS2 ENGINE OIL
0.50 mm² 125F 728/A1566
0.75 mm² 406

BATT To RH Column Sw
0.50 mm² 301G
0.50 mm² 125C
TO
/11.F1
IGNITION To Hazard Sw 332/E3213 C/3
/11.D1 J1-1 Digital Input Pin 2
To RH Column Sw (IND)
TO
0.50 mm² 301K BATT -CB_DJ

TO
/11.D1 2/20
BATT To Hazard Sw
0.50 mm² 301L 3/20
TO
/11.D1 J1-4 Digital Input Pin 4 5V REF J2-11
From Fuse B2 J1-5 Digital Input Pin 3
BATT 1.00 mm² 301 1.00 mm² 301A 0.50 mm² 660F
/1.B4 FROM
10/20
J1-10 +VBATT Ground
J1-9
-CB_S7 9/20
J1-11 FREQ
-CB_GA
J1-12 Digital Input Pin 14 0.75 mm² 407
From Water In Fuel Sensor #539
Ground J2-4
0.75 mm² 429 4/20 42/62
/13.C1 FROM
E 332/V0520 7220/0058 332/W5209 7220/0061 J1-14 Digital Input Pin 12 Ground J2-9
9/20
TO AIR FILTER -CBR_JR -AFT_JB -AFT_JN -TE_JM -TE_XF -CB_GA J1-15 Digital Input Pin 11
432 15/20
0.75 mm² 413 0.75 mm² 413 0.75 mm² 413 0.75 mm² 413
/7.E1 TO
31/62 31/62
J1-16 Digital Input Pin 10 HS Out 1 J2-19
19/20
16/20
R/23 R/23 24/31 24/31 J1-17 Digital Input Pin 9
-CB_GA
J1-18 Digital Input Pin 8 HS Out 2 J2-20 0.75 mm² 405
20/20 35/62

J2-5
FUEL LEVEL SEND
LS Out 1
J2-1 ---
7212/0052 334/T9237
To Earth Splice 332/R4343 7219/0055
J2-2 J2-13 0.75 mm²
GND
-RC_BD -RC_ML -CB_FZ
--- LS Out 2
0.75 mm² 650L 1/2 2/2 0.75 mm² 431

/14.C5 TO
1/2 2/2 21/31 21/31

J2-3 ---
332/C8190
J2-10 ---
0.50 mm² 431

-CB_DK
HYD OIL TEMP SEND J2-12 Analogue 1
12/20
7212/0052 333/U7228
GND
-RC_MC -RC_ML -CB_FZ
S/W Config 7 DIG/AN
D /14.C5 TO 0.75 mm² 650M

2/2
2/2 -B6 1/2
1/2
0.75 mm² 401
22/31 22/31
0.50 mm² 401
17/20
J2-18 Analogue 2
CAN Shield
CAN High
CAN Low
Page 33-17
J1-6
J1-8
J1-7
ROTARY CONTROL
-SW3
728/A1568
C 7214/0078
To Earth Splice
0.50 mm² 125C-CB_AA 0.50 mm² 610S GND
1/4
1 POWER GROUND 2
2/4 /14.E1
TO
CAN-H
4 CAN-L
3
MEMBRANE SW PAD #1
-SW7
333/D7363
7219/0023
7218/0071 IMMOBILISER
To Earth Splice -CB_EMA
0.50 mm² 301E-CB_CS 0.50 mm² 610C GND 9916E 0.50 mm² -B127
1/8
5
5/8
TO
/14.F1 728/E6334
Config Ground
6 1/12
11/12
2/12
8/12
7/12
1/12
Config Pin 2 7
Config Pin 1
8 2/12
11/12
7/12
8/12
1/12
2/12
7219/0019
-CB_EM
CAN S
CAN H
CAN L
4 3 2
B
0.75 mm² 600G
0.50 mm² 301C
0.50 mm² 101C

1.00 mm² 107
0.50 mm² 132
MEMBRANE SW PAD #2
-SW6 IGN TO IGN RELAY
/1.D5
333/D7363
TO
7218/0071 To Earth Splice IGNITION TO SPLICE CB_S73

TO
/13.D1
0.50 mm² 125G-CB_CR 0.50 mm² 610B GND
1/8
5
5/8
TO
/14.F1 From Fuse A6 To Earth Splice CB_S67
IGN GND
Config Ground
6
6/8 /1.D4 FROM TO
/14.B1
Config Pin 2 7
Config Pin 1
8 0.50 mm² 500
8/8
CAN S
CAN H
CAN L
4 3 2
1 2 3 4
33 - 16 9813/6500-1 33 - 16
33-16 33-17
5 6 7 8
To Earth Splice GND 0.50 mm² 610U

/14.E1 TO
F
CAMERA INPUT
7216/0021 -B126
ENGINE OIL 7213/0031 -CB_VID 4/6
LEVEL -TE_ET 3/6 4/6
A/3
MED DISPLAY 3/6
332/J7924
C/3 -B3 A/3 -DIS1
C/3 B/3 333/A0895 0.50 mm² 480 1/6
B/3 1/6
J1-9 GND To Earth Splice S24

J2-11 332/E3213 J1-1 DIGITAL INPUT 2 GROUND 0.50 mm² 610P TO
/14.E1
-CB_DD 9/20
J1-2 DIGITAL INPUT 1
0.50 mm² 660F #1438 To Earth Splice 2/20

J1-9 /14.F4
TO
J1-3 NOT USED
9/20
-CB_GA -TE_XF J1-4 DIGITAL INPUT PIN 4
J2-4 0.75 mm² 407 0.75 mm² 407 J1-5 DIGITAL INPUT PIN 3 USB NEG
J2-1
4/20 42/62 42/62 J1-10 +VBATT USB POS
J2-2
10/20
J2-9 0.50 mm² 480 J1-11 USB VBUS
J2-3
E
VIDEO 1
9/20 TO EARTH SPLICE S24 GND 11/20
0.50 mm² 610N
/14.E1 TO
12/20
J1-12 VIDEO GROUND 1 USB GROUND
J2-4
J2-19 0.75 mm² 405 J1-13 VIDEO 2 NOT USED
J2-5
19/20
-CB_GA -TE_XF J1-14 VIDEO GROUND 2 NOT USED
J2-6
J2-20 0.75 mm² 405 0.75 mm² 405 J1-15 NOT USED NOT USED
J2-7
20/20 35/62 35/62
J2-8
J2-5 J1-17 NOT USED NOT USED
J2-9
From Alternator D+ J1-18 NOT USED
J2-10
NOT USED
0.75 mm² 418-CB_GA -TE_XF 1.00 mm² 418812D

J2-13
25/62 25/62
FROM
/1.F8 J1-19 NOT USED NOT USED
J2-11
J1-20 NOT USED
J2-12
NOT USED
J2-13
NOT USED

NOT USED
0.50 mm² 660G #1438 TO

/14.F4 J2-15
NOT USED
J2-16
NOT USED
J2-17
NOT USED
GROUND
J2-18
J2-19
UART_RX
J2-20
UART_TX
D
CAN SHIELD
CAN HIGH
CAN LOW
J1-8
J1-7
J1-6
Page 33-16
0.50 mm² 125E
IGN TO IGN RELAY

TO
/1.D5
IGNITION TO SPLICE CB_S73 MEMBRANE SW PAD #3 ATC
/13.D1
-SW5
TO
GND To Earth Splice CB_S67 333/D7363

TO
/14.B1 7218/0071
-CB_CB To Earth Splice
0.50 mm² 610K GND
5 TO
/14.F1
1/8 5/8
Config Ground
6
6/8 0.50 mm² 501
Config Pin 2 7
7/8
Config Pin 1
8
CAN S
CAN H
CAN L
4 3 2
335-C0779-7
5 6 7 8
33 - 17 9813/6500-1 33 - 17
33 - 18 9813/6500-1 33 - 18
Page 33-20 Figure 633. Engine Management ECU Page 33-21

1 2 3 4 5 6 7 8
SEC. STEER
126 To Loader ECU PRESS SENSOR
0.50 mm² 117P TO
/5.B2 7219/0055 332/R4343
-CB_FZ -RC_ML 7213/0031
F 0.50 mm² 117B 0.75 mm² 117F -RC_BE A/3 B/3 0.75 mm² 651A
A/3 B/3 F
332/C8166
15/31 15/31 334/T0070
-SW10 C/3 0.75 mm² 432B
LIFT RESET C/3
THIS PART IS NOT TO BE USED
7219/0221 7219/0218 7214/0025

- SPEAK TO PURCHASING 2 0.75 mm² 853
-FC_NF -CB_DH 0.50 mm² 853
From Fuse C2 -CB_S59 -FC_S27
White
2/4 13/62
126 0.75 mm² 117 0.50 mm² 117K -CB_DH -FC_NF 0.75 mm² 117K 0.75 mm² 117L
-FC_ND 1Brown 3 0.75 mm² 852 -FC_NF 0.50 mm² 852
/1.C7 FROM
17/62 17/62 1/4 (Input)

Black
3/4 14/62 14/62
0.75 mm² 117A Blue
4
(-VE)
4/4 To Earth Splice
0.50 mm² 117N 0.75 mm² 660H #1438 TO
/14.E4
-SW23
332/W8793
BUCKET RESET
7214/0025
- SPEAK TO PURCHASING
White
2 0.75 mm² 851 -FC_NF -CB_DH
-FC_NC 1Brown 3 2/4 16/62 16/62
0.75 mm² 117M Black 0.75 mm² 854
1/4 (Input) 3/4 15/62 15/62
Blue
4 BRAKE ACC
(-VE)
4/4 #1438 To Earth Splice PRESS SENSOR
0.75 mm² 660R TO
/14.E4
-CB_FZ -RC_ML 7213/0031
E 0.75 mm² 117A -RC_JU A/3 B/3 0.75 mm² 651C
0.50 mm² 117E
18/31 18/31 A/3 B/3 E

334/T0070
0.50 mm² 117N C/3 0.75 mm² 422B
C/3
QUICK HITCH SOLENOID
7212/0052
7219/0218 7219/0221 MAIN PRESS SENSOR
From Module 2 -FC_NH 225/221923 -FC_NH -FC_NF -CB_DH
0.75 mm² 858 -CB_DH -FC_NF0.75 mm² 858 0.75 mm² 858 1/2 2/2 0.75 mm² 660V 0.75 mm² 660V 36/62 36/62 0.75 mm² 660V 7213/0031
/11.D4 FROM
-CB_DH -FC_NF
IGNITION 18/62 18/62 1/2 1/2 1/2 2/2 2/2 2/2 -R8 0.75 mm² 117N -FC_NP A/3 B/3 0.75 mm² 651B
A/3 B/3
333/S5959 29/62 29/62
334/T0070
QUICK HITCH RELAY C/3 0.75 mm² 412B
4 C/3
-RC_ML
-RC_ML
-FC_NF
-FC_NF
-RC_ML
2 1
-RC_ML
0.75 mm² 630V
17/31
29/31
20/31
16/31
30/62
31/62
TO EARTH SPLICE S68 GND 0.75 mm² 630V 5 3 0.50 mm² 856
/14.C1 TO
-CB_FZ
-CB_DH
-CB_DH
-CB_FZ
17/31
-CB_FZ
29/31
16/31
20/31
30/62
31/62
-CB_GR
-CB_FZ
7241/0003
7212/0052
QHITCH/HEATD RER SCRN RLY
AUX DUMP SOL
D -FC_PA
1/2 2/2 #1438 TO EARTH SPLICE S22 D
0.75 mm² 651C

0.75 mm² 808 0.75 mm² 660W
0.50 mm² 651A

TO
/14.E4
1/2 2/2
0.50 mm² 651B

7212/0052
-TE_XK VARIFLOW SOLENOID
0.75 mm² 7000 2/2 1/2 0.75 mm² 9501
From HVAC Harness 874
2/2 1/2
/8.D7 FROM
-TE_XF
-TE_XF
-FC_NF
0.50 mm² 874
0.50 mm² 854
0.50 mm² 851
0.50 mm² 852
0.50 mm² 853

40/62
39/62
19/62
To MCM & CPC (START SIGNAL) #892

From Fuse B5 BATT /1.D7
-CB_GA
-CB_GA
TO
-CB_S61 -CB_S5
-CB_DH
2.00 mm² 302

/1.A4 FROM
FROM FUSE FB8 IGN

40/62
39/62
19/62
SPLICE FUSE B5 /1.E5 FROM
0.50 mm² 651D

1.50 mm² 302C
1.50 mm² 302D
0.75 mm² 412B

1.50 mm² 302A
1.50 mm² 302B
1.50 mm² 302E
0.50 mm² 422
0.50 mm² 432

332/F8043
0.50 mm² 002A
0.75 mm² 9501

0.75 mm² 7000
0.75 mm² 1840
0.75 mm² 808
-CB_PY
332/F8042
23/35
33/35
20/35
22/35
31/35
26/35
19/35
15/35
-CB_PX
17/35
2/35
3/35
C
13/35
11/35
7/35
2/35
4/35
6/35
3/35
5/35
C
22/35
27/35
26/35
12/35
ECU CONNECTOR 2
ECU CONNECTOR 1
DIN21 34/35
DIN22 35/35
DIN16 27/35
DIN18 28/35
DIN9 13/35
DIN10 25/35
DIN11 14/35
DIN19 17/35
HSOUT1 23/35
DIN15 DET ON 3/35
DIN14 DET OFF 15/35
2/35
DIN13 DET ON 26/35
DIN20 29/35
DIN17 16/35
33/35
AN IN 8 31/35
AN IN 7 19/35
AN IN 9 20/35
SENSOR GND 22/35

332/F0181
-B16
17/35 GND VBATT 2/35
VBATT 3/35
VBATT 4/35
VBATT 5/35
VBATT 6/35
7/35
DIN1 VIGN 11/35
DIN2 22/35
HSOUT8 27/35
HSOUT7 26/35
LSOUT18 12/35
DIN4 21/35
DIN5 9/35
DIN3 10/35
DIN8 8/35
HSOUT3 1/35
HSOUT4 13/35
DIN12 DET OFF

332/F0181
10/35 HSOUT10
0.50 mm² 651E

9/35 HSOUT11
5/35 HSOUT15
24/35 LSOUT19
7/35 HSOUT13
4/35 HSOUT16
8/35 HSOUT12
6/35 HSOUT14
11/35 HSOUT9
1/35 LSOUT20
12/35 HSOUT2
30/35 AN IN 6
18/35 AN IN 5
34/35 CAN A (H)
35/35 LSOUT17
33/35 CAN A (L)
24/35 HSOUT5
23/35 CAN SH
25/35 HSOUT6
28/35 +5VREF
31/35 ANA3
19/35 ANA4
15/35 GND
16/35 GND
14/35 GND
-AX_S126
OPTIONAL HARNESS
30/35
12/35
18/35
11/35
10/35
4/35
9/35
8/35
24/35
7/35
6/35
1/35
5/35
To Aux Control Lever 651
/4.E1
14/35
25/35
24/35
28/35
15/35
16/35
17/35
TO
35/35
19/35
31/35
0.75 mm² 1814
0.75 mm² 1815
0.75 mm² 1602
0.75 mm² 1816
0.75 mm² 1817
0.75 mm² 1603
0.75 mm² 803

To Aux. Control Lever
0.50 mm² 1826 1826
1.00 mm² 1602B
1.00 mm² 1602A
0.50 mm² 1818C 1818C

/4.D1
TO TO
/4.D1 To Boom Cntr lever Detent
0.50 mm² 1823 1823
1.50 mm² 600D
1.50 mm² 600C

1.50 mm² 620A
1.50 mm² 600B
From Aux Lever /4.D1 To Bucket Lever Detent

0.75 mm² 857
0.75 mm² 845
0.75 mm² 866
TO
0.75 mm² 867
0.50 mm² 1613 1613 0.50 mm² 1827 1827

/4.D1 /4.D1 From Aux Control Lever
7219/0221
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
FROM FROM
864
0.75 mm² 864
/12.B2 To Sec Steer Relay
10/62
11/62
12/62
1/62
From Aux Lever
TO
8/62
9/62
7/62
1619 0.50 mm² 1828 1828
B 0.50 mm² 1619
/4.D1 /4.D1 From Aux Control Lever
2/2
2/2
FROM FROM
B
7219/0218
FAN CONTROL HARNESS OPTIONAL HARNESS

-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
7214/0025 7214/0024
7/62
8/62
9/62
10/62
11/62
12/62
1/62
7212/0052 7212/0013 SRS SOLENOID
PROPORTIONAL FAN
-CB_DH
3 RD SPOOL B
3RD SPOO L A
GND
/14.B1 To Earth Splice -CB_FZ -RC_ML -RC_MG -FA_GZ -FA_GU -FC_NJ To Earth Splice
34/62
335/F2397
2/2
2/2
-RC_ML
TO
-CB_FZ 0.75 mm² 660E #1438

335/F2397
GND 0.75 mm² 867 0.75 mm² 867 2/2 1/2 0.75 mm² 866 0.75 mm² 866 0.75 mm² 803 2/2 1/2
/14.B1 To Earth Splice /14.E4
-FC_NG0.75 mm² 1814
-FC_NG0.75 mm² 1815
-FC_NG0.75 mm² 1602
-FC_NG0.75 mm² 1816
-FC_NG0.75 mm² 1817
-FC_NG0.75 mm² 1603

TO TO
23/31 23/31 2/4 24/31 24/31 2/2 1/2

GND 1/4 1/4 2/2 1/2 2/4
TO
/14.B1 To Earth Splice 333/T3222
GND
-FC_NF
/14.B1 To Earth Splice

34/62
TO
7219/0055 332/R4343 7212/0052 REVERSE FAN 1.00 mm² 1603

-CB_FZ
1/2
1/2
-RC_ML -FA_AE GND TO EARTH SPLICE S70

7218/0013
0.75 mm² 845 0.75 mm² 845 1/2 2/2 0.75 mm² 650F 0.75 mm² 650F TO
/14.C5
10/31 10/31
3/4 3/4 1/2 2/2 4/4 4/4 7212/0052
4TH SPOOL B
4/8
6/8
3/8
5/8
7/8
8/8
-AX_NT
7212/0052
1.00 mm² 1817 1/2 2/2 1.00 mm² 1603B

7212/0052
1/2
1/2
-AX_NQ
-AX_NR
1/2 2/2
7218/0012
-AX_PC
-AX_PC
-AX_PC
-AX_PC
-AX_PC
-AX_PC
-AX_S127
SERVO ISOLATOR SOL 335/F0315
3/8
4/8
5/8
6/8
7/8
8/8
7212/0052
-FC_NY #1438 To Earth Splice S22
1.00 mm² 857 1/2 2/2 0.75 mm² 600CV 1.00 mm² 1814
1/2 2/2
TO
/14.E4 4 TH SPOOL A
333/R0847 1.00 mm² 1815 7212/0052
1.00 mm² 1602 1.00 mm² 1816 -AX_NS 1/2 2/2 1.00 mm² 1603A
1/2 2/2
335/F0315
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 19 9813/6500-1 33 - 19
33-20 33-21
1 2 3 4
126 To Loader ECU

0.50 mm² 117P TO
/5.B2 7219/0055
-CB_FZ
F 0.50 mm² 117B
15/31
332/C8166
-SW10
LIFT RESET
7219/0221 7219/0218 7214/0025

- SPEAK TO PURCHASING 2 0.75 mm² 853
-FC_NF
From Fuse C2 -CB_S59 -FC_S27
White
2/4
126 0.75 mm² 117 0.50 mm² 117K -CB_DH -FC_NF 0.75 mm² 117K 0.75 mm² 117L
-FC_ND 1Brown 3 0.75 mm² 852 -FC_NF
/1.C7 FROM
17/62 17/62 1/4 (Input)

Black
3/4 14/62
0.75 mm² 117A Blue
4
(-VE)
4/4 To Earth Splice
0.50 mm² 117N 0.75 mm² 660H #1438 TO
/14.E4
-SW23
332/W8793
BUCKET RESET
7214/0025
- SPEAK TO PURCHASING
White
2 0.75 mm² 851 -FC_NF
-FC_NC 1Brown 3 2/4 16/62
0.75 mm² 117M Black 0.75 mm² 854
1/4 (Input)
4 3/4 15/62
Blue
(-VE)
4/4 #1438 To Earth Splice
0.75 mm² 660R TO
/14.E4
-CB_FZ
E
0.50 mm² 117E
18/31
0.50 mm² 117N
QUICK HITCH SOLENOID

7212/0052
7219/0218 7219/0221
From Module 2 -FC_NH 225/221923 -FC_NH -FC_NF -CB_DH
0.75 mm² 858 -CB_DH -FC_NF0.75 mm² 858 0.75 mm² 858 1/2 2/2 0.75 mm² 660V 0.75 mm² 660V 36/62 36/62 0.75 mm² 660V
/11.D4 FROM
-CB_DH
IGNITION 18/62 18/62 1/2 1/2 1/2 2/2 2/2 2/2 -R8
333/S5959 29/62
QUICK HITCH RELAY
4
0.75 mm² 630V 2 1
TO EARTH SPLICE S68 GND 0.75 mm² 630V 5 3 0.50 mm² 856
/14.C1 TO
-CB_GR
7241/0003
7212/0052
QHITCH/HEATD RER SCRN RLY
AUX DUMP SOL
D -FC_PA
#1438 TO EARTH SPLICE S22
0.75 mm² 808 1/2 2/2 0.75 mm² 660W TO
/14.E4
1/2 2/2
7212/0052
-TE_XK VARIFLOW SOLENOID
0.75 mm² 7000 2/2 1/2 0.75 mm² 9501
From HVAC Harness
2/2 1/2
/8.D7
-TE_XF
-TE_XF
-FC_NF
40/62
39/62
19/62
Page 33-21
To MCM & CPC (START SIGNAL) #892
From Fuse B5 BATT /1.D7
-CB_GA
-CB_GA
TO
-CB_S61
-CB_DH
2.00 mm² 302

/1.A4 FROM
FROM FUSE FB8 IGN

40/62
39/62
19/62
SPLICE FUSE B5 /1.E5 FROM

1.50 mm² 302C
1.50 mm² 302D
1.50 mm² 302A
1.50 mm² 302B
1.50 mm² 302E
0.50 mm² 002A
0.75 mm² 9501

0.75 mm² 7000
0.75 mm² 1840
0.75 mm² 808

332/F8042
-CB_PX
13/35
11/35
7/35
2/35
4/35
6/35
3/35
5/35
22/35
27/35
26/35
12/35
ECU CONNECTOR 1
DIN21 34/35
DIN22 35/35
DIN16 27/35
DIN18 28/35
DIN9 13/35
-B16
17/35 GND VBATT 2/35
VBATT 3/35
VBATT 4/35
VBATT 5/35
VBATT 6/35
7/35
DIN1 VIGN 11/35
DIN2 22/35
HSOUT8 27/35
HSOUT7 26/35
LSOUT18 12/35
DIN4 21/35
DIN5 9/35
DIN3 10/35
DIN8 8/35
HSOUT3 1/35
HSOUT4 13/35
332/F0181
34/35 CAN A (H)
35/35 LSOUT17
33/35 CAN A (L)
24/35 HSOUT5
23/35 CAN SH
25/35 HSOUT6
28/35 +5VREF
31/35 ANA3
19/35 ANA4
15/35 GND
16/35 GND
14/35 GND
14/35
25/35
24/35
28/35
15/35
16/35
17/35
35/35
19/35
31/35
1818C To Aux. Control Lever

0.50 mm² 1818C
/4.D1
TO
1.50 mm² 600D
1.50 mm² 600C

1.50 mm² 620A
1.50 mm² 600B
From Aux Lever

0.75 mm² 857
0.75 mm² 845
0.75 mm² 867
0.50 mm² 1613 1613

/4.D1
FROM
1619 From Aux Lever

B 0.50 mm² 1619
/4.D1
FROM
7214/0024
FAN CONTROL HARNESS
7214/0025 7212/0052
PROPORTIONAL FAN
-CB_DH
GND
/14.B1 -CB_FZ -RC_ML -RC_MG -FA_GZ -FA_GU
34/62
TO
To Earth Splice -RC_ML

GND 0.75 mm² 867 0.75 mm² 867 2/2 1/2 0.75 mm² 866 0.75 mm² 866 -CB_FZ
TO
/14.B1 To Earth Splice 24/31
GND 23/31 23/31 1/4 1/4 2/2 1/2 2/4 2/4
TO
GND
-FC_NF
/14.B1
34/62
TO
To Earth Splice 7219/0055 332/R4343 7212/0052 REVERSE FAN
-CB_FZ -RC_ML -FA_AE
0.75 mm² 845 0.75 mm² 845 1/2 2/2 0.75 mm² 650F GND
0.75 mm² 650F TO EARTH SPLICE S70
10/31 10/31
TO
/14.C5
3/4 3/4 1/2 2/2 4/4 4/4
SERVO ISOLATOR SOL

7212/0052
-FC_NY #1438 To Earth Splice S22
1.00 mm² 857 1/2 2/2 0.75 mm² 600CV
1/2 2/2
TO
/14.E4
333/R0847
1 2 3 4
33 - 20 9813/6500-1 33 - 20
33-20 33-21
5 6 7 8
SEC. STEER
PRESS SENSOR
7219/0055 332/R4343
-CB_FZ -RC_ML 7213/0031
0.75 mm² 117F -RC_BE A/3 B/3 0.75 mm² 651A
A/3 B/3 F
15/31 15/31 334/T0070
C/3 0.75 mm² 432B
C/3
853
-FC_NF -CB_DH 0.50 mm² 853
-FC_NF 13/62
852 0.50 mm² 852
14/62 14/62
To Earth Splice
660H #1438 TO
/14.E4
851 -FC_NF -CB_DH

16/62 16/62
854
15/62 15/62 BRAKE ACC
#1438 To Earth Splice PRESS SENSOR
660R TO
/14.E4
-CB_FZ -RC_ML 7213/0031
0.75 mm² 117A -RC_JU A/3 B/3 0.75 mm² 651C
18/31 18/31 A/3 B/3 E
334/T0070
C/3 0.75 mm² 422B
C/3
MAIN PRESS SENSOR

660V -CB_DH -FC_NF 7213/0031
0.75 mm² 117N -FC_NP A/3 B/3 0.75 mm² 651B
A/3 B/3
29/62 29/62
334/T0070
C/3 0.75 mm² 412B
C/3
-RC_ML
-RC_ML
-FC_NF
-FC_NF
-RC_ML
-RC_ML
17/31
29/31
20/31
16/31
30/62
31/62
-CB_FZ
-CB_DH
-CB_DH
-CB_FZ
17/31
-CB_FZ
29/31
16/31
20/31
30/62
31/62
-CB_FZ
#1438 TO EARTH SPLICE S22 D
0.75 mm² 651C
0.50 mm² 651A

TO
/14.E4
0.50 mm² 651B
From HVAC Harness 874

/8.D7 FROM
0.50 mm² 874
0.50 mm² 854
0.50 mm² 851
0.50 mm² 852
0.50 mm² 853

Page 33-20
-CB_S5
0.50 mm² 651D
0.75 mm² 412B
0.50 mm² 422
0.50 mm² 432

332/F8043
-CB_PY
23/35
33/35
20/35
22/35
31/35
26/35
19/35
15/35
17/35
2/35
3/35
ECU CONNECTOR 2 C
DIN21 34/35
DIN22 35/35
DIN16 27/35
DIN18 28/35
DIN9 13/35
DIN10 25/35
DIN11 14/35
DIN19 17/35
HSOUT1 23/35
DIN15 DET ON 3/35
DIN14 DET OFF 15/35
2/35
DIN13 DET ON 26/35
DIN20 29/35
DIN17 16/35
33/35
AN IN 8 31/35
AN IN 7 19/35
AN IN 9 20/35
SENSOR GND 22/35
332/F0181
DIN12 DET OFF
10/35 HSOUT10
0.50 mm² 651E

9/35 HSOUT11
5/35 HSOUT15
24/35 LSOUT19
7/35 HSOUT13
4/35 HSOUT16
8/35 HSOUT12
6/35 HSOUT14
11/35 HSOUT9
1/35 LSOUT20
12/35 HSOUT2
30/35 AN IN 6
18/35 AN IN 5
-AX_S126
OPTIONAL HARNESS
30/35
12/35
18/35
11/35
10/35
4/35
9/35
8/35
24/35
7/35
6/35
1/35
5/35
To Aux Control Lever 651

/4.E1 TO
0.75 mm² 1814
0.75 mm² 1815
0.75 mm² 1602
0.75 mm² 1816
0.75 mm² 1817
0.75 mm² 1603
0.75 mm² 803
0.50 mm² 1826 1826

1.00 mm² 1602B
1.00 mm² 1602A
TO
/4.D1 To Boom Cntr lever Detent
0.50 mm² 1823 1823
/4.D1 To Bucket Lever Detent
0.75 mm² 866
TO
0.50 mm² 1827 1827

/4.D1 From Aux Control Lever
7219/0221
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
FROM
864
0.75 mm² 864
/12.B2 To Sec Steer Relay
10/62
11/62
12/62
1/62
TO
8/62
9/62
7/62
0.50 mm² 1828 1828

/4.D1 From Aux Control Lever
2/2
2/2
FROM
B
7219/0218
OPTIONAL HARNESS
-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
7/62
8/62
9/62
10/62
11/62
12/62
1/62
7212/0013 SRS SOLENOID

3 RD SPOOL B
3RD SPOO L A
-FC_NJ To Earth Splice

335/F2397
2/2
2/2
-RC_ML -CB_FZ 0.75 mm² 660E #1438

335/F2397
0.75 mm² 866 0.75 mm² 803 2/2 1/2

/14.E4
-FC_NG0.75 mm² 1814
-FC_NG0.75 mm² 1815
-FC_NG0.75 mm² 1602
-FC_NG0.75 mm² 1816
-FC_NG0.75 mm² 1817
-FC_NG0.75 mm² 1603
TO
2/4 24/31 24/31 2/2 1/2

333/T3222
1.00 mm² 1603

1/2
1/2
GND TO EARTH SPLICE S70

7218/0013
0.75 mm² 650F TO

/14.C5
7212/0052
4TH SPOOL B
4/8
6/8
3/8
5/8
7/8
8/8
-AX_NT
7212/0052
1.00 mm² 1817 1/2 2/2 1.00 mm² 1603B

7212/0052
1/2
1/2
-AX_NQ
-AX_NR
1/2 2/2
7218/0012
-AX_PC
-AX_PC
-AX_PC
-AX_PC
-AX_PC
-AX_PC
-AX_S127
335/F0315
3/8
4/8
5/8
6/8
7/8
8/8
#1438 To Earth Splice S22

1.00 mm² 1814
TO
/14.E4 4 TH SPOOL A
1.00 mm² 1815 7212/0052
1.00 mm² 1602 1.00 mm² 1816 -AX_NS 1/2 2/2 1.00 mm² 1603A
1/2 2/2
335/F0315
335-C0779-7
5 6 7 8
33 - 21 9813/6500-1 33 - 21
33 - 22 9813/6500-1 33 - 22
Page 33-24 Figure 634. Joystick (Option) Page 33-25

1 2 3 4 5 6 7 8
F
F
JOYSTICK OPTION CONNECTIONS
JOYSTICK
332/R4343 7219/0055 -B148

-CB_CC -JY_JH 7218/0014 334/T8650
IGNITION 20/31 20/31 -JY_JG 1/8 24V
From Fuse FA2 /6.E1 FROM 0.50 mm² 9916C 0.50 mm² 9916C
651 0.50 mm² 890A 10/31 10/31 0.50 mm² 890A
1/8
2/8 DIFFLOCK ERGO TRACTION MAN
DETENTS COIL
TO ERGOTRACTION SOLENOID /6.B6 TO
E From Fuse FA2 /6.E1

IGNITION 0.50 mm² 9916L 11/31 11/31 0.50 mm² 9916R
2/8
3/8 DIFFLOCK ERGOTRACTION MAN -B149
E
FROM
3/6 CROWD
4/6 CROWD
3/8
FLOAT
FLOAT
#765
From ZF TCU /6.D3 FROM 0.50 mm² 9543A 23/31 23/31 0.50 mm² 9543A 5/8 R
5/8
2/6 LIFT
5/6 LIFT
#766
From ZF TCU /6.D3 0.50 mm² 9542A 22/31 22/31 0.50 mm² 9542A 7/8 N
AUX1
FROM
HORN
HORN
AUX2
AUX2
AUX2
#770 7/8
From ZF TCU /6.E3 0.50 mm² 9541A 21/31 21/31 0.50 mm² 9541A 8/8 F
6/6
1/6
5V
FROM
0V
8/8
KD KD
10/12
11/12
12/12
2/12
4/12
6/12
3/12
5/12
7/12
8/12
9/12
1/12
4/8
6/8
7216/0018
-JY_JL
1/6
6/6
2/6
5/6
3/6
4/6
7219/0058
-JY_JC
4/8
6/8
2/12
1/12
3/12
4/12
5/12
6/12
7/12
8/12
332/R4343
0.50 mm² 1826B
0.50 mm² 610C
0.50 mm² 610B
0.50 mm² 610A

-CB_CC
0.50 mm² 1826
0.50 mm² 1823

651 0.50 mm² 651E 1/31 1/31 0.50 mm² 651
From Management ECU /3.B8 FROM
1818C 0.50 mm² 1818C 2/31 2/31 0.50 mm² 1818C

1827 0.50 mm² 1827 3/31 3/31 0.50 mm² 1827

To Management ECU /3.B7 TO
332/R4343
1828 0.50 mm² 1828 4/31 4/31 0.50 mm² 1828
7219/0055 -JY_JH -CB_CC To Earth Splice
1613 0.50 mm² 1613 5/31 5/31 0.50 mm² 1613 0.50 mm² 610 19/31 19/31 0.50 mm² 610F GND
To Management ECU /3.B4 TO TO
/14.E1
1619 0.50 mm² 1619 6/31 6/31 0.50 mm² 1619 -JY_SJ19
#771 0.50 mm² 9532B 7/31 7/31 0.50 mm² 9532B

To ZF TCU /6.F3 TO
IGNITION
D From Fuse FA2 /6.E1 FROM 0.50 mm² 9916V 8/31 8/31 0.50 mm² 9916V

1823 0.50 mm² 1823 9/31 9/31 0.50 mm² 1823 D
117
From Splice CB_S34 /13.F1 FROM 1.00 mm² 105D 25/31 25/31 0.50 mm² 105D
811 1.00 mm² 811A 26/31 26/31 0.50 mm² 811A
From Splice CB_S14 /13.F3 TO
1826 0.50 mm² 1826 12/31 12/31 0.50 mm² 1826

-JY_SJ20
C
C
B
B
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 23 9813/6500-1 33 - 23
33-24 33-25
1 2 3 4
JOYSTICK OPTION CONNECTIONS
JOYSTICK
332/R4343 7219/0055 -B148

-CB_CC -JY_JH 7218/0014 334/T8650
IGNITION 20/31 20/31 -JY_JG 1/8 24V
From Fuse FA2 /6.E1 FROM 0.50 mm² 9916C 0.50 mm² 9916C
651 1/8
0.50 mm² 890A 10/31 10/31 0.50 mm² 890A 2/8 DIFFLOCK ERGO TRACTION MAN
TO ERGOTRACTION SOLENOID /6.B6 TO
E From Fuse FA2 /6.E1 FROM

IGNITION 0.50 mm² 9916L 11/31 11/31 0.50 mm² 9916R
2/8
3/8 DIFFLOCK ERGOTRACTION MAN
#765 3/8
From ZF TCU /6.D3 FROM 0.50 mm² 9543A 23/31 23/31 0.50 mm² 9543A 5/8 R
#766 5/8
From ZF TCU /6.D3 0.50 mm² 9542A 22/31 22/31 0.50 mm² 9542A 7/8 N
AUX1
FROM
HORN
HORN
AUX2
AUX2
AUX2
#770 7/8
From ZF TCU /6.E3 0.50 mm² 9541A 21/31 21/31 0.50 mm² 9541A 8/8 F
5V
FROM
0V
8/8
KD KD
10/12
11/12
12/12
2/12
4/12
6/12
3/12
5/12
7/12
8/12
9/12
1/12
4/8
6/8
7219/0058
-JY_JC
4/8
6/8
2/12
1/12
3/12
4/12
5/12
6/12
7/12
8/12
332/R4343
-CB_CC
651 0.50 mm² 651E 1/31 1/31 0.50 mm² 651
1818C 0.50 mm² 1818C 2/31 2/31 0.50 mm² 1818C

1827 0.50 mm² 1827 3/31 3/31 0.50 mm² 1827

1828 0.50 mm² 1828 4/31 4/31 0.50 mm² 1828

1613 0.50 mm² 1613 5/31 5/31 0.50 mm² 1613

1619 0.50 mm² 1619 6/31 6/31 0.50 mm² 1619

#771 0.50 mm² 9532B 7/31 7/31 0.50 mm² 9532B

To ZF TCU /6.F3 TO
IGNITION
D From Fuse FA2 /6.E1 FROM
1823
0.50 mm² 9916V 8/31 8/31 0.50 mm² 9916V
From Management ECU /3.B7 FROM 0.50 mm² 1823 9/31 9/31 0.50 mm² 1823
117
From Splice CB_S34 /13.F1 FROM 1.00 mm² 105D 25/31 25/31 0.50 mm² 105D
811 1.00 mm² 811A 26/31 26/31 0.50 mm² 811A
From Splice CB_S14 /13.F3 TO
1826 0.50 mm² 1826 12/31 12/31 0.50 mm² 1826

Page 33-25
C
1 2 3 4
33 - 24 9813/6500-1 33 - 24
33-24 33-25
5 6 7 8
DETENTS COIL
-B149
E
3/6 CROWD
4/6 CROWD
FLOAT
FLOAT
2/6 LIFT
5/6 LIFT
HORN
6/6
1/6
10/12
11/12
12/12
8/12
9/12
7216/0018
-JY_JL
1/6
6/6
2/6
5/6
3/6
4/6
8/12
0.50 mm² 1826B
0.50 mm² 610C
0.50 mm² 610B
0.50 mm² 610A

0.50 mm² 1826
0.50 mm² 1823
332/R4343
7219/0055 -JY_JH -CB_CC To Earth Splice
0.50 mm² 610 19/31 19/31 0.50 mm² 610F GND TO
/14.E1
-JY_SJ19
-JY_SJ20
Page 33-24
335-C0779-7
5 6 7 8
33 - 25 9813/6500-1 33 - 25
33 - 26 9813/6500-1 33 - 26
Page 33-28 Figure 635. Multi lever (Option) Page 33-29

1 2 3 4 5 6 7 8
MULTILEVER OPTION CONNECTIONS

BUCKET CNTRL LEVER LSL BOOM CNTRL LEVER LSL PADDLE LEVER MOUNTED
AUXILIARY CONTROL LEVER LST 2 LEVERS
F DIFF LOCK 334/ T2821 334/ T5033 WITH LEVER CONTROLS
KICKDOWN SW ERGO .MANUAL AUXLIARY LEVER 1 AUXLIARY LEVER 2 BUCKET LEVER ELEC DETENT OPTION BOOM LEVER ELEC DETENT OPTION F-N-R SW F
-B160 -B161 -B156 -B157 -B158 -B158 -B159 -B159 -B193
334/T4409 334/T4411 333/C3434 333/C3434 LEVER HORN SW 334/S6485
/5.F5 /5.F4 /5.F6 /5.F5 7219/0013
-EH_DX
VOUT SEC
VOUT SEC
VOUT PRI
VOUT PRI
VOUT SEC
VOUT SEC
-B136 2/10
VOUT PRI
VOUT PRI
2/10
2/2
-VREF
+VREF
-VREF
+VREF
-VERF
+VREF
-VERF
+VREF
1/2
+BAT
+BAT
DOUT
DOUT
0.50 mm² 9917 4/10

4/10
1/2
2/2
-EH_FU
2/2
2/2
2/4
4/4
2/4
4/4
2/6
4/6
6/6
2/6
4/6
6/6
3/4
3/4
3/6
5/6
3/6
5/6
1/2
1/2
1/4
1/4
1/6
1/6
7212/0052
6/10
5/10
3/10
1/10
7214/0061
-EH_NW
-EH_NZ
7214/0061
7212/0052
7212/0052
7216/0018
7216/0018
7216/0018
7216/0018
-EH_NU
-EH_NU
-EH_MR
-EH_NV
-EH_NV
-EH_NK
2/2
1/2
2/2
1/2
1/4
2/4
3/4
4/4
1/4
2/4
3/4
4/4
1/6
2/6
3/6
4/6
5/6
6/6
1/6
2/6
3/6
4/6
5/6
6/6
5/10
6/10
3/10
1/10
7219/0055
-EH_LV
0.50 mm² 1604D
0.50 mm² 1818D
0.50 mm² 1604E
0.50 mm² 1818E

7/31 0.50 mm² 9532B
0.50 mm² 610FB

0.50 mm² 1604A
0.50 mm² 1818A
0.50 mm² 1604B
0.50 mm² 1818B

-EH_LV
0.50 mm² 1821
0.50 mm² 1822
0.50 mm² 1823
0.50 mm² 1824
0.50 mm² 1825
0.50 mm² 1826

0.50 mm² 610FA
0.50 mm² 9916C
0.50 mm² 9543A
0.50 mm² 9542A
0.50 mm² 9541A

0.50 mm² 811A
0.50 mm² 105D
8/31 0.50 mm² 9916V
E -EH_LV
1/31 0.50 mm² 651E E
-EH_LV -EH_S3
2/31 0.50 mm² 1818C
-EH_LV -EH_S9 -EH_S129

3/31 0.50 mm² 1827
-EH_LV -EH_S128
4/31 0.50 mm² 1828
-EH_LV
-EH_SJ16
5/31 0.50 mm² 1613
0.75 mm² 1604
0.75 mm² 1818

-EH_LV
0.50 mm² 610F

6/31 0.50 mm² 1619
-EH_LV
9/31 0.50 mm² 1823
-EH_LV
12/31 0.50 mm² 1826
-EH_LV
D 10/31 0.50 mm² 890A
D
7219/0055
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
11/31 0.50 mm² 9916R
25/31
26/31
20/31
23/31
22/31
21/31
13/31
14/31
15/31
16/31
17/31
18/31
19/31
-CB_CC
-CB_CC
-CB_CC
-CB_CC
-CB_CC
-CB_CC
From Fuse FB4 BATT -CB_S63
13/31
14/31
15/31
16/31
17/31
18/31
CONNECTIONS TO MACHINE ARE SHOWN /1.A4 FROM 2.00 mm² 303 CONNECTIONS TO MACHINE ARE SHOWN
ON SHEET 4 WITH THE CONNECTOR ON SHEET 4 WITH THE CONNECTOR
REFERNCE "CB_CC" REFERNCE "CB_CC"
1.50 mm² 303C
1.50 mm² 303D

1.50 mm² 303A
1.50 mm² 303B
1.50 mm² 303E
0.75 mm² 1604
0.75 mm² 1818
0.50 mm² 1821
0.50 mm² 1822
0.50 mm² 1824
0.50 mm² 1825

-CB_NX
28/35
31/35
14/35
19/35
18/35
2/35
4/35
6/35
3/35
5/35
7/35
332/F8042
LOADER ECU CONNECTOR 1
332/F0181
C
VBATT 2/35
VBATT 3/35
4/35
GND VBATT 5/35
GND VBATT 6/35
DIN 2 22/35
DIN3 10/35
DIN4 21/35
-VREF 14/35
+5VREF 28/35
AN IN 3 31/35
AN IN 4 19/35
DIN 5 9/35
AN IN 1 7/35
AN IN 2 18/35
DIN 8 8/35
C
VBATT
DIN1 VIGN
A (H)
LSOUT18
A (L)
HSOUT8
35/35 LSOUT17
HSOUT6
26/35 HSOUT7
HSOUT5
13/35 HSOUT4
HSOUT3
CAN SH
GND
34/35 CAN
33/35 CAN
24/35
25/35
27/35
20/35
23/35
11/35
15/35
16/35
17/35
12/35
1/35
15/35
16/35
17/35
13/35
24/35
35/35
25/35
26/35
12/35
11/35
27/35
1/35
From Splice CB_S59

0.75 mm² 1810
0.75 mm² 1600
0.75 mm² 1812
0.75 mm² 1813
0.75 mm² 1601

0.75 mm² 1811
126 0.50 mm² 117P

/3.F3 FROM
7219/0221 7219/0218 7213/0031 REAR DIVERTER SOL
To Earth Splice GND -CB_DH -FC_NF -FC_NO
1.50 mm² 600L 1.00 mm² 863 1.00 mm² 863 0.75 mm² 606 #1438
/14.B1 TO
A/3 A/3 C/3 C/3

TO
/14.E4
20/62 20/62
To Earth Splice GND
7219/0221
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
1.50 mm² 600K

/14.B1 TO
23/62
To Earth Splice GND 7212/0052

2/62
4/62
6/62
3/62
5/62
7219/0055 332/R4343 TOW HITCH SOL

B /14.B1 TO 1.50 mm² 600J -CB_FZ -RC_ML -RC_MV
1.00 mm² 868 1.00 mm² 868
1/2 1/2 2/2 2/2
1.00 mm² 6001 TO
/14.B5 B
19/31 19/31
7219/0218
-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
2/62
3/62
4/62
5/62
6/62
23/62
CROWD SOLENOID 7216/0018 7216/0017

7212/0052 1.00 mm² 1601
-FC_ME -EH_PK 1.00 mm² 1601
-EH_NL -B154 1/2 -EH_PK -FC_ME 1/6 1/6
1.00 mm² 1600A 2/2 1.00 mm² 1810 1.00 mm² 1810
1.00 mm² 1600
1.00 mm² 1812

1.00 mm² 1811
2/2 1/2 2/6 2/6 7212/0052 LOWER SOLENOID

1.00 mm² 1813
-FC_ME -EH_PK 1.00 mm² 1813-EH_PG 1.00 mm² 1601B
DUMP SOLENOID 6/6 6/6 1/2 1/2 2/2 2/2 -EH_S125
7212/0052
-EH_S124 1.00 mm² 1600B
-EH_NM 2/2
-B153 1/2 1.00 mm² 1811
-EH_PK -FC_ME
2/2 1/2 3/6 3/6 7212/0052 LIFT SOLENOID
-FC_ME -EH_PK 1.00 mm² 1812 -EH_NN 1.00 mm² 1601A
-EH_PK -FC_ME 5/6 5/6 1/2 1/2 2/2 2/2
1.00 mm² 1600
4/6 4/6
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 27 9813/6500-1 33 - 27
33-28 33-29
1 2 3 4
MULTILEVER OPTION CONNECTIONS

BUCKET CNTRL LEVER LSL
AUXILIARY CONTROL LEVER LST 2 LEVERS
F DIFF LOCK 334/ T2821
KICKDOWN SW ERGO .MANUAL AUXLIARY LEVER 1 AUXLIARY LEVER 2 BUCKET LEVER ELEC DETENT OPTION
-B160 -B161 -B156 -B157 -B158 -B158

334/T4409 334/T4411 333/C3434 333/C3434
/5.F5 /5.F4
VOUT SEC
VOUT SEC
VOUT PRI
VOUT SEC
VOUT PRI
VOUT PRI
-VREF
+VREF
-VREF
+VREF
-VERF
+VREF
+BAT
+BAT
DOUT
DOUT
2/2
2/2
2/4
4/4
2/4
4/4
2/6
4/6
3/4
3/4
3/6
5/6
1/2
1/2
1/4
1/4
1/6
7214/0061
-EH_NW
-EH_NZ
7214/0061
7212/0052
7212/0052
7216/0018
7216/0018
-EH_NU
-EH_NU
-EH_MR
-EH_NK
2/2
1/2
2/2
1/2
1/4
2/4
3/4
4/4
1/4
2/4
3/4
4/4
1/6
2/6
3/6
4/6
5/6
7219/0055
-EH_LV
0.50 mm² 1604D
0.50 mm² 1818D
0.50 mm² 1604E
0.50 mm² 1818E

7/31 0.50 mm² 9532B
0.50 mm² 1604A
0.50 mm² 1818A

-EH_LV
0.50 mm² 1821
0.50 mm² 1822
0.50 mm² 610FA

8/31 0.50 mm² 9916V
E -EH_LV
1/31 0.50 mm² 651E
-EH_LV -EH_S3
2/31 0.50 mm² 1818C
-EH_LV -EH_S9 -EH_S129

3/31 0.50 mm² 1827
-EH_LV -EH_S128
4/31 0.50 mm² 1828
-EH_LV
5/31 0.50 mm² 1613
0.75 mm² 1604
0.75 mm² 1818

-EH_LV
6/31 0.50 mm² 1619
-EH_LV
9/31 0.50 mm² 1823
-EH_LV
12/31 0.50 mm² 1826
-EH_LV
D 10/31 0.50 mm² 890A
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
11/31 0.50 mm² 9916R
13/31
14/31
15/31
16/31
-CB_CC
-CB_CC
-CB_CC
-CB_CC
From Fuse FB4 BATT -CB_S63
13/31
14/31
15/31
16/31
CONNECTIONS TO MACHINE ARE SHOWN /1.A4 FROM 2.00 mm² 303
ON SHEET 4 WITH THE CONNECTOR
REFERNCE "CB_CC"
1.50 mm² 303C
1.50 mm² 303D

1.50 mm² 303A
1.50 mm² 303B
1.50 mm² 303E
0.75 mm² 1604
0.75 mm² 1818
0.50 mm² 1821
0.50 mm² 1822
Page 33-29
-CB_NX
28/35
31/35
14/35
19/35
2/35
4/35
6/35
3/35
5/35
332/F8042
LOADER ECU CONNECTOR
C
VBATT 2/35
VBATT 3/35
4/35
GND VBATT 5/35
6/35
DIN 2 22/35
DIN3 10/35
DIN4 21/35
-VREF 14/35
+5VREF 28/35
AN IN 3 31/35
AN IN 4 19/35
DIN 5 9/35
VBATT
GND VBATT
DIN1 VIGN
LSOUT18
HSOUT8
35/35 LSOUT17
25/35 HSOUT6
26/35 HSOUT7
HSOUT5
13/35 HSOUT4
GND
24/35
27/35
11/35
15/35
16/35
17/35
12/35
15/35
16/35
17/35
13/35
24/35
35/35
25/35
26/35
12/35
11/35
27/35
From Splice CB_S59
0.75 mm² 1810
0.75 mm² 1600
0.75 mm² 1812
0.75 mm² 1813
0.75 mm² 1601

0.75 mm² 1811
126 0.50 mm² 117P

/3.F3 FROM
To Earth Splice GND

1.50 mm² 600L
/14.B1 TO
To Earth Splice GND

7219/0221
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
-CB_DH
1.50 mm² 600K

/14.B1 TO
23/62
To Earth Splice GND

2/62
4/62
6/62
3/62
5/62
B /14.B1 TO 1.50 mm² 600J

7219/0218
-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
-FC_NF
2/62
3/62
4/62
5/62
6/62
23/62
CROWD SOLENOID
7212/0052
-EH_NL -B154 1/2 -EH_PK -FC_ME
1.00 mm² 1600A 2/2 1.00 mm² 1810 1.00 mm² 1810
1.00 mm² 1600
1.00 mm² 1812

1.00 mm² 1811
2/2 1/2 2/6 2/6
DUMP SOLENOID
7212/0052
-EH_S124 1.00 mm² 1600B
-EH_NM 2/2
-B153 1/2 1.00 mm² 1811
-EH_PK -FC_ME
2/2 1/2 3/6 3/6
1.00 mm² 1600

-EH_PK -FC_ME
4/6 4/6
1 2 3 4
33 - 28 9813/6500-1 33 - 28
33-28 33-29
5 6 7 8
BUCKET CNTRL LEVER LSL BOOM CNTRL LEVER LSL PADDLE LEVER MOUNTED
334/ T2821 334/ T5033 WITH LEVER CONTROLS
ELEC DETENT OPTION BOOM LEVER ELEC DETENT OPTION F-N-R SW F
-B158 -B159 -B159 -B193
LEVER HORN SW 334/S6485
/5.F4 /5.F6 /5.F5 7219/0013
-EH_DX
VOUT PRI
VOUT SEC
-B136 2/10
2/10
2/2
-VERF
+VREF
1/2
0.50 mm² 9917 4/10
4/10
1/2
2/2
-EH_FU
6/6
2/6
4/6
6/6
5/6
3/6
5/6
1/6
7212/0052
6/10
5/10
3/10
1/10
7216/0018
7216/0018
7216/0018
-EH_NU
-EH_NV
-EH_NV
5/6
6/6
1/6
2/6
3/6
4/6
5/6
6/6
5/10
6/10
3/10
1/10
0.50 mm² 610FB
0.50 mm² 1604B
0.50 mm² 1818B

0.50 mm² 1823
0.50 mm² 1824
0.50 mm² 1825
0.50 mm² 1826

0.50 mm² 610FA
0.50 mm² 9916C
0.50 mm² 9543A
0.50 mm² 9542A
0.50 mm² 9541A

0.50 mm² 811A
0.50 mm² 105D
E
-EH_SJ16
0.50 mm² 610F
D
7219/0055
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
-EH_LV
25/31
26/31
20/31
23/31
22/31
21/31
17/31
18/31
19/31
-CB_CC
-CB_CC
-CB_CC
17/31
18/31
CONNECTIONS TO MACHINE ARE SHOWN

REFERNCE "CB_CC"
0.50 mm² 1824
0.50 mm² 1825

Page 33-28
18/35
7/35
LOADER ECU CONNECTOR 1
332/F0181
DIN 5 9/35
AN IN 1 7/35
AN IN 2 18/35
DIN 8 8/35
C
A (H)
LSOUT18
A (L)
HSOUT8
HSOUT6
26/35 HSOUT7
HSOUT3
CAN SH
34/35 CAN
33/35 CAN
27/35
20/35
23/35
12/35
1/35
25/35
26/35
12/35
27/35
1/35
0.75 mm² 1813
0.75 mm² 1601
7219/0221 7219/0218 7213/0031 REAR DIVERTER SOL

-CB_DH -FC_NF -FC_NO
1.00 mm² 863 1.00 mm² 863 0.75 mm² 606 #1438
A/3 A/3 C/3 C/3
TO
/14.E4
20/62 20/62
-CB_DH
-CB_DH
23/62
7212/0052
6/62
5/62
7219/0055 332/R4343 TOW HITCH SOL

-CB_FZ -RC_ML -RC_MV
1.00 mm² 868 1.00 mm² 868
1/2 1/2 2/2 2/2
1.00 mm² 6001 TO
/14.B5 B
19/31 19/31
-FC_NF
-FC_NF
5/62
6/62
23/62
7216/0018 7216/0017
1.00 mm² 1601
-FC_ME -EH_PK 1.00 mm² 1601
1/6 1/6
7212/0052 LOWER SOLENOID

1.00 mm² 1813
-FC_ME -EH_PK 1.00 mm² 1813-EH_PG 1.00 mm² 1601B
6/6 6/6 1/2 1/2 2/2 2/2 -EH_S125
7212/0052 LIFT SOLENOID

-FC_ME -EH_PK 1.00 mm² 1812 -EH_NN 1.00 mm² 1601A
5/6 5/6 1/2 1/2 2/2 2/2
335-C0779-7
5 6 7 8
33 - 29 9813/6500-1 33 - 29
33 - 30 9813/6500-1 33 - 30
Page 33-32 Figure 636. Gearbox ECU Page 33-33

1 2 3 4 5 6 7 8
0.50 mm² 9916M
F ZF TCU ZF DIAGNOSTIC PORT

0.75 mm² 9916T IGNITION TO FM-ERGOTRACTION RELAY From Fuse B3 BATT 1.00 mm² 9836 334/R5461 15/68 0.50 mm² 9644
7236/0009
-CB_GB 2/6
F
TO
/6.B5 /1.B4 FROM
SDDK
15/68 2/6
7219/0072 1/6
From Fuse B3 To Earth Splice
BATT -CB_DW 68/68 VEP2 4/6 3/6
1/6 GND
From Fuse A2 /1.A4 FROM 1.00 mm² 9832 EUPR 18/68 0.50 mm² 9652 0.50 mm² 630A TO
/14.C1
IGNITION 68/68 18/68 4/6 3/6
1.00 mm² 9916 0.50 mm² 9916A
/1.E4 FROM
To Earth Splice
-CB_S1 23/68 VPE1 VM1 1/68 1.00 mm² 600E GND
/14.B1
From Bucket Lever
TO
23/68 1/68
LH COLUMN SW Kickdown SW #771 To Earth Splice INT GEAR CHAIN SPEED SEND
0.50 mm² 9532B 45/68 VP1 VM2 2/68 1.00 mm² 600F GND -TP06:TW1 7212/0176
/4.D1 FROM
2/68
TO
/14.B1
45/68 -CB_GA -TE_XF -TP01:TW1 -TE_XD 717/20065
EF3 42/68 0.75 mm² 9420 0.75 mm² 9420 1/2
701/44200 42/68 3/62 3/62 1/2
10/10 0.50 mm² 9532 0.50 mm² 9532A 22/68 FUNCTION (ED7) -CB_GA -TE_XF
10/10 -CB_S10 22/68
7219/0001 3/10 0.50 mm² 9540 43/68 F (ED4) 0.75 mm² 9900D 1/62 1/62 0.75 mm² 9900H 2/2
-CB_DF 3/10 43/68 2/2
0.50 mm² 9916B 1/10 2/10 0.50 mm² 9548 67/68 N (ED6)
1/10 2/10 67/68
4/10 0.75 mm² 9544 64/68 R (ED5)
4/10 64/68
5/10 0.50 mm² 9528 63/68 B1 (ED1) TURBINE SPEED SENSOR
0.50 mm² 9916W
0.50 mm² 9916D
0.50 mm² 9916C

0.50 mm² 9916S
0.50 mm² 9916P
0.50 mm² 9916K
0.50 mm² 9916V

0.50 mm² 9916F
0.50 mm² 9916L
5/10 63/68
6/10 0.50 mm² 9524 65/68 B2 (ED2) -TP05:TW1 7212/0013
6/10 65/68 -CB_GA -TE_XF -TP02:TW1 -TE_XC
EP2 41/68 0.75 mm² 9410 0.75 mm² 9410 1/2
41/68 4/62 4/62 1/2
-CB_GA -TE_XF
E 0.75 mm² 9900C 2/62 2/62 0.75 mm² 9900G 2/2
2/2 E
To Ergotraction Sw Manual ENGINE SPEED SENSOR
IGNITION -TP04:TW1 7212/0034
TO
/4.E1
-CB_GA -TE_XF -TP03:TW1 -TE_XB
To Bucket Lever Kickdown EF1 19/68 0.75 mm² 9400 0.75 mm² 9400 1/2
IGNITION 19/68 5/62 5/62 1/2
TO
/4.D1
-CB_GA -TE_XF
VMG1 3/68 0.75 mm² 9900A 0.75 mm² 9900B 0.75 mm² 9900E 2/2
IGNITION To Aux Control Lever 3/68 6/62 6/62 2/2
TO
/4.E1 -CB_S55
JOYSTICK FNR #770 PARK BRK SOL

0.50 mm² 9541A 44/68 F (ED8)
/4.E1 TO
44/68
7212/0052
JOYSTICK FNR #766 -CB_FZ -RC_ML -RC_MK 25/223225
0.50 mm² 9542A 20/68 N (ED3) ADM5 57/68 1.00 mm² 848 1.00 mm² 848 2/2 1/2
/4.E1 TO
20/68 57/68 13/31 13/31 2/2 1/2

-CB_S12 -CB_FZ -RC_ML
VPS2 8/68 1.00 mm² 893A 1.00 mm² 893 1.00 mm² 893
8/68 14/31 14/31
VPS2 53/68 1.00 mm² 893C
JOYSTICK FNR #765 53/68 LOCKUP CLUTCH SOL
0.50 mm² 9543A 31/68 R (ED13)
/4.E1 TO
31/68
7212/0044
-CB_GA -TE_XF -TE_XH
D 0.75 mm² 893D
8/62
0.75 mm² 893D 1/2 2/2
2/2
8/62 1/2
D
ARM POSITION SW 50/68 0.75 mm² 891 -CB_GA -TE_XF 0.75 mm² 891
AIP7 50/68 7/62
(LOCKUP) 7/62
7219/0218 332/C8166 GEARBOX

7219/0221 7214/0025
-CB_DH -FC_NF 0.75 mm² 9916F
-FC_NI 1/4 2/4 0.75 mm² 9860
-FC_NF -CB_DH 0.50 mm² 9860 59/68 7219/0078
21/62 21/62 1/4 2/4 22/62 22/62 59/68 ED15 -CB_GA -TE_XF -TE_XE
56/68 0.50 mm² 9430 0.75 mm² 9430 1/16
AIP1
#1438 To Earth Splice (NO INPUT= LOCKUP ENABLED) 56/68 -CB_GA 10/62 1/16
4/4 0.75 mm² 605 10/68 0.50 mm² 9434 0.75 mm² 9434 2/16
4/4
TO
/14.E4 AIP2 10/68 9/62 2/16
32/68 0.50 mm² 9438 -CB_GA 0.75 mm² 9438 3/16
AIP3 32/68 11/62
-CB_GA 3/16
55/68 0.50 mm² 9442 0.75 mm² 9442 4/16
AIP4 55/68 12/62
-CB_GA 4/16
9/68 0.50 mm² 9446 0.75 mm² 9446 5/16
AIP5
SPEED SENSOR 51/68
9/68
0.50 mm² 9450 -CB_GA 13/62
0.75 mm² 9450
5/16
6/16
AIP6
7213/0024 12/68
51/68
0.50 mm² 9454A
-CB_S4 0.50 mm² 9454 -CB_GA 14/62
0.75 mm² 9454
6/16
7/16
VSP1 12/68 15/62 15/62
-CB_GA -TE_XF -TE_XA 3/3 1/3 -TE_XF -CB_GA 4/68 VMG2
7/16
0.75 mm² 9916K 0.75 mm² 9500 0.50 mm² 9500 VSP1 13/68 0.50 mm² 9454B
19/62 19/62 3/3 1/3 20/62 20/62 4/68 13/68 -CB_GA -TE_XF
ER1 39/68 0.50 mm² 9458 0.75 mm² 9458 8/16
-TE_XF -CB_GA 39/68 -CB_GA 16/62 -TE_S8 8/16
2/3 0.75 mm² 9504 0.50 mm² 9504 62/68 EF4 VMGA2 46/68 0.50 mm² 9462 1.00 mm² 9462A 0.75 mm² 9462C 9/16
2/3 21/62 21/62 62/68 46/68 17/62 17/62 9/16
0.75 mm² 9462B

C
PARK BRAKE SW FILTER BIPASS PRE SW C
7213/0031 7212/0044
-CB_FZ -RC_ML -RC_MZ -CB_GA -TE_XF -TE_XG
-RC_ML -CB_FZ
0.75 mm² 9462D

0.75 mm² 9916P A/3 C/3 0.75 mm² 9821 0.50 mm² 9821 35/68 ED14 ER3 17/68 0.50 mm² 9580 0.75 mm² 9580A 1/2 2/2
11/31 11/31 A/3 C/3 12/31 12/31 35/68 17/68 24/62 24/62 1/2 2/2
332/W8383
GND To Earth Splice
B/3 0.75 mm² 650E
0.50 mm² 893B

B/3
TO
/14.C5
TORQUE CONVERTER
ICCO/BRAKE SW TEMP SENDER
-CB_DH -FC_NF 7214/0025
0.75 mm² 9916S -FC_CE 1/4 2/4 0.75 mm² 600M GND To ECU Earth 7212/0013
2/4
TO
/14.A1 -CB_GA -TE_XF -TE_XJ
32/62 32/62 1/4
334/T0070 ER2 49/68 0.50 mm² 9570 0.75 mm² 9570 1/2 2/2
4/4 0.75 mm² 9464 -FC_NF -CB_DH 0.50 mm² 9464 38/68 38/68 EU1
49/68 18/62 18/62 1/2 2/2
4/4 33/62 33/62
846 To I/O Module
3/4 0.75 mm² 846
3/4
TO
/11.D1
PARKBRAKE SWITCH
400/C3365
CANHF_H 25/68
B GND To Earth Splice
6/6 6/6 0.50 mm² 610A TO
/14.F1
651 FROM JOYSTICK
B
7236/0017 CANF_L 26/68 -R9 0.50 mm² 890A FROM
/4.E1
-CB_DM 3/6 3/6 0.50 mm² 9820A
-CB_S30 0.50 mm² 9820 21/68ED10
0.50 mm² 9916D 2/6 2/6
21/68 ERGOTRACTION
RELAY ERGOTRACTION SOL. (LB)
FROM S1 SPLICE 9
TO SPLICE S71
IGNITION0.75 mm² 9916T 6 7 1.00 mm² 890 0.75 mm² 890 0.75 mm² 890 1/2 1/2 2/2 2/2 0.75 mm² 600CX 0.75 mm² 600CX
/6.F2 FROM
28/62 28/62 1/2 1/2 2/2 2/2

TO
/14.E4
#1438
-CB_DH -FC_NF -FC_NR -ER_LA -ER_LA -FC_NR
66/68 8 10
ED9 (INPUT=ICCO OFF)
7/68 -CB_FM
ADM2 7241/0003
29/68ED11 TRAILER & ERGOTRAC RLY
7212/0034
-CB_KA PARKBRAKE 30/68ED12 ADM6 11/68 11/68 0.50 mm² 892
0.50 mm² 9916W 1/2 1/2 2/2 2/2 0.50 mm² 9820B
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 31 9813/6500-1 33 - 31
33-32 33-33
1 2 3 4
0.50 mm² 9916M
F ZF TCU
IGNITION TO FM-ERGOTRACTION RELAY From Fuse B3 BATT
0.75 mm² 9916T TO
/6.B5 /1.B4 FROM 1.00 mm² 9836 334/R5461
SDDK
15/68
7219/0072
From Fuse B3 BATT -CB_DW
1.00 mm² 9832 68/68 VEP2 EUPR 18/68
From Fuse A2 /1.A4 FROM
68/68
IGNITION 1.00 mm² 9916 0.50 mm² 9916A
/1.E4 FROM
-CB_S1 23/68 VPE1 VM1 1/68

From Bucket Lever 23/68
LH COLUMN SW Kickdown SW #771
0.50 mm² 9532B 45/68 VP1 VM2 2/68
/4.D1 FROM
45/68
EF3 42/68
701/44200 10/10 0.50 mm² 9532 0.50 mm² 9532A 22/68 FUNCTION (ED7)
10/10 -CB_S10 22/68
7219/0001 3/10 0.50 mm² 9540 43/68 F (ED4)
-CB_DF 3/10 43/68
0.50 mm² 9916B 1/10 2/10 0.50 mm² 9548 67/68 N (ED6)
1/10 2/10 67/68
4/10 0.75 mm² 9544 64/68 R (ED5)
4/10 64/68
5/10 0.50 mm² 9528 63/68 B1 (ED1)
0.50 mm² 9916W
0.50 mm² 9916D
0.50 mm² 9916C

0.50 mm² 9916S
0.50 mm² 9916P
0.50 mm² 9916K
0.50 mm² 9916V

0.50 mm² 9916F
0.50 mm² 9916L
5/10 63/68
6/10 0.50 mm² 9524 65/68 B2 (ED2)
6/10 65/68
EP2 41/68
To Ergotraction Sw Manual
IGNITION TO
/4.E1
To Bucket Lever Kickdown EF1 19/68
IGNITION TO
/4.D1
VMG1 3/68
IGNITION To Aux Control Lever
TO
/4.E1
JOYSTICK FNR #770 0.50 mm² 9541A 44/68 F (ED8)
/4.E1 TO
44/68
JOYSTICK FNR #766 20/68 N (ED3)
/4.E1 TO 0.50 mm² 9542A ADM5 57/68
20/68
VPS2 8/68
VPS2 53/68
JOYSTICK FNR #765 0.50 mm² 9543A 31/68 R (ED13)
/4.E1 TO
31/68
D
ARM POSITION SW AIP7
50/68
(LOCKUP)
7219/0221 7219/0218 7214/0025 332/C8166

-CB_DH -FC_NF 0.75 mm² 9916F
-FC_NI 1/4 2/4 0.75 mm² 9860
-FC_NF -CB_DH 0.50 mm² 9860 59/68
21/62 21/62 1/4 2/4 22/62 22/62 59/68 ED15 56/68
AIP1
#1438 To Earth Splice (NO INPUT= LOCKUP ENABLED)
4/4 0.75 mm² 605 10/68
4/4
TO
/14.E4 AIP2
32/68
AIP3
55/68
Page 33-33
AIP4
9/68
AIP5
SPEED SENSOR 51/68
AIP6
7213/0024 12/68
VSP1
-CB_GA -TE_XF -TE_XA 3/3 1/3 -TE_XF -CB_GA 4/68 VMG2
0.75 mm² 9916K 0.75 mm² 9500 0.50 mm² 9500 VSP1 13/68
19/62 19/62 3/3 1/3 20/62 20/62 4/68
ER1 39/68
2/3 0.75 mm² 9504 -TE_XF -CB_GA 0.50 mm² 9504 62/68 EF4 VMGA2 46/68
2/3 21/62 21/62 62/68
C
PARK BRAKE SW
7213/0031
-CB_FZ -RC_ML -RC_MZ -RC_ML -CB_FZ
0.75 mm² 9916P A/3 C/3 0.75 mm² 9821 0.50 mm² 9821 35/68 ED14 ER3 17/68
11/31 11/31 A/3 C/3 12/31 12/31 35/68
332/W8383
GND To Earth Splice
B/3 0.75 mm² 650E
B/3
TO
/14.C5
ICCO/BRAKE SW
-CB_DH -FC_NF 7214/0025
0.75 mm² 9916S -FC_CE 1/4 2/4 0.75 mm² 600M GND To ECU Earth
2/4
TO
/14.A1
32/62 32/62 1/4
334/T0070 ER2 49/68
4/4 0.75 mm² 9464 -FC_NF -CB_DH 0.50 mm² 9464 38/68 38/68 EU1
4/4 33/62 33/62
846 To I/O Module
3/4 0.75 mm² 846
3/4
TO
/11.D1
PARKBRAKE SWITCH
400/C3365
CANHF_H 25/68
B 6/6 6/6 0.50 mm² 610A GND To Earth Splice
TO
/14.F1
7236/0017 CANF_L 26/68
-CB_DM 3/6 3/6 0.50 mm² 9820A
-CB_S30 0.50 mm² 9820 21/68ED10
21/68
0.50 mm² 9916D 2/6 2/6
66/68
7/68
ADM2
29/68ED11
7212/0034
-CB_KA PARKBRAKE 30/68ED12 ADM6 11/68
0.50 mm² 9916W 1/2 1/2 2/2 2/2 0.50 mm² 9820B
1 2 3 4
33 - 32 9813/6500-1 33 - 32
33-32 33-33
5 6 7 8
ZF TCU ZF DIAGNOSTIC PORT

334/R5461 15/68 0.50 mm² 9644
7236/0009
-CB_GB 2/6
F
SDDK 2/6
15/68
1/6
1/6 To Earth Splice
68/68 VEP2 4/6 3/6 GND
EUPR 18/68 0.50 mm² 9652 0.50 mm² 630A TO
/14.C1
18/68 4/6 3/6
To Earth Splice
23/68 VPE1 VM1 1/68 1.00 mm² 600E GND
1/68
TO
/14.B1
To Earth Splice INT GEAR CHAIN SPEED SEND
45/68 VP1 VM2 2/68 1.00 mm² 600F GND -TP06:TW1 7212/0176
TO
/14.B1
2/68 -CB_GA -TE_XF -TP01:TW1 -TE_XD 717/20065
EF3 42/68 0.75 mm² 9420 0.75 mm² 9420 1/2
42/68 3/62 3/62 1/2
22/68 FUNCTION (ED7) -CB_GA -TE_XF
43/68 F (ED4) 0.75 mm² 9900D 1/62 1/62 0.75 mm² 9900H 2/2
2/2
67/68 N (ED6)
64/68 R (ED5)
63/68 B1 (ED1) TURBINE SPEED SENSOR
65/68 B2 (ED2) -TP05:TW1 7212/0013
EP2 41/68 0.75 mm² 9410 -CB_GA -TE_XF -TP02:TW1 0.75 mm² 9410 -TE_XC 1/2
41/68 4/62 4/62 1/2
-CB_GA -TE_XF
0.75 mm² 9900C 2/62 2/62 0.75 mm² 9900G 2/2
2/2 E
ENGINE SPEED SENSOR
-TP04:TW1 7212/0034
-CB_GA -TE_XF -TP03:TW1 -TE_XB
EF1 19/68 0.75 mm² 9400 0.75 mm² 9400 1/2
19/68 5/62 5/62 1/2
-CB_GA -TE_XF
VMG1 3/68 0.75 mm² 9900A 0.75 mm² 9900B 0.75 mm² 9900E 2/2
3/68 6/62 6/62 2/2
-CB_S55
PARK BRK SOL

44/68 F (ED8)
7212/0052
-CB_FZ -RC_ML -RC_MK 25/223225
20/68 N (ED3) ADM5 57/68 1.00 mm² 848 1.00 mm² 848 2/2 1/2
57/68 13/31 13/31 2/2 1/2
-CB_S12 -CB_FZ -RC_ML
VPS2 8/68 1.00 mm² 893A 1.00 mm² 893 1.00 mm² 893
8/68 14/31 14/31
VPS2 53/68 1.00 mm² 893C
53/68 LOCKUP CLUTCH SOL
31/68 R (ED13)
7212/0044
0.75 mm² 893D -CB_GA -TE_XF 0.75 mm² 893D
-TE_XH 1/2 2/2
8/62 2/2
8/62 1/2
D
50/68 0.75 mm² 891 -CB_GA -TE_XF 0.75 mm² 891
AIP7 50/68 7/62
7/62
GEARBOX
59/68 7219/0078
ED15 56/68 0.50 mm² 9430 -CB_GA -TE_XF 0.75 mm² 9430 -TE_XE 1/16
O INPUT= LOCKUP ENABLED) AIP1 56/68 10/62
-CB_GA 1/16
10/68 0.50 mm² 9434 0.75 mm² 9434 2/16
AIP2 10/68 9/62
-CB_GA 2/16
32/68 0.50 mm² 9438 0.75 mm² 9438 3/16
AIP3 32/68 11/62
-CB_GA 3/16
55/68 0.50 mm² 9442 0.75 mm² 9442 4/16
Page 33-32
AIP4 55/68 12/62

-CB_GA 4/16
9/68 0.50 mm² 9446 0.75 mm² 9446 5/16
AIP5 9/68 13/62
-CB_GA 5/16
51/68 0.50 mm² 9450 0.75 mm² 9450 6/16
AIP6
12/68
51/68
0.50 mm² 9454A
-CB_S4 0.50 mm² 9454 -CB_GA 14/62
0.75 mm² 9454
6/16
7/16
VSP1 12/68 15/62 15/62 7/16
VMG2 VSP1 13/68 0.50 mm² 9454B
13/68 -CB_GA -TE_XF
ER1 39/68 0.50 mm² 9458 0.75 mm² 9458 8/16
39/68 -CB_GA 16/62 -TE_S8 8/16
62/68 EF4 VMGA2 46/68 0.50 mm² 9462 1.00 mm² 9462A 0.75 mm² 9462C 9/16
46/68 17/62 17/62 9/16
0.75 mm² 9462B
FILTER BIPASS PRE SW C

7212/0044
-CB_GA -TE_XF -TE_XG
0.75 mm² 9462D
35/68 ED14 ER3 17/68 0.50 mm² 9580 0.75 mm² 9580A 1/2 2/2
17/68 24/62 24/62 1/2 2/2
0.50 mm² 893B
TORQUE CONVERTER
TEMP SENDER
7212/0013
-CB_GA -TE_XF -TE_XJ
ER2 49/68 0.50 mm² 9570 0.75 mm² 9570 1/2 2/2
49/68 18/62 18/62 1/2 2/2
38/68 EU1
CANHF_H 25/68
651 FROM JOYSTICK

B
CANF_L 26/68 -R9 0.50 mm² 890A FROM
/4.E1
21/68ED10
ERGOTRACTION
RELAY ERGOTRACTION SOL. (LB)
FROM S1 SPLICE 9
TO SPLICE S71
IGNITION0.75 mm² 9916T 6 7 1.00 mm² 890 0.75 mm² 890 0.75 mm² 890 1/2 1/2 2/2 2/2 0.75 mm² 600CX 0.75 mm² 600CX
/6.F2 FROM
28/62 28/62 1/2 1/2 2/2 2/2

TO
/14.E4
#1438
-CB_DH -FC_NF -FC_NR -ER_LA -ER_LA -FC_NR
66/68 8 10
-CB_FM
ADM2 7241/0003
29/68ED11 TRAILER & ERGOTRAC RLY
30/68ED12 ADM6 11/68 11/68 0.50 mm² 892
335-C0779-7
5 6 7 8
33 - 33 9813/6500-1 33 - 33
33 - 34 9813/6500-1 33 - 34
Page 33-36 Figure 637. Engine ECU Page 33-37

1 2 3 4 5 6 7 8
-R11
FROM ALTERNATOR IGNITION 1.00 mm² 133A HTR RELAY - 1
/1.F8 FROM
-CB_S90 4 SPLICE_DEF HTR PIPE 1

-CB_GA -TE_XF
F FROM FUSE FA7 BATT 1.50 mm² 370 1.00 mm² 370A 1 2 1.00 mm² 362 1.00 mm² 362
-TE_S96
1.00 mm² 362B
/1.C4 FROM
52/62 52/62
F
-CB_S92
SPLICE_DEF PIPE HTR 1.00 mm² 370B 3 5 0.50 mm² 365C
ENGINE ECU J2 CONN
-TE_JM
0.75 mm² 362A
TO STARTER LOCKOUT RELAY #1156 0.75 mm² 522 83/94 -CB_EK SPLICE_DEF PIPE RELAYS
/1.E7 TO
7241/0003
1/31
83/120
From Fuse FA5 IGNITION -R12

-CB_GA -TE_XF 5/94 HTR RELAY - 2
-AFT_JN
1.00 mm² 133 1.00 mm² 133 1.00 mm² 133B
/1.D4 FROM
29/62 29/62 9 SPLICE_DEF HTR PIPE 2
1/31
-TE_S11 5/120 -CB_GA -TE_XF
FROM SPLICE CB_S78 125 SPLICE_ IGN 6 7 -TE_S95
1.00 mm² 521A 76/94 1.00 mm² 370C 1.00 mm² 361 1.00 mm² 361 1.00 mm² 361B
GRID HEATER RELAY /1.E7 FROM
76/120 51/62 51/62
-TE_JM
7207/1316 7207/1316 7211/0006 7207/1316 GRID HEATER
7211/0030 8 10
-MU-A -MR -GY -GZ -GX 1.00 mm² 370D 0.50 mm² 365B
FROM BATTERY POSITIVE
2/31
#1189 M6 1/1 1/1 1/1
16.00 mm² R 16.00 mm² 999 1/1 1/1 16.00 mm² 991
/1.F5 FROM
M6 M6 -CB_EK
7241/0003
-AFT_JN
7212/0044
-R13
2/31
-CB_FZ -RC_ML -RC_BH -RC_ML -CB_FZ -CB_GA -TE_XF
FROM SPLICE CB_S78 125 -B1 HTR RELAY - 3
1.00 mm² 521B 9/31 9/31 1.00 mm² 521B 2/2 1/2 1.00 mm² 518 1.00 mm² 518 1.00 mm² 518 75/94
/1.E7 FROM
E 2/2 1/2 31/31 31/31 37/62 37/62 75/120 9

-CB_GA -TE_XF -TE_JM -AFT_JN
1.00 mm² 680A 49/94 1.00 mm² 370E 6 7 1.00 mm² 360A 1.00 mm² 360A
-TE_S94 1.00 mm² 360 E
1.00 mm² 680B 49/120 50/94 54/62 54/62 3/31 3/31
1.00 mm² 361B
1.00 mm² 362B

1.00 mm² 360
1.00 mm² 680C 50/120 51/94 1.00 mm² 370F 8 10 0.50 mm² 365A
1.00 mm² 680D 51/120 52/94
1.00 mm² 680E 52/120 73/94 -CB_EG
AIR FILTER SW 7212/0013 332/V0520 7220/0058 332/W5209 7220/0061 7241/0003
-AFT_JB
-AFT_JB
-AFT_JB
73/120 40/94
FROM FRONT DISPLAY -CBA_JJ -CBR_JR -AFT_JB -AFT_JN -TE_JM 0.75 mm² 360B
432 0.75 mm² 413 1/2 2/2 0.75 mm² 680J 0.75 mm² 680J 0.75 mm² 680J 40/120
/2.E1 FROM
M/23
1/2
O/23
2/2
L/23
P/23 P/23 28/31 28/31 39/94 0.75 mm² 361A
39/120
FROM AC COMPRESSOR 600 SPLICE EARTH
0.75 mm² 680T 38/94 0.75 mm² 362A
-CBR_JR
-CBR_JR
-CBR_JR
/8.A6 FROM
-TE_S69
L/23
M/23
O/23
38/120
TO TRANS/ENGINE EARTH 600 4.00 mm² 680
Need to confirm twisted DEF DOSING
/14.D3 332/W5209
pairs used (TP24). 7220/0061
TO
7212/0148
VALVE
-TP24:TW1 -TE_JM -AFT_JN -AFT_EE 7212/0052
FROM CAN SPLICE CAN SHLD 1.00 mm² 571 46/94 77/94 1.00 mm² 7101 15/31 15/31 1.00 mm² 7101 1/2 -CBA_EP HOSE HTR 3
/16.B4 FROM
46/120 77/120 1/2 2/2

1.00 mm² 352A
-B6 1/2 1.00 mm² 360
FROM CAN SPLICE CAN H 1.00 mm² 570 22/94 53/94 1.00 mm² 7102 16/31 16/31 1.00 mm² 7102 2/2 2/2 1/2
ELECTR. THROTTLE PEDAL /16.B4 FROM
-B21
D 7216/0059
7219/0219 7219/0075 22/120 53/120 2/2
-CB_JX -CB_GA -TE_XF 7212/0052 D

CAN- H SPLICE_DEF HTR CURRENT HOSE HTR 2
A/6 0.75 mm² 511 0.50 mm² 511 10/94 -TE_JM -AFT_JN -AFT_JB -CBR_JR -CBA_EN
27/62 27/62 -TE_S62
A/6 10/120 84/94 2/2
-CB_GA -TE_XF
0.75 mm² 351 1.00 mm² 352 1.00 mm² 352 1.00 mm² 352 1.00 mm² 352B
-B7 1/2 1.00 mm² 361B
B/6 0.75 mm² 512 0.50 mm² 512 33/94 84/120 20/31 20/31 N/23 N/23 -CBA_S97 2/2 1/2
28/62 28/62
B/6 33/120
-CB_GA -TE_XF
C/6 0.75 mm² 510 0.50 mm² 510 GND
9/94 GND 85/94 0.75 mm² 350
7212/0052
22/62 22/62
C/6 9/120 85/120 -CBA_EL HOSE HTR 1
-CB_GA -TE_XF
D/6 2/2
0.75 mm² 514A
41/62 41/62
0.50 mm² 514A 1.00 mm² 352C
-B8 1/2 1.00 mm² 362B
D/6 -TE_XF -CB_GA 2/2 1/2
-CB_GA -TE_XF
E/6 0.75 mm² 513 0.50 mm² 513 64/94 GND 3/94 0.75 mm² 365 0.75 mm² 365
-B9 36/62 36/62
43/62 43/62
E/6 64/120 3/120
-CB_GA -TE_XF
F/6 0.75 mm² 515 0.50 mm² 515 61/94
33/62 33/62 7212/0052
F/6 61/120 WATER IN FUEL
-TE_S36 -TE_JF
COOLANT LEVEL 1.00 mm² 514 8/94 13/94 0.75 mm² 519 1/2
SPLICE_SENSOR SUPPLY 5V HF- GND -B178
SENSOR 7213/0047
8/120 13/120 1/2
-CBA_ES -CBR_JR -AFT_JB -AFT_JN -TE_JM 334/S6606
A/3 1.00 mm² 514B 1.00 mm² 514B 13/31 13/31 1.00 mm² 514B 62/94 0.75 mm² 520 2/2
A/3 U/23 U/23 -AFT_JN -TE_JM 62/120 2/2
C B/3 1.00 mm² 532 1.00 mm² 532 12/31 12/31 0.75 mm² 532 35/94 -CB_GA -TE_XF -TE_JM -AFT_JN
B/3 V/23 V/23 -AFT_JN -TE_JM
SPLICE_OEM SENSOR RETURN 35/120 FROM FUSE FC8 100 1.00 mm² 114 1.00 mm² 114 C
-B31 -TE_S89 /1.D7 FROM
C/3 1.00 mm² 533A 1.00 mm² 533A 11/31 11/31 1.00 mm² 533A 0.75 mm² 533 32/94 26/62 26/62 17/31 17/31
7214/0091
C/3 W/23 W/23 32/120 -AFT_EH SRC TEMP
1.00 mm² 680P 1/4 -B14 4/4 1.00 mm² 114A
1.00 mm² 114

1/4 4/4
7214/0079 SRC NOX SENSOR
DEF SUPPLY MODULE -CBA_EB
7219/0224 332/V0520 7220/0058 -AFT_EC
-CBR_JR -AFT_JB -AFT_JN -TE_JM 1.00 mm² 680M 4/4 -B15 1/4 1.00 mm² 114B
-AFT_JB -CBR_JR 4/12 1.00 mm² 533B 1.00 mm² 533B 1.00 mm² 533B 4/4 1/4
A/23 A/23 10/31 10/31
1.00 mm² 680F 1.00 mm² 680F 6/12 4/12
-CBR_JR -AFT_JB -AFT_JN -TE_JM 7214/0080
DOC NOX SENSOR
J/23 J/23 6/12 2/12 1.00 mm² 514C 1.00 mm² 514C 1.00 mm² 514C -AFT_ER
B/23 B/23 9/31 9/31
-TE_JM -AFT_JN -AFT_JB -CBR_JR 2/12 -AFT_S32 1.00 mm² 680H 4/4 -B16 1/4 1.00 mm² 114C -AFT_S85
-CBR_JR -AFT_JB -AFT_JN -TE_JM
1.00 mm² 7013 14/31 14/31 1.00 mm² 7013 1.00 mm² 7013 5/12 3/12 1.00 mm² 7003 1.00 mm² 7003 0.75 mm² 7003 16/94 4/4 1/4
C/23 C/23 8/31 8/31 7214/0092 DOC TEMP
H/23 H/23 5/12 3/12 16/120
-CBR_JR -AFT_JB -AFT_JN -TE_JM -AFT_EJ
8/12 1.00 mm² 7007 1.00 mm² 7007 0.75 mm² 7007 54/94 1.00 mm² 680G 1/4 -B17 4/4 1.00 mm² 114D
D/23 D/23 7/31 7/31
-TE_XF -CB_GA 8/12 54/120 1/4 4/4
53/62 53/62 9/12 1.00 mm² 7009 1.00 mm² 7009 0.75 mm² 7009 79/94 7214/0025
E/23 E/23 4/31 4/31 DEF SUPPLY TANK
9/12 79/120 -AFT_ED
B -CBR_JR -AFT_JB -AFT_JN -TE_JM
-R15
10/12 1.00 mm² 7010
F/23 F/23
1.00 mm² 7010
6/31 6/31
0.75 mm² 7010 6/94 1.00 mm² 680R 4/4
/17.F5
3/4 1.00 mm² 114E B
10/12 6/120 4/4 3/4
DEF MODULE RELAY -CBR_JR -AFT_JB -AFT_JN -TE_JM
11/12 1.00 mm² 7011 1.00 mm² 7011 0.75 mm² 7011 81/94
4 -B11 G/23 G/23 5/31 5/31 600 TO ENGINE EARTH TE_JT
11/12 81/120 1.00 mm² 680N
-CBR_JR -AFT_JB
TO
/14.D1
FROM FUSE FA8 BATT 1.00 mm² 410 1 2 1.00 mm² 7013 12/12 1.00 mm² 7012A 1.00 mm² 7012A 1.00 mm² 680F
/1.C4 FROM
K/23 K/23
12/12 SPLICE_+VE BATT FEED
-CB_GA -TE_XF -TE_SA1 From Primary Fuse 9
1.00 mm² 410A 3 5 1.00 mm² 7014 COOLANT FLOW VALVE 7214/0087 -AFT_JN -TE_JM 28/94 1.00 mm² 320E 4.00 mm² 320 #888
-AFT_GE 28/120 /1.F5
FROM
50/62 50/62 4/4 1.00 mm² 7012B 1.00 mm² 7012 0.75 mm² 7012 57/94 27/94 1.00 mm² 320D
-CB_EG -B12 25/31 25/31 27/120
4/4 -AFT_S76 57/120 26/94 1.00 mm² 320C
7241/0003 -AFT_JN -TE_JM 26/120
1/4 1.00 mm² 7201 0.75 mm² 7201 82/94 25/94 1.00 mm² 320B
26/31 26/31 25/120
1/4 82/120 1/94 1.00 mm² 320A
1/120
0.75 mm² 7014 7/120 7/94
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 35 9813/6500-1 33 - 35
33-36 33-37
1 2 3 4
FROM ALTERNATOR IGNITION 1.00 mm² 133A

/1.F8 FROM
F FROM FUSE FA7 BATT 1.50 mm² 370

/1.C4 FROM
TO STARTER LOCKOUT RELAY #1156 0.75 mm² 522

/1.E7 TO
83/120
From Fuse FA5 IGNITION -CB_GA -TE_XF

1.00 mm² 133 1.00 mm² 133 1.00 mm² 133B
/1.D4 FROM
29/62 29/62
-TE_S11 5/120
FROM SPLICE CB_S78 125 SPLICE_ IGN 1.00 mm² 521A
GRID HEATER RELAY /1.E7 FROM
76/120
7207/1316 7207/1316 7211/0006 7207/1316 GRID HEATER
7211/0030
-MU-A -MR -GY -GZ -GX
FROM BATTERY POSITIVE #1189 16.00 mm² R
M6 1/1 1/1 16.00 mm² 999 1/1 1/1 16.00 mm² 991 1/1
/1.F5 FROM
M6 M6
7212/0044
-CB_FZ -RC_ML -RC_BH -RC_ML -CB_FZ -CB_GA -TE_XF
FROM SPLICE CB_S78 125 -B1
1.00 mm² 521B 9/31 9/31 1.00 mm² 521B 2/2 1/2 1.00 mm² 518 1.00 mm² 518 1.00 mm² 518
/1.E7 FROM
E 2/2 1/2 31/31 31/31 37/62 37/62 75/120

1.00 mm² 680A
1.00 mm² 680B 49/120
1.00 mm² 680C 50/120
1.00 mm² 680D 51/120
1.00 mm² 680E 52/120
7212/0013 332/V0520 7220/0058 332/W5209 7220/0061
AIR FILTER SW 73/120
FROM FRONT DISPLAY -CBA_JJ -CBR_JR -AFT_JB -AFT_JN -TE_JM
432 0.75 mm² 413 1/2 2/2 0.75 mm² 680J 0.75 mm² 680J 0.75 mm² 680J
/2.E1 FROM
1/2 2/2
P/23 P/23 28/31 28/31
FROM AC COMPRESSOR 600 SPLICE EARTH

0.75 mm² 680T
/8.A6 FROM
-TE_S69
TO TRANS/ENGINE EARTH 600 4.00 mm² 680
Need to confirm twisted
/14.D3
pairs used (TP24).
TO
FROM CAN SPLICE CAN SHLD -TP24:TW1

1.00 mm² 571
/16.B4 FROM
46/120
FROM CAN SPLICE CAN H 1.00 mm² 570
ELECTR. THROTTLE PEDAL /16.B4 FROM
D 7216/0059
7219/0219 7219/0075 22/120
-CB_JX -CB_GA -TE_XF

A/6 0.75 mm² 511 0.50 mm² 511
27/62 27/62
A/6 10/120
-CB_GA -TE_XF
B/6 0.75 mm² 512 0.50 mm² 512
28/62 28/62
B/6 33/120
-CB_GA -TE_XF
C/6 0.75 mm² 510 0.50 mm² 510
22/62 22/62
C/6 9/120
-CB_GA -TE_XF
D/6 0.75 mm² 514A 0.50 mm² 514A
41/62 41/62
D/6
Page 33-37
-CB_GA -TE_XF
E/6 0.75 mm² 513 0.50 mm² 513
-B9 36/62 36/62
E/6 64/120
-CB_GA -TE_XF
F/6 0.75 mm² 515 0.50 mm² 515
33/62 33/62
F/6 61/120
COOLANT LEVEL -TE_S36
1.00 mm² 514
SPLICE_SENSOR SUPPLY 5V
SENSOR 7213/0047
8/120
-CBA_ES -CBR_JR -AFT_JB -AFT_JN -TE_JM
A/3 1.00 mm² 514B 1.00 mm² 514B 13/31 13/31 1.00 mm² 514B
A/3 U/23 U/23 -AFT_JN -TE_JM
C B/3 1.00 mm² 532 1.00 mm² 532 12/31 12/31 0.75 mm² 532
B/3 V/23 V/23 SPLICE_OEM SENSOR RETURN 35/120
-B31 -AFT_JN -TE_JM -TE_S89
C/3 1.00 mm² 533A 1.00 mm² 533A 11/31 11/31 1.00 mm² 533A 0.75 mm² 533
C/3 W/23 W/23 32/120
7219/0224 332/V0520 7220/0058

DEF SUPPLY MODULE -CBA_EB
-AFT_JB -CBR_JR 4/12 1.00 mm² 533B 1.00 mm² 533B 1.00 mm² 533B
A/23 A/23 10/31 10/31
1.00 mm² 680F 1.00 mm² 680F 6/12 4/12
J/23 J/23 6/12 2/12 1.00 mm² 514C 1.00 mm² 514C 1.00 mm² 514C
B/23 B/23 9/31 9/31
-TE_JM -AFT_JN -AFT_JB -CBR_JR 2/12
1.00 mm² 7013 14/31 14/31 1.00 mm² 7013 1.00 mm² 7013 5/12 3/12 1.00 mm² 7003 1.00 mm² 7003 0.75 mm² 7003
C/23 C/23 8/31 8/31
H/23 H/23 5/12 3/12 16/120
8/12 1.00 mm² 7007 1.00 mm² 7007 0.75 mm² 7007
D/23 D/23 7/31 7/31
-TE_XF -CB_GA 8/12 54/120
53/62 53/62 9/12 1.00 mm² 7009 1.00 mm² 7009 0.75 mm² 7009
E/23 E/23 4/31 4/31
9/12 79/120
B 10/12 1.00 mm² 7010
-CBR_JR -AFT_JB
1.00 mm² 7010
-AFT_JN -TE_JM
0.75 mm² 7010
-R15 F/23 F/23 6/31 6/31
10/12 6/120
DEF MODULE RELAY -CBR_JR -AFT_JB -AFT_JN -TE_JM
11/12 1.00 mm² 7011 1.00 mm² 7011 0.75 mm² 7011
4 -B11 G/23 G/23 5/31 5/31
11/12 81/120
FROM FUSE FA8 BATT 1 2 -CBR_JR -AFT_JB
1.00 mm² 410 1.00 mm² 7013 12/12 1.00 mm² 7012A 1.00 mm² 7012A
/1.C4 FROM
K/23 K/23
-CB_GA -TE_XF 12/12
1.00 mm² 410A 3 5 1.00 mm² 7014 COOLANT FLOW VALVE 7214/0087 -AFT_JN -TE_JM
-AFT_GE
50/62 50/62 4/4 1.00 mm² 7012B 1.00 mm² 7012 0.75 mm² 7012
-CB_EG -B12 25/31 25/31
4/4 -AFT_S76 57/120
7241/0003 -AFT_JN -TE_JM
1/4 1.00 mm² 7201 0.75 mm² 7201
1/4 26/31 26/31 82/120
0.75 mm² 7014 7/120
1 2 3 4
33 - 36 9813/6500-1 33 - 36
33-36 33-37
5 6 7 8
-R11
HTR RELAY - 1
-CB_S90 4 SPLICE_DEF HTR PIPE 1
-CB_GA -TE_XF -TE_S96
1.50 mm² 370 1.00 mm² 370A 1 2 1.00 mm² 362 1.00 mm² 362 1.00 mm² 362B
52/62 52/62
F
-CB_S92
SPLICE_DEF PIPE HTR 1.00 mm² 370B 3 5 0.50 mm² 365C
ENGINE ECU J2 CONN
-TE_JM
0.75 mm² 362A
0.75 mm² 522 83/94 -CB_EK SPLICE_DEF PIPE RELAYS
7241/0003
1/31
83/120
-R12
5/94 HTR RELAY - 2
-AFT_JN
1.00 mm² 133B
9 SPLICE_DEF HTR PIPE 2
1/31
5/120 -CB_GA -TE_XF
6 7 -TE_S95
1.00 mm² 521A 76/94 1.00 mm² 370C 1.00 mm² 361 1.00 mm² 361 1.00 mm² 361B
76/120 51/62 51/62
-TE_JM
1.00 mm² 370D 8 10 0.50 mm² 365B
2/31
-CB_EK
7241/0003
-AFT_JN
-R13
2/31
HTR RELAY - 3
1.00 mm² 518 75/94
75/120 9
-CB_GA -TE_XF -TE_JM -AFT_JN
1.00 mm² 680A 49/94 1.00 mm² 370E 6 7 1.00 mm² 360A 1.00 mm² 360A
-TE_S94 1.00 mm² 360 E
1.00 mm² 680B 49/120 50/94 54/62 54/62 3/31 3/31
1.00 mm² 361B
1.00 mm² 362B

1.00 mm² 360
1.00 mm² 680C 50/120 51/94 1.00 mm² 370F 8 10 0.50 mm² 365A
1.00 mm² 680D 51/120 52/94
1.00 mm² 680E 52/120 73/94 -CB_EG
7241/0003
-AFT_JB
-AFT_JB
-AFT_JB
73/120 40/94 0.75 mm² 360B
40/120
M/23
O/23
L/23
39/94 0.75 mm² 361A
39/120
SPLICE EARTH 38/94 0.75 mm² 362A
-CBR_JR
-CBR_JR
-CBR_JR
L/23
M/23
O/23
38/120
Need to confirm twisted DEF DOSING
332/W5209
pairs used (TP24). 7220/0061 7212/0148
VALVE
-TE_JM -AFT_JN -AFT_EE 7212/0052
1.00 mm² 571 46/94 77/94 1.00 mm² 7101 15/31 15/31 1.00 mm² 7101 1/2 -CBA_EP HOSE HTR 3
46/120 77/120 1/2 2/2
1.00 mm² 352A
-B6 1/2 1.00 mm² 360
1.00 mm² 570 22/94 53/94 1.00 mm² 7102 16/31 16/31 1.00 mm² 7102 2/2 2/2 1/2
-B21
22/120 53/120 2/2
7212/0052 D
CAN- H SPLICE_DEF HTR CURRENT HOSE HTR 2
0.50 mm² 511 10/94 -TE_JM -AFT_JN -AFT_JB -CBR_JR -CBA_EN
-TE_S62
10/120 84/94 0.75 mm² 351 1.00 mm² 352 1.00 mm² 352 1.00 mm² 352 1.00 mm² 352B 2/2 1/2 1.00 mm² 361B
-B7
0.50 mm² 512 33/94 84/120 20/31 20/31 N/23 N/23 -CBA_S97 2/2 1/2
33/120
0.50 mm² 510 GND
9/94 GND 85/94 0.75 mm² 350
7212/0052
9/120 85/120 -CBA_EL HOSE HTR 1
2/2
1.00 mm² 352C
-B8 1/2 1.00 mm² 362B
-TE_XF -CB_GA 2/2 1/2

Page 33-36
0.50 mm² 513 64/94 GND 3/94 0.75 mm² 365 0.75 mm² 365
64/120 3/120 43/62 43/62
0.50 mm² 515 61/94
7212/0052
61/120 WATER IN FUEL
-TE_S36 -TE_JF
1.00 mm² 514 8/94 HF- GND 13/94 0.75 mm² 519 1/2
SPLICE_SENSOR SUPPLY 5V -B178
8/120 13/120 1/2 334/S6606
62/94 0.75 mm² 520 2/2
62/120 2/2
35/94 -CB_GA -TE_XF -TE_JM -AFT_JN
SPLICE_OEM SENSOR RETURN 35/120 FROM FUSE FC8 100 1.00 mm² 114 1.00 mm² 114 C
-TE_S89 /1.D7 FROM
0.75 mm² 533 32/94 26/62 26/62 17/31 17/31

7214/0091
32/120 -AFT_EH SRC TEMP
1.00 mm² 680P 1/4 -B14 4/4 1.00 mm² 114A
1.00 mm² 114
1/4 4/4
7214/0079 SRC NOX SENSOR
-AFT_EC
1.00 mm² 680M 4/4 -B15 1/4 1.00 mm² 114B
1.00 mm² 533B 4/4 1/4
7214/0080
DOC NOX SENSOR
1.00 mm² 514C -AFT_ER
-AFT_S32 1.00 mm² 680H 4/4 -B16 1/4 1.00 mm² 114C -AFT_S85
0.75 mm² 7003 16/94 4/4 1/4
7214/0092 DOC TEMP
16/120
-AFT_EJ
0.75 mm² 7007 54/94 1.00 mm² 680G 1/4 -B17 4/4 1.00 mm² 114D
54/120 1/4 4/4
0.75 mm² 7009 79/94 7214/0025
79/120 DEF SUPPLY TANK
-AFT_ED
0.75 mm² 7010 6/94 1.00 mm² 680R 4/4
/17.F5
3/4 1.00 mm² 114E B
6/120 4/4 3/4
0.75 mm² 7011 81/94
81/120 1.00 mm² 680N 600 TO ENGINE EARTH TE_JT
TO
/14.D1
1.00 mm² 680F
SPLICE_+VE BATT FEED
-TE_SA1 #888 From Primary Fuse 9
-TE_JM 28/94 1.00 mm² 320E 4.00 mm² 320
/1.F5
FROM
28/120
0.75 mm² 7012 57/94 27/94 1.00 mm² 320D
25/31 27/120
57/120 26/94 1.00 mm² 320C
-TE_JM 26/120
0.75 mm² 7201 82/94 25/94 1.00 mm² 320B
26/31 25/120
82/120 1/94 1.00 mm² 320A
1/120
7/120 7/94
335-C0779-7
5 6 7 8
33 - 37 9813/6500-1 33 - 37
33 - 38 9813/6500-1 33 - 38
Page 33-40 Figure 638. Automatic

Temperature Control (ATC) Page 33-41
1 2 3 4 5 6 7 8
ATC HARNESS CKT

BLOWER MOTOR
F 7212/0064 7212/0063 7216/0064
From Fuse FC9 112 2.50 mm² 112
-CB_DP_F -ATC_DP_M 2.00 mm² 112
-ATC_BM A/6 334/T2669 7212/0063 7212/0064
F
/1.B7 FROM
1/2 -CB_DP_F To Earth Splice

1/2 A/6 -ATC_DP_M 3.00 mm² 610 GND TO
/14.F1
CLIMATE CONTROL UNIT 2/2 2/2
7216/0064 Pins wire C/6
C/6 2.00 mm² 610CA
334/T2669 size issue.
332/F8042
-ATC_DT
BLOWER PWM 35/35 0.50 mm² 1135 F/6
35/35 F/6
DUCT TEMP GND 19/35 0.50 mm² 2119 D/6

19/35 D/6 CAB AIR THERMISTOR
DUCT AIR TEMP 7/35 0.50 mm² 1107 E/6 7212/0166
7/35 E/6
-ATC_B37A
CAB AIR TEMP 10/35 0.50 mm² 1110A 0.50 mm² 1110A B/2 B/2
10/35
CAB AIT TEMP GND 17/35 0.50 mm² 1117A 0.50 mm² 1117A A/2 A/2
17/35
THERMOSTATE PROBE
3.00 mm² 610

E 7212/0005
11/35 0.50 mm² 1111
-ATC_B211 2/2 Part of ATC E
THERMOSTATE PROBE
11/35 B/2
1/2
THERMO PROBE GND 16/35 0.50 mm² 1116
16/35 A/2
HIGH PRESS. TRANSDUCER

320/09643
-ATC_B210
PRESS TRANS SIGNAL30/35 1.00 mm² 1130 C/3
30/35 C/3
+5 VDC REF 28/35 1.00 mm² 1128 B/3

28/35 B/3
PRESS TRANS GND 18/35 1.00 mm² 1118 A/3

18/35 A/3
WATER VALVE ACTR
7214/0025
-ATC_A23
D 0.50 mm² 109G 1/4 4/4 1.00 mm² 610B -ATC_SJ13
1/4
334/S1489
4/4
D
WATER VALVE CNTRL
33/35 1.00 mm² 1133 2/4
33/35 2/4
WV ACTUATOR FB 8/35 1.00 mm² 1108 3/4

8/35 3/4
FAN REQUEST PRESS. SW
7212/0070 7218/0012 7218/0013

-ATC_S6 -ATC_DC To Management ECU
13/35 0.75 mm² 109C 0.50 mm² 109E -ATC_DN A/2 B/2 0.50 mm² 874
-CB_AH 0.50 mm² 874 874
POWER IN
13/35 A/2 B/2 4/8
/3.D5
TO
4/8
CLUTCH RELAY IN 4/35 0.50 mm² 109D

4/35
23/35
CAN H
RECIRC. DOOR ACTUATOR

7214/0025
26/35 0.50 mm² 109F
-ATC_A22 1/4 Part of ATC 4/4 0.50 mm² 610A
C CAN L
1/4 4/4
FRESH / RECIRC CNTRL 15/35 0.50 mm² 1115 2/4 C

15/35 2/4
F / R ACTUATOR FB 9/35 0.50 mm² 1109 3/4

9/35 3/4
SCREEN VENT DOOR ACTR
7214/0025
0.50 mm² 109L
-ATC_VD1 1/4 4/4 0.50 mm² 610SA
1/4 4/4
Part of ATC
DEFROST DOOR 1 25/35 0.50 mm² 1131 2/4
25/35 2/4
DEFROST DOOR 1 FB
31/35 0.50 mm² 1125 3/4
31/35 3/4
REVERSE RADAR
7213/0031 112 From Fuse FC10
0.75 mm² 109
-ATC_RR1 /1.B7
FROM
0.50 mm² 109N A/3 C/3 C/3 0.50 mm² 610SB

A/3 -R21
DEFROST DOOR 2 32/35 B/3 333/S5959
B 0.50 mm² 844A
B/3 RELAY COMPRESSOR
9
B
7219/0219 7219/0075
6 7 0.75 mm² 860 -CB_GA -TE_XF
7218/0012 23/62 23/62
7218/0013
-ATC_DC -CB_AH 8 10 GND
To Earth Splice
5/35 0.50 mm² 1105 0.50 mm² 869 0.50 mm² 630D
CLUTCH RELAY OUT
5/35
TO
/14.C1
2/8 2/8
7212/0167 -CB_FE
B/2 -ATC_DT2 2.00 mm² 610C 7241/0003
B/2
AUTOLUB/ COMPRESSOR CLUTCH

7214/0025 7214/0060 AUTOLUBE I/F
From Fuse FC10 112 -CB_AH -ATC_DC WEIGHTLOAD 7212/0052
/1.B7 FROM 0.75 mm² 109A 0.50 mm² 109A -ATC_GVA -ATC_VG -B172
3/8 3/8
1/4 1/4 1.50 mm² 104 1/4 1/4 TO SPLICE S69 6000.75 mm² 680T 2/2 1/2
-TE_JK 0.75 mm² 860
FROM I/O MODULE REV SIGNAL -CB_AH -ATC_DC /7.E3 TO
1/2
REV 0.75 mm² 844A 1/8 1/8 2/4 2/4 1.50 mm² 610L 2/4 2/4 2/2
/10.E6 FROM
3/4 3/4 0.75 mm² 852B 3/4 3/4

30/926343
4/4 4/4 0.75 mm² 113 4/4 4/4
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 39 9813/6500-1 33 - 39
33-40 33-41
1 2 3 4
ATC HARNESS CKT

BLOWER MOTOR
F 7212/0064 7212/0063 7216/0064
From Fuse FC9 112 2.50 mm² 112
-CB_DP_F -ATC_DP_M 2.00 mm² 112
-ATC_BM A/6 334/T2669
/1.B7 FROM
1/2 1/2 A/6
CLIMATE CONTROL UNIT

7216/0064 Pins wire C/6
C/6 2.00 mm² 610CA
334/T2669 size issue.
332/F8042
-ATC_DT
BLOWER PWM 35/35 0.50 mm² 1135 F/6
35/35 F/6
DUCT TEMP GND 19/35 0.50 mm² 2119 D/6

19/35 D/6
DUCT AIR TEMP 7/35 0.50 mm² 1107 E/6 7212/0166

7/35 E/6
-ATC_B37A
CAB AIR TEMP 10/35 0.50 mm² 1110A 0.50 mm² 1110A B/2
10/35
CAB AIT TEMP GND 17/35 0.50 mm² 1117A 0.50 mm² 1117A A/2
17/35
THERMOSTATE PROBE
E 7212/0005
-ATC_B211 2/2 Part of ATC
11/35 0.50 mm² 1111
THERMOSTATE PROBE
11/35 B/2
1/2
THERMO PROBE GND 16/35 0.50 mm² 1116
16/35 A/2
HIGH PRESS. TRANSDUCER

320/09643
-ATC_B210
PRESS TRANS SIGNAL30/35 1.00 mm² 1130 C/3
30/35 C/3
+5 VDC REF 28/35 1.00 mm² 1128 B/3

28/35 B/3
PRESS TRANS GND 18/35 1.00 mm² 1118 A/3

18/35 A/3
WATER VALVE ACTR
7214/0025
-ATC_A23
D 0.50 mm² 109G
1/4
1/4 4/4
334/S1489
WATER VALVE CNTRL
33/35 1.00 mm² 1133 2/4
33/35 2/4
WV ACTUATOR FB 8/35 1.00 mm² 1108 3/4

8/35 3/4
7212/0070
Page 33-41
13/35 0.75 mm² 109C
-ATC_S6 0.50 mm² 109E -ATC_DN A/2 B/2
POWER IN
13/35 A/2 B/2
CLUTCH RELAY IN 4/35 0.50 mm² 109D

4/35
23/35
CAN H

7214/0025
26/35 0.50 mm² 109F
-ATC_A22 1/4 Part of ATC 4/4
C CAN L
1/4 4/4
FRESH / RECIRC CNTRL 15/35 0.50 mm² 1115 2/4

15/35 2/4
F / R ACTUATOR FB 9/35 0.50 mm² 1109 3/4

9/35 3/4
SCREEN VENT DOOR AC
7214/0025
0.50 mm² 109L
-ATC_VD1
1/4
DEFROST DOOR 1 25/35 0.50 mm² 1131

25/35 2/4
DEFROST DOOR 1 FB
31/35 0.50 mm² 1125
31/35 3/4
REVERSE RADAR
7213/0031
0.50 mm² 109N

-ATC_RR1 A/3 C/3 C/3
A/3
DEFROST DOOR 2 32/35 B/3

B 0.50 mm² 844A
B/3
CLUTCH RELAY OUT

5/35 0.50 mm² 1105
5/35
7212/0167
B/2 -ATC_DT2 2.00 mm² 610C
B/2
AUTOLUB/
From Fuse FC10 112 WEIGHTLOAD 7214/0025
-CB_AH -ATC_DC
/1.B7 FROM 0.75 mm² 109A 0.50 mm² 109A -ATC_GVA
3/8 3/8
-CB_AH -ATC_DC 1/4 1/4 1.50 mm²
FROM I/O MODULE REV SIGNAL
REV 0.75 mm² 844A 1/8 1/8 2/4 2/4 1.50 mm²
/10.E6 FROM
3/4 3/4 0.75 mm²

4/4 4/4 0.75 mm²
1 2 3 4
33 - 40 9813/6500-1 33 - 40
33-40 33-41
5 6 7 8
7212/0063 7212/0064
F
-ATC_DP_M -CB_DP_F GND To Earth Splice
3.00 mm² 610
2/2 2/2
TO
/14.F1
2.00 mm² 610CA
CAB AIR THERMISTOR
7212/0166
-ATC_B37A
0.50 mm² 1110A B/2 B/2
0.50 mm² 1117A A/2 A/2

3.00 mm² 610
WATER VALVE ACTR
-ATC_A23 1/4 4/4 1.00 mm² 610B -ATC_SJ13

334/S1489
4/4
D
2/4
3/4

7218/0012 7218/0013
To Management ECU
Page 33-40
B/2 0.50 mm² 874

-ATC_DC -CB_AH 0.50 mm² 874 874
B/2 4/8
/3.D5
TO
4/8
Part of ATC 4/4 0.50 mm² 610A

4/4
C
SCREEN VENT DOOR ACTR

7214/0025
-ATC_VD1 1/4 4/4 0.50 mm² 610SA
1/4 4/4
Part of ATC
2/4
2/4
3/4
3/4
REVERSE RADAR
112 From Fuse FC10
0.75 mm² 109
/1.B7
FROM
C/3 C/3 0.50 mm² 610SB

-R21
333/S5959
RELAY COMPRESSOR
9
B
7219/0219 7219/0075
6 7 0.75 mm² 860 -CB_GA -TE_XF
7218/0012 23/62 23/62
7218/0013
-ATC_DC -CB_AH 8 10 GND
To Earth Splice
0.50 mm² 869 0.50 mm² 630D TO
/14.C1
2/8 2/8
-CB_FE
7241/0003
COMPRESSOR CLUTCH
7214/0025 7214/0060 AUTOLUBE I/F 7212/0052
-ATC_GVA -ATC_VG -B172
1/4 1.50 mm² 104 1/4 1/4 TO SPLICE S69 6000.75 mm² 680T 2/2 1/2
-TE_JK 0.75 mm² 860
/7.E3 TO
1/2
2/4 1.50 mm² 610L 2/4 2/4 2/2
3/4 0.75 mm² 852B 3/4 3/4

30/926343
4/4 0.75 mm² 113 4/4 4/4
335-C0779-7
5 6 7 8
33 - 41 9813/6500-1 33 - 41
33 - 42 9813/6500-1 33 - 42
Page 33-44 Figure 639. HVAC Page 33-45

1 2 3 4 5 6 7 8
HVAC HARNESS CONNECTIONS
F HEATER MOTOR SW HVAC UNIT
-B140 7216/0064 can not take 2.5 Sqmm. 7216/0064 -B141

F
334/S5839 4/5 2.00 mm² 820 -HV_AC1 D/6
7235/0006 L/5 D/6 7212/0063
7212/0063
-HV_DP_M -HV_AC2 -HV_SJ1 -HV_DP_M
2.50 mm² 112 1/5 5/5 2.00 mm² 821 B/6 C/6 2.00 mm² 610C 3.00 mm² 610
1/2 B/5 M/5 B/6 C/6 2/2
-BC45 SPLICE EARTH
3/5 2.00 mm² 822 A/6
H/5 A/6
2/5 1.00 mm² 843
ON SHEET 8 WITH THE CONNECTOR C/5
REFERNCE "CB_DP"
HVAC CONTROL PANEL
-B100
E 334/S7138 7218/0071
1/8 -HV_HV E
1/8
6/8 0.50 mm² 610H

6/8
THERMOSTAT
8/8 8/8 0.50 mm² 610W
-B142
7213/0047 C/3 0.50 mm² 610X
-HV_DS C/3 HI-LO BINARY SW
2/8 0.50 mm² 840 A/3
2/8 A/3 7218/0012
7212/0070 -B147
-HV_EF 701/80231 -HV_DC_M
B/3 0.50 mm² 841 A/2 B/2 0.50 mm² 869
B/3 A/2 B/2 2/8
FRESH / RECIRC. DOOR ACTR

-B143
Part of HVAC
3/4 4/4 0.50 mm² 610A
4/4
D 7214/0025
3/8 0.50 mm² 2015 -HV_FD 2/4 D
3/8 2/4
0.50 mm² 109F 1/4

1/4 AUTOLUB/
7214/0025 7214/0060
WEIGHTLOAD AUTOLUBE I/F
-HV_GVA -HV_VG
1/4 1/4 1.50 mm² 104 1/4 1/4
2/4 2/4 1.50 mm² 610L 2/4 2/4

SCRN VENT DOOR ACTUATOR 1
-B1 -B2
-B144 3/4 3/4 0.75 mm² 852B 3/4 3/4
3/4 4/4 0.50 mm² 610SA
7214/0025 4/4
Part of HVAC 4/4 4/4 0.75 mm² 113 4/4 4/4
4/8 0.50 mm² 2018 -HV_VD1 2/4
4/8 2/4
0.50 mm² 1069L 1/4

1/4
C
REVERSE RADAR C
-B146
C/3 0.50 mm² 610SB
7213/0031 C/3
-HV_RR2 B/3
B/3
0.50 mm² 109N A/3

A/3
WATER VALVE ACTUATOR

7214/0025
-B145
-HV_WV
5/8 0.50 mm² 2033 2/4 4/4 0.50 mm² 610B
5/8 2/4 4/4
REFERNCE "CB_DC" 7/8 7/8 0.50 mm² 109M
7218/0012 0.50 mm² 109G 1/4

1/4
B -HV_DC_M
1/8 0.50 mm² 844A
FAN REQUEST PRESS. SW B
7218/0012 7212/0070 7218/0012
-HV_DC_M -HV_DN -B184 -HV_DC_M
0.50 mm² 109A 0.75 mm² 109E A/2 B/2 0.75 mm² 874
3/8 A/2 B/2 4/8
-HV_SJ6
SPLICE 24V
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 43 9813/6500-1 33 - 43
33-44 33-45
1 2 3 4
HVAC HARNESS CONNECTIONS
F HEATER MOTOR SW HVAC UNIT
-B140 7216/0064 can not take 2.5 Sqmm. 7216/0064 -B141

334/S5839 4/5 2.00 mm² 820 -HV_AC1 D/6
7235/0006 L/5 D/6
7212/0063
-HV_DP_M -HV_AC2
2.50 mm² 112 1/5 5/5 2.00 mm² 821 B/6
1/2 B/5 M/5 B/6
-BC45
3/5 2.00 mm² 822 A/6
H/5 A/6
2/5 1.00 mm² 843
ON SHEET 8 WITH THE CONNECTOR C/5
REFERNCE "CB_DP"
HVAC CONTROL PANEL
-B100
E 334/S7138 7218/0071
1/8 -HV_HV
1/8
6/8 0.50 mm² 610H

6/8
THERMOSTAT
8/8 8/8 0.50 mm² 610W
-B142
7213/0047
2/8 0.50 mm² 840 -HV_DS A/3
2/8 A/3

-B143
Part of HVAC
3/4
D 7214/0025
-HV_FD
3/8 0.50 mm² 2015 2/4
3/8 2/4
0.50 mm² 109F 1/4

1/4
Page 33-45
-B144
3/4
7214/0025
Part of HVAC
4/8 0.50 mm² 2018 -HV_VD1 2/4
4/8 2/4
0.50 mm² 1069L 1/4

1/4
7213/0031
-HV_RR2
B/3
0.50 mm² 109N

A/3

7214/0025
-B145
-HV_WV
5/8 0.50 mm² 2033 2/4 4/4
5/8 2/4
REFERNCE "CB_DC" 7/8 7/8 0.50 mm² 109M
7218/0012 0.50 mm² 109G 1/4

1/4
B -HV_DC_M
1/8 0.50 mm² 844A
7218/0012 7212/0070
-HV_DC_M -HV_DN -B184
0.50 mm² 109A 0.75 mm² 109E A/2 B/2
3/8 A/2
-HV_SJ6
SPLICE 24V
1 2 3 4
33 - 44 9813/6500-1 33 - 44
33-44 33-45
5 6 7 8
HVAC UNIT
-B141
F
D/6
7212/0063
-HV_SJ1 -HV_DP_M
B/6 C/6 2.00 mm² 610C 3.00 mm² 610
C/6 2/2
-BC45 SPLICE EARTH
A/6
THERMOSTAT
-B142
7213/0047 C/3 0.50 mm² 610X
-HV_DS C/3 HI-LO BINARY SW
A/3
A/3 7218/0012
7212/0070 -B147
-HV_EF 701/80231 -HV_DC_M
B/3 0.50 mm² 841 A/2 B/2 0.50 mm² 869
B/3 A/2 B/2 2/8

-B143
Part of HVAC
3/4 4/4 0.50 mm² 610A
7214/0025 4/4
-HV_FD 2/4 D
2/4
1/4
1/4 AUTOLUB/
7214/0025 7214/0060
WEIGHTLOAD AUTOLUBE I/F
-HV_GVA -HV_VG
1/4 1/4 1.50 mm² 104 1/4 1/4
2/4 2/4 1.50 mm² 610L 2/4 2/4

Page 33-44
-B1 -B2
-B144 3/4 3/4 0.75 mm² 852B 3/4 3/4
3/4 4/4 0.50 mm² 610SA
7214/0025 4/4
Part of HVAC 4/4 4/4 0.75 mm² 113 4/4 4/4
-HV_VD1 2/4
2/4
1/4
1/4
REVERSE RADAR C
-B146
C/3 0.50 mm² 610SB
7213/0031 C/3
-HV_RR2 B/3
B/3
A/3
A/3

-B145
2/4 4/4 0.50 mm² 610B
4/4
1/4
FAN REQUEST PRESS. SW B

7218/0012
-B184 -HV_DC_M
A/2 B/2 0.75 mm² 874
B/2 4/8
335-C0779-7
5 6 7 8
33 - 45 9813/6500-1 33 - 45
33 - 46 9813/6500-1 33 - 46
Page 33-48 Figure 640. Front, Rear worklights and Beacon Page 33-49
1 2 3 4 5 6 7 8
LH OUTER FRONT W/L 1

I/O MODULE 1 7212/0052 -B206 To Earth Splice
F -CR_ECU1 1.50 mm² 809A -CR_RF 1/2 2/2 1.50 mm² 600AE 600
728/A3879 1/2 334/U0901 2/2

TO
/14.E6 F
7212/0063
From Primary Fuse PF5 -CB_YYY
-CB_S52 7212/0064
-CR_RE
BATT 4.00 mm² 316B 4.00 mm² 316C 1/2 1/2 4.00 mm² 316BB
/1.B3 FROM
7207/1302 RH OUTER FRONT W/L 2

-CR_CMA -CR_CM
4.00 mm² 316D 2/2 2/2 4.00 mm² 316BC 4.00 mm² 316BA 2/16 2.00 mm² 600AL 600 To Earth Splice 7212/0052 -B207
J3 Perm Supply V-Ground J1-2 TO
/14.F6 -CR_S38 To Earth Splice
-CR_S18 M6
1.50 mm² 809B -CR_DU 1/2 2/2 1.50 mm² 600AD 600
+5V Output Ref J1-11 TO
/14.E6
1/2 334/U0901 2/2
Ground
(for config address daisy chain) J1-15
J1-3 Config Address 3 (active low) 7219/0233
-CR_CMB 1.50 mm² 809
LH MIDDLE FRONT W/L 1
Channel 5 - 12V - 10A
J2-1
- 24V - 6A
1/12
7212/0112 J1-4 Config Address 1 (active low) 7212/0052 -B208 To Earth Splice
-CR_RD DOOR SW -CR_RC 600
-CR_CM 1.00 mm² 810A 1/2 2/2 1.00 mm² 600AF
/14.E6
-CB_CXR -CR_RXR J2-2 TO
334/U0901
- 24V - 6A
FROM SPLICE S31 BATT 0.50 mm² 305E 1/2
1/2 2/2
/12.D2 FROM 1.00 mm² 306
-B1142/2 1.00 mm² 877 5/16 J1-5 Input 3
10/14 10/14 1/2 2/2 Channel 8 - 12V - 10A

J2-3 1.50 mm² 854
- 24V - 6A
3/12
J1-6 Input 1
RH MIDDLE FRONT W/L 2
J2-4 1.00 mm² 823
E 4/12
- 24V - 6A
J1-7 -CR_RA -CB_DY 7212/0052 -B209 To Earth Splice

E
Analog Input 3
1.50 mm² 855 2.00 mm² 855 1.00 mm² 810B -CR_RG 1/2 2/2 1.00 mm² 600AC 600
/14.E6
J2-5 TO
334/U0901
- 24V - 6A
5/12 1/2 2/2
J1-8 Analog Input 1 9/14 9/14 -CR_S39
J2-6 1.50 mm² 810
- 24V - 6A
6/12 REV
TO SPLICE S50
-CR_RA -CB_DY 0.75 mm² 844B
-CB_S80 /11.C1
TO

J2-7 1.00 mm² 844 0.75 mm² 844
TO HVAC/ ATC
- 24V - 6A
7/12 10/14 10/14 REV
0.75 mm² 844A TO
/8.A1 LH FRONT INNER WL
J2-8 1.00 mm² 873
- 24V - 2.5A
8/12
J1-12 Config Address 2 (active low) -CR_RA -CB_DY 7212/0052 -B210 To Earth Splice
0.50 mm² 303 1.00 mm² 842A -CR_RH 1/2 2/2 1.00 mm² 600AA 600
/14.E6
J2-9 TO
334/U0901
- 24V - 2.5A
-CR_CM 9/12
7212/0052 STEP LIGHT 2/14 2/14 1/2 2/2
J1-13 Input 4
13/16 To Earth Splice
1.00 mm² 1841 -CR_TJ 600
Ignition Wake up
1/2 2/2 1.00 mm² 600AJ
J2-10
10/12 1/2
TO
/14.E6
-CR_CM RH FRONT INNER WL
- 24V - 2.5A
2/2
J1-14 Digital Input 2 (active high/low)
14/16
- 24V - 2.5A J2-11 0.50 mm² 304D 7212/0052 -B211 To Earth Splice
11/12 -CR_RJ 600
CAN Shield
1/2 2/2
CAN High
1.00 mm² 842B 1.00 mm² 600AB

CAN Low
J1-16 Analog Input 2 TO

/14.E6
1.50 mm² 842 -CR_S188 1/2 334/U0901 2/2
- 24V - 6A J2-12
J1-10
12/12
J1-9
J1-1
D WORKLAMP SPLITTER LH HARNESS

7212/0052 7212/0051
-CR_RK -RK -RWL_S81
7212/0052
-RWL_RK1
LH REAR WL 1
-RWL_S80 -RK -CR_RK D
1.00 mm² 461 1.00 mm² 854A 1/2 1/2 1.00 mm² 200 0.75 mm² 202 1/2 1/2 2/2 2/2 0.75 mm² 204 1.00 mm² 201 2/2 2/2
-B212
-CR_S189
1.00 mm² 460
335/D1532 1.00 mm² 600BS
-R20 7212/0052
333/S5959 LH REAR WL 2
-RWL_RK2 To Earth Splice
RELAY HEATED REAR SCREEN HEATED REAR SCREEN 0.75 mm² 203 1/2 1/2 2/2 2/2 0.75 mm² 205 600
/14.F6
-CR_RA
TO
9
7201/0403 334/R4096 7201/0403
-B3
From Fuse FB6 BATT To Earth Splice 335/D1532
7/14
2.00 mm² 490 6 7 2.00 mm² 495 -CB_HS1 1/1 1/1 -CB_HS2 2.00 mm² 630F GND
/1.B4 FROM
1/1 -B115 1/1

TO
/14.C1
0.50 mm² 873C 8 10 0.50 mm² 630H GND From IGN RLY 1 WORKLAMP SPLITTER RH HARNESS
/1.D7
-CB_DY
7212/0052 7212/0051 7212/0052
FROM
7/14
-CR_RL -RL -RWL_S82 -RWL_RK3 RH REAR WL 1 -RWL_S83 -RL -CR_RL
-CB_GR 1.00 mm² 854B 1/2 1/2 1.00 mm² 200 0.75 mm² 202 1/2 2/2 0.75 mm² 204 1.00 mm² 201 2/2 2/2
7241/0003 1/2 -B213 2/2
7219/0006 7219/0005 335/D1532
-CB_CXR -CR_RXR 1.00 mm² 600BR
-CR_S190
1.00 mm² 873A 1.00 mm² 873
7212/0052
3/14 3/14 -RWL_RK4 RH REAR WL 2

C 0.75 mm² 203 1/2 2/2 0.75 mm² 205 600 To Earth Splice
/14.F6
C
TO
1/2 -B4 2/2

335/D1532
MIRROR CONTROL JOYSTICK
332/R5228
FROM SPLICE CB_S73 -B119
7216/0019 LH HEATED MIRROR
-CB_CH -CR_RZ 7219/0029 7219/0189 7212/0052
IGNITION -CB_DY -CR_RA -B116
1/6 AUX WORKLIGHT
/13.D1 0.50 mm² 101A 4/8 6/8 0.50 mm² 450 0.50 mm² 450 -CB_PS -RC_PR -RC_MD
To Earth Splice
FROM
4/8 6/8 3/14 3/14 1/6 TO EARTH SPLICE S77

334/S3046 3/6 3/6 1.00 mm² 600AG 600 2.00 mm² 855 1/2 2/2 1.00 mm² 651F GND
TO
/14.E6 TO
/14.B5
1/8 0.50 mm² 451 -CB_DY -CR_RA 0.50 mm² 451 2/6 K/16 K/16 1/2 2/2
1/8 12/14 12/14 2/6
-CR_S197
7/8 0.50 mm² 452 -CB_DY -CR_RA 0.50 mm² 452 0.50 mm² 452A 5/6
7/8 5/6 BEACON
13/14 13/14
7232/0023
1.00 mm² 873B 6/6 -CR_RP
6/6 To Earth Splice
1.00 mm² 823 2/2 1/2 1.00 mm² 600CH 600 TO
/14.F6
2/2 333/T0717 1/2
332/S5515 -CB_RQR2
332/C2505
B TO WHITE LAMP RESISTOR
1 2
0.50 mm² 304EA 0.50 mm² 610EA B
-CB_RQR1
334/G3723
TO RED LAMP RESISTOR
7216/0019 RH HEATED MIRROR 0.50 mm² 303AA 1 2 0.50 mm² 610TA
-CB_DY -CR_RA -CR_TA 1/6 -B118
5/8 0.50 mm² 453 0.50 mm² 453 7234/0002
5/8 11/14 11/14 1/6 334/S3046 To Earth Splice
3/6 3/6 1.00 mm² 600AH600 -CB_RQ INTERIOR LIGHT
TO
/14.E6 To Earth Splice
2/8 0.50 mm² 454 -CB_DY -CR_RA 0.50 mm² 454 2/6 0.50 mm² 303 0.50 mm² 303A 1/4 -B219 3/4 0.50 mm² 610T 0.50 mm² 610X GND
2/8 14/14 14/14 2/6 1/4 3/4
TO
/14.F1
-CB_S56 334/S4834 -CB_S57
5/6 GND To Earth Splice
0.50 mm² 452B 0.50 mm² 304D 0.50 mm² 304E 2/4 2/4 4/4 0.50 mm² 610E 0.50 mm² 610Y
5/6
TO
/14.F1
-CB_S58 4/4 7201/0407 -CB_S60
1.00 mm² 873C 6/6 1/1 -CB_RQ1 0.50 mm² 460
7201/0407
6/6 From splice CB_S31 BATT -CB_RQ2 1/1
0.50 mm² 305B 1/1 7201/0407
To Earth Splice /12.D2 FROM
8/8 0.50 mm² 610D GND 1/1

1/1 -CB_RQ3 0.50 mm² 461
8/8
TO
/14.F1 7219/0005 7219/0006 1/1
-CR_RXR -CB_CXR
0.50 mm² 461
2/14 2/14
0.50 mm² 460
1/14 1/14
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 47 9813/6500-1 33 - 47
33-48 33-49
1 2 3 4
I/O MODULE 1
F -CR_ECU1
728/A3879
7212/0063
From Primary Fuse PF5 -CB_YYY
-CB_S52 7212/0064
-CR_RE
BATT 4.00 mm² 316B 4.00 mm² 316C 1/2 1/2 4.00 mm² 316BB
/1.B3 FROM
7207/1302
-CR_CMA -CR_CM
4.00 mm² 316D 2/2 2/2 4.00 mm² 316BC 4.00 mm² 316BA 2/16 2.00 mm² 600AL 600 To Earth Splice
M6
J3 Perm Supply V-Ground J1-2 TO
/14.F6
-CR_S18 +5V Output Ref J1-11
Ground
J1-3 Config Address 3 (active low) 7219/0233
-CR_CMB 1.50 mm² 809
J2-1
- 24V - 6A
1/12
7212/0112 J1-4 Config Address 1 (active low)
-CR_RD DOOR SW
-CB_CXR -CR_RXR -CR_CM Channel 4 - 12V - 10A
- 24V - 6A J2-2
FROM SPLICE S31 BATT 0.50 mm² 305E 1/2
/12.D2 FROM 1.00 mm² 306
-B1142/2 1.00 mm² 877 5/16 J1-5 Input 3
10/14 10/14 1/2 2/2 Channel 8 - 12V - 10A

J2-3 1.50 mm² 854
- 24V - 6A
3/12
J1-6 Input 1

J2-4 1.00 mm² 823
E 4/12
- 24V - 6A
J1-7 Analog Input 3

-CR_RA -CB_DY
J2-5 1.50 mm² 855
- 24V - 6A
5/12
J1-8 Analog Input 1 9/14 9/14
J2-6 1.50 mm² 810
- 24V - 6A
6/12
-CR_RA -CB_DY
J2-7 1.00 mm² 844
- 24V - 6A
7/12 10/14 10/14
J2-8 1.00 mm² 873
- 24V - 2.5A
8/12
J1-12 Config Address 2 (active low) -CR_RA -CB_DY
J2-9 0.50 mm² 303
- 24V - 2.5A
-CR_CM 9/12
7212/0052 STEP LIGHT 2/14 2/14
J1-13 Input 4
13/16
1.00 mm² 1841 -CR_TJ
Ignition Wake up
J2-10 1/2 2/2 1.00 mm²
-CR_CM
- 24V - 2.5A
10/12 1/2 2/2
14/16
Channel 3 - 12V - 5A 0.50 mm² 304D
- 24V - 2.5A J2-11
11/12
CAN Shield
CAN High
CAN Low
J1-16 Analog Input 2
1.50 mm² 842
- 24V - 6A J2-12
J1-10
12/12
J1-9
J1-1
D
1.00 mm² 461
1.00 mm² 460
-R20
333/S5959
RELAY HEATED REAR SCREEN HEATED REAR SCREEN
9 334/R4096
7201/0403 7201/0403
From Fuse FB6 BATT 6 7 -CB_HS1 -CB_HS2 GND To Earth Splice
2.00 mm² 490 2.00 mm² 495 1/1 1/1 2.00 mm² 630F
/1.B4 /14.C1
Page 33-49
-B115
FROM TO
1/1 1/1
0.50 mm² 873C 8 10 0.50 mm² 630H GND From IGN RLY 1
FROM
/1.D7
-CB_GR
7241/0003
7219/0006 7219/0005
-CB_CXR -CR_RXR -CR_S190
1.00 mm² 873A 1.00 mm² 873
3/14 3/14
C
MIRROR CONTROL JOYSTICK

332/R5228
FROM SPLICE CB_S73 -B119
7216/0019 LH HEATED MIRROR
-CB_CH -CR_RZ
IGNITION 0.50 mm² 101A 4/8 6/8 0.50 mm² 450 -CB_DY -CR_RA 0.50 mm² 450 -B116
1/6
/13.D1 FROM
6/8 3/14 3/14 1/6 To Earth Splice

4/8 334/S3046 3/6 600
3/6 1.00 mm² 600AG TO
/14.E6
1/8 0.50 mm² 451 -CB_DY -CR_RA 0.50 mm² 451 2/6
1/8 12/14 12/14 2/6
-CR_S197
7/8 0.50 mm² 452 -CB_DY -CR_RA 0.50 mm² 452 0.50 mm² 452A 5/6
7/8 5/6
13/14 13/14
1.00 mm² 873B 6/6
6/6
332/S5515
7216/0019 RH HEATED MIRROR

-CB_DY -CR_RA -CR_TA 1/6 -B118
5/8 0.50 mm² 453 0.50 mm² 453
5/8 11/14 11/14 1/6 334/S3046 To Earth Splice
3/6 3/6 1.00 mm² 600AH600 TO
/14.E6
2/8 0.50 mm² 454 -CB_DY -CR_RA 0.50 mm² 454 2/6
2/8 14/14 14/14 2/6
0.50 mm² 452B 5/6

5/6
1.00 mm² 873C 6/6

6/6
GND To Earth Splice

8/8 0.50 mm² 610D
8/8
TO
/14.F1
1 2 3 4
33 - 48 9813/6500-1 33 - 48
33-48 33-49
5 6 7 8
LH OUTER FRONT W/L 1

7212/0052 -B206 To Earth Splice
1.50 mm² 809A -CR_RF 1/2 2/2 1.50 mm² 600AE 600
1/2 334/U0901 2/2
TO
/14.E6 F
RH OUTER FRONT W/L 2

600 To Earth Splice 7212/0052 -B207
TO
/14.F6 -CR_S38 To Earth Splice
1.50 mm² 809B -CR_DU 1/2 2/2 1.50 mm² 600AD 600 TO
/14.E6
1/2 334/U0901 2/2
LH MIDDLE FRONT W/L 1

1.00 mm² 810A -CR_RC 1/2 2/2 1.00 mm² 600AF 600 TO
/14.E6
1/2 334/U0901 2/2
RH MIDDLE FRONT W/L 2
-CR_RA -CB_DY 7212/0052 -B209 To Earth Splice

2.00 mm² 855 1.00 mm² 810B -CR_RG 1/2 2/2 1.00 mm² 600AC 600 E
TO
/14.E6
9/14 9/14 -CR_S39 1/2 334/U0901 2/2
REV
TO SPLICE S50
-CR_RA -CB_DY 0.75 mm² 844B
-CB_S80 /11.C1
TO
0.75 mm² 844

10/14 10/14 0.75 mm² 844A REV TO HVAC/ ATC
TO
/8.A1 LH FRONT INNER WL
-CR_RA -CB_DY 7212/0052 -B210 To Earth Splice

1.00 mm² 842A -CR_RH 1/2 2/2 1.00 mm² 600AA 600 TO
/14.E6
STEP LIGHT 2/14 2/14 1/2 334/U0901 2/2
1/2 2/2 1.00 mm² 600AJ 600 To Earth Splice

TO
/14.E6
2/2 RH FRONT INNER WL
1.00 mm² 842B -CR_RJ 1/2 2/2 1.00 mm² 600AB 600 TO
/14.E6
-CR_S188 1/2 334/U0901 2/2
WORKLAMP SPLITTER LH HARNESS

7212/0052 7212/0051
-CR_RK -RK -RWL_S81
7212/0052
-RWL_RK1
LH REAR WL 1
-RWL_S80 -RK -CR_RK D
1.00 mm² 854A 1/2 1/2 1.00 mm² 200 0.75 mm² 202 1/2 1/2 2/2 2/2 0.75 mm² 204 1.00 mm² 201 2/2 2/2
-B212
-CR_S189
335/D1532 1.00 mm² 600BS
7212/0052 LH REAR WL 2
-RWL_RK2 To Earth Splice
0.75 mm² 203 1/2 1/2 2/2 2/2 0.75 mm² 205 600
/14.F6
-CR_RA
TO
-B3
To Earth Splice 335/D1532
7/14
/14.C1
Page 33-48
From IGN RLY 1 WORKLAMP SPLITTER RH HARNESS

/1.D7
-CB_DY
7212/0052 7212/0051 7212/0052

7/14
-CR_RL -RL -RWL_S82 -RWL_RK3 RH REAR WL 1 -RWL_S83 -RL -CR_RL

1.00 mm² 854B 1/2 1/2 1.00 mm² 200 0.75 mm² 202 1/2 2/2 0.75 mm² 204 1.00 mm² 201 2/2 2/2
1/2 -B213 2/2
335/D1532
1.00 mm² 600BR
7212/0052
-RWL_RK4 RH REAR WL 2
600 To Earth Splice
0.75 mm² 203 1/2 2/2 0.75 mm² 205
/14.F6
C
TO
1/2 -B4 2/2

335/D1532
7219/0029 7219/0189 7212/0052

AUX WORKLIGHT
-CB_PS -RC_PR -RC_MD
To Earth Splice GND TO EARTH SPLICE S77
2.00 mm² 855 1/2 2/2 1.00 mm² 651F
/14.E6 TO
/14.B5
K/16 K/16 1/2 2/2
BEACON
7232/0023
-CR_RP To Earth Splice
1.00 mm² 823 2/2 1/2 1.00 mm² 600CH 600 TO
/14.F6
2/2 333/T0717 1/2
-CB_RQR2
332/C2505
TO WHITE LAMP RESISTOR
1 2
0.50 mm² 304EA 0.50 mm² 610EA B
-CB_RQR1
334/G3723
TO RED LAMP RESISTOR
0.50 mm² 303AA 1 2 0.50 mm² 610TA
7234/0002
To Earth Splice
-CB_RQ INTERIOR LIGHT
/14.E6 To Earth Splice
0.50 mm² 303 0.50 mm² 303A 1/4 -B219 3/4 0.50 mm² 610T 0.50 mm² 610X GND
1/4 3/4
TO
/14.F1
-CB_S56 334/S4834 -CB_S57
GND To Earth Splice
0.50 mm² 304D 0.50 mm² 304E 2/4 2/4 4/4 0.50 mm² 610E 0.50 mm² 610Y TO
/14.F1
-CB_S58 4/4 7201/0407 -CB_S60
1/1 -CB_RQ1 0.50 mm² 460
7201/0407
From splice CB_S31 BATT -CB_RQ2 1/1
0.50 mm² 305B 1/1 7201/0407
/12.D2 FROM
1/1
1/1 -CB_RQ3 0.50 mm² 461
7219/0005 7219/0006 1/1
-CR_RXR -CB_CXR
0.50 mm² 461
2/14 2/14
0.50 mm² 460
1/14 1/14
335-C0779-7
5 6 7 8
33 - 49 9813/6500-1 33 - 49
33 - 50 9813/6500-1 33 - 50
Page 33-52 Figure 641. Road Lighting Page 33-53

1 2 3 4 5 6 7 8
0.50 mm² 805

7212/0112 MMI ILLUMINATION
From Primary Fuse PF6 BATT -CB_RW
1/2 GND TO EARTH SPLICE S24
/1.B3 FROM 4.00 mm² 317 0.50 mm² 810D -B161 2/2 0.50 mm² 610W TO
/14.F1
I/O MODULE 2 1/2 2/2 LH NO PLATE LIGHT (ROOF)
F -CB_ECU2 7219/0005 7219/0006 7212/0006
728/A3879 1.00 mm² 801 1.00 mm² 801H

-CB_DY -CR_RA 1.00 mm² 801H
-CR_S84 -CR_RT
1.00 mm² 801K 1/2 2/2 1.00 mm² 600BT 600
To Earth Splice F
B/2
TO
/14.F6
-CB_S46 1.00 mm² 801A
1/14 1/14 A/2 700/35100
1.00 mm² 801B
7207/1302
-CB_CNR 600
To Earth Splice RH NO PLATE LIGHT (ROOF)
2.00 mm² 612
M6
J3 Perm Supply V-Ground J1-2
2/16
TO
/14.E1 7212/0006
-SW4 +5V Output Ref J1-11 -CR_RS To Earth Splice
701/A5644 1.00 mm² 801J 1/2 2/2 1.00 mm² 600BU 600
B/2
TO
/14.F6
RH COLUMN SWITCH Ground
A/2 700/35100
7219/0005 15/16
From CB_S7 BATT -CB_DE J1-3 Config Address 3 (active low) 7219/0233 -L1
0.50 mm² 301G 5 7 0.50 mm² 403
7219/0231 -CB_CNB
0.75 mm² 812 700/50196
/2.F2 FROM
-CB_CN
J2-1
1/12
5/14 7/14 - 24V - 6A
LH FRONT HEADLAMP
J1-4 Config Address 1 (active low)
4/16
J2-2 1.00 mm² 807 7216/0018 Dipped
From Splice CB_S31 BATT 4
- 24V - 6A
2/12 TO TRAILER RELAY -FC_NB
0.50 mm² 305C 0.50 mm² 802E 802 1.00 mm² 806A 2
/12.D2 FROM
5/16
J1-5 Input 3
To Rear Wiper
TO
/18.B1 2/6
4/14 6 814
0.50 mm² 402 1.00 mm² 814
J2-3 TO
/13.D1 -FC_S45 Main
6/14
- 24V - 6A
3/12 -CB_DH -FC_NF 1.50 mm² 807 1.00 mm² 807A 3
J1-6 Input 1
To Earth Splice
MAIN / DIP ONLY 6/16
1.00 mm² 802
-CB_S47 1.00 mm² 802A
59/62 59/62 3/6 6 1.50 mm² 660J #1438
From Rear Wiper Park 600
J2-4
-FC_NF
Side TO
/14.E4
E 4/12 -CB_DH 6/6
- 24V - 6A
0.50 mm² 827 1.00 mm² 802B 1.00 mm² 801A 4

/13.D6 J1-7
E
FROM Analog Input 3
7/16
0.75 mm² 815 815 To Rear Wash Pump 24/62 24/62 4/6
/13.D1
J2-5 TO
DI
- 24V - 6A
5/12 -CB_DH -FC_NF 5
J1-8 Analog Input 1 0.75 mm² 835A 1.00 mm² 835A
8/16 25/62 25/62 5/6 1
J2-6 1.00 mm² 801
- 24V - 6A
6/12
7219/0221 7219/0218
Channel 7 - 12V - 10A 1.00 mm² 806D -CB_DH -FC_NF 1.50 mm² 806D -L2
J2-7 58/62
- 24V - 6A
7/12 58/62 -FC_S44 700/50197
Channel 9 - 12V - 5A 1.00 mm² 847 RH FRONT HEADLAMP
J2-8
- 24V - 2.5A
8/12
-SW4 J1-12 Config Address 2 (active low) 7216/0018 Dipped
RH COLUMN SWITCH -CB_S43 -FC_NA 2
J2-9 0.75 mm² 835B 1.00 mm² 806B
2
- 24V - 2.5A
9/12 2/6
From CB_S7 7219/0005 0.50 mm² 836 J1-13 Input 4 To QUICK HITCH SOLENOID Main
BATT -CB_DE 1 2/14 13/16
0.75 mm² 858 IGNITION 3
Ignition Wake up
0.50 mm² 301K 1.00 mm² 807B
/2.F2 FROM
1/14
- 24V - 2.5A J2-10
10/12
TO
/3.E1 3/6 To Earth Splice
3 0.50 mm² 835 6 1.50 mm² 660L #1438
3/14 14/16
J1-14 Digital Input 2 (active high/low) Side TO
/14.E4
Channel 3 - 12V - 5A 0.75 mm² 836B -CB_DH -FC_NF 1.00 mm² 802A 4 6/6
- 24V - 2.5A J2-11
11/12 27/62 27/62 4/6
CAN Shield
INDICATORS ONLY
CAN High
CAN Low
J1-16 Analog Input 2 DI

16/16 -CB_DH -FC_NF 5
0.75 mm² 836A 1.00 mm² 836A
- 24V - 6A J2-12 -CB_S42
J1-10
12/12 26/62 26/62 5/6 1

J1-9
J1-1
From ECCO Sw -FC_NF

846 -CB_DH
D /6.B3 FROM 0.75 mm² 846 0.50 mm² 846
35/62 35/62
1.00 mm² 801T 802 TO TRAILER ELECTRICS
/18.F1 D
0.75 mm² 836D
1.00 mm² 802B
1.00 mm² 801B

TO
1.00 mm² 847

-SW22
701/E0575
7219/0013 HAZARD SW
From Splice CB_S18 To Earth Splice
IGNITION 0.50 mm² 125F
-CB_CF 8 7 0.50 mm² 610M GND 1.00 mm² 835T 835C TO TRAILER ELECTRICS
/2.F1 FROM
8/10 7/10
/14.E1TO TO
/18.F1
1
From CB_S7 BATT 2
0.50 mm² 301L
/2.E2 FROM
2/10 LH REAR COMBI LAMP

3 0.50 mm² 440
3/10 7214/0025
7219/0055 332/R4343 -RC_MH 700/50068/69
4 -CB_FZ -RC_ML 2/4
1.00 mm² 801B 1.00 mm² 801C TAIL To Earth Splice
5 BAT POS TO TRAILER RELAY 1/31 1/31 -RC_S111 2/4
GND
0.50 mm² 440A TO
/18.B1 GND 3/4 1.00 mm² 650B TO
/14.B5
6 1.00 mm² 847A 4/4 STOP 3/4
10 9 4/4
10/10 -CB_FZ -RC_ML 1/4
0.75 mm² 835D 1.00 mm² 835D 1.00 mm² 835F IND
5/31 5/31
-RC_S112 1/4
0.50 mm² 800 TO TRAILER ELECTRICS 812 1.00 mm² 812T
/18.E1 TO
7214/0025
LHS FOG/REV LAMP
-RC_S48 -RC_MT
C 0.75 mm² 812 -CB_FZ -RC_ML 1.00 mm² 812 0.75 mm² 812A 2/4 FOG
3/31 3/31
2/4 GND TO EARTH SPLICE S77 C
GND 3/4 1.00 mm² 600G TO
/14.B5
0.75 mm² 844K 4/4 REVERSE 3/4
4/4
7214/0025
-RC_MS RHS FOG/REV LAMP
0.75 mm² 812B 2/4 FOG
-RC_S50 GND 3/4 1.00 mm² 600M TO
/14.C5
FROM SPLICE S80 REV -CB_FZ -RC_ML 4/4 3/4
/10.E6 FROM 0.75 mm² 844B 0.75 mm² 844B 0.75 mm² 844L REVERSE
7/31 7/31
4/4
REVERSE ALARM
-B107 1.00 mm² 847T 812D TO TRAILER ELECTRICS
7212/0001
333/S1282 To Earth Splice
TO
/18.F1
0.75 mm² 844C -RC_MM 1/2 2/2 0.75 mm² 651D GND TO
/14.B5
1/2 2/2 TO TRAILER ELECTRICS 802 1.00 mm² 802T
/18.E1 TO
RH REAR COMBI LAMP

7214/0025
-RC_MF 700/50068/69
-CB_FZ -RC_ML -RC_S29
1.00 mm² 802B 1.00 mm² 802BA 2/4
2/31 2/31
TAIL To Earth Splice
2/4 1.00 mm² 650A GND
B GND 3/4 TO
/14.B5
QUARRY OPTION -CB_FZ -RC_ML 3/4
1.00 mm² 847 1.00 mm² 847B 4/4STOP B
1.00 mm² 844D
7212/0001 OPTION REVERSE ALARM 4/31 4/31

-RG_GHH -RC_S110 -RC_S72 4/4
0.75 mm² 844J 1/2 1/2-B218 2/2 2/2 0.75 mm² 651G
-CB_FZ -RC_ML 1.00 mm² 836D 1.00 mm² 836E 1/4
6/31 6/31
IND
335/E9029 1/4
OPTION STROBE 1 TO TRAILER ELECTRICS 812D 1.00 mm² 836T BONNET NUM
7214/0025 /18.E1 TO
-B123 7212/0052 PLATE LAMP

-RG_AJJ
0.75 mm² 844F 1/4 1/4 4/4 4/4 0.75 mm² 651E -RC_MJ -B199
2/4 3/4 3/4 0.75 mm² 600 1.00 mm² 802BB 1/2 2/2 0.75 mm² 651G GND TO
/14.C5
1/2 2/2
OPTION STROBE 2
7212/0052 7214/0025 7212/0052
-RC_BJ -RG_AKK -B124 3/4 3/4 -RC_BJ
1/2 1.00 mm² 844D 0.75 mm² 844G 1/4 1/4 4/4 4/4 0.75 mm² 651F 1.00 mm² 651E 1.00 mm² 651E GND TO EARTH SPLICE S70
TO
/14.C5
1/2 -RG_SG2 2/4 -RG_SG3 2/2 2/2
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 51 9813/6500-1 33 - 51
33-52 33-53
1 2 3 4
0.50 mm² 805

From Primary Fuse PF6 BATT
4.00 mm² 317
/1.B3 FROM
I/O MODULE 2
F -CB_ECU2
728/A3879 1.00 mm² 801
-CB_S46
7207/1302
-CB_CNR 600
To Earth Splice
2.00 mm² 612
M6
2/16 /14.E1
TO
-SW4 +5V Output Ref J1-11

701/A5644
RH COLUMN SWITCH Ground
7219/0005 15/16
From CB_S7 BATT -CB_DE J1-3 Config Address 3 (active low) 7219/0233
0.50 mm² 301G 5 7 0.50 mm² 403
7219/0231 -CB_CNB
0.75 mm² 812
/2.F2 FROM
7/14 -CB_CN
J2-1
1/12
5/14 - 24V - 6A

4/16
J2-2 1.00 mm² 807
From Splice CB_S31 BATT 4
- 24V - 6A
2/12
0.50 mm² 305C
/12.D2 FROM
5/16
J1-5 Input 3
To Rear Wiper
4/14 6 814
0.50 mm² 402 1.00 mm² 814
- 24V - 6A J2-3
3/12
TO
/13.D1
6/14
J1-6 Input 1
MAIN / DIP ONLY 6/16
1.00 mm² 802
-CB_S47
From Rear Wiper Park 600
J2-4
E 4/12
- 24V - 6A
0.50 mm² 827

/13.D6 FROM
J1-7 Analog Input 3
7/16
0.75 mm² 815 815 To Rear Wash Pump
/13.D1
J2-5 TO
- 24V - 6A
5/12
J1-8 Analog Input 1
8/16
J2-6 1.00 mm² 801
- 24V - 6A
6/12

J2-7 1.00 mm² 806D
- 24V - 6A
7/12
J2-8 1.00 mm² 847
- 24V - 2.5A
8/12
-SW4 J1-12 Config Address 2 (active low)
RH COLUMN SWITCH Channel 6 - 12V - 5A 0.75 mm² 835B
- 24V - 2.5A J2-9
2 9/12
From CB_S7 7219/0005 0.50 mm² 836 J1-13 Input 4 To QUICK HITCH SOLENOID
BATT -CB_DE 1 2/14 13/16
0.75 mm² 858 IGNITION
Ignition Wake up
0.50 mm² 301K
/2.F2 FROM
1/14
- 24V - 2.5A J2-10
10/12
TO
/3.E1
3 0.50 mm² 835 J1-14 Digital Input 2 (active high/low)
3/14 14/16
Channel 3 - 12V - 5A 0.75 mm² 836B
- 24V - 2.5A J2-11
11/12
CAN Shield
INDICATORS ONLY
CAN High
CAN Low
16/16 Channel 11 - 12V - 10A
- 24V - 6A J2-12 -CB_S42
J1-10
12/12
J1-9
J1-1
From ECCO Sw -FC_NF
846 -CB_DH
D /6.B3 FROM 0.75 mm² 846
35/62 35/62
0.50 mm² 846
1.00 mm² 847

-SW22
701/E0575
7219/0013 HAZARD SW
From Splice CB_S18 To Earth Splice
IGNITION 0.50 mm² 125F
-CB_CF 8 7 0.50 mm² 610M GND
/2.F1 FROM
8/10 7/10
TO
/14.E1
1
From CB_S7 BATT 2
0.50 mm² 301L
/2.E2 FROM
2/10 3 0.50 mm² 440

3/10
Page 33-53
4
5 0.50 mm² 440A BAT POS TO TRAILER RELAY
TO
/18.B1
6
10 9
10/10
0.50 mm² 800
FROM SPLICE S80 REV -CB_FZ -RC_ML -RC_S50

0.75 mm² 844B 0.75 mm² 844B
/10.E6 FROM
7/31 7/31
REVERSE ALARM
-B107
7212/0001
333/S1282 GND
To Earth Splice
0.75 mm² 844C -RC_MM 1/2 2/2 0.75 mm² 651D
1/2 2/2
TO
/14.B5
B
QUARRY OPTION
1.00 mm² 844D
7212/0001 OPTION REVERSE ALARM

-RG_GHH
0.75 mm² 844J 1/2 1/2-B218 2/2 2/2 0.75 mm² 651G
335/E9029
OPTION STROBE 1
7214/0025
-RG_AJJ -B123
0.75 mm² 844F 1/4 1/4 4/4 4/4 0.75 mm² 651E
2/4 3/4 3/4 0.75 mm² 600
OPTION STROBE 2
7212/0052 7214/0025 7212/0052
-RC_BJ -RG_AKK -B124 3/4 3/4 -RC_BJ
1/2 1.00 mm² 844D 0.75 mm² 844G 1/4 1/4 4/4 4/4 0.75 mm² 651F 1.00 mm² 651E 1.00 mm²
1/2 -RG_SG2 2/4 -RG_SG3 2/2 2/2
1 2 3 4
33 - 52 9813/6500-1 33 - 52
33-52 33-53
5 6 7 8
7212/0112 MMI ILLUMINATION

-CB_RW
0.50 mm² 810D -B161 2/2 0.50 mm² 610W TO
/14.F1
1/2 2/2 LH NO PLATE LIGHT (ROOF)
7219/0005 7219/0006 7212/0006
1.00 mm² 801 1.00 mm² 801H

-CB_DY -CR_RA 1.00 mm² 801H
-CR_S84 -CR_RT
1.00 mm² 801K 1/2 2/2 1.00 mm² 600BT 600
To Earth Splice F
B/2
TO
/14.F6
-CB_S46 1.00 mm² 801A
1/14 1/14 A/2 700/35100
1.00 mm² 801B
600
To Earth Splice RH NO PLATE LIGHT (ROOF)
TO
/14.E1 7212/0006
-CR_RS To Earth Splice
1.00 mm² 801J 1/2 2/2 1.00 mm² 600BU 600
B/2
TO
/14.F6
A/2 700/35100
-L1
700/50196
LH FRONT HEADLAMP
7216/0018 Dipped
0.50 mm² 802E 802 TO TRAILER RELAY 1.00 mm² 806A
-FC_NB 2
To Rear Wiper
TO
/18.B1 2/6
TO
/13.D1 -FC_S45 Main
-CB_DH -FC_NF 1.50 mm² 807 1.00 mm² 807A 3
-CB_S47 59/62 59/62 3/6 6 To Earth Splice
1.00 mm² 802A 1.50 mm² 660J #1438
-FC_NF
Side
6/6
TO
/14.E4
1.00 mm² 802B -CB_DH 1.00 mm² 801A 4
To Rear Wash Pump 24/62 24/62 4/6 E
TO
/13.D1 DI
0.75 mm² 835A -CB_DH -FC_NF 1.00 mm² 835A 5
25/62 25/62 5/6 1
7219/0221 7219/0218
-CB_DH -FC_NF 1.50 mm² 806D -L2
58/62 58/62
-FC_S44 700/50197
RH FRONT HEADLAMP
7216/0018 Dipped
-CB_S43 -FC_NA 2
1.00 mm² 806B
2/6
To QUICK HITCH SOLENOID Main
1.00 mm² 807B 3
/3.E1 3/6 To Earth Splice
6 1.50 mm² 660L #1438
Side TO
/14.E4
-CB_DH -FC_NF 1.00 mm² 802A 4 6/6
27/62 27/62 4/6
DI
0.75 mm² 836A -CB_DH -FC_NF 1.00 mm² 836A 5
-CB_S42 26/62 26/62 5/6 1
1.00 mm² 801T 802 TO TRAILER ELECTRICS

/18.F1 D
0.75 mm² 836D
1.00 mm² 802B
1.00 mm² 801B
TO
1.00 mm² 847
1.00 mm² 835T 835C TO TRAILER ELECTRICS

TO
/18.F1
LH REAR COMBI LAMP

7214/0025
7219/0055 332/R4343 -RC_MH 700/50068/69
Page 33-52
-CB_FZ -RC_ML 2/4

1.00 mm² 801B 1.00 mm² 801C TAIL To Earth Splice
1/31 1/31 -RC_S111 2/4
GND
GND 3/4 1.00 mm² 650B TO
/14.B5
1.00 mm² 847A 4/4 STOP 3/4
4/4
-CB_FZ -RC_ML 1/4
0.75 mm² 835D 1.00 mm² 835D 1.00 mm² 835F IND
5/31 5/31
-RC_S112 1/4
TO TRAILER ELECTRICS 812 1.00 mm² 812T
/18.E1 TO
7214/0025
LHS FOG/REV LAMP
-RC_S48 -RC_MT
-CB_FZ -RC_ML 2/4
0.75 mm² 812 1.00 mm² 812 0.75 mm² 812A FOG
3/31 3/31
2/4 GND TO EARTH SPLICE S77 C
GND 3/4 1.00 mm² 600G TO
/14.B5
0.75 mm² 844K 4/4 REVERSE 3/4
4/4
7214/0025
-RC_MS RHS FOG/REV LAMP
0.75 mm² 812B 2/4 FOG
GND 3/4 1.00 mm² 600M TO
/14.C5
0.75 mm² 844L 4/4 REVERSE 3/4
4/4
1.00 mm² 847T 812D TO TRAILER ELECTRICS

To Earth Splice
TO
/18.F1
TO TRAILER ELECTRICS 802 1.00 mm² 802T
/18.E1 TO
RH REAR COMBI LAMP

7214/0025
-RC_MF 700/50068/69
-CB_FZ -RC_ML -RC_S29
1.00 mm² 802B 1.00 mm² 802BA 2/4
2/31 2/31
TAIL To Earth Splice
2/4 1.00 mm² 650A GND
GND 3/4 TO
/14.B5
-CB_FZ -RC_ML 3/4
4/31 4/31
1.00 mm² 847 1.00 mm² 847B 4/4 STOP B
-RC_S110 -RC_S72 4/4
-CB_FZ -RC_ML 1.00 mm² 836D 1.00 mm² 836E 1/4
6/31 6/31
IND
1/4
TO TRAILER ELECTRICS 812D 1.00 mm² 836T BONNET NUM

/18.E1 TO
7212/0052 PLATE LAMP

-RC_MJ -B199
1.00 mm² 802BB 1/2 2/2 0.75 mm² 651G GND TO
/14.C5
1/2 2/2
7212/0052
-RC_BJ
651E 1.00 mm² 651E GND TO EARTH SPLICE S70
TO
/14.C5
2/2 2/2
335-C0779-7
5 6 7 8
33 - 53 9813/6500-1 33 - 53
33 - 54 9813/6500-1 33 - 54
Page 33-56 Figure 642. Radio, Heated Mirrors, Livelink,

Seat, Auxiliary Power Feed and Weigh load Page 33-57
1 2 3 4 5 6 7 8
RADIO
RADIO 24V
RADIO 24V (POWER)
F -B129
7238/0003
-CB_RU 4/8 MEMORY
/12.E2 F
4/8 GND To Earth Splice 717/C5944 -CS1
From Fuse FC3 117 -CB_S49 GND 8/8 1.00 mm² 610-24V TO
/14.F1 715/08100
8/8 24/12V DROPPER
/1.C7 FROM 1.00 mm² 106A-24V 1.00 mm² 106B-24V 7/8
ON/OFF -CB_FB POWER SOCKET (12V)
7/8 7232/0031
-FB10 10A -CB_S15 To Earth Splice
2 1 -CB_GJ GND
+12V SWITCHED 5/6 1.50 mm² 308C-12V 1.50 mm² 308-12V 1.50 mm² 308B-12V 2/2 1.50 mm² 610J-12V TO
/14.E1
5/6 19 20 1/2
RADIO 24V GND
RADIO SPEAKER 7238/0002 LH SPEAKER -B88
7231/0010
-B129 5/8 -CR_RV 1.00 mm² 860 -CR_RW1 717/20020
5/8 1/1 1/1 12V AUX FEED
/12.F2 7231/0011 -B92 7232/0031
6/8 1.00 mm² 602 -CR_RW2 -CB_GK
6/8 1/1 1/1 -B128 To Earth Splice
1.50 mm² 308D-12V 2/2 2/2 1/2 1.50 mm² 630L-12V GND TO
/14.C1
1/2
RH SPEAKER
7231/0010
3/8 1.00 mm² 859 -CR_RX1 717/20020
3/8 1/1 1/1
7231/0011 -B93
4/8 1.00 mm² 601 -CR_RX2 RADIO 12V (POWER)
4/8 1/1
E 1/1
7238/0003 -B90
-CB_FB 1.50 mm² 308A-12V -CB_TD 7/8 ON/OFF GND 8/8 0.75 mm² 610-12V GND To Earth Splice E
717/00500 7/8 8/8
TO
/14.F1
-FB9 3A
+12V MEMORY 4/6 0.75 mm² 300-12V 0.75 mm² 300A-12V 4/8 MEMORY
4/6 17 18 4/8
7216/0041
FROM FUSE FC3 117 1.00 mm² 106-24V
-CB_GG 2/6 V IGN
/1.C7 FROM
24V POWER SOCKET

1.50 mm² 309A-24V 1.00 mm² 309C-24V TO TRAILER RELAY 2/6 GND 6/6
TO
/18.B1 7232/0028
BATT 334/U1838 -CB_FP
From Fuse FB7 BATT GND To Earth Splice From Fuse FC1 126 GND To Earth Splice
2.00 mm² 309-24V 2.00 mm² 309B-24V 1/6 +24V INPUT GND 3/6 2.00 mm² 630E 2.00 mm² 124-24V 2/2 2/2 1/2 2.00 mm² 610G
/1.B4 FROM
-R10 1/6 3/6

TO
/14.C1 /1.C7 FROM
-B94 1/2
TO
/14.E1
-CB_S82
SPLICE FUSE B7 LIVELINK RELAY
9
0.50 mm² 106C 6 7 0.75 mm² 106

LIVELINK 3
8 10 GND To GND Splice

0.50 mm² 106D 0.50 mm² 630M
/14.C1 -CB_DY -CR_RA
TO
-CR_LL
0.75 mm² 106 M2/48
-CB_HA 4/14 M2/48
4/14
7241/0003 7219/0285
D From Fuse B1 BATT -CB_S31
/1.B4 FROM 0.50 mm² 305 0.50 mm² 305A
-CB_DY -CR_RA 0.75 mm² 305B
M4/48
M4/48 D
5/14 5/14
0.50 mm² 305B BATT To Interior Light

TO
/10.A5
7219/0285
BATT To RH Column Sw 7219/0005 J1/48 J1/48
0.50 mm² 305C TO
/11.E1 7219/0006 0.75 mm² 1000
FROM Battery Fused NEG BAT NEG 1.00 mm² 611 -CB_DY -CR_RA 0.75 mm² 611 L2/48
/1.F3 FROM
L2/48
0.50 mm² 305E BATT TO DOOR SW 8/14 8/14
TO
/10.E1
-CR_RA 7219/0285
0.75 mm² 417A E2/48 K1/48 K1/48
E2/48
6/14
DESTINATION CONNECTION
IS NOT AVILABLE IN HARNESS
TO EARTH SPLICE -CR_S84

1.00 mm² 600AY 0.75 mm² 600AYA L3/48
/14.E6 TO
L3/48
600
C 0.75 mm² 600AYB M3/48

333/A5313
M3/48 C
SEAT SW
7219/0058 -B130
From Fuse FC6 100 -CB_AB
2.00 mm² 872 7/12 8/12 2.00 mm² 630JA
/1.D7 FROM
7/12 8/12

From Fuse FC6 100 GND
2.00 mm² 119B 9/12 10/12 2.00 mm² 630J 2.00 mm² 630J
/1.D7 FROM TO
/14.C1
9/12 10/12 -CB_S41
SEAT SW
BELT BUCKLE
GREEN STROBE
7232/0023
7219/0006 7219/0005
7219/0058 -B130 -CB_CXR -CR_RXR -CR_TE
From Fuse A3 IGNITION -CB_AB 600 To Earth Splice
/1.D4 FROM 1.00 mm² 1609 5/12 /12.B3 6/12 1.00 mm² 1610 1.00 mm² 1610 2/2 1/2 1.00 mm² 600AK TO
/14.E6
5/12 6/12 11/14 11/14 2/2 1/2
-R19 120 A
716/30295
B RELAY SEC. STEER PUMP EMERGENCY STEER PUMP
7207/1419 7207/1419 B
7207/1304 7207/1316 -ES_PA2
From Primary Fuse PF11 -ES_PA1
BAT POS 16.00 mm² 336
-MU-B 3 5 -ES_MU_NO 16.00 mm² 337 POS 1/1 1/1 10.00 mm² 338 NEG
/1.F5 FROM
M6 M6
7212/0044
M8 333/S1623 M8
From Main ECU 864 -CB_FZ -RC_ML -RC_BC 1 2 GND To Earth Splice 7207/1514
0.75 mm² 864 1.00 mm² 864 1.00 mm² 650C
/3.B7 FROM
2/2
TO
/14.C5 -ES_PE M10
25/31 25/31 1/2
WEIGHLOAD/ AUTOLUBE PLUG -G5

7214/0025
From Fuse FC5 -CB_GV To Earth Splice
117 1.50 mm² 104 1/4 2/4 1.50 mm² 610L GND
/1.B7 FROM
1/4 2/4
TO
/14.E1
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 55 9813/6500-1 33 - 55
33-56 33-57
1 2 3 4
RADIO
RADIO 24V
RADIO 24V (POWER)
F 7238/0003 -B129
-CB_RU /12.E2
4/8 MEMORY
4/8 GND To Earth Splice 717/C5944
From Fuse FC3 117 -CB_S49 GND 8/8 1.00 mm² 610-24V TO
/14.F1
8/8 24/12V DROPPER
/1.C7 FROM 1.00 mm² 106A-24V 1.00 mm² 106B-24V 7/8
ON/OFF -CB_FB
7/8
-FB10
+12V SWITCHED 5/6 1.50 mm² 308C-12V
RADIO 24V 5/6 19
RADIO SPEAKER 7238/0002 LH SPEAKER -B88
7231/0010
-B129 5/8 -CR_RV 1.00 mm² 860 -CR_RW1 717/20020
5/8 1/1 1/1
/12.F2 7231/0011 -B92
6/8 1.00 mm² 602 -CR_RW2
6/8 1/1 1/1
RH SPEAKER
7231/0010
3/8 1.00 mm² 859 -CR_RX1 717/20020
3/8 1/1 1/1
7231/0011 -B93
4/8 1.00 mm² 601 -CR_RX2
4/8 1/1
E 1/1
717/00500 -CB_FB
-FB9
+12V MEMORY 4/6 0.75 mm² 300-12V
7216/0041 4/6 17
FROM FUSE FC3 117 1.00 mm² 106-24V
-CB_GG 2/6 V IGN
/1.C7 FROM
1.50 mm² 309A-24V 1.00 mm² 309C-24V TO TRAILER RELAY 2/6 GND 6/6
BATT
TO
/18.B1
From Fuse FB7 BATT GND 3/6 GND To Earth Splice
2.00 mm² 309-24V 2.00 mm² 309B-24V 1/6 +24V INPUT 2.00 mm² 630E
/1.B4 FROM
-R10 1/6 3/6

TO
/14.C1
-CB_S82
SPLICE FUSE B7 LIVELINK RELAY
9
0.50 mm² 106C 6 7 0.75 mm² 106
8 10 GND To GND Splice

0.50 mm² 106D 0.50 mm² 630M TO
/14.C1 -CB_DY -CR_RA
-CB_HA 4/14
4/14
7241/0003
D From Fuse B1 BATT -CB_S31 -CB_DY -CR_RA
0.50 mm² 305 0.50 mm² 305A
/1.B4 FROM
5/14 5/14
0.50 mm² 305B BATT To Interior Light

TO
/10.A5
BATT To RH Column Sw 7219/0005
0.50 mm² 305C TO
/11.E1 7219/0006
FROM Battery Fused NEG BAT NEG 1.00 mm² 611 -CB_DY -CR_RA
/1.F3 FROM
0.50 mm² 305E BATT TO DOOR SW 8/14 8/14

TO
/10.E1
-CR_RA
Page 33-57
6/14
DESTINATION CONNECTION
IS NOT AVILABLE IN HARNESS
TO EARTH SPLICE -CR_S84

1.00 mm² 600AY
/14.E6 TO
600
C
333/A5313
SEAT SW
7219/0058 -B130
From Fuse FC6 100 -CB_AB
2.00 mm² 872 7/12 8/12 2.00 mm² 630JA
/1.D7 FROM
7/12 8/12
/12.B3
From Fuse FC6 100
2.00 mm² 119B 9/12 10/12 2.00 mm² 630J
/1.D7 FROM
9/12 10/12 -CB_S41
SEAT SW
BELT BUCKLE
7219/0006
7219/0058 -B130 -CB_CXR
From Fuse A3 IGNITION -CB_AB
/1.D4 FROM 1.00 mm² 1609 5/12 /12.B3 6/12 1.00 mm² 1610
5/12 6/12 11/14
-R19 120 A
716/30295
B RELAY SEC. STEER PUMP
7207/1304 7207/1316
From Primary Fuse PF11
BAT POS 16.00 mm² 336
-MU-B 3 5 -ES_MU_NO 16.00 mm² 337 POS
/1.F5 FROM
M6 M6
7212/0044
From Main ECU 864 -CB_FZ -RC_ML -RC_BC 1 2
0.75 mm² 864 1.00 mm² 864 1.00 mm² 650C
/3.B7 FROM
2/2
25/31 25/31 1/2
WEIGHLOAD/ AUTOLUBE PLUG

7214/0025
From Fuse FC5 -CB_GV
117 1.50 mm² 104 1/4 2/4 1.50 mm² 610L
/1.B7 FROM
1/4 2/4
1 2 3 4
33 - 56 9813/6500-1 33 - 56
33-56 33-57
5 6 7 8
F
-CS1
715/08100
-CB_FB POWER SOCKET (12V)
7232/0031
-FB10 10A -CB_S15 To Earth Splice
1.50 mm² 308C-12V 1.50 mm² 308-12V 1.50 mm² 308B-12V 2/2 2 1 -CB_GJ 1.50 mm² 610J-12V GND
19 20 1/2
TO
/14.E1
GND
12V AUX FEED

7232/0031
-B128 -CB_GK
GND To Earth Splice
1.50 mm² 308D-12V 2/2 2/2 1/2 1.50 mm² 630L-12V TO
/14.C1
1/2
RADIO 12V (POWER)

7238/0003 -B90
-CB_FB 1.50 mm² 308A-12V -CB_TD 7/8 ON/OFF GND 8/8 0.75 mm² 610-12V GND To Earth Splice E
7/8 8/8
TO
/14.F1
-FB9 3A
0.75 mm² 300-12V 0.75 mm² 300A-12V 4/8 MEMORY
17 18 4/8
24V POWER SOCKET

7232/0028
334/U1838 -CB_FP
GND To Earth Splice From Fuse FC1 126 GND To Earth Splice
2.00 mm² 630E 2.00 mm² 124-24V 2/2 2/2 1/2 2.00 mm² 610G
TO
/14.C1 /1.C7 FROM
-B94 1/2
TO
/14.E1
LIVELINK 3
-CR_LL
0.75 mm² 106 M2/48
M2/48
7219/0285
0.75 mm² 305B

M4/48
M4/48 D
7219/0285
J1/48 J1/48 0.75 mm² 1000
0.75 mm² 611 L2/48
L2/48
7219/0285
0.75 mm² 417A E2/48 K1/48 K1/48
Page 33-56
E2/48
TINATION CONNECTION
OT AVILABLE IN HARNESS
-CR_S84
0.75 mm² 600AYA L3/48
L3/48
0.75 mm² 600AYB M3/48

M3/48 C
To Earth Splice
2.00 mm² 630J GND TO
/14.C1
-CB_S41
GREEN STROBE
7232/0023
7219/0006 7219/0005
-CB_CXR -CR_RXR -CR_TE
600 To Earth Splice
1.00 mm² 1610 2/2 1/2 1.00 mm² 600AK TO
/14.E6
11/14 11/14 2/2 1/2
EMERGENCY STEER PUMP

7207/1419 7207/1419 B
-ES_PA1 -ES_PA2
16.00 mm² 337 POS 1/1 1/1 10.00 mm² 338 NEG
M8 333/S1623 M8
GND To Earth Splice 7207/1514

1.00 mm² 650C TO
/14.C5 -ES_PE M10
-G5
GND To Earth Splice

1.50 mm² 610L TO
/14.E1
335-C0779-7
5 6 7 8
33 - 57 9813/6500-1 33 - 57
33 - 58 9813/6500-1 33 - 58
Page 33-60 Figure 643. Rear bonnet,

Front wiper and Rear wiper Page 33-61
1 2 3 4 5 6 7 8
-SW4
F 701/A5644 FRONT WIPER
RH COLUMN SWITCH F
WIPE WASH ONLY
7218/0013 -B134
9 -CB_DG #1438 To Earth Splice
7219/0005 2.00 mm² 831 7/8 1/8 2.00 mm² 660D
From Fuse C4 117 9/14 333/V2460
TO
/14.E4
2.00 mm² 105 -CB_S34 2.00 mm² 105A -CB_DE 8 10 2.00 mm² 828
7/8
3/8
1/8
/1.C7FROM
8/14 10/14 3/8

11 2.00 mm² 817 2/8 8/8 2.00 mm² 105B
12 11/14 2/8 8/8
2.00 mm² 818 4/8
Wash 12/14 4/8
1.00 mm² 105D 117 To Servo Horn Sw 13 2.00 mm² 819 2.00 mm² 819
TO
/4.D1 13/14 FRONT WASHER MOTOR
Horn 1.00 mm² 811 2.00 mm² 819B 6/8
14 14/14 -CB_S35 6/8 7219/0055 332/R4343 7212/0008
-B135
-CB_FZ -RC_ML -RC_MU 331/49936 To Earth Splice
From Servo Horn Sw 811 1.00 mm² 811A 1.00 mm² 819A 1.00 mm² 819A 1/2 1/2 2/2 1.00 mm² 660S GND
/4.D1 FROM
-CB_S14 2/2
TO
/14.C5
26/31 26/31
-R9
333/S5959 -A1
FOR HORN WIRING RELAY HORN -CB_HN 717/20152
4 7514/0006 HORN
DE TAILS SEE SHEET 4 HORN DIODE 7212/0008
1 2 1 2 -CB_DH -FC_NF -FC_NE 1
2.00 mm² 105C 2.00 mm² 816 2.00 mm² 832 2.00 mm² 832
57/62 57/62 1/2
To Earth Splice
E 1.00 mm² 811B 3 5 1.00 mm² 630NM GND
/14.C1 2.00 mm² 660N 2
E
TO
2/2
-CB_HA
7241/0003
#1438
To Earth Splice
TO
/14.E4
REAR WIPER MOTOR

7214/0061
From I/O Module 1 814 -CB_FR GND To Earth Splice
1.00 mm² 814 3/4 1/4 1.00 mm² 630G
/11.E4 FROM
3/4 1/4
TO
/14.C1
-B137
332/S1570
From Fuse A4 IGNITION -CB_S73 600 To I/O Module 1
0.50 mm² 101 0.50 mm² 101B 4/4 2/4 0.50 mm² 827
/1.D4 FROM
4/4 2/4
TO
/11.E1
FROM IMMOBILISER IGNITION 0.50 mm² 101C
/2.B4 FROM
D TO MIRROR CONTROL JOYSTICK

/10.C1 TO
IGNITION 0.50 mm² 101A D
7219/0055 332/R4343
7212/0008 REAR WASHER PUMP
From I/O Module 2 815 -CB_FZ -RC_ML To Earth Splice
0.75 mm² 815 0.75 mm² 815
-RC_MX 1/2 2/2 0.75 mm² 660T GND
/11.E4 FROM
1/2
TO
/14.B5
27/31 27/31 2/2
331/49936
7212/0044 SCREEN WASH LEVEL

To Instrument Panel -CB_FZ -RC_ML -RC_MY
#539 0.75 mm² 429 0.75 mm² 429 1/2 1/2 2/2 2/2 0.75 mm² 660K GND TO EARTH SPLICE S77
/2.E3 TO TO
/14.B5
28/31 28/31
7219/0029 7219/0189 7212/0052 ENGINE BAY LAMP

-CB_PS -RC_PR -RC_BG
FROM FUSE A9 BATT 2.00 mm² 1842 2.00 mm² 1842 1/2 2/2 1.00 mm² 650KA GND TO EARTH SPLICE S70
/1.C4 FROM TO
/14.C5
L/16 L/16 1/2 2/2
C
C
B
B
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 59 9813/6500-1 33 - 59
33-60 33-61
1 2 3 4
-SW4
F 701/A5644 FRONT WIPER
RH COLUMN SWITCH
WIPE WASH ONLY
7218/0013
7219/0005 9 2.00 mm² 831 -CB_DG 7/8
From Fuse C4 117 -CB_S34 -CB_DE 8 10 9/14 7/8
2.00 mm² 105 2.00 mm² 105A 2.00 mm² 828 3/8
/1.C7FROM
8/14 10/14 3/8

11 2.00 mm² 817 2/8
12 11/14 2/8
2.00 mm² 818 4/8
Wash 12/14 4/8
1.00 mm² 105D 117 To Servo Horn Sw 13 2.00 mm² 819 2.00 mm² 819
TO
/4.D1 13/14
Horn 1.00 mm² 811 2.00 mm² 819B 6/8
14 14/14 -CB_S35 6/8
From Servo Horn Sw 811 1.00 mm² 811A 1.00 mm² 819A
/4.D1 FROM
-CB_S14
-R9
333/S5959
FOR HORN WIRING RELAY HORN -CB_HN
4 7514/0006
DE TAILS SEE SHEET 4 HORN DIODE
2.00 mm² 105C 1 2 2.00 mm² 816 1 2
To Earth Splice
E 1.00 mm² 811B 3 5 1.00 mm² 630NM GND TO
/14.C1
-CB_HA
7241/0003
From I/O Module 1 814

1.00 mm² 814
/11.E4 FROM
From Fuse A4 IGNITION -CB_S73

0.50 mm² 101 0.50 mm² 101B
/1.D4 FROM
FROM IMMOBILISER IGNITION 0.50 mm² 101C

/2.B4 FROM
D TO MIRROR CONTROL JOYSTICK IGNITION 0.50 mm² 101A

/10.C1 TO
7219/0055 332/R4343
From I/O Module 2 815 -CB_FZ -RC_ML
0.75 mm² 815 0.75 mm² 815
/11.E4 FROM
27/31 27/31
Page 33-61
To Instrument Panel -CB_FZ -RC_ML
#539 0.75 mm² 429 0.75 mm² 429
/2.E3 TO
28/31 28/31
7219/0029 7219/0189
-CB_PS -RC_PR
FROM FUSE A9 BATT 2.00 mm² 1842 2.00 mm² 1842
/1.C4 FROM
L/16 L/16
C
1 2 3 4
33 - 60 9813/6500-1 33 - 60
33-60 33-61
5 6 7 8
FRONT WIPER
-B134
F
7218/0013
-CB_DG #1438 To Earth Splice
7/8 1/8 2.00 mm² 660D
7/8 333/V2460 1/8
TO
/14.E4
3/8
3/8
2/8 8/8 2.00 mm² 105B
2/8 8/8
4/8
4/8
FRONT WASHER MOTOR

819B 6/8
6/8 7219/0055 332/R4343 7212/0008
-B135
-CB_FZ -RC_ML -RC_MU 331/49936 To Earth Splice
819A 1.00 mm² 819A 1/2 1/2 2/2 1.00 mm² 660S GND
2/2
TO
/14.C5
26/31 26/31
-A1
-CB_HN 717/20152
7514/0006 HORN
HORN DIODE 7212/0008
1 2 -CB_DH -FC_NF -FC_NE 1
2.00 mm² 832 2.00 mm² 832
57/62 57/62 1/2
GND To Earth Splice 2
2.00 mm² 660N
/14.C1
E
TO
2/2
#1438
To Earth Splice
TO
/14.E4
REAR WIPER MOTOR

7214/0061
-CB_FR GND To Earth Splice
1.00 mm² 814 3/4 1/4 1.00 mm² 630G
3/4 1/4
TO
/14.C1
-B137
332/S1570
600 To I/O Module 1
0.50 mm² 101B 4/4 2/4 0.50 mm² 827
4/4 2/4
TO
/11.E1
7212/0008 REAR WASHER PUMP

-RC_MX GND To Earth Splice
0.75 mm² 815 1/2 2/2 0.75 mm² 660T
1/2
TO
/14.B5
2/2
331/49936
Page 33-60
7212/0044 SCREEN WASH LEVEL

-RC_MY
0.75 mm² 429 1/2 1/2 2/2 2/2 0.75 mm² 660K GND TO EARTH SPLICE S77
TO
/14.B5
7212/0052 ENGINE BAY LAMP

-RC_BG
2.00 mm² 1842 1/2 2/2 1.00 mm² 650KA GND TO EARTH SPLICE S70
TO
/14.C5
1/2 2/2
335-C0779-7
5 6 7 8
33 - 61 9813/6500-1 33 - 61
33 - 62 9813/6500-1 33 - 62
Page 33-64 Figure 644. Earthing Page 33-65

1 2 3 4 5 6 7 8
GND 3.00 mm² 610

From HVAC OR ATC /8.F7 FROM
600
-CR_S65
1.00 mm² 600BT 4.00 mm² 600CRB
From LH No Plate Light /11.F8 FROM
600 1.00 mm² 600BU

From RH No Plate Light /11.F8
F
FROM
600 1.00 mm² 600BS

GND 0.50 mm² 610Y
FROM LH WORKLAMP /10.D8 FROM
600 1.00 mm² 600BR

F
From Int Light /10.A8 FROM
FROM RH WORKLAMP /10.C8 FROM
GND #1438 0.50 mm² 660F -CB_S66 600

From Climate Control Panel /2.A8 FROM 0.50 mm² 610K
From Instrument Cluster /2.E5
FROM From Beacon /10.B7 FROM 1.00 mm² 600CH
GND 0.50 mm² 610X #1438 0.50 mm² 660G
From Int Light /10.B8 FROM
From Instrument Cluster /2.D5

FROM
GND 1.00 mm² 610-24V #1438 0.50 mm² 660H

From Radio /12.F3 FROM
FROM CAN SPLICE SX25 /15.A1 FROM
GND 0.75 mm² 610-12V

From 12V Radio /12.E7 FROM
GND 0.50 mm² 610A FRONT CONSOLE

From Park Brake Sw /6.B3 FROM
GND 0.50 mm² 610C

From Sw Pad 1 /2.B2 FROM
GND -CB_S24 600

From Sw Pad 2 /2.B2 FROM 0.50 mm² 610B
From I/O MOD. 1 /10.F5 FROM 2.00 mm² 600AL -CR_S86
GND 0.50 mm² 610D
From Mirror Sw /10.A3 FROM
GND 0.50 mm² 610W

FROM MMI ILLUMINATION CB_RW:2 /11.F6 FROM
-CR_S64
#1438 0.75 mm² 660W 600 1.50 mm² 600AE 4.00 mm² 600CRA
FROM AUX DUMP SOL /3.D4 FROM
From LH Outer FWL /10.F7 FROM
GND 0.50 mm² 610F #1438 0.75 mm² 606 7219/0218 7219/0221 600 1.50 mm² 600AD
From Boom Control Lever /4.D7 FROM
FROM FRONT TO REAR DIVERTER SOL /5.B7 FROM
-FC_NF -CB_DH From RH Outer FWL /10.F7 FROM
GND 2.00 mm² 610G #1438 0.75 mm² 660H 2.00 mm² 660B 600 1.00 mm² 600AF
3.00 mm² 610A

From 24V Power Socket /12.E7 FROM
From Lift Reset Proxy /3.F4 FROM
62/62 62/62 From LH Middle FWL /10.E7 FROM
GND 1.50 mm² 610J-12V #1438 1.50 mm² 660J 600 1.00 mm² 600AC
From 12V Power Socket /12.F7 FROM
From LH Headlight /11.E8 FROM
-FC_S22 From RH Middle FWL /10.E7 FROM
GND #1438 0.75 mm² 605 600

From Weight Load Plug /12.A6 FROM 1.50 mm² 610L From Boom Position Sw /6.D3 FROM
From RH Aux FWL /10.D7 FROM 1.00 mm² 600AB
GND #1438 0.75 mm² 660E 600
0.50 mm² 610M From SRS Sol From LH Aux FWL 1.00 mm² 600AA
2.00 mm² 660B

From Hazard Sw /11.D3 FROM
/3.B8 FROM
/10.E7 FROM
E From Medium Spec. Inst. /2.E5

GND 0.50 mm² 610N From Servo Isolator Sol /3.A4
#1438 0.75 mm² 600CV
From LH Heated Mirror /10.C4
600 1.00 mm² 600AG
E
FROM FROM FROM
GND 600
From Medium Spec. Inst. /2.E7 FROM 0.50 mm² 610P From RH Heated Mirror /10.B4 FROM 1.00 mm² 600AH
600
From Step Light /10.D6 FROM 1.00 mm² 600AJ
GND 7219/0218 7219/0221 600
From Rotary Control 0.50 mm² 610S -CB_DH From Green Beacon 1.00 mm² 600AK
8.00 mm² 600CR

/2.C2 FROM
-FC_S71 -FC_NF /12.B7 FROM
GND #1438 1.50 mm² 660L 600

From Rear View Camera /2.F7 FROM 0.50 mm² 610U
7207/1502 From RH Headlight /11.D8 FROM 2.00 mm² 660C 2.00 mm² 660C
From LiveLink /12.C3 FROM 1.00 mm² 600AY
#1438 2.00 mm² 660N 61/62 61/62
-CB_ABC -CB_S38
M10 From Horn /13.E6 FROM
#1438 0.75 mm² 600CX

From Ergotraction Solenoid /6.B8 FROM
ROOF
600 2.00 mm² 612 #1438 0.75 mm² 660R
2.00 mm² 660A

From I/O Mod. 2 /11.F4 From Shovel Reset Proxy /3.E4
4.00 mm² 660

FROM FROM
-G10
7207/1501 #1438 2.00 mm² 660D
-CB_ABD M10 From Front Wiper Motor /13.F7
FROM
SIDE CAB EARTH
7207/1510
FRONT CHASSIS -CR_TC M10
-GND5
7207/1510
D -CB_DQ M10
D
-G6
FROM SPLICE S69 600 4.00 mm² 680 -G7 ROOF EARTH POINT
-AFT_JN -TE_JM /7.D3 FROM
FROM SPLICE AFT_S32 600 1.00 mm² 680N 1.00 mm² 680N
/7.B6 FROM
EARTH POINT FRONT CONSOLE

27/31 27/31
7207/1502 M10
-TE_JT
-GND1
GND GND -RC_S70
FROM TRAILER RELAY /18.A2 FROM 1.00 mm² 630N
FROM QUARRY OPTION /11.A5 FROM 1.00 mm² 651E 4.00 mm² 650 35.00 mm² EARTH BOND 1
GND GND
From Heated Rear Screen /10.D4 FROM 2.00 mm² 630F From Fuel Sensor /2.E1 FROM 0.75 mm² 650L
GND 0.75 mm² 630V GND 0.75 mm² 651G
FROM QUICK HITCH RELAY /3.D3 FROM
From LH No Plate Light /11.A8 FROM
GND 0.50 mm² 630B GND 0.75 mm² 650E

From HVAC Relay /1.B6 FROM
From Prk Brk Status Pre Sw /6.C3 FROM
7208/1048 7208/1060
GND 0.50 mm² 630D GND 0.75 mm² 650F
From Compressor Relay /8.B7 FROM HYD COOLING FAN OPTION /3.B5 -E1 -CHAS1 M10
C M8
FROM FROM
GND 2.00 mm² 630E GND 0.75 mm² 650M

From 24/12V Dropper /12.E5 From Hyd Oil Temp Sensor /2.D1
C
FROM FROM
GND 1.00 mm² 630R

-CB_S68 GND 1.00 mm² 650C
FROM MAIN START RLY /1.E7 FROM
From Secondary Steer Relay /12.B5 FROM
GND GND
From Rear Wiper Motor /13.D6 FROM 1.00 mm² 630G
FROM ENGINE BAY LAMP /13.C6 FROM 1.00 mm² 650KA
GND GND -G8
From Seat /12.C7 FROM 2.00 mm² 630J
FROM TRAILER ELECTRICS /18.E1 FROM 1.50 mm² 651T
GND 0.50 mm² 630K
From CAN Dignostic Port /17.C7 FROM
GND
From 12V Aux Feed /12.E7 FROM 1.50 mm² 630L-12V
GND
From ZF Dignostic Port /6.F7 FROM 0.50 mm² 630A
GND GND
From Horn Relay /13.E4 FROM 1.00 mm² 630NM
FROM RHS FOG/REV LAMP
/11.C8 FROM 1.00 mm² 600M
GND GND
From Livelink Relay /12.D3 FROM 0.50 mm² 630M From Front Wash Motor
/13.F7 FROM 1.00 mm² 660S
GND 0.75 mm² 660T
From Rear Wash Motor
/13.D6 FROM
GND 1.50 mm² 620A GND 1.00 mm² 6001

/5.B7
FROM TOW HITCH SOL FROM
GND 1.50 mm² 600B GND 1.00 mm² 600G

/11.C8
FROM LHS FOG/REV LAMP FROM
GND 1.50 mm² 600C GND 1.00 mm² 650A SPLICE EARTH
From Management ECU /3.B1 /11.B8
From RH Rear Combi
4.00 mm² 630
-RC_S77
FROM FROM
GND 1.50 mm² 600D GND 1.00 mm² 650B 4.00 mm² 650N
/11.C8
From LH Rear Combi FROM
GND 1.00 mm² 600E GND 0.75 mm² 660K

From ZF TCU /6.F5 FROM
FROM WASHER LEVEL
/13.C6 FROM
GND 1.00 mm² 600F GND 1.00 mm² 651F

-CB_S67 FROM AUX WORKLIGHT

/10.C7 FROM
GND 0.75 mm² 600G GND 0.75 mm² 651D

From Immobiliser /2.B4 FROM
FROM REVERSE ALARM /11.B4 FROM
GND
From Loader ECU
B /5.B2 1.50 mm² 600J
4.00 mm² 600
FROM
GND
From Loader ECU /5.B2 FROM
GND
1.50 mm² 600K B
From Loader ECU /5.B2 FROM 1.50 mm² 600L
GND REAR CHASSIS
From Immobiliser /1.D7 FROM 0.50 mm² 600A
REAR CAB
0.50 mm² 600M
7207/1510 7207/1510
-CB_DR M10 -RC_MW M10
7219/0218 7219/0221
GND 0.75 mm² 600M
-FC_NF -CB_DH -G9
From Brake Light Press Sw /6.B3 FROM
39/62
39/62
REAR CONSOLE
-GND8
CAB EARTH POINT 1
EARTH POINT REAR CHASSIS
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 63 9813/6500-1 33 - 63
33-64 33-65
1 2 3 4
GND 3.00 mm² 610

From HVAC OR ATC /8.F7 FROM
F
GND 0.50 mm² 610Y
From Int Light /10.A8 FROM
-CB_S66
GND 0.50 mm² 610K #1438 0.50 mm² 660F
From Climate Control Panel /2.A8 FROM
From Instrument Cluster /2.E5

FROM
GND 0.50 mm² 610X #1438 0.50 mm² 660G

From Int Light /10.B8 FROM
From Instrument Cluster /2.D5

FROM
GND 1.00 mm² 610-24V #1438 0.50 mm² 660H

From Radio /12.F3 FROM
FROM CAN SPLICE SX25 /15.A1 FROM
GND 0.75 mm² 610-12V

From 12V Radio /12.E7 FROM
GND 0.50 mm² 610A FRONT CONSOLE

From Park Brake Sw /6.B3 FROM
GND 0.50 mm² 610C

GND 0.50 mm² 610B

-CB_S24
GND 0.50 mm² 610D

From Mirror Sw /10.A3 FROM
GND 0.50 mm² 610W

FROM MMI ILLUMINATION CB_RW:2 /11.F6 FROM
#1438 0.75 mm² 660W

FROM AUX DUMP SOL /3.D4 FROM
GND 0.50 mm² 610F #1438 0.75 mm² 606

From Boom Control Lever /4.D7 FROM
FROM FRONT TO REAR DIVERTER SOL /5.B7 FROM
GND 2.00 mm² 610G #1438 0.75 mm² 660H 2.00 mm² 660B
3.00 mm² 610A

From 24V Power Socket /12.E7 FROM
From Lift Reset Proxy /3.F4 FROM
GND 1.50 mm² 610J-12V #1438 1.50 mm² 660J

From 12V Power Socket /12.F7 FROM
From LH Headlight /11.E8 FROM
-FC_S22
GND 1.50 mm² 610L #1438 0.75 mm² 605
From Weight Load Plug /12.A6 FROM
From Boom Position Sw /6.D3 FROM
GND #1438 0.75 mm² 660E

From Hazard Sw /11.D3 FROM 0.50 mm² 610M From SRS Sol /3.B8 FROM
E From Medium Spec. Inst. /2.E5 FROM

GND 0.50 mm² 610N From Servo Isolator Sol /3.A4 FROM
#1438 0.75 mm² 600CV
GND
From Medium Spec. Inst. /2.E7 FROM 0.50 mm² 610P
GND
From Rotary Control /2.C2 FROM 0.50 mm² 610S
GND #1438 1.50 mm² 660L -FC_S71
From Rear View Camera /2.F7 FROM 0.50 mm² 610U
7207/1502 From RH Headlight /11.D8 FROM 2.00 mm² 660C
#1438 2.00 mm² 660N
-CB_ABC M10 From Horn /13.E6 FROM
#1438 0.75 mm² 600CX

From Ergotraction Solenoid /6.B8 FROM
600 2.00 mm² 612 #1438 0.75 mm² 660R

From I/O Mod. 2 /11.F4 FROM
From Shovel Reset Proxy /3.E4 FROM
-G10
7207/1501 #1438 2.00 mm² 660D
-CB_ABD M10 From Front Wiper Motor /13.F7
FROM
SIDE CAB EARTH
FRONT CHASSIS
-GND5
FROM SPLICE S69 600 4.00 mm² 680

-AFT_JN -TE_JM /7.D3 FROM
FROM SPLICE AFT_S32 600 1.00 mm² 680N 1.00 mm² 680N
/7.B6 FROM
27/31 27/31
7207/1502 M10
-TE_JT
Page 33-65
-GND1
FROM TRAILER RELAY /18.A2 GND 1.00 mm² 630N
FROM
FROM QUARRY OPTION /11.A5
GND
From Heated Rear Screen /10.D4 FROM 2.00 mm² 630F From Fuel Sensor /2.E1
GND 0.75 mm² 630V
FROM QUICK HITCH RELAY /3.D3 FROM
From LH No Plate Light /11.A8

GND 0.50 mm² 630B
From HVAC Relay /1.B6 FROM
From Prk Brk Status Pre Sw /6.C3
GND 0.50 mm² 630D
From Compressor Relay /8.B7 FROM HYD COOLING FAN OPTION /3.B5
C
FROM
GND 2.00 mm² 630E

From 24/12V Dropper /12.E5 FROM
From Hyd Oil Temp Sensor /2.D1
GND 1.00 mm² 630R
-CB_S68
FROM MAIN START RLY /1.E7 FROM
From Secondary Steer Relay /12.B5
GND
From Rear Wiper Motor /13.D6 FROM 1.00 mm² 630G
FROM ENGINE BAY LAMP /13.C6
GND
From Seat /12.C7 FROM 2.00 mm² 630J
FROM TRAILER ELECTRICS /18.E1
GND 0.50 mm² 630K
From CAN Dignostic Port /17.C7 FROM
GND
From 12V Aux Feed /12.E7 FROM 1.50 mm² 630L-12V
GND
From ZF Dignostic Port /6.F7 FROM 0.50 mm² 630A
GND
From Horn Relay /13.E4 FROM 1.00 mm² 630NM
/11.C8
GND
From Livelink Relay /12.D3 FROM 0.50 mm² 630M From Front Wash Motor
/13.F7
/13.D6
GND 1.50 mm² 620A
/5.B7
FROM TOW HITCH SOL
GND 1.50 mm² 600B
/11.C8
FROM LHS FOG/REV LAMP
GND 1.50 mm² 600C
From Management ECU /3.B1 /11.B8
From RH Rear Combi
4.00 mm² 630
FROM
GND 1.50 mm² 600D

/11.C8
From LH Rear Combi
GND 1.00 mm² 600E
FROM WASHER LEVEL
/13.C6
GND 1.00 mm² 600F
-CB_S67 FROM AUX WORKLIGHT

/10.C7
GND 0.75 mm² 600G
From Immobiliser /2.B4 FROM
FROM REVERSE ALARM /11.B4
GND
From Loader ECU
B /5.B2 1.50 mm² 600J
4.00 mm² 600
FROM
GND
From Loader ECU /5.B2 FROM 1.50 mm² 600K
GND
From Loader ECU /5.B2 FROM 1.50 mm² 600L
GND
From Immobiliser /1.D7 FROM 0.50 mm² 600A
REAR CAB
0.50 mm² 600M
7207/1510
-CB_DR M10
7219/0218 7219/0221
GND 0.75 mm² 600M
-FC_NF -CB_DH -G9
From Brake Light Press Sw /6.B3 FROM
39/62
39/62
REAR CONSOLE
CAB EARTH POINT 1
1 2 3 4
33 - 64 9813/6500-1 33 - 64
33-64 33-65
5 6 7 8
-CR_S65
600 1.00 mm² 600BT 4.00 mm² 600CRB
From LH No Plate Light /11.F8 FROM
600 1.00 mm² 600BU

From RH No Plate Light /11.F8 FROM
600 1.00 mm² 600BS

FROM LH WORKLAMP /10.D8 FROM
600 1.00 mm² 600BR

F
FROM RH WORKLAMP /10.C8 FROM
-CB_S66 600
660F From Beacon /10.B7 FROM 1.00 mm² 600CH
660G
660H
FRONT CONSOLE
600
From I/O MOD. 1 /10.F5 FROM 2.00 mm² 600AL -CR_S86
-CR_S64
660W 600 1.50 mm² 600AE 4.00 mm² 600CRA
From LH Outer FWL /10.F7 FROM
606 7219/0218 7219/0221 600 1.50 mm² 600AD

-FC_NF -CB_DH From RH Outer FWL /10.F7 FROM
660H 2.00 mm² 660B 600 1.00 mm² 600AF

62/62 62/62 From LH Middle FWL /10.E7 FROM
660J 600 1.00 mm² 600AC

-FC_S22 From RH Middle FWL /10.E7 FROM
600
605 From RH Aux FWL /10.D7 FROM 1.00 mm² 600AB
600
660E From LH Aux FWL 1.00 mm² 600AA
2.00 mm² 660B
/10.E7 FROM
600
600CV From LH Heated Mirror /10.C4 1.00 mm² 600AG
E
FROM
600
From RH Heated Mirror /10.B4 FROM 1.00 mm² 600AH
600
From Step Light /10.D6 FROM 1.00 mm² 600AJ
7219/0218 7219/0221 600
-CB_DH From Green Beacon 1.00 mm² 600AK
8.00 mm² 600CR

-FC_S71 -FC_NF /12.B7 FROM
660L 2.00 mm² 660C 2.00 mm² 660C 600 1.00 mm² 600AY
61/62 61/62 From LiveLink /12.C3 FROM
660N -CB_S38
600CX
ROOF
660R
2.00 mm² 660A
4.00 mm² 660
660D
7207/1510
FRONT CHASSIS -CR_TC M10
7207/1510
-CB_DQ M10
D
-G6
-G7 ROOF EARTH POINT
EARTH POINT FRONT CONSOLE

Page 33-64
GND -RC_S70
1.00 mm² 651E 4.00 mm² 650 35.00 mm² EARTH BOND 1
FROM QUARRY OPTION /11.A5 FROM
GND 0.75 mm² 650L

From Fuel Sensor /2.E1 FROM
GND 0.75 mm² 651G

From LH No Plate Light /11.A8 FROM
GND 0.75 mm² 650E

From Prk Brk Status Pre Sw /6.C3 FROM
7208/1048 7208/1060
GND 0.75 mm² 650F
FROM HYD COOLING FAN OPTION /3.B5 FROM
-E1 M8 -CHAS1 M10
GND 0.75 mm² 650M
From Hyd Oil Temp Sensor /2.D1
C
FROM
GND 1.00 mm² 650C

From Secondary Steer Relay /12.B5 FROM
GND 1.00 mm² 650KA

FROM ENGINE BAY LAMP /13.C6 FROM
GND 1.50 mm² 651T -G8

FROM TRAILER ELECTRICS /18.E1 FROM
GND 1.00 mm² 600M

/11.C8 FROM
GND 1.00 mm² 660S

From Front Wash Motor
/13.F7 FROM
GND 0.75 mm² 660T

/13.D6 FROM
GND 1.00 mm² 6001

/5.B7
FROM TOW HITCH SOL FROM
GND 1.00 mm² 600G

/11.C8
FROM LHS FOG/REV LAMP FROM
GND 1.00 mm² 650A SPLICE EARTH

/11.B8
From RH Rear Combi FROM
-RC_S77
GND 1.00 mm² 650B 4.00 mm² 650N
/11.C8
From LH Rear Combi FROM
GND 0.75 mm² 660K

FROM WASHER LEVEL
/13.C6 FROM
GND 1.00 mm² 651F

FROM AUX WORKLIGHT
/10.C7 FROM
GND 0.75 mm² 651D

FROM REVERSE ALARM /11.B4 FROM
B
REAR CHASSIS
7207/1510
-RC_MW M10
-GND8
EARTH POINT REAR CHASSIS
335-C0779-7
5 6 7 8
33 - 65 9813/6500-1 33 - 65
33 - 66 9813/6500-1 33 - 66
Page 33-68 Figure 645. CAN Network (Page 1) Page 33-69

1 2 3 4 5 6 7 8
E
F
-DIS_1#1
728/A1566
Low Spec Display (Front)
F Medium Spec Display
E

-DIS_3
J1-4 Digital Input Pin 4 5V REF J2-11 333/A0895
J1-10 +VBATT Ground

J1-9
J1-9
J1-11 FREQ
J1-1 DIGITAL INPUT 2 GROUND
J1-12 Digital Input Pin 14 Ground J2-4 J1-2 DIGITAL INPUT 1
J1-13 Digital Input Pin 13 J1-3 NOT USED
J1-14 Digital Input Pin 12 Ground J2-9 J1-4 DIGITAL INPUT PIN 4
J1-15 Digital Input Pin 11 J1-5 DIGITAL INPUT PIN 3 USB NEG
J2-1
J1-16 Digital Input Pin 10 HS Out 1 J2-19 J1-10 +VBATT USB POS
J2-2
J2-3
J1-18 Digital Input Pin 8 HS Out 2 J2-20 J1-12 VIDEO GROUND 1 USB GROUND
J2-4
J2-5
J1-20 Digital Input Pin 6 LS Out 1
J2-5 J1-14 VIDEO GROUND 2 NOT USED
J2-6
J2-1 ---
J2-7
D J2-2 --- LS Out 2 J2-13 J1-16 NOT USED NOT USED
J2-8
J2-3 ---
J2-9
D
J2-6 S/W Config 3 DIG/AN J1-18 NOT USED J2-10
NOT USED
J2-7 S/W Config 2 DIG/AN J1-19 NOT USED NOT USED

J2-11
J1-20 NOT USED J2-12
NOT USED
J2-10 ---
J2-13
NOT USED
J2-12 Analogue 1 J2-14

NOT USED
IMMOBILISER
J2-15
NOT USED

NOT USED Membrane SW Pad #3
J2-16 J2-17
-SW_ATC(CB)1 Membrane SW pad #1 (CS) Membrane S Pad #2 (CR)
S/W Config 6 DIG/AN NOT USED

J2-18
UART_RX 333/D7363 -SW_CS1 -SW_CR1
6/12 J2-20
UART_TX 333/D7363 333/D7363
3/12
5 1 V_ Supply V_Ground
5
4/12 11/12 Config Ground
6 Config Ground
6 Config Ground
6
CAN Shield
CAN High
7 7 7
CAN SHIELD
CAN Low
Config Pin 2 Config Pin 2 Config Pin 2

CAN HIGH
CAN LOW
12/12
C Config Pin 1
8 Config Pin 1
8 Config Pin 1
8
C
J1-6
J1-8
J1-7
10/12
CAN S
CAN S
CAN S
CAN H
CAN H
CAN H
J1-6
J1-8
J1-7
CAN L
CAN L
CAN L
9/12
8/12
4 3 2 4 3 2 2 3 4
7218/0071
7218/0071
7219/0019
332/E3213
332/E3213
7218/0071
-CB_DJ
-CB_DD
-CB_CB
-CB_CS
-CB_CR
-CB_EM
6/20
8/20
7/20
9/12
10/12
8/20
7/20
6/20
4/8
3/8
2/8
4/8
3/8
2/8
2/8
3/8
4/8
0.50 mm² 561
0.50 mm² 541

0.50 mm² 562
0.50 mm² 542
0.50 mm² 543

0.50 mm² 560
0.50 mm² 540
0.50 mm² 539
0.50 mm² 538

170mm 170mm 170mm
0.50 mm² 547
0.50 mm² 557
0.50 mm² 535
0.50 mm² 536
0.50 mm² 544
0.50 mm² 545
0.50 mm² 546

0.50 mm² 558
190mm 190mm 200mm UTP UTP UTP

UTP UTP UTP
-TP20:TW1
-TP22:TW1
-TP21:TW1
-TP19:TW1
-TP18:TW1
-TP23:TW1
420mm 2490mm 680mm 860mm 240mm

-CB_CNR1 150mm STP STP STP STP STP
7213/0015 UTP TO CAN SPLICE SX38
B 0.50 mm² 558A 0.50 mm² CAN 15H 0.50 mm² CAN 14H 0.50 mm² CAN 13H 0.50 mm² CAN 12H 0.50 mm² CAN 11H 0.50 mm² CAN 10H TO
/16.A1
A/3 -SX30 -SX31 -SX22 -SX16 -SX19 -SX35 B
C B A
B/3 0.50 mm² 557A 0.50 mm² CAN 15L 0.50 mm² CANSPLICE_CAN.H.DPM
14L 0.50 mm² CAN 13L SPLICE_CAN.H.KP
0.50 mm² CAN 12L 0.50 mm² CAN 11L 0.50 mm² CAN 10L TO CAN SPLICE SX39
TO
/16.A1
-SX29 -SX47 -SX23 -SX17 -SX20 -SX36
#1438 #1438
0.50 mm² 660H 0.50 mm² CAN 15S #1438 0.50 mm² CAN 14S SPLICE_CAN.L.DPM 0.50 mm² CAN 13S 0.50 mm² CAN 12S SPLICE_CAN.L.KP 0.50 mm² CAN 11S 0.50 mm² CAN 10S TO CAN SPLICE SX40
TO
/16.A1
CAN TERMINATING RES. 1 -SX25 -SX48 -SX24 -SX18 -SX21 -SX37
-MC13:SH1
-CB_CNR1R SPLICE_CAN.S.DPM -MC12:SH1
-MC14:SH1
TO EARTH SPLICE S66 #1438

/14.F4 TO
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 67 9813/6500-1 33 - 67
33-68 33-69
1 2 3 4
-DIS_1#1
728/A1566
Low Spec Display (Front)
F J1-1 Digital Input Pin 2 Medium Spec Display

-DIS_3
J1-4 Digital Input Pin 4 5V REF J2-11 333/A0895
J1-10 +VBATT Ground

J1-9
J1-9
J1-11 FREQ
J1-1 DIGITAL INPUT 2 GROUND
J1-12 Digital Input Pin 14 Ground J2-4 J1-2 DIGITAL INPUT 1
J1-13 Digital Input Pin 13 J1-3 NOT USED
J1-14 Digital Input Pin 12 Ground J2-9 J1-4 DIGITAL INPUT PIN 4
J1-15 Digital Input Pin 11 J1-5 DIGITAL INPUT PIN 3 USB NEG
J2-1
J1-16 Digital Input Pin 10 HS Out 1 J2-19 J1-10 +VBATT USB POS
J2-2
J2-3
J1-18 Digital Input Pin 8 HS Out 2 J2-20 J1-12 VIDEO GROUND 1 USB GROUND
J2-4
J2-5
J1-20 Digital Input Pin 6 LS Out 1
J2-5 J1-14 VIDEO GROUND 2 NOT USED
J2-6
J2-1 ---
J2-7
D J2-2 --- LS Out 2 J2-13 J1-16 NOT USED NOT USED
J2-8
J2-3 ---
J2-9
J2-6 S/W Config 3 DIG/AN J1-18 NOT USED J2-10
NOT USED
J2-7 S/W Config 2 DIG/AN J1-19 NOT USED NOT USED

J2-11
J1-20 NOT USED J2-12
NOT USED
J2-10 ---
J2-13
NOT USED

NOT USED
IMMOBILISER
J2-15
NOT USED

NOT USED
Page 33-69
J2-17
NOT USED

J2-18
UART_RX
6/12 J2-20
UART_TX
3/12
4/12 11/12
CAN Shield
CAN High
CAN SHIELD
CAN Low
CAN HIGH
12/12 CAN LOW

C
J1-6
J1-8
J1-7
10/12
J1-6
J1-8
J1-7
9/12
8/12
7219/0019
332/E3213
332/E3213
-CB_DJ
-CB_DD
-CB_EM
6/20
8/20
7/20
9/12
10/12
8/20
7/20
6/20
0.50 mm² 547
0.50 mm² 557
0.50 mm² 535
0.50 mm² 536
0.50 mm² 544
0.50 mm² 545
0.50 mm² 546

0.50 mm² 558
190mm 190mm 200mm

UTP UTP UTP
-TP22:TW1
-TP21:TW1
-TP23:TW1
420mm 2490mm 680mm

-CB_CNR1 150mm STP STP STP
7213/0015 UTP
B 0.50 mm² 558A 0.50 mm² CAN 15H 0.50 mm² CAN 14H 0.50 mm²
A/3 -SX30 -SX31 -SX22
C B A
B/3 0.50 mm² 557A 0.50 mm² CAN 15L 0.50 mm² CANSPLICE_CAN.H.DPM
14L 0.50 mm²
-SX29 -SX47 -SX23
#1438 SPLICE_CAN.L.DPM #1438
0.50 mm² 660H 0.50 mm² CAN 15S 0.50 mm² CAN 14S 0.50 mm²
CAN TERMINATING RES. 1 -SX25 -SX48 -SX24 -MC13:SH1
-CB_CNR1R SPLICE_CAN.S.DPM
-MC14:SH1
TO EARTH SPLICE S66 #1438

/14.F4 TO
1 2 3 4
33 - 68 9813/6500-1 33 - 68
33-68 33-69
5 6 7 8
GROUND
J1-9
USB NEG
J2-1
USB POS
J2-2
USB VBUS
J2-3
USB GROUND
J2-4
NOT USED
J2-5
NOT USED
J2-6
NOT USED
J2-7
NOT USED
J2-8
NOT USED
J2-9
D
J2-10
NOT USED
NOT USED
J2-11
J2-12
NOT USED
J2-13
NOT USED
J2-14
NOT USED
J2-15
NOT USED
J2-16
NOT USED Membrane SW Pad #3
-SW_ATC(CB)1
Page 33-68
J2-17 Membrane SW pad #1 (CS) Membrane S Pad #2 (CR)

NOT USED
GROUND
J2-18
J2-19
UART_RX 333/D7363 -SW_CS1 -SW_CR1
J2-20
UART_TX 333/D7363 333/D7363
5
Config Ground
6 Config Ground
6 Config Ground
6
Config Pin 2 7 Config Pin 2 7 Config Pin 2 7
Config Pin 1
8 Config Pin 1
8 Config Pin 1
8
C
CAN S
CAN S
CAN S
CAN H
CAN H
CAN H
CAN L
CAN L
CAN L
4 3 2 4 3 2 2 3 4
7218/0071
7218/0071
7218/0071
-CB_CB
-CB_CS
-CB_CR
4/8
3/8
2/8
4/8
3/8
2/8
2/8
3/8
4/8
0.50 mm² 561
0.50 mm² 541

0.50 mm² 562
0.50 mm² 542
0.50 mm² 543

0.50 mm² 560
0.50 mm² 540
0.50 mm² 539
0.50 mm² 538
170mm 170mm 170mm

200mm UTP UTP UTP
-TP20:TW1
-TP19:TW1
-TP18:TW1
680mm 860mm 240mm

STP STP STP
0.50 mm² CAN 13H 0.50 mm² CAN 12H 0.50 mm² CAN 11H 0.50 mm² CAN 10H TO CAN SPLICE SX38
TO
/16.A1
-SX16 -SX19 -SX35 B
0.50 mm² CAN 13L 0.50 mm² SPLICE_CAN.H.KP
CAN 12L 0.50 mm² CAN 11L 0.50 mm² CAN 10L TO CAN SPLICE SX39
TO
/16.A1
-SX17 -SX20 -SX36
#1438
0.50 mm² CAN 13S 0.50 mm² CAN 12S SPLICE_CAN.L.KP 0.50 mm² CAN 11S 0.50 mm² CAN 10S TO CAN SPLICE SX40
TO
/16.A1
-MC13:SH1 -SX18 -SX21 -SX37
-MC12:SH1
335-C0779-7
5 6 7 8
33 - 69 9813/6500-1 33 - 69
33 - 70 9813/6500-1 33 - 70

1 2 3 4 5 6 7 8
E
F
F
E
Climate Control Unit

CAN H
CAN L
-ECU#2
728/A3879
I/O MODULE 1
23/35
26/35

332/F8042
J1-11
-ATC_DT
+5V Output Ref

23/35
26/35
D
-MC17:TW1
Ground
D

J2-1
-ATC_C2 - 24V - 6A

CUT END Channel 4 - 12V - 10A
NO CONNECTOR - 24V - 6A J2-2
LEAD CUT 1/1
J1-5 Input 3
Connector for ECU not currently in Zuken

#1438

- 24V - 6A J2-3
J1-6 Input 1
1000mm
0.50 mm² CAN 17S

- 24V - 6A J2-4
0.50 mm² CAN 17H
0.50 mm² CAN 17L
STP J1-7 Analog Input 3

- 24V - 6A J2-5
J1-8 Analog Input 1

- 24V - 6A J2-6

- 24V - 6A J2-7
-ATC_DC
C
Rotary Controller - 24V - 2.5A J2-8
6/8
5/8
7/8

C
-SW_AA1 Channel 6 - 12V - 5A
- 24V - 2.5A J2-9
728/A1568 J1-13 Input
-CB_AH
4
5/8
6/8
7/8
Ignition Wake up
- 24V - 2.5A J2-10
- 24V - 2.5A J2-11
CAN Shield
CAN High
CAN Low
1 POWER GROUND 2 - 24V - 6A J2-12
J1-10
J1-9
J1-1
TO ENGINE ECU
TO ENGINE ECU
3
CAN-H
CAN-L
7219/0231
-CR_CM
1/16
9/16
10/16
/7.D4
/7.D4
#1438
7214/0078
-CB_AA
3/4
4/4
0.50 mm² CAN 17H
0.50 mm² CAN 17S

0.50 mm² CAN 17L
TO
TO
CAN SHLD
CAN H
0.50 mm² 559
0.50 mm² 560
170mm 160mm 190mm

B UTP UTP UTP
B
0.50 mm² 586
0.50 mm² 587
0.50 mm² 585

-TP17:TW1
1.00 mm² 571

1.00 mm² 570
-TP09:TW1
230mm 1010mm 1040mm 2080mm 2080mm 1010mm 1990mm
STP STP STP 7219/0219 7219/0075
STP STP STP 7219/0006
7219/0005 STP
-MC16:TW1 -TE_XF -CB_GA -MC8:TW1 -CB_CXR -CR_RXR -MC17:TW1
FROM CAN SPLICE SX35 -CB_GA -TE_XF -SX1 CAN H TO CAN SPLICE S185
0.50 mm² CAN 10H 0.50 mm² CAN 9H 0.50 mm² CAN 2H 0.50 mm² CAN 17H 0.50 mm² CAN 16H 46/62 46/62 0.50 mm² CAN 8H 0.50 mm² CAN H9 0.50 mm² CAN 8H
/15.B7 FROM
49/62 49/62
TO
/17.B1
-SX38 -SX44 SPLICE_CAN-H -TE_XF -CB_GA 4/14 4/14 -CR_S182
FROM CAN SPLICE SX36 -CB_GA -TE_XF -SX2 CAN SHLD TO CAN SPLICE S186
0.50 mm² CAN 10L 0.50 mm² CAN 9L 0.50 mm² CAN 2L 0.50 mm² CAN 17L 0.50 mm² CAN 16L 47/62 47/62 0.50 mm² CAN 8L 0.50 mm² CAN L9 0.50 mm² CAN 8L
/15.B7 FROM
55/62 55/62
TO
/17.B1
-SX39 -SX45 SPLICE_CAN-L -TE_XF -CB_GA 5/14 5/14 -CR_S183
FROM CAN SPLICE SX37 #1438 -CB_GA -TE_XF #1438 -SX3 #1438 #1438 #1438 #1438 #1438 TO CAN SPLICE S187
0.50 mm² CAN 10S 0.50 mm² CAN 9S 0.50 mm² CAN 2S 0.50 mm² CAN 17S 0.50 mm² CAN 16S 48/62 48/62 0.50 mm² CAN 8S 0.50 mm² CAN S9 0.50 mm² CAN 8S
/15.B7 FROM
56/62 56/62
TO
/17.A1
-SX40 -SX46 -MC2:SH1 SPLICE_SCRN 6/14 6/14 -CR_S184
-MC9:SH1 -MC17:SH1 -MC16:SH1 -MC8:SH1 -MC9:SH1 -MC17:SH1
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 71 9813/6500-1 33 - 71
33-72 33-73
1 2 3 4
Climate Control Unit

CAN H
CAN L
23/35
26/35
332/F8042
-ATC_DT
23/35
26/35
D
-MC17:TW1
-ATC_C2
CUT END
NO CONNECTOR
LEAD CUT 1/1
Connector for ECU not currently in Zuken

#1438
1000mm
Page 33-73
0.50 mm² CAN 17S
0.50 mm² CAN 17H
0.50 mm² CAN 17L
STP
-ATC_DC
C Rotary Controller
6/8
5/8
7/8
-SW_AA1
728/A1568
-CB_AH
5/8
6/8
7/8
1 POWER GROUND 2
TO ENGINE ECU
TO ENGINE ECU
3
CAN-H
CAN-L
4
/7.D4
/7.D4
#1438
7214/0078
-CB_AA
3/4
4/4
0.50 mm² CAN 17H
0.50 mm² CAN 17S

0.50 mm² CAN 17L
TO
TO
CAN SHLD
CAN H
0.50 mm² 559
0.50 mm² 560
170mm 160mm
B UTP UTP
-TP17:TW1
1.00 mm² 571

1.00 mm² 570
230mm 1010mm 1040mm 2080mm 2080mm

STP STP STP 7219/0219 7219/0075
STP STP
-MC16:TW1 -TE_XF -CB_GA
FROM CAN SPLICE SX35 -CB_GA -TE_XF -SX1
0.50 mm² CAN 10H 0.50 mm² CAN 9H 0.50 mm² CAN 2H 0.50 mm² CAN 17H 0.50 mm² CAN 16H 46/62 46/62
/15.B7 FROM
49/62 49/62
-SX38 -SX44 SPLICE_CAN-H -TE_XF -CB_GA
FROM CAN SPLICE SX36 -CB_GA -TE_XF -SX2
0.50 mm² CAN 10L 0.50 mm² CAN 9L 0.50 mm² CAN 2L 0.50 mm² CAN 17L 0.50 mm² CAN 16L 47/62 47/62
/15.B7 FROM
55/62 55/62
-SX39 -SX45 SPLICE_CAN-L -TE_XF -CB_GA
FROM CAN SPLICE SX37 #1438 -CB_GA -TE_XF #1438 -SX3 #1438
0.50 mm² CAN 10S 0.50 mm² CAN 9S 0.50 mm² CAN 2S 0.50 mm² CAN 17S 0.50 mm² CAN 16S 48/62 48/62
/15.B7 FROM
56/62 56/62
-SX40 -SX46 -MC2:SH1 SPLICE_SCRN
-MC9:SH1 -MC17:SH1 -MC16:SH1
1 2 3 4
33 - 72 9813/6500-1 33 - 72
33-72 33-73
5 6 7 8
-ECU#2
728/A3879
I/O MODULE 1

+5V Output Ref J1-11
Ground
D

- 24V - 6A
J2-1

- 24V - 6A J2-2
J1-5 Input 3

- 24V - 6A J2-3
J1-6 Input 1
Page 33-72

- 24V - 6A J2-4
J1-7 Analog Input 3

- 24V - 6A J2-5
J1-8 Analog Input 1

- 24V - 6A J2-6

- 24V - 6A J2-7
- 24V - 2.5A J2-8
C
- 24V - 2.5A J2-9
J1-13 Input 4
Ignition Wake up
- 24V - 2.5A J2-10
- 24V - 2.5A J2-11
CAN Shield
CAN High
CAN Low

- 24V - 6A J2-12
J1-10
J1-9
J1-1
7219/0231
-CR_CM
1/16
9/16
10/16
190mm
UTP
B
0.50 mm² 586
0.50 mm² 587
0.50 mm² 585

-TP09:TW1
1010mm 1990mm
STP 7219/0006
7219/0005 STP
-TE_XF -CB_GA -MC8:TW1 -CB_CXR -CR_RXR -MC17:TW1
46/62 46/62 0.50 mm² CAN 8H 0.50 mm² CAN H9 0.50 mm² CAN 8H CAN H TO CAN SPLICE S185
TO
/17.B1
-TE_XF -CB_GA 4/14 4/14 -CR_S182
47/62 47/62 0.50 mm² CAN 8L 0.50 mm² CAN L9 0.50 mm² CAN 8L CAN SHLD TO CAN SPLICE S186
TO
/17.B1
-TE_XF -CB_GA 5/14 5/14 -CR_S183
#1438 #1438 #1438 #1438 #1438 TO CAN SPLICE S187
48/62 48/62 0.50 mm² CAN 8S 0.50 mm² CAN S9 0.50 mm² CAN 8S TO
/17.A1
6/14 6/14 -CR_S184
-MC16:SH1 -MC8:SH1 -MC9:SH1 -MC17:SH1
335-C0779-7
5 6 7 8
33 - 73 9813/6500-1 33 - 73
33 - 74 9813/6500-1 33 - 74

1 2 3 4 5 6 7 8
SRC NOX DOC NOX

SENSOR SRC TEMP SENSOR DOC TEMP DEF SUPPLY TANK
E
F
ENGINE CAN
2/4
2/4
2/4
2/4
2/4
3/4
3/4
3/4
3/4
1/4
/7.B6
7214/0092
7214/0091
7214/0079
-AFT_EC
-AFT_EH
-AFT_ED
-AFT_EJ
-AFT_ER
7214/0025
7214/0080
3/4
2/4
3/4
2/4
3/4
2/4
3/4
2/4
1/4
2/4
0.75 mm² CAN HD
0.75 mm² CAN LD
0.75 mm² CAN HH
0.75 mm² CAN HK

0.75 mm² CAN HF
0.75 mm² CAN LH
0.75 mm² CAN LK

0.75 mm² CAN LF
0.75 mm² CAN HB
0.75 mm² CAN LB

-TP14:TW1
-TP16:TW1
-TP18:TW1
-TP20:TW1
-TP12:TW1
CAN TERM RESISTOR

7220/0061 332/W5209
1
-TE_JM -AFT_JN
320/B9881
-CNR3
0.75 mm² CAN HA 0.75 mm² CAN HC 0.75 mm² CAN HE 0.75 mm² CAN HG 0.75 mm² CAN HJ 0.50 mm² CNR3A
19/31 19/31 -SX51 -SX53 -SX55 -SX57 -SX49
F 0.75 mm² CAN LA 0.75 mm² CAN LC 0.75 mm² CAN LE 0.75 mm² CAN LG 0.75 mm² CAN LJ 0.50 mm² CNR3B
E
2
18/31 18/31 -SX52 -SX54 -SX56 -SX58 -SX50
-TP11:TW1 -TP13:TW1 -TP15:TW1 -TP17:TW1 -TP19:TW1
7219/0161
OEM 24 WAY
-TE_KP FEMALE CONN.
0.75 mm² CAN L 3/24
23/24
0.75 mm² CAN H 2/24 -ECU#1
22/24 728/A3879
-TP21:TW1
I/O MODULE 2

MANAGEMENT ECU LOADER ECU +5V Output Ref J1-11
Ground
D J1-3 Config Address 3 (active low)
9/35 Channel 5 - 12V - 10A

J2-1
D
- 24V - 6A
14/35 10/35 12/35 J1-4 Config Address 1 (active low)
11/35 Channel 4 - 12V - 10A

- 24V - 6A J2-2
15/35 27/35 J1-5 Input 3
26/35 Channel 8 - 12V - 10A

J2-3
- 24V - 6A
16/35 6/35 J1-6

LIVELINK 3
Input 1

- 24V - 6A J2-4
17/35 25/35 J1-7 Analog Input 3
5/35 Channel 10 - 12V - 10A

J2-5
- 24V - 6A
24/35 J1-8 Analog Input 1
35/35 Channel 1 - 12V - 10A

J2-6
- 24V - 6A
C3/48
D4/48
E4/48
25/35 4/35
ZF TCU Channel 7 - 12V - 10A
- 24V - 6A J2-7
35/35 22/35 24/35
3/35 Channel 9 - 12V - 5A
J2-8
CAN HF_H
D4/48
E4/48
C3/48
- 24V - 2.5A
27/35
CANF_L

J1939 CAN
13/35
C Connector
J2-9
- 24V - 2.5A
-CB_EA
12/35 2/35 J1-13 Input 4
Ignition Wake up
B/9
7219/0098
0.50 mm² 301B BATT
From Fuse B2 C
J2-10 /1.B4
FROM
CAN A (H)
CAN A (L)
- 24V - 2.5A
25/68
26/68
11/35 17/35 J1-14 Digital Input 2 (active high/low) B/9

CAN SH
1/35 Channel 3 - 12V - 5A

J2-11
- 24V - 2.5A
To Earth Splice
CAN Shield
20/35 16/35 0.50 mm² 630K GND
CAN High
A/9
CAN Low
/14.C1
7219/0072
21/35 Channel 11 - 12V - 10A

J2-12 A/9
-CB_DW
- 24V - 6A
J1-10
25/68
26/68
23/35
23/35
34/35
33/35
34/35
33/35
J1-9
J1-1
15/35 22/35
C/9
D/9
E/9
-CB_CN
7219/0231
332/F8042
1/16
9/16
10/16
-CB_NX
0.50 mm² 531
0.50 mm² 530
7219/0098
332/F8042
-CB_EA
-CB_PX
34/35
33/35
23/35
34/35
33/35
23/35
C/9
D/9
E/9
0.50 mm² 532
0.50 mm² 533
0.50 mm² 534

556
185mm 175mm 120mm 190mm 190mm

0.50 mm² 555
0.50 mm² 554
0.50 mm² 524
0.50 mm² 525
0.50 mm² 526
0.50 mm² 527
0.50 mm² 528
0.50 mm² 529
-MC18:SH1
#1438
UTP UTP UTP UTP UTP 250mm
0.75 mm²
STP
-TP13:TW1
-TP11:TW1
-TP10:TW1
-TP12:TW1
0.50 mm² CAN 18H
0.50 mm² CAN 18S

0.50 mm² CAN 18L
-TP14:TW1
B
B
220mm 1755mm 315mm 735mm 150mm 1110mm 460mm 160mm
STP STP 7219/0005 7219/0006 STP STP UTP STP STP UTP
-CR_RXR -CB_CXR -MC4:TW1 -CB_CNR2
TO CAN SPLICE S182 CAN H 7213/0015
0.50 mm² CAN 8H 0.50 mm² CAN H11 0.50 mm² CAN 7H 0.50 mm² CAN 6H 0.50 mm² CAN 5H 0.50 mm² CAN 4H 0.50 mm² CAN 3H
/16.A7 FROM
-CR_S185 7/14 7/14 -SX4 -SX10 -SX7 -SX13 -SX26 0.50 mm² CAN 22H A/3
C B A
TO CAN SPLICE S183 CAN SHLD 0.50 mm² CAN 8L 0.50 mm² CAN L11 0.50 mm² CAN 7L 0.50 mm² CAN 6L SPLICE_CAN.H.ZF 0.50 mm² CAN 5L 0.50 mm² CAN 4L 0.50 mm² CAN 3L 0.50 mm² CAN 22L B/3
/16.A7 FROM
-CR_S186 8/14 8/14 -SX5 -SX11 -SX8 -SX14 -SX27

TO CAN SPLICE S184 #1438 #1438 #1438 SPLICE_CAN.L.ZF #1438 #1438 SPLICE_CAN.L.DIAG
0.50 mm² CAN 8S 0.50 mm² CAN S11 0.50 mm² CAN 7S 0.50 mm² CAN 6S 0.50 mm² CAN 5S 0.50 mm² CAN 4S 0.50 mm² CAN 3S
/16.A7 FROM
-CR_S187 9/14 9/14 -SX6 -MC6:SH1 -SX12 -SX9 -SX15 -SX28 CAN TERMINATING RES. 2
-MC7:SH1 -MC5:SH1 -MC4:SH1 -MC3:SH1
-MC11:SH1 SPLICE_CAN.S SPLICE_CAN.S.DIAG -CB_CNR2R
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 75 9813/6500-1 33 - 75
33-76 33-77
1 2 3 4
SRC NOX DOC NOX

SENSOR SRC TEMP SENSOR DOC TEMP
2/4
2/4
2/4
2/4
3/4
3/4
3/4
3/4
7214/0092
7214/0091
7214/0079
-AFT_EC
-AFT_EH
-AFT_EJ
-AFT_ER
7214/0080
3/4
2/4
3/4
2/4
3/4
2/4
3/4
2/4
0.75 mm² CAN HD
0.75 mm² CAN LD
0.75 mm² CAN HH

0.75 mm² CAN HF
0.75 mm² CAN LH

0.75 mm² CAN LF
0.75 mm² CAN HB
0.75 mm² CAN LB

-TP14:TW1
-TP16:TW1
-TP18:TW1
-TP12:TW1
7220/0061 332/W5209
-TE_JM -AFT_JN
0.75 mm² CAN HA 0.75 mm² CAN HC 0.75 mm² CAN HE 0.75 mm² CAN HG 0.75 mm² CAN HJ
19/31 19/31 -SX51 -SX53 -SX55 -SX57
F 0.75 mm² CAN LA 0.75 mm² CAN LC 0.75 mm² CAN LE 0.75 mm² CAN LG 0.75 mm² CAN LJ
18/31 18/31 -SX52 -SX54 -SX56 -SX58
-TP11:TW1 -TP13:TW1 -TP15:TW1 -TP17:TW1 -TP19:TW1
7219/0161
OEM 24 WAY
-TE_KP FEMALE CONN.
0.75 mm² CAN L 3/24
23/24
0.75 mm² CAN H 2/24
22/24
-TP21:TW1
MANAGEMENT ECU LOADER ECU
D
9/35
14/35 10/35
11/35
15/35 27/35
16/35 6/35
LIVELINK 3
17/35
5/35
Page 33-77
24/35
C3/48
D4/48
E4/48
25/35 4/35
ZF TCU
35/35 22/35
3/35
CAN HF_H
D4/48
E4/48
C3/48
27/35
CANF_L
C 12/35 2/35
CAN A (H)
CAN A (L)
25/68
26/68
11/35
CAN SH
1/35
20/35
7219/0072
21/35
-CB_DW
25/68
26/68
23/35
34/35
33/35
34/35
15/35 22/35
332/F8042
-CB_NX
0.50 mm² 531
0.50 mm² 530
332/F8042
-CB_PX
34/35
33/35
23/35
34/35
556
185mm 175mm 120mm

0.50 mm² 555
0.50 mm² 554
0.50 mm² 524
0.50 mm² 525
0.50 mm² 526
0.50 mm² 527
UTP UTP UTP

0.75 mm²
-TP13:TW1
-TP10:TW1
-TP12:TW1
-TP14:TW1
B
220mm 1755mm 315mm 735mm 150mm
STP STP 7219/0005 7219/0006 STP STP UTP
-CR_RXR -CB_CXR
TO CAN SPLICE S182 CAN H 0.50 mm² CAN 8H 0.50 mm² CAN H11 0.50 mm² CAN 7H 0.50 mm² CAN 6H 0.50 mm² CAN 5H
/16.A7 FROM
-CR_S185 7/14 7/14 -SX4 -SX10 -SX7

TO CAN SPLICE S183 CAN SHLD 0.50 mm² CAN 8L 0.50 mm² CAN L11 0.50 mm² CAN 7L 0.50 mm² CAN 6L SPLICE_CAN.H.ZF 0.50 mm² CAN 5L
/16.A7 FROM
-CR_S186 8/14 8/14 -SX5 -SX11

TO CAN SPLICE S184 #1438 #1438 #1438 SPLICE_CAN.L.ZF
0.50 mm² CAN 8S 0.50 mm² CAN S11 0.50 mm² CAN 7S 0.50 mm² CAN 6S 0.50 mm² CAN 5S
/16.A7 FROM
-CR_S187 9/14 9/14 -SX6 -MC6:SH1 -SX12 -MC5:SH1

-MC7:SH1 SPLICE_CAN.S
-MC11:SH1
1 2 3 4
33 - 76 9813/6500-1 33 - 76
33-76 33-77
5 6 7 8
DEF SUPPLY TANK
F
ENGINE CAN
2/4
1/4
/7.B6
-AFT_ED
7214/0025
1/4
2/4
0.75 mm² CAN HK
0.75 mm² CAN LK
-TP20:TW1
CAN TERM RESISTOR

1
320/B9881
-CNR3
0.75 mm² CAN HJ 0.50 mm² CNR3A

-SX49
0.75 mm² CAN LJ 0.50 mm² CNR3B
E
2
-SX50
-TP19:TW1
-ECU#1
728/A3879
I/O MODULE 2

LOADER ECU +5V Output Ref J1-11
Ground
9/35 Channel 5 - 12V - 10A

J2-1
D
- 24V - 6A
10/35 12/35 J1-4 Config Address 1 (active low)
11/35 Channel 4 - 12V - 10A

- 24V - 6A J2-2
27/35 J1-5 Input 3
26/35 Channel 8 - 12V - 10A

J2-3
- 24V - 6A
6/35 J1-6 Input 1

- 24V - 6A J2-4
25/35 J1-7 Analog Input 3
5/35
Page 33-76

- 24V - 6A J2-5
J1-8 Analog Input 1
35/35 Channel 1 - 12V - 10A

J2-6
- 24V - 6A
4/35
- 24V - 6A J2-7
24/35
3/35 Channel 9 - 12V - 5A
J2-8
- 24V - 2.5A
J1-12 Config Address 2 (active low) J1939 CAN

13/35
Connector
J2-9
- 24V - 2.5A
-CB_EA
2/35 J1-13 Input 4
Ignition Wake up
B/9
7219/0098
0.50 mm² 301B BATT
From Fuse B2 C
- 24V - 2.5A J2-10 /1.B4
FROM
17/35 J1-14 Digital Input 2 (active high/low) B/9

1/35 Channel 3 - 12V - 5A
J2-11
- 24V - 2.5A
To Earth Splice
CAN Shield
20/35 16/35 0.50 mm² 630K GND

CAN High
A/9
CAN Low

/14.C1
21/35 Channel 11 - 12V - 10A
- 24V - 6A J2-12 A/9
J1-10
23/35
34/35
33/35
J1-9
J1-1
15/35 22/35
C/9
D/9
E/9
-CB_CN
7219/0231
332/F8042
1/16
9/16
10/16
-CB_NX
7219/0098
-CB_EA
34/35
33/35
23/35
C/9
D/9
E/9
0.50 mm² 532
0.50 mm² 533
0.50 mm² 534
190mm 190mm
0.50 mm² 527
0.50 mm² 528
0.50 mm² 529
-MC18:SH1
#1438
UTP UTP 250mm

STP
-TP11:TW1
-TP12:TW1
0.50 mm² CAN 18H
0.50 mm² CAN 18S

0.50 mm² CAN 18L
B
150mm 1110mm 460mm 160mm
UTP STP STP UTP
-MC4:TW1 -CB_CNR2
7213/0015
0.50 mm² CAN 5H 0.50 mm² CAN 4H 0.50 mm² CAN 3H
-SX7 -SX13 -SX26 0.50 mm² CAN 22H A/3
C B A
0.50 mm² CAN 5L 0.50 mm² CAN 4L 0.50 mm² CAN 3L 0.50 mm² CAN 22L B/3
-SX8 -SX14 -SX27
#1438 #1438 SPLICE_CAN.L.DIAG
0.50 mm² CAN 5S 0.50 mm² CAN 4S 0.50 mm² CAN 3S
-SX9 -SX15 -SX28 CAN TERMINATING RES. 2
-MC5:SH1 -MC4:SH1 -MC3:SH1 SPLICE_CAN.S.DIAG -CB_CNR2R
335-C0779-7
5 6 7 8
33 - 77 9813/6500-1 33 - 77
33 - 78 9813/6500-1 33 - 78
Page 33-80 Figure 648. Trailer Electrics Page 33-81

1 2 3 4 5 6 7 8
E RELAY BOX TRAILER -R9

RELAY LH TAIL LIGHT TRAILER SOCKET F
7218/0023 7218/0015 7218/0013
4
-TH_C5 -TH_C6 -TH_C7 -RC_LL -RC_LC
1.00 mm² 310F 1 2 1.00 mm² 801J H/14 H/14 1.00 mm² 801J 1.00 mm² 801J 7/8
7218/0014 7218/0022 LHS TAIL
-RC_LK -TH_C9 -TH_C6 -TH_C5 1/8 1/8 7/8
FROM TAIL LIGHTS 802 1.00 mm² 801T 1.00 mm² 801T A/14 A/14 1.00 mm² 801G 3 5 1.00 mm² 600FN
/11.D7 FROM
1/8 1/8
FROM STOP LAMP 812D 1.00 mm² 847T 1.00 mm² 847T -LMI
/11.B7 FROM
7241/0003
2/8 2/8
FROM LH INDICATOR 835C 1.00 mm² 835T 1.00 mm² 835T
/11.D7 FROM
3/8 3/8
FROM SPLICE S48 812 1.00 mm² 812T 1.00 mm² 812T
-R10
/11.C6 FROM
4/8 4/8 REALY BRAKE LIGHT

FROM RH TAIL LAMP 802 1.00 mm² 802T 1.00 mm² 802T 9
/11.B6 FROM
-TH_C5 -TH_C6
5/8 5/8 1.00 mm² 310E 6 7 1.00 mm² 847E J/14 J/14 1.00 mm² 847E 1.00 mm² 847E 6/8 BRAKE
FROM RH INDICATOR 812D 1.00 mm² 836T 1.00 mm² 836T 2/8 2/8 6/8
/11.B6 FROM
-TH_C6 -TH_C5
6/8 6/8 B/14 B/14 1.00 mm² 847D 8 10 1.00 mm² 600FM
F
-LMI E
7241/0003
TO EARTH SPLICE S70 GND 1.50 mm² 651T 8/8 1.00 mm² 651T
/14.C5 TO
8/8
-R11
REALY LH INDIACTOR
4
-TH_C5 -TH_C6
1.00 mm² 310G 1 2 1.00 mm² 835H K/14 K/14 1.00 mm² 835H 1.00 mm² 835H 1/8 LHS IND
24V TRAILER CONNECTION -TH_C6 -TH_C5 3/8 3/8 1/8

C/14 C/14 1.00 mm² 835F 3 5 1.00 mm² 600FH
-LG1
7241/0003
-TH_LKA -TH_LLA
1.00 mm² 801T-24V 1/8
1/8
-TH_LKA -TH_LLA
-R12
D 2/8 1.00 mm² 812T-24V
2/8
-TH_LKA -TH_LLA
RELAY FOG LIGHT D
3/8 1.00 mm² 835T-24V 3/8 9
-TH_C5 -TH_C6
1.00 mm² 310B 6 7 1.00 mm² 812E L/14 L/14 1.00 mm² 812E 1.00 mm² 812E 2/8 FOG
-TH_LKA -TH_LLA -TH_C6 -TH_C5 4/8 4/8 2/8
4/8 1.00 mm² 847T-24V 4/8 D/14 D/14 1.00 mm² 812D 8 10 1.00 mm² 600FJ
-TH_LKA -TH_LLA
5/8 1.00 mm² 802T-24V 5/8 -LG1
7241/0003
-TH_LKA -TH_LLA
6/8 1.00 mm² 836T-24V 6/8
-TH_LKA -TH_LLA
8/8 2.00 mm² 651-24V
8/8
7218/0023
-R13
-CB_HM RELAY LH TAIL LIGHT
7514/0006 4 7218/0023 7218/0015
From Fuse FC7 TRAILER DIODE -TH_C5 -TH_C6 -TH_C7 -RC_LL
100 1 2 M/14 M/14 5/8
/1.D7 FROM 1.50 mm² 113C 1.00 mm² 310D 1.00 mm² 802Z 1.00 mm² 802Z 1.00 mm² 802Z RHS TAIL
1 2 5/8 5/8 5/8
-TH_C6 -TH_C5
1.50 mm² 113T
C E/14 E/14 1.00 mm² 802AB 3 5 1.00 mm² 600FL

C
7219/0055 332/R4343 -TH_C6 -TH_C5
F/14 F/14 -LK1
-CB_FZ -RC_ML 7241/0003
-CB_ST1 1.50 mm² 113 8/31 8/31 1.50 mm² 113B 1.00 mm² 113B
7/8 7/8
1.50 mm² 113E

-R14
RELAY RH INDICATOR
9
-R10 -TH_C5 -TH_C6
FROM FUSE B7 BATT 1.00 mm² 309C-24V 1.00 mm² 310C 6 7 1.00 mm² 836H N/14 N/14 1.00 mm² 836H 1.00 mm² 836H 4/8 RHS IND
/12.E2 FROM
TRAILER RELAY 6/8 6/8 4/8

4 1.00 mm² 836F 8 10 1.00 mm² 600FK
-TH_C6 -TH_C5
-CB_HK 1 2 2.00 mm² 310 G/14 G/14 1.00 mm² 310
7514/0005 -TH_S57 -LK1
HAZARD DIODE -TH_S24
FROM HAZARD SW BAT POS 0.50 mm² 440A1 2 0.50 mm² 441 3 5 7241/0003
/11.C3 FROM
-TH_S37
2.00 mm² 600DTD 1.50 mm² 651TD 3/8 EARTH
-CB_FM
B -TH_C6 -TH_C5 8/8 8/8 3/8
6/6 2.00 mm² 600DB
3/6 2.00 mm² 600FR
7241/0003
TRAILER & ERGOTRAC RLY 1.00 mm² 600DA P/14 P/14 1.00 mm² 600DA B
-CB_HL
7514/0005
FROM RH SIDE LIGHTS SIDE LIGHT DIODE
802 0.50 mm² 802E1 2 0.50 mm² 441A
4/6
1/6
1.00 mm² 630N
/11.E5 FROM
TEMPERATURE EXTENSION HARNESS(OPTIONAL) 7213/0072

1/6
3/6
6/6
4/6
2/6
5/6
7212/0159
-C001 -C002
1/2 0.75 mm² 4077 1/3
2/2 0.75 mm² 4078 3/3
24/12V VOLTAGE DROPPER
2/3

TO
/14.C1
A
A
335-C0779-7
1 2 3 4 5 6 7 8
33 - 79 9813/6500-1 33 - 79
33-80 33-81
1 2 3 4
E RELAY BOX TRAILER -R9

RELAY LH TAIL LIGHT
4
1.00 mm² 310F 1 2

7218/0014 7218/0022
-RC_LK -TH_C9 -TH_C6 -TH_C5
FROM TAIL LIGHTS 802 1.00 mm² 801T 1.00 mm² 801T A/14 A/14 1.00 mm² 801G 3 5
/11.D7 FROM
1/8 1/8
FROM STOP LAMP 812D 1.00 mm² 847T 1.00 mm² 847T -LMI
/11.B7 FROM
7241/0003
2/8 2/8
FROM LH INDICATOR 835C 1.00 mm² 835T 1.00 mm² 835T
/11.D7 FROM
3/8 3/8
FROM SPLICE S48 812 1.00 mm² 812T 1.00 mm² 812T
-R10
/11.C6 FROM
4/8 4/8 REALY BRAKE LIGHT

FROM RH TAIL LAMP 802 1.00 mm² 802T 1.00 mm² 802T 9
/11.B6 FROM
5/8 5/8 1.00 mm² 310E 6 7

FROM RH INDICATOR 812D 1.00 mm² 836T 1.00 mm² 836T
/11.B6 FROM
-TH_C6 -TH_C5
6/8 6/8 B/14 B/14 1.00 mm² 847D 8 10
F
-LMI
7241/0003
TO EARTH SPLICE S70 GND 1.50 mm² 651T 8/8 1.00 mm² 651T
/14.C5 TO
8/8
-R11
REALY LH INDIACTOR
4
1.00 mm² 310G 1 2
24V TRAILER CONNECTION -TH_C6

C/14
-TH_C5
C/14 1.00 mm² 835F 3 5
-LG1
7241/0003
-TH_LKA -TH_LLA
1.00 mm² 801T-24V 1/8
1/8
-TH_LKA -TH_LLA
-R12
D 2/8 1.00 mm² 812T-24V
2/8
RELAY FOG LIGHT
-TH_LKA -TH_LLA
3/8 1.00 mm² 835T-24V 3/8 9
1.00 mm² 310B 6 7
-TH_LKA -TH_LLA -TH_C6 -TH_C5

4/8 1.00 mm² 847T-24V 4/8 D/14 D/14 1.00 mm² 812D 8 10
-TH_LKA -TH_LLA
5/8 1.00 mm² 802T-24V 5/8 -LG1
7241/0003
-TH_LKA -TH_LLA
6/8 6/8
Page 33-81
1.00 mm² 836T-24V
-TH_LKA -TH_LLA
8/8 2.00 mm² 651-24V
8/8
7218/0023
-R13
-CB_HM RELAY LH TAIL LIGHT
7514/0006 4
From Fuse FC7 TRAILER DIODE
100
1.50 mm² 113C 1.00 mm² 310D 1 2
/1.D7 FROM
1 2 -TH_C6 -TH_C5
1.50 mm² 113T
C E/14 E/14 1.00 mm² 802AB 3 5
7219/0055 332/R4343 -TH_C6 -TH_C5

F/14 F/14 -LK1
-CB_FZ -RC_ML 7241/0003
-CB_ST1 1.50 mm² 113 8/31 8/31 1.50 mm² 113B 1.00 mm² 113B
7/8 7/8
1.50 mm² 113E

-R14
RELAY RH INDICATOR
9
-R10
FROM FUSE B7 BATT 1.00 mm² 309C-24V 1.00 mm² 310C 6 7
/12.E2 FROM
TRAILER RELAY
4 1.00 mm² 836F 8 10
-TH_C6 -TH_C5
-CB_HK 1 2 2.00 mm² 310 G/14 G/14 1.00 mm² 310
7514/0005 -TH_S57 -LK1
HAZARD DIODE -TH_S24
FROM HAZARD SW BAT POS 0.50 mm² 440A1 2 0.50 mm² 441 3 5 7241/0003
/11.C3 FROM
-CB_FM
B -TH_C6 -TH_C5
6/6 2.00 mm² 600DB
3/6 2.00 mm² 600FR
7241/0003
TRAILER & ERGOTRAC RLY 1.00 mm² 600DA P/14 P/14 1.00 mm² 600DA
-CB_HL
7514/0005
FROM RH SIDE LIGHTS SIDE LIGHT DIODE
802 0.50 mm² 802E1 2 0.50 mm² 441A
4/6
1/6
1.00 mm² 630N
/11.E5 FROM
TEMPERATURE EXTENSIO
1/6
3/6
6/6
4/6
2/6
5/6
7212/0159
-C001
1/2
2/2
24/12V VOLTAGE DROPPER

TO
/14.C1
1 2 3 4
33 - 80 9813/6500-1 33 - 80
33-80 33-81
5 6 7 8
-R9
RELAY LH TAIL LIGHT TRAILER SOCKET F
7218/0023 7218/0015 7218/0013
4
-TH_C5 -TH_C6 -TH_C7 -RC_LL -RC_LC
310F 1 2 1.00 mm² 801J H/14 H/14 1.00 mm² 801J 1.00 mm² 801J 7/8 LHS TAIL
1/8 1/8 7/8
801G 3 5 1.00 mm² 600FN
-LMI
7241/0003
-R10
REALY BRAKE LIGHT
9
-TH_C5 -TH_C6
310E 6 7 1.00 mm² 847E J/14 J/14 1.00 mm² 847E 1.00 mm² 847E 6/8 BRAKE
2/8 2/8 6/8
847D 8 10 1.00 mm² 600FM
-LMI E
7241/0003
-R11
REALY LH INDIACTOR
4
-TH_C5 -TH_C6
310G 1 2 1.00 mm² 835H K/14 K/14 1.00 mm² 835H 1.00 mm² 835H 1/8 LHS IND
3/8 3/8 1/8
835F 3 5 1.00 mm² 600FH
-LG1
7241/0003
-R12
RELAY FOG LIGHT D
9
-TH_C5 -TH_C6
310B 6 7 1.00 mm² 812E L/14 L/14 1.00 mm² 812E 1.00 mm² 812E 2/8 FOG
4/8 4/8 2/8
812D 8 10 1.00 mm² 600FJ
-LG1
7241/0003
Page 33-80
-R13
RELAY LH TAIL LIGHT
4 7218/0023 7218/0015
-TH_C5 -TH_C6 -TH_C7 -RC_LL
1 2 M/14 M/14 5/8
310D 1.00 mm² 802Z 1.00 mm² 802Z 1.00 mm² 802Z RHS TAIL
5/8 5/8 5/8
802AB 3 5 1.00 mm² 600FL
C
-LK1
7241/0003
-R14
RELAY RH INDICATOR
9
-TH_C5 -TH_C6
6 7
310C 1.00 mm² 836H N/14 N/14 1.00 mm² 836H 1.00 mm² 836H 4/8 RHS IND
6/8 6/8 4/8
836F 8 10 1.00 mm² 600FK
-LK1
7241/0003
-TH_S37
2.00 mm² 600DTD 1.50 mm² 651TD 3/8 EARTH
8/8 8/8 3/8
B
7212/0159 TEMPERATURE EXTENSION HARNESS(OPTIONAL) 7213/0072

-C001 -C002
0.75 mm² 4077 1/3
0.75 mm² 4078 3/3
2/3
335-C0779-7
5 6 7 8
33 - 81 9813/6500-1 33 - 81
90 - Earth Point
90 - Earth Point
Introduction
The ground or earth refers to the reference point in an

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 - 82 9813/6500-1 33 - 82
03 - Battery
03 - Battery
Contents Page No.
33-03-00 General ........................................................................................................................... 33-85

33-03-03 Isolator Switch ................................................................................................................ 33-94
33 - 83 9813/6500-1 33 - 83
Notes:
33 - 84 9813/6500-1 33 - 84
03 - Battery
00 - General
Introduction .................................................... 33-85 Batteries used in normal temperate climate
Health and Safety .......................................... 33-86 applications should not need topping up. However,
Fault-Finding .................................................. 33-87 in certain conditions (such as prolonged operation
Disconnect and Connect ............................... 33-88 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Check (Condition) .......................................... 33-91 frequently and topped up as necessary.
Charge ........................................................... 33-92
Remove and Install ....................................... 33-92 The electrolyte level should be checked in
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 649.
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 - 85 9813/6500-1 33 - 85
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 - 86 9813/6500-1 33 - 86
03 - Battery
00 - General
put in a closed acid proof receptacle and Fault-Finding

must be disposed of in accordance with local
environmental waste regulations. The most obvious sign of a battery problem is a
Notice: Before carrying out arc welding on the machine not being able to start. However, because
machine, disconnect the battery and alternator to the battery is part of a larger electrical system
protect the circuits and components. The battery connected to other parts of the machine, a flat battery
must still be disconnected even if a battery may indicate another problem.
isolator is installed. If something else is going wrong in the electrical
system, for example, a weak alternator, corrosion or
loose connections, cold weather starting, electrical
equipment being left on without the engine running,
interrogate the cause of the problem.
The best way to test the condition of the battery is
with an electronic battery tester. Refer to Battery-
Check Condition (PIL 33-03).
33 - 87 9813/6500-1 33 - 87
03 - Battery
00 - General
Notice: Before you install a pair of batteries to Figure 650. Parallel and
a machine, make sure you know the machines Series Connection (Example)
voltage. Some machines require two batteries but
have a 12 V electrical system. This means the
batteries need to be connected in parallel.
For 24 V machines, the batteries must be
_ _
connected in series. Incorrect voltage may result
in serious damage to the electrical system. + +
A
C
C
The illustrations show typical battery connections.
The actual battery connections installed on your
machine may look different. _ + _ +
Make sure you connect the batteries correctly for
your machine.
Disconnect 12 V 24 V
1. Make the machine safe. Refer to (PIL 01-03). D B D B
2. Get access to the battery or batteries (depending Figure 651. Twin Battery 12V Ma-
on the specification of your machine). The actual chines- Parallel Connection (Example)
installation on your machine may vary from those
shown below.
3. If the machine has a battery isolator, move the B
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 batteries.
C
6. Disconnect and remove the battery link lead or
leads.
A
A D
A Battery
B Positive lead
C Battery link lead
D Negative lead
33 - 88 9813/6500-1 33 - 88
03 - Battery
00 - General
Figure 652. 24 Volt Machines- Series Connection (Example)

C
_ _ + +
A Battery B Positive lead

C Battery link lead D Negative lead
33 - 89 9813/6500-1 33 - 89
03 - Battery
00 - General
Connect
1. Check the battery as follows:
1.1. If any terminals are dirty, clean them.
1.2. If the terminal is corroded and has white
powder, wash the terminal with hot water.
Make sure the water does not enter the
battery cells.
1.3. If considerable corrosion is found, then
clean with a wire brush or abrasive
paper. Make sure you use eye and hand
protection. Refer to Figure 653.
Figure 653.
1.4. After cleaning, apply a thin coat of

petroleum jelly to the terminals.
2. Connect the leads.
2.1. For single battery machines, connect the
positive lead then the negative lead.
2.2. For twin battery machines, first connect the
link lead or leads, then the positive terminal,
and finally the negative terminal.
3. If the machine has a battery isolator, move the
switch to the ON position.
4. Close and lock the access panels.
33 - 90 9813/6500-1 33 - 90
03 - Battery
00 - General
Check (Condition) Table 172. Fault Diagnosis

Battery Tester Read- Remedy
ings
Battery Test CHECK: 0 -12.6 Volts: Renew battery
LOAD: less than 6 Volts
This test is to determine the electrical condition of
the battery and to give an indication of the remaining CHECK: 6 -12.4 Volts: Recharge and re-test. If
useful life. LOAD: less than 9 Volts tests are still unsatisfac-
and falls steadily but re- tory renew battery
Before you test the battery, make sure that the mains in yellow zone
battery is at least 75% charged (Specific Gravity of CHECK: less than 10 Indicates battery has
1.23 to 1.25 for ambient temperature up to 27°C). Volts: LOAD: less than 3 been over-discharged
Volts and unlikely to recover.
Make sure that the battery is completely Renew battery
disconnected from the vehicle. CHECK: more than 11 Charge battery which
Volts: LOAD: 6 - 10 Volts will probably recover
Figure 654. steady
Specific Gravity Test

The specific gravity of the electrolyte gives an idea
of the state of charge of the battery. Readings
should be taken using a hydrometer, when the
electrolyte temperature is 15°C (60°F). If the battery
has recently been on charge, wait approximately one
hour (or slightly discharge the battery) to dissipate
the surface charge before testing.
Readings should be as tabulated and should not vary

between cells by more than 0.04. A greater variation
indicates an internal fault on that particular cell.
If the electrolyte temperature is other than 15°C

(60°F) a 'correction factor' must be applied to the
reading obtained. Add 0.07 per 10°C (18°F) if the
A Battery voltage switch temperature is higher than 15°C (60°F) and subtract
B Check load switch the same if the temperature is lower.
Connect up the battery tester as follows: Table 173. Specific Gravity at 15°C (60°F))
1. Set the Check Load switch to OFF. Ambient Fully Half Dis- Fully Dis-
Temper- Charged charged charged
2. Set the battery voltage switch to 12V. ature de-
grees C
3. Connect the red flying lead to the battery positive (degrees
(+) terminal and the black flying lead to the F)
battery negative (-) terminal.
Below 27 1.270-1.290 1.190-1.210 1.110-1.130
4. Set the Check/Load switch to CHECK to read the (80)
battery no-load voltage which should be at least Above 27 1.240-1.260 1.170-1.190 1.090-1.110
12.4 volts. (80)
5. Set the Check/Load switch to LOAD and hold

down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
6. If the tests are unsatisfactory, refer to the fault
diagnosis table.
33 - 91 9813/6500-1 33 - 91
03 - Battery
00 - General
Charge Remove and Install
Precautions before Charging Remove

Follow all the precautions described below, to 1. Make the machine safe with the lift arm lowered.
prevent damage to the alternator and battery. Refer to (PIL 01-03).
1. Make the machine safe. Refer to (PIL 01-03). 2. Install the articulation strut. Refer to (PIL 06-27).
2. Make sure that the battery negative terminal 3. Turn the battery isolator switch off and remove it,
is connected to the earth cable. Refer to (PIL to isolate the battery from the electrical circuit.
33-03).
4. Loosen the bolt.
3. Do not connect or disconnect the battery
5. Open the battery compartment cover.
or alternator connections, or any part of the
charging circuit while the engine is in operation. Figure 655.
If you disregard this instruction, the regulator or
rectifying diodes will be damaged.
4. Main output cables are always in active state
of current flow even when the engine is not in
operation. If the alternator connector is removed,
do not earth the moulded plug.
5. When you do arc welding on the machine,
remove the moulded plug (or if the separate
output cables are installed, remove the cables)
to protect the alternator.
6. If it is necessary to jump start the battery then do
the steps below.
6.1. Connect the secondary battery in parallel A
without disconnecting the vehicle battery
from the charging circuit. B
6.2. After the jump start, safely disconnect and

remove the secondary battery.
6.3. Make sure you connect the positive terminal
to the positive terminal and the negative C
terminal to the negative terminal of both the
batteries.
A Battery box
B Battery cover
C Bolt
6. Disconnect the electrical leads from the battery.
You should follow the specified sequence to
remove the leads from the battery.
33 - 92 9813/6500-1 33 - 92
03 - Battery
00 - General
Figure 656. Install

steps.
G 2. Clean the battery terminals if there is any sign of
corrosion.
E
3. Protect the battery terminals with petroleum jelly.
H 4. Connect the positive lead (Red) first and then the
D negative lead (Black).
B Battery cover
C Bolt
D Battery
E Battery positive lead
F Battery negative lead
G Nut
H J-bolt
6.1. Remove the black coloured negative lead
from the upper battery.
6.2. Remove the black coloured negative lead
from the lower battery.
6.3. Remove the red coloured positive lead from
the lower battery.
6.4. Remove the red coloured positive lead from
the upper battery.
7. Loosen the nut from the J-bolts (x2).
8. Remove the J-bolt.
9. Use the battery handle to lift the battery from the
machine.
10. Remove the battery from the machine.
33 - 93 9813/6500-1 33 - 93
03 - Battery
03 - Isolator Switch
03 - Isolator Switch Introduction

Introduction .................................................... 33-94 The battery isolator switch is used to disconnect the
Disconnect and Connect ............................... 33-95 battery from the machine electrics. The switch must
be turned to the OFF position if any maintenance
work is to be performed on the machine.
Some machine systems perform shut down cycles

after the engine stops. Wait until shut down cycles
are complete before setting the battery isolator
switch to the OFF position. For more information
refer to Disconnect and Connect, PIL (33-03-03).
33 - 94 9813/6500-1 33 - 94
03 - Battery
03 - Isolator Switch
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 - 95 9813/6500-1 33 - 95
06 - Battery Cable
06 - Battery Cable
Contents Page No.
33-06-00 General ........................................................................................................................... 33-97
33 - 96 9813/6500-1 33 - 96
06 - Battery Cable
00 - General
00 - General
Introduction
The cables connect the battery positive and negative

terminals to the machine electrical system.
33 - 97 9813/6500-1 33 - 97
09 - Power Distribution
Contents Page No.
33-09-00 General ........................................................................................................................... 33-99

33-09-03 Fuse ............................................................................................................................. 33-101
33-09-06 Relay ............................................................................................................................ 33-104
33 - 98 9813/6500-1 33 - 98
00 - General
Introduction .................................................... 33-99 The electrical circuits are protected by fuses. If a
Health and Safety ........................................ 33-100 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 - 99 9813/6500-1 33 - 99
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 - 100 9813/6500-1 33 - 100

03 - Fuse
03 - Fuse
Introduction
Primary Fuses • Arrow symbol pointing left indicates the left fuse
cover
The primary fuse box covers have identification • Arrow symbol pointing right indicates the right
arrow symbol on each cover. fuse cover
If you remove the fuse box covers make sure you

install them at the correct location as indicated on the
cover.
Figure 657.
6 7
5 8
2 3
1 4
Additional Primary Fuses

Table 174. Primary Fuses Figure 658.
Fuse Circuit(s) Protected Amperage
1 I/O Module 1 30
2 I/O Module 2 30
3 Fuses A7, A8, A9, B6, 30
B7
4 Fuses B1, B2, B, B4, B5 40 A
5 Fuses C6, C7, C8 40
6 Fuses C9, C10 30
7 Fuses C1, C2, C3, C4, 40
C5
8 Fuses A1, A2, A3, A4, 30
A5, A6, B8, C6, C7, C8 B
(Through ignition switch)
33 - 101 9813/6500-1 33 - 101

03 - Fuse
Table 175.
Fuse Circuit(s) Protected Rating
A Secondary steer 125A
B ECU (Electronic Control 40A
Unit)
C Grid heater 125A
Secondary Fuses
Figure 659.
Table 176.
A1 Instrument panel 3A
Keypads
Rear camera
A2 ZF ECU 7.5A
A3 Seat switch 5A
A4 Rear wiper motor 3A
Immobiliser
Mirror control joystick
A5 Engine ECU input 10A
Alternator
A6 Immobiliser (Ignition relay) 3A
A7 Heater relay (Aftertreatment) 15A
33 - 102 9813/6500-1 33 - 102

03 - Fuse

A8 DEF module 15A
A9 Engine bay lamp 5A
A10 Spare NA
B1 Right hand column switch 3A
Interior light
Livelink
B2 Instrument panel 5A
Keypads
Immobiliser
Diagnostics connection
B3 ZF ECU 7.5A
B4 Loader ECU 20A
B5 Management ECU 20A
B6 Heated rear screen 15A
B7 Trailer electrics 15A
Radio
24/12V dropper
B8 Management ECU and starter relay coil 5A
B9 Radio 12V memory 3A
B10 Radio 12V battery 10A
C1 24V power socket 5A
C2 Loader ECU 10A
Seat switch
Main pressure sensor
Brake pressure sensor
C3 Voltage dropper (12–24V) 5A
Livelink
C4 RH column switch 15A
Horn
C5 Autolube 10A
C6 Seat switch 20A
C7 Trailer electrics 5A
C8 Nox, DEF supply tank 10A
C9 HVAC (Heating Ventilation Air Conditioning) 15A
C10 HVAC 5A
AC Compressor
33 - 103 9813/6500-1 33 - 103

06 - Relay
06 - Relay
Introduction
The relays are situated in a fuse box (shown with the Figure 660.
cover removed) behind the operators seat.
To get the access to the relays:
1. Make the machine safe. A
2. Open the operator door to enter into the cab.

3. Remove the cover (not shown) to access the
secondary fuses.
A Relays
Figure 661.
A Secondary steer relay B Grid heater relay
Trailer Electrics (Option) If your machine is installed with 12V trailer electrics
an additional relay box and converter are installed on
This machine is designed for connecting both 24V the right hand side of the engine compartment. Refer
and 12V trailer electrics. to Figure 662.
33 - 104 9813/6500-1 33 - 104

06 - Relay
When a trailer is connected to the machine, make lights are working correctly and are visible by other
sure that the trailer lights and directions indicator road users.
Figure 662.
A Voltage dropper 24–12V B Relay box
33 - 105 9813/6500-1 33 - 105

12 - Harness
12 - Harness
Contents Page No.
33-12-00 General ......................................................................................................................... 33-107

33-12-04 Chassis ......................................................................................................................... 33-117
33-12-05 Rear Chassis ................................................................................................................ 33-126
33-12-09 Engine .......................................................................................................................... 33-135
33-12-11 Cooling Compartment ................................................................................................... 33-148
33-12-12 Operator Station ........................................................................................................... 33-153
33-12-25 Controls ........................................................................................................................ 33-186
33-12-27 Interior Roof ................................................................................................................. 33-190
33-12-34 Trailer Brake ................................................................................................................. 33-199
33-12-36 Work Lights .................................................................................................................. 33-202
33-12-48 LiveLink ........................................................................................................................ 33-203
33-12-89 Speakers ...................................................................................................................... 33-223
33-12-93 Selective Catalytic Reduction (SCR) ........................................................................... 33-224
33-12-95 Cooling Fan .................................................................................................................. 33-229
33 - 106 9813/6500-1 33 - 106

12 - Harness
00 - General
Introduction .................................................. 33-107
Health and Safety ........................................ 33-108
Harness Drawings
Component Identification ............................. 33-109 Drawings are reproduced from production electrical
Repair .......................................................... 33-111 harness drawings. Each harness drawing includes
Check (Condition) ........................................ 33-113 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 - 107 9813/6500-1 33 - 107

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 - 108 9813/6500-1 33 - 108

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 663.
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 177. 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 178. 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 - 109 9813/6500-1 33 - 109

12 - Harness
00 - General
Table 179. Wires 200-399, 2000-3999 (These Table 183. 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 180. Wires 400-599, 4000-5999
Figure 665.
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 181. 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 664. when it is part of equipment supplied by other
manufacturers.
600
Table 182. 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 - 110 9813/6500-1 33 - 110

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 667.
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 668.
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 666.
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 - 111 9813/6500-1 33 - 111

12 - Harness
00 - General
cartridge up into the reflector assembly as Figure 671.

far as possible until the two elements are
clasped firmly together. An audible click will
be heard.
Figure 669.
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 670. 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 672.
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 - 112 9813/6500-1 33 - 112

12 - Harness
00 - General
Figure 673. 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 674.
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 - 113 9813/6500-1 33 - 113

12 - Harness
00 - General
Figure 675. Fluke 85 Multimeter Figure 676. 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 677. 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 - 114 9813/6500-1 33 - 114

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 - 115 9813/6500-1 33 - 115

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 - 116 9813/6500-1 33 - 116

12 - Harness
04 - Chassis
04 - Chassis
Diagram
33 - 117 9813/6500-1 33 - 117

Notes:
33 - 118 9813/6500-1 33 - 118

12 - Harness
04 - Chassis
Page 33-120 Figure 678. 336/D6475 (Sheet 1 of 2) Page 33-121
336-D6475-2
33 - 119 9813/6500-1 33 - 119

12 - Harness
04 - Chassis
33-120 33-121
Page 33-121
33 - 120 9813/6500-1 33 - 120

12 - Harness
04 - Chassis
33-120 33-121
Page 33-120
336-D6475-2
33 - 121 9813/6500-1 33 - 121

12 - Harness
04 - Chassis
33 - 122 9813/6500-1 33 - 122

12 - Harness
04 - Chassis
Page 33-124 Figure 679. 336/D6475 (Sheet 2 of 2) Page 33-125
336-D6475-2
33 - 123 9813/6500-1 33 - 123

12 - Harness
04 - Chassis
33-124 33-125
Page 33-125
33 - 124 9813/6500-1 33 - 124

12 - Harness
04 - Chassis
33-124 33-125
Page 33-124
336-D6475-2
33 - 125 9813/6500-1 33 - 125

12 - Harness
05 - Rear Chassis
05 - Rear Chassis
Diagram
33 - 126 9813/6500-1 33 - 126

12 - Harness
05 - Rear Chassis
Page 33-128 Figure 680. 335/C7768 (Sheet 1 of 3) Page 33-129
-RC_MF
-P575
7243/0186
1 4
-RC_MM 2 3
1 2
2 1
20 mm
-RC_ML 21
20
8
31
30
-RC_MF#1
9 19 7214/0025
10 2 18
TO RH REAR COMBI LAMP
-RC_MM#1 NC12
-RC_PR 22 3 7 29
-MM_CAP
S F
mm
23
11
4
1
6
17
28
7212/0001
7212/0002 REVERSE ALARM
20
R E A H
12 5 16
20
13 15
mm
P D B J
24 14 27
30 mm
N 25 26
7243/0147
C K
-RC_MG
-P347
M L
-P501 REVERSED -RC_MV

100 mm
7243/0147
-RC_ML#1 -RC_BG -RC_MJ 1 4
-RC_PR#1
332/R4343
7219/0189 2 3
7243/0148
TO CAB HARNESS
-P565
TO BATTERY BOX OUTLET 2 1
760 mm
230
-ID12 -RC_MG#1 -RC_MV#1 NC08

ID Label 2 1 2 1 -P543 -RC_JU
mm
7243/0138
7214/0025 7212/0052 7000/3206
700 20
-P576
7243/0137
7243/0157
7243/0137
7243/0137
-P5 06
130 mm
-RC_BG#1 -RC_MJ#1 A B TO FAN CONTROL HARNESS TO TOW HITCH SOL

-P535
NC12
-P550
-P551
20 mm
20 mm
-P536
0/32
NC
20 mm
63
7212/0052 7212/0052
20 mm
20 mm
7000/3206
-P562 TO ENGINE BAY LAMP TO BONNET NO PLATE LAMP -RC_MS
NC20 NC12
NC08 NC08 NC08 C NC08
-RC_JU#1 1 4
2 3
NC20
7213/0031
-P624 7243/0091
NC2
TO BRK ACCUM PRESS SENS -RC_MS#1

0
500 mm
7214/0025
7000/3206 TO RHS FOG/REV LAMP
330 mm
-P566
60 mm
60 mm NC08
NC28
NC08 NC08 NC08
100 mm
30 mm
NC12
7000/3206 7000/3206 7000/3206
NC08
250 mm
-P539 -P540 -P542
-P572 7243/0012
250 mm
7000/3206 -P571
-P547 7243/0186
NC12
NC12
NC28 7000/3206
-P546
7000/3206
20 mm
-P561 7000/3206
NC12
-P574
NC12
50 mm 150 mm 160 mm 75 mm 80 mm 1270 mm 50 mm 100 mm 50 mm 50 mm 20 mm 30 mm 30 mm 30 mm 30 mm 20 mm 50 mm

NC28 NC08 NC12
50 mm
NC08 NC08 NC08 NC08
-P607 7243/0042 -P558 7243/0025 -P559 7243/0025
NC12 NC28 NC25 NC20 NC20 NC20 NC20 NC20
NC28 NC28 NC28 NC25 NC25 NC20 NC20 NC20 NC20 NC20 NC20 NC20 NC20 NC20 NC20 NC20
30
NC20 NC20 NC20 NC20
mm
7000/3206 7000/3206 7000/3206 7000/3206 7000/3206 7000/3206 7000/3206 7000/3206 7000/3206
mm
7000/3206 7000/3206
100 mm
7243/0047 -P564 -P533 7243/0415 7243/0021 -P534 7243/0021 -P544 7243/0025 -P549 7243/0021 -P560 -P568 7243/0021
-P520 -P519 -P537 -P538 -P541 -P545 -P548 -P554 -P555
-RC_S29 -RC_S111 -P567 -RC_S110 -RC_S112 -RC_S72 -RC_S48 -RC_S50 -P570
10 NC25 NC20 NC12 NC12 NC20 NC20

SPLICE SIDELIGHT SPLICE_LH TAIL LIGHTS SPLICE_RH INDICATOR SPLICE_LH IND SPLICE BRAKE LIGHT SPLICE_REAR FOG SPLICE REVERSE
-RC_BH
80 mm
-RC_BC
80 mm
NC12 NC12
140 mm
50 mm
1 2 2 1 7000/3206 7000/3206
-P556 -P557
7000/3206
-P518
mm
1 2
NC25
-RC_BH#1
50
20 mm
-RC_BH_CAP
NC20
7212/0044
7212/0045 150 mm
50 mm
-RC_BC#1
-P569 7243/0025
TO GRID HEATER RELAY
20 mm
7212/0044 OPTION : BLANKING CAP
-RC_MC
NC12
7243/0173
TO SECONDARY STEER REL AY
NC08
-P504
7243/0173
NC08
7000/3206
-P622
NC20
-P573
2 1 -RC_BE NC12
30 mm
-RC_S70
NC12
NC12
20 mm
20 mm
7243/0174
-RC_MC#1 RED TAPE MARKER
-P553
SPLICE_REAR EARTH
7243/0174
A B
7243/0138
-P552
7212/0052
NC12
-P608
20 mm
530 mm
105 mm
TO HYD OIL TEMP SEND
-P606 7243/0007
7243/0002
-P351
7000/3206
NC08
NC08
NC08
C -P527
08
NC
-RC_BE#1 NC08
7000/3206
20 mm
NC12
mm
-P521 7213/0031
NC08
TO SEC. STEER PRES. SENSR
135
-P5 206
-RC_LL
28
0/3
200 mm
700
-RC_LK
NC08
KEY B BLACK
-P505 7243/0057
NC0
GRAY
4
KEY A
-RC_LL#1
4
-RC_LK#1 7218/0015
NC12
680 mm
7218/0014 TO TRAILER ELECTRICS

NC08
TO TRAILER ELECTRICS W/H
7000/3206
-P515
750 mm
560 mm
7000/3206
-P522 NC12
NC12

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

SERVICE MANUAL SERVICE MANUAL

Acronyms Glossary .................................................................................................................................... 01-2

FOPS Falling Object Protective Structure

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual and on the machine, there are safety

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system (shown) also helps to identify

Figure 1. The safety alert system

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety Worksites

Electrical Power Cables Hands and Feet

21 - Worksite Safety An applicable worksite organisation is required in

24 - Risk Assessment Loading/Unloading Area

27 - Maintenance Positions Introduction

Lift Arm Lowered

1. If necessary, empty the shovel.

A Maintenance strut 1 B Strap 1

C Strap 2 D Maintenance strut 2

Stow the Maintenance Struts

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

A Loader arms B Quickhitch

15 - Service Point Locations

A Engine fuel filter B Fuel filter

E Hydraulic oil filler cap F Air filter

A Engine oil drain

A Hydraulic level gauge

A Dipstick B Drain plug - Output

Contents Page No.

01-33-00 General ........................................................................................................................... 01-29

Clean the product with water and/or steam. Do not

Before you do any service procedures that require

• The cleaning must be done either in the area

When you remove components, be aware of

Always obey the local regulations regarding the