Service Manual

WLS 432ZX
Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering

Publication No.
550/43477/1

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 1

General Information
Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering

Publication No.
550/43477/1

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section 1 - General Information

Notes:

1-0 550/43477/1 1-0

 Section 1 - General Information
Contents

Contents Page No.

General Information
Introduction ...............................................................................................1 - 1
Colour Codes ............................................................................................1 - 2
............................................................................................................1 - 2
Identification Plate ...............................................................................1 - 4

1-i 1-i
 Section 1 - General Information
General Information
Introduction

General Information
Introduction

This publication is designed for the benefit of JCB
INDIA LTD. distributor Service Engineers who are
receiving, or have received, training by JCB INDIA
Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques
Associated with the maintenance and repair of
hydraulic earthmoving equipment
Renewal of oil seals, gaskets, etc., and any component
showing obvious signs of wear or damage is expected
as a matter 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 and
ingress of dirt. Finally, please remember above all else
SAFETY MUST COME FIRST!
The page numbering in each alphabetically coded
section is not continuous. This allows for the insertion of
new items in later issues of the manual.
Section contents, technical data, circuit descriptions,
operation descriptions etc. are inserted at the beginning
of each alphabetically coded section.
Where a torque setting is given as a single figure it may
be varied by plus or minus 3%. Torque figures indicated
are for dry threads, hence for lubricated threads may be
reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear
of the machine facing forwards.

The manual is compiled in sections, the first three are

numbered and contain information as follows

1 General Information

Includes torque settings and service tools

2 Care & Safety

Includes warnings and cautions pertinent to

aspects of workshop procedures etc.

3 Routine Maintenance

Includes service schedules and recommended

lubricants for all the machine.

The remaining sections are alphabetically coded and

deal with Dismantling, Overhaul etc. of specific
components, for example

a Attachments

b Body & Framework

1-1 550/43477/1 1-1

 Section 1 - General Information
General Information
Colour Codes

Colour Codes

The following colour coding, used on illustrations to denote

various conditions of oil pressure and flow, is standardised
throughout JCB Service Publications

Table 1.
Red Full Presssure

Pressure generated from operation of a service. Depending on application this may be

anything between neutral circuit pressure and M.R.V. operating pressure.
Pink Pressure

Pressure that is above neutral circuit pressure but lower than that denoted by red.
Orange Servo

Oil pressure used in controlling a device (servo).

Blue Neutral

Neutral circuit pressure.

Green Exhaust

Light Green

Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Yellow Lock Up

Oil trapped within a chamber or line, preventing movement of components (lock up).

Black and White Codes

The following black and white coding, used on illustrations
to denote various conditions of oil pressure and flow, is
standardised throughout JCB Service Publications

1-2 550/43477/1 1-2

 Section 1 - General Information
General Information
Colour Codes
Table 2.
Neutral Circuit Pressure.

Pressure generated by the operation of a service. Depending on application this may be anything
between Neutral Circuit Pressure and M.R.V. Operation Pressure.

Pressure that is above Neutral Circuit Pressure but lower than that denoted above.

Exhaust.

Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Oil trapped within a chamber or line preventing movement of componenets (lock-up).

Oil pressure used in a controlling device (servo).

1-3 550/43477/1 1-3

 Section 1 - General Information
General Information
Colour Codes

Identification Plate Torque Settings

Your machine has an identification plate X mounted on the Use only where no torque setting is specified in the text.
left hand side of the machine. The serial numbers of the Values are for dry threads and may be within three per cent
machine and its major units are stamped on the plate of the figures stated. For lubricated threads the values
K Fig 1. ( T 1-4) should be REDUCED by one third K Fig 3. ( T 1-6).

Fig 1.

Explanation of Vehicle Identification

Number (VIN)
The serial number of each major unit is also stamped on
the unit itself. If a major unit is replaced by a new one, the
serial number on the identification plate will be wrong.
Either stamp the new number of the unit on the
identification plate, or simply stamp out the old number.
This will prevent the wrong unit number being quoted when
replacement parts are ordered.

The machine and engine serial numbers can help identify

exactly the type of equipment you have K Fig 2. ( T 1-4).

Fig 2.

1-4 550/43477/1 1-4

 Section 1 - General Information
General Information
Colour Codes
Table 3.
Bolt Size Hexagon (A/F) Torque Settings
in (mm) in Nm kgf m lbf ft
1 /4 (6.3) 7 /16 14 1.4 10
5 /16 (7.9) 1 /2 28 2.8 20
3 /8 (9.5) 9 /16 49 5.0 36
7 /16 (11.1) 5 /8 78 8.0 58
1 /2 (12.7) 3 /4 117 12.0 87
9 /16 (14.3) 13 /16 170 17.3 125
5 /8 (15.9) 15 /16 238 24.3 175
3 /4 (19.0) 1 1 /8 407 41.5 300
7 /8 (22.2) 1 15 /16 650 66.3 480
1 (25.4) 1 1 /2 970 99.0 715
1 1 /4 (31.7) 1 7 /8 1940 198.0 1430
1 1 /2 (38.1) 2 1 /4 3390 345.0 2500

Metric Grade 8.8 Bolts

Table 4.
Bolt Size Hexagon (A/F) Torque Settings
(mm) mm Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105

Rivet Nut Bolts/Screws

Table 5.
Bolt Size Torque Settings (for steel rivet nuts)
(mm) Nm kgf m kgf m
M3 (3) 1.2 0.12 0.9
M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10.0 1.0 7.5

1-5 550/43477/1 1-5

 Section 1 - General Information
General Information
Colour Codes

M8 (8) 24.0 2.5 18.0

M10 (10) 48.0 4.9 35.5
M12 (12) 82.0 8.4 60.5

Note: All bolts used on JCB machines are high tensile and Note: All adapters, elbows and hoses should be tightened
must not be replaced by bolts of a lesser tensile to JCB standard torque settings unless stated otherwise
specification.

Fig 3.

1-6 550/43477/1 1-6

 Section 1 - General Information
General Information
Colour Codes

Fig 4.

Service Tools

Section B - Body and Framework

826/01179 M6 x 16mm Rivet Nut

826/01106 M6 x 19mm Rivet Nut
826/01177 M8 x 18mm Rivet Nut
826/01176 M10 x 23mm Rivet Nut
826/01333 M10 x 26mm Rivet Nut
Installation Tool Available from : Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
The Willenhall
Willenhall
West Midlands, WV13 2JW

Folding Stand for Holding Glass Essential for preparing new glass prior to installation. JCB
part number - 892/00843 K Fig 5. ( T 1-8)

1-7 550/43477/1 1-7

 Section 1 - General Information
General Information
Colour Codes

Fig 5.

Glass Lifter
Fig 7.
Minimum 2 off - essential for glass installation, 2 required
to handle large panes of glass. Ensure suction cups are
protected from damage during storage. JCB part number -
892/00842 K Fig 6. ( T 1-8)

Fig 6. Fig 8.

Nylon Spatula

General tool used for smoothing sealants - also used to re-

install glass in rubber glazing because metal tools will chip
the glass edge. JCB part number - 892/00847 K Fig
7. ( T 1-8)

1-8 550/43477/1 1-8

 Section 1 - General Information
General Information
Colour Codes

Service Tools
JCB part number - 892/00846

Wire Starte - sed to access braided cutting wire (below)

polyurethan seal K Fig 9. ( T 1-9).

Fig 11.

Cut - Out Knife

Used to remove broken glass JCB part number - 992/

12800 K Fig 12. ( T 1-9)
Fig 9.

Glass Extractor (Handles)

Used with braided cutting wire (belwo) to cut out broken

glass. JCB part number K Fig 10. ( T 1-9)

Fig 12.

‘L’ Blades

25 mm (1 in) cut - replacement blased for cut-out knife

(avbove). JCB part number - 992/12801 (unit quanitity = 5
Fig 10. off) K Fig 13. ( T 1-10)

Braided Cutting Wire

JCB part number - 892/00849 (approx 25 m length) K Fig

11. ( T 1-9)

1-9 550/43477/1 1-9

 Section 1 - General Information
General Information
Colour Codes

Fig 13.

Section B - Body & Framework

Long Knife
Fig 15.
25 mm (1 in) cut - replacement blased for cut-out knife
(avbove). JCB part number - 992/12801 (unit quanitity = 5 Dummy Bush
off) K Fig 14. ( T 1-10)
Used with bearing locator to set up Upper Centre Pivot.
JCB part number - 825/99849K Fig 16. ( T 1-10)

Fig 14.
Fig 16.
Bearing Locator
Service Tools
Used with dummy bush to set up Upper Centre Pivot. JCB
part number - 825/99851K Fig 15. ( T 1-10)
Section C - Electrics K Fig 17. ( T 1-11) andK Fig
18. ( T 1-11)

1 - 10 550/43477/1 1 - 10
 Section 1 - General Information
General Information
Colour Codes

Fig 19.

Fig 17.

Fig 20.

K Fig 21. ( T 1-12) and K Fig 22. ( T 1-12)

Fig 18.

K Fig 19. ( T 1-11) and K Fig 20. ( T 1-11)

1 - 11 550/43477/1 1 - 11
 Section 1 - General Information
General Information
Colour Codes

Fig 21.
Fig 23.
992/09300 55 mm
992/09400 65 mm
992/09500 75 mm
992/09600 85 mm
992/09700 95 mm
992/10000 125mm
Hexagon Spanners for Ram Pistons and End Caps

816/00294 1 /4 in. BSP

816/00189 3 /8 in. BSP
816/00190 1 /2 in. BSP
816/00197 5 /8 in. BSP
816/00196 3 /4 in. BSP
816/00193 1 in. BSP

Fig 22.
Male Cone Blanking Cap
892/00055 1/4 in BSP
892/00056 3/8 in BSP
892/00074 3 /8 in. BSP x 3 /8 in.
892/00057 1/2 in BSP
892/00075 1 /2 in. BSP x 1 /2 in.
892/00058 5/8 in BSP
892/00076 5 /8 in. BSP x 5 /8 in.
892/00059 3/4 in BSP
892/00077 3 /4 in. BSP x 3 /4 in.

Female Connectors
Female Cone Blanking Cap 892/00060 1 in BSP

K Fig 23. ( T 1-12)

1 - 12 550/43477/1 1 - 12
 Section 1 - General Information
General Information
Colour Codes

892/00039 Spool Clamp Spool Clamps

992/10100 Spool Clamp

Hand Pump Equipment

892/00223 Micro-bore Hose 1 /4 in. BSP x 5 metres

892/00137 Adapter 1 /4 in. M BSP x 3 /8 in. M BSP Taper
892/00274 Adapter 1 /4 in. M BSP x 3 /8 in. M BSP Taper
892/00262 1 /4 in. M BSP x 1 /4 in. F BSP x Test Point
892/00706 Test Probe
892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in 2)

892/00239 Charging Tool (Diaphragm Accumulators)

892/01042 Charging Tool (Diaphragm Accumulators)
892/01043 Adapter (use with 892/01042)

892/00948 Charging Tool (Piston Accumulators)

Section F - Transmission

992/07603 Replacer - Bearing Cup

1 - 13 550/43477/1 1 - 13
 Section 1 - General Information
General Information
Colour Codes

Heavy Duty Socket for Durlock Bolts

892/00817 17 mm A/F x 3/4 in. Square Drive
892/00818 22 mm A/F x 3/4 in. Square Drive
892/00819 15 mm A/F x 1/2 in. Square Drive

Torque Multiplier
Use in conjunction with a torque
Wrench to give a 5:1
Multiplication.

992/04000 When tightening pinion nuts etc

AEB Starter for ZF Transmission

0501211778 AEB Starter for ZF Transmission

892/01001 Bearing Tool

892/01004 Bearing Tool
892/01005 Bearing Tool

1 - 14 550/43477/1 1 - 14
 Section 1 - General Information
General Information
Colour Codes

892/01006 110 Volt Heater

892/01002 Spring compressor

892/01007 Pipe Swaging Tool

892/01008 Pipe Swaging Tool
892/01009 Pipe Swaging Tool
892/01010 Pipe Swaging Tool

892/01014 Retainer

1 - 15 550/43477/1 1 - 15
Section 2

Care and Safety

Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering

Publication No.
550/43477/1

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section 2 - Care and Safety

Notes:

2-0 550/43477/1 2-0

 Section 2 - Care and Safety
Contents

Contents Page No.

Care & Safety
Safety Notices ........................................................................................... 2-1
General Safety ......................................................................................2-2
Operating Safety ...................................................................................2-4
Maintenance Safety ...............................................................................2-7
Safety Decals ......................................................................................2-12

2-i 2-i
 Section 2 - Care and Safety

Care & Safety

Safety Notices

In this publication and on the machine, there are safety
notices. Each notice starts with a signal word. The signal
word meanings are given below.
!MDANGER
Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
injured.
INT-1-2-1
!MWARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2
!MCAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3
All construction and agricultural equipment can be
hazardous. When a JCB machine is correctly operated
and properly maintained, it is a safe machine to work with.
But when it is carelessly operated or poorly maintained it
can become a danger to you (the operator) and others.
Remember
BE CAREFUL
BE ALERT
BE SAFE
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
As well as the warnings in this chapter, specific warnings
are given throughout the book. This section is designed to
give a safety code for use of the machine generally and
formaintenance practices.
!MWARNING
Clothing
You can be injured if you do not wear the proper
clothing. Loose clothing can get caught in the
machinery. Wear protective clothing to suit the job.
Examples of protective clothing are: a hard hat, safety
shoes, safety glasses, a well fitting overall, ear-
protectors and industrial gloves. Keep cuffs fastened.
Do not wear a necktie or scarf. Keep long hair
restrained. Remove rings, watches and personal
jewellery.
INT-1-3-6_2
!MWARNING
Care and Alertness
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always be
alert for hazards.
INT-1-3-5
!MWARNING
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
INT-1-3-7_2

Do not work with the machine until you are sure that you
can control it.

Do not start any job until you are sure that you and those
around you will be safe.

2-1 550/43477/1 2-1

 Section 2 - Care and Safety
Care & Safety
Safety Notices

!MWARNING
Entering/Leaving
Entering or leaving the cab or canopy must only be
made where steps and handrails are provided. Always
face the machine when entering and leaving. Make
sure the step(s), handrails and your boot soles are
clean and dry. Do not jump from the machine. Do not
use the machine controls as handholds, use the
handrails.
INT-2-1-7_1
General Safety
T1-007
!MWARNING
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.
INT-1-3-9_2
!MWARNING
Feeling Unwell
Do not attempt to operate the machine if you are

!MWARNING feeling unwell. By doing so you could be a danger to

Operator Manual
You and others can be injured if you operate or
maintain the machine without first studying the
Operator Manual. Read the safety instructions before
operating the machine. If you do not understand
anything, ask your employer or JCB dealer to explain
it. Keep the Operator Manual clean and in good
condition. Do not operate the machine without an
Operator Manual in the cab, or if there is anything on
the machine you do not understand.
INT-1-3-2_2
yourself and those you work with.
8-1-2-4
!MWARNING
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.

!MWARNING INT-3-3-9

Care and Alertness

All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always be
alert for hazards.
INT-1-3-5
!MWARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local

!MWARNING regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
Clothing INT-1-3-7
You can be injured if you do not wear the proper
clothing. Loose clothing can get caught in the
machinery. Wear protective clothing to suit the job.
!MWARNING
Examples of protective clothing are: a hard hat, safety Raised Equipment
shoes, safety glasses, a well fitting overall, ear- Raised equipment can fall and injure you. Do not walk
protectors and industrial gloves. Keep cuffs fastened. or work under raised equipment unless safely
Do not wear a necktie or scarf. Keep long hair supported.
restrained. 13-1-1-6
INT-1-3-6

2-2 550/43477/1 2-2

 Section 2 - Care and Safety
Care & Safety
Safety Notices

!MWARNING
Raised Machine
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1

!MDANGER
Lightning
Lightning can kill you. Do not use the machine if there
is lightning in your area.
5-1-1-2

!MWARNING
Machine Modifications
This machine is manufactured in compliance with
legislative and other requirements. It should not be
altered in any way which could affect or invalidate any
of these requirements. For advice consult your JCB
Distributor.
INT-1-3-10_2

2-3 550/43477/1 2-3

 Section 2 - Care and Safety
Care & Safety
Safety Notices

Operating Safety !MWARNING

!MWARNING
Machine Condition
A defective machine can injure you or others. Do not
operate a machine which is defective or has missing
parts. Make sure the maintenance procedures in this
manual are completed before using the machine.
INT-2-1-2_2
You could be killed or seriously injured if you operate
a machine with a damaged or missing ROPS/FOPS. If
the Roll Over Protection Structure (ROPS)/Falling
Objects Protection Structure (FOPS) 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 certification.
INT-2-1-9_6

!MWARNING
Machine Limits
Operating the machine beyond its design limits can
damage the machine, it can also be dangerous. Do not
operate the machine outside its limits. Do not try to
upgrade the machine performance with unapproved
modifications.
INT-2-1-4
!MWARNING
Work Sites
Work sites can be hazardous. Inspect the site before
working on it. Look for potholes, weak ground, hidden
rocks etc. Check for utilities such as electric cables
(overhead and underground), gas and water pipes etc.
Mark the positions of the underground cables and
pipes. Make sure that you have enough clearance

!MWARNING beneath overhead cables and structures.

INT-2-2-1
Engine/Steering Failure
If the engine or steering fails, stop the machine as
quickly as possible. Do not operate the machine until
!MWARNING
the fault has been corrected. Communications
Bad communications can cause accidents. Keep
INT-2-1-5
people around you informed of what you will be doing.

!MWARNING
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.
If you will be working with other people, make sure any
hand signals that may be used are understood by
everybody. Work sites can be noisy, do not rely on
spoken commands.
INT-2-2-3

!MWARNING
5-2-6-5

!MWARNING Parking
Exhaust Gases An incorrectly parked machine can move without an
Breathing the machine exhaust gases can harm and operator. Follow the instructions in the Operator
possibly kill you. Do not operate the machine in closed Manual to park the machine correctly.
spaces without making sure there is good ventilation. INT-2-2-4_2
If possible, fit an exhaust extension. If you begin to
feel drowsy, stop the machine at once and get into
fresh air.
!MWARNING
Banks and Trenches
INT-2-1-10_2
Banked material and trenches can collapse. Do not
work or drive too close to banks and trenches where
there is danger of collapse.
INT-2-2-5

2-4 550/43477/1 2-4

 Section 2 - Care and Safety
Care & Safety
Safety Notices

!MWARNING
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers
are clean before driving onto them. Use extreme
caution when driving onto ramps and trailers.
INT-2-2-6
!MWARNING
Practice
You or others can be killed or seriously injured if you
do unfamiliar operations without first practising them.
Practise away from the work site on a clear area. Keep
other people away. Do not perform new operations
until you are sure you can do them safely.
INT-2-1-1

!MWARNING
Safety Barriers
!MWARNING
Unguarded machines in public places can be Reversing
dangerous. In public places, or where your visibility is Reversing at high speeds can cause accidents. Do not
reduced, place barriers around the work area to keep reverse in a high gear with full throttle. Always drive at
people away. a safe speed to suit working conditions.
INT-2-2-8 INT-2-2-9_1

!MDANGER !MWARNING
Sparks Airborne particles of light combustible material such
Explosions and fire can be caused by sparks from the as straw, grass, wood shavings, etc. must not be
exhaust or the electrical system. Do not use the allowed to accumulate within the engine compartment
machine in closed areas where there is flammable or in the propshaft guards (when fitted). Inspect these
material, vapour or dust. areas frequently and clean at the beginning of each
INT-2-2-10 work shift or more often if required. Before opening
the engine cover, ensure that the top is clear of debris.
!MWARNING 5-3-1-12_3

Hazardous Atmospheres
This machine is designed for use in normal out door
atmospheric conditions. It should 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 Distributor.
INT-2-1-14
!MCAUTION
Regulations
Obey all laws, work site and local regulations which
affect you and your machine.
INT-1-3-3
!MWARNING
Keep the machine controls clean and dry. Your hands
and feet could slide off slippery controls. If that
happens you could lose control of the machine.
2-2-3-6
!MWARNING
Visibility
Accidents can be caused by working in poor visibility.
Use your lights to improve visibility. Keep the road
lights, windows and mirrors clean.
Do not operate the machine if you cannot see clearly.
5-1-4-7

2-5 550/43477/1 2-5

 Section 2 - Care and Safety
Care & Safety
Safety Notices

!MWARNING
Electrical Power Cables
You could be electrocuted or badly burned if you get
the machine or its attachments too close to electrical
power cables.

You are strongly advised to make sure that the safety

arrangements on site comply with the local laws and
regulations concerning work near electric power lines.

Before you start using the machine, check with your

electricity supplier if there are any buried power
cables on the site.

There is a minimum clearance required for working

beneath overhead power cables. You must obtain
details from your local electricity supplier.
2-2-5-4

!MCAUTION
If you have an attachment which is not covered in the
Operator 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.
5-5-1-1_2

!MWARNING
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.
2-4-5-2_1

!MWARNING
Powershift Transmission
Do not change from a high gear to a low gear (for
instance, 4th to 1st) in one sudden movement when
the machine is moving. Otherwise the machine will
rapidly decelerate, you or others could be killed or
seriously injured. When selecting lower gears, allow
the engine speed to drop before each gear change.
2-1-1-9_1

2-6 550/43477/1 2-6


Maintenance Safety
!MWARNING
Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
!MWARNING
Repairs
If your machine does not function correctly in any way,
get it repaired straight away. Neglect of necessary
repairs could result in an accident or affect your
health. Do not try to do repairs or any other type of
maintenance work you do not understand. To avoid
injury and/or damage get the work done by a specialist
engineer.
GEN-1-5_2
!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2
!MWARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4
!MCAUTION
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14
2-7 550/43477/1
Section 2 - Care and Safety
Care & Safety
Safety Notices
!MWARNING
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.
0125
!MWARNING
Battery Gases
Batteries give off explosive gases. Keep flames and
sparks away from the battery. Do not smoke close to
the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
the terminals with metal; use a hydrometer or
voltmeter.
INT-3-1-8
!MDANGER
Electrolyte
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.
INT-3-2-1_3
!MWARNING
Battery Terminals
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.
INT-3-1-9
!MWARNING
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 protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2
2-7
 Section 2 - Care and Safety
Care & Safety
Safety Notices

!MWARNING !MWARNING
Hydraulic Pressure Soft Ground
Hydraulic fluid at system pressure can injure you. A machine can sink into soft ground. Never work
Before connecting or removing any hydraulic hose, under a machine on soft ground.
residual hydraulic pressure trapped in the service INT-3-2-4
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
!MWARNING
the hoses are open. Hot Coolant
INT-3-1-11_2 The cooling system is pressurised when the engine is
hot. Hot coolant can spray out when you remove the
!MWARNING filler cap. Let the system cool before removing the
filler cap. To remove the cap; turn it to the first notch
Petrol and let the system pressure escape, then remove the
Do not use petrol in this machine. Do not mix petrol cap.
with the diesel fuel; in storage tanks the petrol will rise INT-3-2-9_1
to the top and form flammable vapours.
INT-3-1-6
!MWARNING
!MWARNING Always wear safety glasses when dismantling
assemblies containing components under pressure
Diesel Fuel from springs. This will protect against eye injury from
Diesel fuel is flammable; keep naked flames away from components accidentally flying out.
the fuel system. Do not smoke while refuelling or GEN-6-2
working on the fuel system. Do not refuel with the
engine running. There could be a fire and injury if you
do not follow these precautions.
!MCAUTION
INT-3-2-2_1 Rams
The efficiency of the rams will be affected if they are
!MWARNING not kept free of solidified dirt. Clean dirt from around
the rams regularly. When leaving or parking the
Oil machine, close all rams if possible to reduce the risk
Oil is toxic. If you swallow any oil, do not induce of weather corrosion.
vomiting, seek medical advice. Used engine oil INT-3-2-10
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
!MCAUTION
prevent skin contact. Wash skin contaminated with oil Cleaning
thoroughly in warm soapy water. Do not use petrol, Cleaning metal parts with incorrect solvents can cause
diesel fuel or paraffin to clean your skin. corrosion. Use only recommended cleaning agents
INT-3-2-3 and solvents.
INT-3-2-11

!MCAUTION
It is illegal to pollute drains, sewers or the ground.
!MWARNING
Clean up all spilt fluids and/or lubricants. When using cleaning agents, solvents or other
chemicals, you must adhere to the manufacturer's
Used fluids and/or lubricants, filters and contaminated instructions and safety precautions.
materials must be disposed of in accordance with GEN-1-9
local regulations. Use authorised waste disposal sites.
INT-3-2-14

2-8 550/43477/1 2-8

 Section 2 - Care and Safety
Care & Safety
Safety Notices

!MCAUTION !MWARNING
'O' rings, Seals and Gaskets Certain seals and gaskets (e.g. crankshaft oil seal) on
Badly fitted, damaged or rotted 'O' rings, seals and JCB machines contain fluoroelastomeric materials
gaskets can cause leakages and possible accidents. such as Viton, Fluorel and Technoflon.
Renew whenever disturbed unless otherwise Fluoroelastomeric materials subjected to high
instructed. Do not use Triochloroethane or paint temperatures can produce highly corrosive
thinners near 'O' rings and seals. hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
INT-3-2-12
New fluoroelastomeric components at ambient
!MWARNING temperature require no special safety precautions.

Hydraulic Hoses Used fluoroelastomeric components whose

Damaged hoses can cause fatal accidents. Inspect the temperatures have not exceeded 300°C (572°F) require
hoses regularly for: no special safety precautions. If evidence of
decomposition (e.g. charring) is found, refer to the
– Damaged hose ends next paragraph for safety instructions DO NOT TOUCH
– Chafed outer covers COMPONENT OR SURROUNDING AREA.
– Ballooned outer covers Used fluoroelastomeric components subjected to
– Kinked or crushed hoses temperatures greater than 300°C (572°F) (e.g. engine
– Embedded armouring in outer covers fire) must be treated using the following safety
procedure. Make sure that heavy duty gloves and
– Displaced end fittings.
special safety glasses are worn:
INT-3-3-2
1 Thoroughly wash contaminated area with 10%
!MCAUTION calcium hydroxide or other suitable alkali
solution, if necessary use wire wool to remove
Waxoyl contains turpentine substitute which is burnt remains.
flammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep 2 Thoroughly wash contaminated area with
flames away during the drying period. detergent and water.

Do not weld near the affected area during the drying
period. Take the same precautions as for oil to keep
Waxoyl off your skin. Do not breathe the fumes. Apply
in a well-ventilated area.
5-3-1-9
!MWARNING
3 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 FLUOROELASTOMERIC MATERIALS.
INT-3-3-5_3

Working Under the Machine

Make the machine safe before getting beneath it.
Ensure that any fitments on the machine are secure;
engage the park brake, remove the starter key,
disconnect the battery.
INT-3-3-8_2
!MWARNING
Protect your eyes when grinding metal. Wear safety
glasses or goggles. Remove or protect any
combustible materials from the area which could be
ignited by sparks.
GEN-1-12

2-9 550/43477/1 2-9


!MWARNING
To avoid burning, wear protective gloves when
handling hot components. To protect your eyes, wear
goggles when using a wire brush to clean
components.
HYD-1-3
!MWARNING
Arc Welding
To prevent the possibility of damage to electronic
components, disconnect the battery and the alternator
before arc-welding on the machine or attached
implements.
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
units (E.C.U.s), monitor displays, etc., then disconnect
them before welding. Failure to disconnect the
sensitive electrical equipment could result in
irreparable damage to these components.
Parts of the machine are made from cast iron; welds
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable or
apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to the
same component that is being welded, i.e. boom or
dipper, to avoid damage to pivot pins, bearings and
bushes. Attach the welder earth (ground) cable no
more than 0.6 metres (2 feet) from the part being
welded.
INT-3-1-15_2
!MWARNING
Counterweights
Your machine may be fitted with counterweights. They
are extremely heavy. Do not attempt to remove them.
INT-3-2-5
!MWARNING
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
0094
2 - 10 550/43477/1
Section 2 - Care and Safety
Care & Safety
Safety Notices
!MWARNING
Accumulators
The accumulators contain hydraulic fluid and gas at
high pressure. Prior to any work being carried out on
systems incorporating accumulators, the system
pressure must be exhausted by a JCB distributor, as
the sudden release of the hydraulic fluid or gas may
cause injury.
INT-3-1-17
!MWARNING
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.
2-3-2-7_2
!MWARNING
Jacking
A machine can roll off jacks and crush you unless the
wheels have been blccked. Always block the wheels at
the opposite end of the machine that is to be jacked.
Do not work underneath a machine supported only by
jacks. Always support a jacked-up machine on axle
stands before working underneath it.
INT-3-2-8
!MWARNING
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.
INT-3-1-16
!MWARNING
Wheels and tyres are heavy. Take care when lifting or
moving them.
Store with care to ensure that they cannot fall and
cause injury.
13-3-1-7_1
2 - 10
 Section 2 - Care and Safety
Care & Safety
Safety Notices

!MWARNING !MWARNING
Machine Modifications Make the machine safe before working underneath it.
This machine is manufactured in compliance with Park the machine on level ground, lower the
legislative and other requirements. It should not be attachments to the ground. Apply the park brake, put
altered in any way which could affect or invalidate any the transmission in neutral and stop the engine. Block
of these requirements. For advice consult your JCB both sides of all four wheels.
Distributor.
INT-1-3-10_2 Disconnect the battery, to prevent the engine being
started while you are beneath the machine.
!MWARNING GEN-4-1_1

Fires
If your machine is equipped with a fire extinguisher,
make sure it is checked regularly. Keep it in the correct
machine location until you need to use it.
Do not use water to put out a machine fire, you could
spread an oil fire or get a shock from an electrical fire.
Use carbon dioxide, dry chemical or foam
extinguishers. Contact your nearest fire department as
quickly as possible. Firefighters should use self-
contained breathing apparatus.
INT-3-2-7_2
!MWARNING
JCB Extradig Dipper Lubricant
JCB Extradig dipper lubricant contains 1.53% lead.
The repeated swallowing of very small quantities can
cause chronic lead poisoning. Do not smoke or touch
food while handling this lubricant. Dispose of waste
(rags etc.) in accordance with local regulations.
2-1-1-8

!MWARNING
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).
13-2-3-7

!MWARNING
Raised Machine
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1

2 - 11 550/43477/1 2 - 11
 Section 2 - Care and Safety
Care & Safety
Safety Notices

Safety Decals
Decals on the machine warn you of particular hazards.
Each decal is attached close to a part of the machine
where there is a possible hazard. Read and make sure you
understand the safety message before you work with or on
that part of the machine K Fig 1. ( T 2-12).
Keep all decals clean and readable. Replace lost or
damaged decals. The decals and their attachment points
are as illustrated. Each decal has a part number printed on
it, use this number to order a new decal from your JCB
dealer.

Fig 1.

2 - 12 550/43477/1 2 - 12
Section 3

Maintenance
Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering

Publication No.
550/43477/1

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section 3 - Maintenance

Notes:

3-0 550/43477/1 3-0

 Section 3 - Maintenance
Contents

Contents Page No.

Routine Maintenance
Service Schedules ..................................................................................... 3-1
Greasing .................................................................................................... 3-6
Z-Bar Loader Arm Pivot Points ..............................................................3-6
Propshafts .............................................................................................3-6
Loader Arm Safety Strut ............................................................................ 3-7
Installing the Safety Strut .......................................................................3-7
Articulation Lock ........................................................................................ 3-8
Installing the Articulation Lock ...............................................................3-8
Hydraulic System ....................................................................................... 3-9
Hydraulic System ..................................................................................3-9
Front & Rear Axles .................................................................................. 3-12
Front & Rear Axles ..............................................................................3-12
Front & Rear Axles ..............................................................................3-12
Engine Oil and Filter ................................................................................ 3-14
Checking the Oil Level ........................................................................3-14
Changing the Oil and Filter ..................................................................3-14
Fuel System ............................................................................................. 3-16
Types of Fuel .......................................................................................3-16
Draining the Fuel Filter (Spin-on) ........................................................3-17
Cooling System ....................................................................................... 3-18
Checking the Coolant Level ................................................................3-18
Changing the Coolant ..........................................................................3-18
Fan Belt ................................................................................................... 3-20
Alternator Drive Belts ..........................................................................3-20
Engine Drive Belt .................................................................................3-21
Engine Air Filter ....................................................................................... 3-23
Changing the Air Filter Elements .........................................................3-23

3-i 3-i
 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Routine Maintenance

Service Schedules

A badly maintained machine is a danger to the operator machine which is due for a service. Make sure any defects
and the people working around him. Make sure that the found during the regular maintenance checks are rectified
regular maintenance and lubrication jobs listed in the immediately.
schedules are done to keep the machine in a safe and
efficient working condition.
z Initial 100 Hour Check Only
The schedules are based on machine running hours. Keep
a regular check on the hourmeter readings. Do not use a
… Regular Maintenance Check

Table 1.
Pre-start Cold Checks Service Points and Operatio 10 100 250 As and 500 1000 2000
Fluid Levels n Hr Hr Hr When Hr Hr Hr
ENGINE …
Oil level … …
Oil and Filter (First Change @ 250 Hrs. thereafter every - Check … …
250 Hrs.)
Air Cleaner Outer Element - Change … …
Air Cleaner Inner Element - Change … … …
Fuel Filter - Drain …
Fuel Filter - Change z …
Coolant Level - Check …
Coolant - Test
Antifreeze Strength - Check z …
Coolant - Change
Fuel Sedimenter - Drain …
Fan Belt Tension/Condition - Check z … …
Engine Mount Security - Check z

3-1 550/43477/1 3-1

 Section 3 - Maintenance
Routine Maintenance
Service Schedules
Table 2.
TRANSMISSION AND AXLES Operation 10 100 250 As and 500 1000 2000
Hr Hr Hr When Hr Hr Hr
Transmission Oil Level - Check …
Transmission Oil - Change z
Transmission Strainer/Filter - Change z
Axle(s) Oil Level - Check z
Axle(s) Oil - Change z …
Hub Oil Levels - Check
Hub Oil - Change …
Prop. Shaft and Universal joints - Grease z
Prop. Shaft Security - Check
Centre Prop. Shaft Slide - Grease z
Axle Breather(s) - Check z
Tyre Pressures and Condition - Check …
Wheel Nut Security - Check z
Axle Mount Security - Check z
Transmission Mount Security - Check z
Parking Brake Operation - Check and …
Adjust
Rear Axle Pivot - Grease …
Bevel Ring Gear Deflection Plunger - Check and
Adjust

Table 3.
HYDRAULICS 10 Hr 100 Hr 250 As and 500 1000 2000
Hr When Hr Hr Hr

Oil Level - Check …

Oil Filter - Change z …
Oil - Sample … …
Oil - Change …
Suction Strainer - Clean
Tank Filler Cap - Check …
Hoses & Pipework - Damage or Leaks - Check
Table 4.
Pre-start Cold Checks Operation 10 100 250 As and 500 1000 2000
Hr Hr Hr When Hr Hr Hr
Service Points and Fluid Levels
ELECTRICS
Instrument Panel Operation - Check …

3-2 550/43477/1 3-2

 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Wiring for Chaffing - Check z …

Battery Terminals for Condition and - Check z …
Tightness
Battery Charge Condition - Check z

BODY AND FRAMEWORK

Loader End Pivots - Grease …
All Hinges - Grease z …
Lower Centre Pivot - Grease …
Steer Ram Pivots - Grease …
Upper Centre Pivot - Grease z
Machine Condition Generally - Check z … …

CAB
ROPS/FOPS Structures - Check …
Seat Belt Security and Condition - Check …
Table 5.
Functional Test Operation 10 100 250 As and 500 1000 2000
Hr Hr Hr When Hr Hr Hr
and Final Inspection
ENGINE z … …
Idle Speed - Check and Adjust … … …
Torque Converter Stall Speed - Check … …
Combined Stall Speed - Check z … …
Max. No Load Speed - Check z
Max. No Load Speed - Check and Adjust z
Throttle System and Control Cable - z
Check
Operation of Stop Control/E.S.O.S. - z
Check
Exhaust Smoke - Check z
Fuel System For Leaks and - Check z … …
Contamination
Exhaust System Security - Check z … …
Air Inlet System Security - Check z
Coolant System for Leaks
Table 6.
Functional Test Operation 10 100 250 As and 500 1000 2000
Hr Hr Hr When Hr Hr Hr
and Final Inspection

3-3 550/43477/1 3-3

 Section 3 - Maintenance
Routine Maintenance
Service Schedules

TRANSMISSION AND AXLES - Check z …

Clutch Pack Pressures - Check z …
Clutch Disconnect/Dump Button - Check …
Clutch Pack Calibration - Check z …
Speed Change and Selection - Check z
Forward/Reverse Selection/Operation - Check z
Neutral Start Operation - Check z z
Reverse Alarm (if fitted) - Check z
Oil Cooler and Pipework - Check z

Table 7.
Functional Test Operation 10 Hr 100 250 As and 500 1000 2000
Hr Hr When Hr Hr Hr
HYDRAULICS
MRV Pressure - Check and z …
Adjust
Steer Circuit MRV Pressure - Check and z …
Adjust
ARV Pressure - Check and …
Adjust
Operation of All Services - Check z …
Hoses for Damage and Leaks - Check …
Pipework for Damage and Leaks - Check …
Piston Rods and Gland Seals - Check …
Table 8.
Functional Test Operation 10 100 250 As and 500 1000 2000
Hr Hr Hr When Hr Hr Hr
ELECTRICS
Starter Motor - Check z …
Alternator - Check z …
Gauges and Warning Lights - Check z …
Proximity Sensor Function - Check z …
Cab Switches - Check z …
Wiper Motors - Check z
Heater - Check …
Other (give details) - Check …

CAB
Glazing for Correct Fit - Check z

3-4 550/43477/1 3-4

 Section 3 - Maintenance
Routine Maintenance
Service Schedules

Doors and Hinges - Check z

Tool Kit and Handbook - Check z
Locks and Keys - Check z
Seat/Seat Belts - Check …
PAINTWORK
Condition - Check …

Note: Operations must be carried out at the end of each Note: 100 Hour operations marked with the symbol are
set period, ie. The 10 Hour operations must be carried out carried out at the Initial 100 Hour Service ONLY.
after every 10 hours.

OIL LUBRICATION CHART

ITEM STD. BRANDS GROUP STD. CAPACITY CHECKING FIRST CHANGE DRAIN /
NO. IN LTR. INTERVAL REFILL
PERIOD
ENGINE OIL JCB ENGINE OIL SPECIAL 14 BEGINNING 100 HOURS / 30 250 HOURS /
4001/0800 OF SHIFT DAYS 45 DAYS
TRANSMISSIO JCB ENGINE OIL SPECIAL 26 BEGINNING 100 HOURS / 30 1000 HOURS /
N OIL 4001/0800 OF SHIFT DAYS 180 DAYS
AXLE OIL JCB GEAR OIL LS 4000 /1200 26 Each EVERY 250 100 HOURS / 30 500 HOURS /
HOURS DAYS 90 DAYS
HYDRAULIC JCB HYDRAULIC OIL SPECIAL 180 BEGINNING 1700 HOURS / 1700 HOURS /
OIL 4002 / 0800 OF SHIFT 270 DAYS 270 DAYS
GREASE JCB GREASE SPECIAL 4003 / 2 KGS. BEGINNING GREASE
2000 NOMINAL OF SHIFT EVERY 4 HR.

3-5 550/43477/1 3-5

 Section 3 - Maintenance
Routine Maintenance
Greasing

Greasing

Z-Bar Loader Arm Pivot Points

Total of 11 grease points (4 to 13) K Fig 1. ( T 3-6)

Shovel Pivot Pins

Total of 3 grease points (1 to 3)

For interval see Service Schedule

Fig 2.

Propshafts
Total of 7 grease points K Fig 3. ( T 3-6)

Note: Centre Propshaft Sliding Spline - grease point 1.

For interval see Service Schedule

!MWARNING
Fig 1. Make the machine safe before working underneath it.
Park the machine on level ground and lower the
Centre Pivot and Steering Ram attachments, (If it is necessary to work with the loader
arms raised, then the loader arm safety strut must be
Total of 7 grease points K Fig 2. ( T 3-6) fitted). See Loader Arm Safety Strut in MAINTENANCE
section. Engage the park brake, put the transmission
For interval see Service Schedule in neutral and stop the engine. Block both sides of all
four wheels. If you are working near the articulation
danger zone, fit the articulation safety lock. See
Articulation Lock in MAINTENANCE section.
4-3-2-4_1

Fig 3.

3-6 550/43477/1 3-6

 Section 3 - Maintenance
Routine Maintenance
Loader Arm Safety Strut

Loader Arm Safety Strut

Installing the Safety Strut Removing the Safety Strut

!MWARNING
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).
13-2-3-7
!MWARNING
You could be killed or seriously injured if the loader
control is accidentally operated. Make sure that no-
one goes near the machine when fitting/removing the
transit strut.
4-2-5-8_1
!MWARNING
You could be killed or injured if the loader control is
accidentally operated. Make sure no-one comes near
the machine while you remove the safety strut.
2-3-1-3
1 Make sure the park brake is engaged and that the
transmission is in neutral
2 Raise the loader arm to take the weight off safety strut
A Stop the engine.
3 Remove the strut:
a Release securing strap B K Fig 4. ( T 3-7)

1 Empty the shovel and raise the loader arm enough to b Remove safety strut A.
fit safety strut A.
c Return the safety strut to its stowage position
2 Apply the park brake, put the transmission in neutral
and stop the engine.

3 Fit the Strut:

a Remove the strut from its stowage position

b Place the strut around the ram.

c Secure the strut into position using strap B.

4 Start the engine.

5 Slowly lower the loader arm onto the safety strut Stop
the movement immediately the weight of the arm is
supported by the strut. Fig 4.

Note: Extreme care must be taken when lowering the

loader arm onto the safety strut. ‘Feather’ the lever to lower
the loader arm slow/y.

3-7 550/43477/1 3-7

 Section 3 - Maintenance
Routine Maintenance
Articulation Lock

Articulation Lock

Installing the Articulation Lock

!MDANGER
Make sure the articulation safety lock is fitted before
transporting the machine. The articulation safety lock
must also be fitted if you are carrying out daily checks
or doing any maintenance work in the articulation
danger zone.

If the articulation lock is not fitted you could be

crushed between the two parts of the chassis.
GEN-3-1_1

On the Wheeled Loader, the articulation safety lock is Fig 5.

stowed on the machine as shown. The articulation lock is
fitted with the machine in a ‘straight ahead’ position. 1 Remove pin A.

1 Steer the machine to bring the front and rear wheels 2 Return the articulation lock to its stowage position as
in a straight line. shown.

2 Apply the parking brake, put the transmission in 3 Lock the articulation lock into its stowage position by
neutral. replacing pin at position 2 as shown.

3 Remove pin A and pivot articulation lock into locking

position, replace pin A at position 1. If pin will not fit,
turn steering wheel slightly to align hole K Fig
5. ( T 3-8).

4 Stop the engine.

Removing the Articulation Lock

!MWARNING
Always make sure the articulation safety lock has
been removed before attempting to drive the machine.
The machine cannot be steered with the articulation
lock fitted.
16-3-1-4

1 Remove pin A .

2 Return the articulation lock to its stowage position as

shown.

3 Lock the articulation lock into its stowage position by

replacing pin at position 2 as shown.

3-8 550/43477/1 3-8


Hydraulic System
Hydraulic System
!MWARNING
Fine jets of hydraulic fluid at high pressure can
penetrate the skin. Do not use your fingers to check
for hydraulic fluid leaks. Do not put your face close to
suspected leaks. Hold a piece of cardboard close to
suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates
your skin, get medical help immediately.
IND-016
Checking the Fluid Level
1 Apply the parking brake, put the transmission in
neutral, lower the shovel/attachment to the ground.
Make sure it is flat on the ground. Stop the engine.
2 Look at the fluid level in the sight glass A. The level
should be visible in the sight glassK Fig 6. ( T 3-9).
Fig 6.
3 If necessary, top up with hydraulic fluid.
4 Open the right side engine cover. Open filler cap B.
5 Top up the system with hydraulic fluid. See Fluids,
Capacities and Lubricants (MAINTENANCE
section).
6 Refit filler cap B. Make sure it is secure. Close and
lock the engine cover K Fig 7. ( T 3-9).
3-9 550/43477/1
Section 3 - Maintenance
Routine Maintenance
Hydraulic System
Fig 7.
!MWARNING
If the fluid in the tube appears cloudy, then water or air
has entered the system. The hydraulic pump could be
severely damaged if the machine is operated. Contact
your JCB distributor immediately.
IND-017
Changing the Filter Element
1 Open the right side engine cover.
2 Remove hydraulic tank cap.
3 Unscrew and remove nuts C, cover plate D and seal
E.
4 Pull out the complete element assembly F and seals
G and H.
5 Remove the nut and spring K. Remove the filter
element L from the spindle and clean magnets J.
6 Fit the new element L and the new seals G and H.
7 Replace the cover plate D and tighten nuts C to 7 Nm
(5 lbf ft) K Fig 8. ( T 3-10)
8 Top up the system with hydraulic fluid. See Fluids,
Capacities and Lubricants (MAINTENANCE
section).
3-9
 Section 3 - Maintenance
Routine Maintenance
Hydraulic System
9 Refit filler cap. Make sure it is secure. Close and lock 4 Make sure the oil is at the correct mark on the dipstick
the engine cover.
5 If necessary, add recommended oil at dipstick/filler
point A.

The dipstick is marked as follows :

HOT - When the engine/transmission is at working

temperature.

Note: The transmission may overheat if the oil level isb

above the HOT mark.

COLD - When the engine/transmission has not

warmed up.

6 Close and lock the engine cover.

Changing the Oil and Filter

!MWARNING
Make the machine safe before getting beneath it.
Lower the tipper body to the fully lowered position;
engage the park brake; remove the starter key,
Fig 8. disconnect the battery.

!MWARNING
0197

1 Place a suitable container beneath the transmission

Working Under the Machine
Make the machine safe before getting beneath it.
Ensure that any fitments on the machine are secure;
engage the park brake, remove the starter key,
disconnect the battery.
INT-3-3-8_2
(to catch the oil).
2 Remove the dipstick A and drain plug B K Fig
9. ( T 3-11).
3 Drain the oil. Clean and refit drain plug B.

4 Unscrew and discard old filter C. Clean the mounting

Transmission face and lubricate the seal on the new filter with clean
torque converter fluid.
Checking the Oil Level
5 Fit the new filter C hand tight only.
1 Park the machine on level ground.
6 Fill the system with new oil at dipstick/filler point A.
2 Apply the parking brake, put the transmission in
neutral.
Note: Do not fill past the top mark on the dipstick.
3 Open the left side engine cover. Remove, wipe and
replace the dipstick A.

Note: Turn ‘T’ handle D two full turns anti-clockwise to

release the dipstick. Turn ‘T’ handle D two full turns
clockwise to fasten in position. Check that the dipstick is
secure.

3 - 10 550/43477/1 3 - 10
 Section 3 - Maintenance
Routine Maintenance
Hydraulic System

Fig 9.

3 - 11 550/43477/1 3 - 11
 Section 3 - Maintenance
Routine Maintenance
Front & Rear Axles

Front & Rear Axles

Front & Rear Axles Draining and Refilling the Differential Oil

Checking the Differential Oil Level !MWARNING

Make the machine safe before getting beneath it.
!MWARNING Lower the tipper body to the fully lowered position;
engage the park brake; remove the starter key,
Make the machine safe before getting beneath it.
disconnect the battery.
Lower the tipper body to the fully lowered position;
0197
engage the park brake; remove the starter key,
disconnect the battery.
1 Clean the area around fill/level plug A.
0197

2 Remove fill/level plug A and its seal.

!MCAUTION
3 Place a suitable container beneath the drain plug B
The axle oil level must be checked with the machine (to catch the oil).
level, otherwise a false indication of the amount of oil
in the axle will be given. 4 Remove drain plug B. Allow the oil to drain fully.
16-3-5-3

1 Clean the area around fill/level plug A. !MCAUTION

Oil will gush from the hole when the drain plug is
2 Remove fill/level plug A and its seal, oil should be
removed. Keep to one side when you remove the plug.
level with the bottom of the hole.
2-3-4-2

3 Top up with the recommended oil if necessary.

5 Clean and refit drain plug B and its seal. Plug B is
magnetic, make sure all debris is removed. Tighten to
4 Clean and refit fill/level plug A and its seal. Tighten to
85 Nm (60 lbt ft.)
85 Nm (60 lbf ft) K Fig 10. ( T 3-12).
6 Fill the axle with the recommended oil through fill/
Note: The 436 axle is shown, the 426 axle filler plug is at
level plug A.
the opposite side.
7 Clean and refit fill/drain plug A and its seal. Tighten to
85 Nm (60 lbf ft).

Front & Rear Axles

Checking the Hub Oil Level

!MWARNING
Make the machine safe before getting beneath it.
Lower the tipper body to the fully lowered position;
Fig 10. engage the park brake; remove the starter key,
disconnect the battery.
0197

1 Make sure the OIL LEVEL mark on the hub is

horizontal, as shown at B K Fig 11. ( T 3-13).

3 - 12 550/43477/1 3 - 12

2 Clean the area around fill/drain plug A.
3 Remove fill/drain plug A and its seal, oil should be
level with the bottom of the hole.
4 Top up with the recommended oil if necessary.
5 Clean and refit fill/drain plug A and its seal. Tighten to
85 Nm (60 lbf ft).
Note: The hubs must be treated separately, a total of four
hubs.
Section 3 - Maintenance
Routine Maintenance
Front & Rear Axles
!MCAUTION
There will be no oil in the hub when the machine is
driven forward. Only drive the machine forward one
quarter revolution of the wheel. Do not drive the
machine more than is necessary.
4-3-5-1
4 Drive the machine slowly forward to bring the OIL
LEVEL mark on the hubs into the horizontal position,
as shown at B.
5 Fill the hub with the recommended oil through fill/
drain plug A, until oil starts to dribble out.

6 Clean and refit fill/drain plug A and its seal. Tighten to

85 Nm (60 lbf ft).

Note: The hubs must be treated separately, a total of four

hubs.

Fig 11.

Draining and Refilling the Hub Oil

!MWARNING
Make the machine safe before getting beneath it.
Lower the tipper body to the fully lowered position;
engage the park brake; remove the starter key,
disconnect the battery.
0197

1 Make sure both fill/drain plug A are at the bottom, as

shown at C.

2 Clean the area around fill/drain plug A.

3 Remove fill/drain plug A and its seal, drain the oil into
a suitable container. Allow the oil to drain fully.

3 - 13 550/43477/1 3 - 13
 Section 3 - Maintenance
Routine Maintenance
Engine Oil and Filter

Engine Oil and Filter

Checking the Oil Level Changing the Oil and Filter

!MCAUTION
Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
2-3-3-2
1 Park the machine on level ground and lower the
attachments to the ground.
!MWARNING
Make the machine safe before getting beneath it.
Lower the tipper body to the fully lowered position;
engage the park brake; remove the starter key,
disconnect the battery.
0197

2 Stop the engine. Put the transmission in neutral and

!MCAUTION
remove the starter key. Hot oil and engine components can burn you. Make
sure the engine is cool before doing this job.
3 Open the right side engine cover. 2-3-3-2

4 Check that the oil level is between the two marks on 1 Park the machine on level ground and lower the
the dipstick A K Fig 12. ( T 3-14). attachments to the ground.

5 If necessary, add the recommended oil through the 2 Stop the engine. Put the transmission in neutral and
filler point B. remove the starter key.

6 Make sure the filler cap and the dipstick are secure. 3 Open the left side engine cover.
Close and lock the engine cover.
4 Place a suitable container beneath the drain plug (to
catch the oil).K Fig 13. ( T 3-15)

5 Unscrew the drain plug A .

6 Drain the sump oil.

Fig 12.

3 - 14 550/43477/1 3 - 14
 Section 3 - Maintenance
Routine Maintenance
Engine Oil and Filter

Fig 13.

7 Clean the area around the filter head. Unscrew the

filter canister C. Remember that it will be full of oil.
Fig 14.
8 Clean filter head D. Make sure that the ‘O’ ring is
removed K Fig 14. ( T 3-15).

9 Add clean engine oil to the new filter canister.

Allowtime for the oil to pass through the filter element.

10 Smear the seal E on the new filter canister with clean

engine oil.

11 Screw in the new filter canister until it just contacts the

filter head.

12 Turn the filter a further 3/4 of a turn.

13 Fill the engine with the recommended oil, to the MAX

mark on the dipstick, through the filler point. Wipe off
any spilt oil, refit the filler cap and make sure it is
secure. Close the engine covers.

14 Make sure the engine will not start and turn the
engine using the starter key until the oil pressure
warning light is extinguished.

15 Start the engine. Check for leaks. When the engine

has cooled, check the oil level.

3 - 15 550/43477/1 3 - 15

Fuel System
Types of Fuel
Use good quality diesel fuel to get the correct power and
performance from your engine. The recommended
fuelspecification for Perkins engines is given below.
Cetane Number 45 (minimum)
Viscosity 2.5/4.5 centistokes at 40°C (104°F)
Density 0.835/0.855 kg/litre
(0.872/0.904 lb/pint)
Sulphur 0.5% of mass (maximum)
Distillation 85% at 350°C (662°F)
Cetane Number
Indicates ignition performance. Fuel with a low cetane
number can cause cold start problems and affect
combustion.
Viscosity
Is the resistance to flow. If this is outside limits, the engine
performance can be affected.
Density
Lower density will reduce engine power. Higher density will
increase both engine power and exhaust smoke.
Sulphur
High sulphur content can cause engine wear. (High
sulphurfuel is not normally found in North America, Europe
or Australia). If you have to use high sulphur fuel you must
also use a highly alkaline engine lubricating oil; or change
the normal oil more frequently. Low sulphur fuels are
commonly used throughout the world. These fuels contain
fewer lubrication additives. The fuel injection pumps fitted
to the Perkins engine (with exception of 160TW, Euro 1
engine) are lubricated by the fuel; therefore using low
sulphur fuel may, in the long term, affect the pump.
If you have to use a low sulphur fuel your are advised to
use a lubrication additive as recommended by your fuel
supplier.
3 - 16 550/43477/1
Section 3 - Maintenance
Routine Maintenance
Fuel System
Distillation
This indicates the mixture of different hydrocarbons in the
fuel. A high ratio of lightweight hydrocarbons can affect the
combustion characteristics.
Low Temperature Fuels
Special winter fuels may be available for engine operation
at temperatures below 0°C (32°F). These fuels have a
lower viscosity. They also limit wax formation in the fuel at
low temperatures. (Wax forming in the fuel can stop the
fuel flowing through the filter).
Flow improvers may also be available. These can be
added to the fuel to reduce wax formation.
Petrol
Note: Do not use petrol in this engine. Do not mix petrol
with the diesel fuel. In storage tanks the petrol could rise to
the top and form flammable vapours.
Advice
If you have to use non-standard fuels, contact your JCB
distributor for advice on engine adjustments and oil
change periods.
Fuel Standards
Consult your fuel supplier, JCB distributor or Perkins
dealer about the suitability of any fuel you are unsure of.
Filling the Tank
!MWARNING
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from
the fuel system. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. There could be a fire and injury if you
do not follow these precautions.
INT-3-2-2_1
At the end of every working day, fill the tank with the
correct type of fuel. This will prevent overnight
condensation from developing in the fuel.
3 - 16

We recommend that, if possible, you lock the fuel cap to
prevent theft and tampering.
Draining the Fuel Filter (Spin-on)
1 Apply the parking brake, put the transmission in
neutral and stop the engine.
2 Open the right side engine cover.
Section 3 - Maintenance
Routine Maintenance
Fuel System
2 Open the left side engine cover.
3 Make sure that there is enough fuel in the fuel tank.
4 Turn the starter key to the IGN position.
5 Operate the fuel lift pump priming lever slowly for
about two minutes till all the air in the system is
expelled.

3 Unscrew the filter element A, the element is hand tight
but may require a strap wrench to remove. The filter
will be full of fuel.
4 Repeat for second filter.
5 To assist with bleeding fill the filter element with fuel
before fitting. Install the filter element A, hand tight
only. Check for leaks K Fig 15. ( T 3-17).
6 Turn the starter key fully clockwise to the HS position
until the engine starts.
Note: If the engine runs smoothly for a short time and then
begins to run roughly or stops, check again for air in the
fuel system.
7 Close and lock the engine cover.

6 Bleed the fuel system. See Bleeding the Fuel

System in MAINTENANCE section.

7 Close and lock the engine cover.

Fig 15.

Bleeding the System

If the engine fails to start, misfires or if any part of the fuel
system has been disconnected or emptied, bleed the
system as follows

1 Apply the parking brake, put the transmission in

neutral and stop the engine.

3 - 17 550/43477/1 3 - 17

Cooling System
!MWARNING
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool
before checking the coolant level or checking the
system.
9-3-3-1_1
Checking the Coolant Level
1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop
the engine and let it cool down. Open the right side
engine cover.
2 Check the coolant level in the header tank A. The
level should be between the MAX and MIN marks. If
not, continue with steps 3 to 6 K Fig 15. ( T 3-17).
3 Close the engine cover. Top up the coolant system
through the filler cap. Access to the filler cap is
through a hole in the engine cover above the filler
cap.
4 Refit the filler cap and make sure it is tight.
5 Run the engine for a while to raise the coolant to
working temperature and pressure. Stop the engine
and check for leaks.
Fig 16.
3 - 18 550/43477/1
Section 3 - Maintenance
Routine Maintenance
Cooling System
To prevent the coolant freezing in cold conditions,
antifreeze must be added.
Antifreeze Solution Starts to freeze at
55% -36°C (-33°F)
Never use less than a 50% solution otherwise there will not
be enough corrosion protection.
Never use more than 60% solution otherwise the cooling
system may be damaged. Leave the antifreeze in all the
year round as it gives protection against corrosion.
Check the strength of antifreeze solution at least once a
year, preferably at the start of the cold period. Always
renew the antifreeze every two years.
A 50% antifreeze mixture should be used even if frost
protection is not needed. This gives protection against
corrosion and raises the coolant’s boiling point.
Changing the Coolant
!MWARNING
Make the machine safe before getting beneath it.
Lower the tipper body to the fully lowered position;
engage the park brake; remove the starter key,
disconnect the battery.
0197
1 Park the machine on level ground. Engage the
parking brake. Put the transmission in neutral. Stop
the engine and let it cool down. Open the left side
engine cover.
!MWARNING
Hot Coolant
The cooling system is pressurised when the engine is
hot. Hot coolant can spray out when you remove the
filler cap. Let the system cool before removing the
filler cap. To remove the cap; turn it to the first notch
and let the system pressure escape, then remove the
cap.
INT-3-2-9_1
3 - 18
 Section 3 - Maintenance
Routine Maintenance
Cooling System

!MCAUTION
Keep your face away from the drain hole when
removing the drain plug.
2-3-3-4

2 Carefully loosen cap. Let any pressure escape.

Remove the cap.

3 Remove drain plug A from the engine block K Fig

17. ( T 3-19).

4 Remove the drain plug B from the engine coolant

section of the cooling pack K Fig 18. ( T 3-19).
Fig 17.
5 Flush the system using clean water.

6 Clean and refit the engine block drain plug A.

7 Renew the aluminium washer on the cooling pack

drain plug B. Refit the plug and torque tighten. (See
Torque Settings.)

8 Fill the system using the necessary mix of water and

anti-freeze.

Note: It is recommended that the cooling system be filled

at a maximum rate of 10 litres per minute. If the fill rate is
any higher than this there is a possibility of air becoming
trapped in the system.

9 Refit the filler cap. Fig 18.

10 Check for leaks. Close and lock the engine cover.

11 Run the engine for a while to raise the coolant to

working temperature and pressure. Stop the engine
and check for leaks.

Torque Settings

Item Nm Kgf m lbf ft

B 55 5.6 40

3 - 19 550/43477/1 3 - 19
 Section 3 - Maintenance
Routine Maintenance
Fan Belt

Fan Belt

Alternator Drive Belts

Adjusting

!MWARNING
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
2-3-3-5

1 Park the machine on level ground.

2 Apply the parking brake, put the transmission in

neutral and stop the engine.

3 Open the left side engine cover.

4 Loosen bolts A, B and C holding the alternator K Fig

19. ( T 3-20).

!MCAUTION Fig 19.

Any leverage required to position the alternator must

be applied at the drive end bracket only, using a
wooden lever.
8-3-2-1

5 Adjust the fan belt by positioning the alternator to give

10 mm ( 3 /8 in) slack at the mid point of the longest
run on the tighter of the two belts.

6 Tighten bolts A, B and C.

Note: Make sure bolt C is the last bolt to be tightened.

7 Close and lock the engine cover.

3 - 20 550/43477/1 3 - 20

Engine Drive Belt
!MWARNING
Make sure the engine cannot be started. Disconnect
the battery before doing this job.
2-3-3-5
Inspection
1 Park the machine on level ground
2 Apply the parking brake, put the transmission in
neutral and stop the engine.
3 Open the engine side covers.
4 Inspect the belt for damage.
a Cracks across the belt width A are acceptable.
b Cracks across the belt which intersect those in the
direction of the belt length B are not acceptable
K Fig 20. ( T 3-21).
c Renew the belt if it has unacceptable cracks or if
it is frayed or has pieces of material missing as at
C.
Fig 20.
Check the belt tension
1 The maximum deflection on the longest run of the belt
as at D should be 9.5 to 12.7 mm (0.375 to 0.5 in). If
3 - 21 550/43477/1
Section 3 - Maintenance
Routine Maintenance
Fan Belt
the deflection is excessive, fit a replacement K Fig
21. ( T 3-21).
Fig 21.
Renew the Belt and Check the Belt
Tensioner
1 Slacken the tension of the air conditioning
compressor drive belt E and lift the belt clear of its
drive pulley. (To refit see Adjusting the Compressor
Drive Belt.)
2 Using a 3/8 in square drive inserted in the belt
tensioner as shown at F, lever the tensioner in the
direction of the
arrow to allow the belt to be lifted clear. Do not use
excessive force or the tensioner will be damaged.
3 Before fitting a new belt, check that the tensioner
roller rotates smoothly and that there is no side play
in the bearings.
4 Fit the new belt and allow the tensioner to return to its
normal position.
5 Check that the tensioner securing bolt G is tightened
to 43 Nm (32 lbf/ft).
6 Refit the air conditioning compressor drive belt. (see
Adjusting the Compressor Drive Belt.)
7 Close and lock the engine side covers K Fig
22. ( T 3-22).
3 - 21
 Section 3 - Maintenance
Routine Maintenance
Fan Belt

Fig 22.

3 - 22 550/43477/1 3 - 22

Engine Air Filter
Changing the Air Filter Elements
Note: In a dusty working environment, the outer element
may have to be renewed more frequently. A new inner
element must be fitted at latest every third time the outer
element is changed. As a reminder, mark the inner
element with a felt tip pen each time you change only the
outer element. DO NOT attempt to wash or clean elements
- they must be renewed.
!MCAUTION
The outer element must be renewed immediately if the
warning light on the instrument panel illuminates.
2-3-3-1
!MCAUTION
Do not run the engine when the outer element has
been removed.
16-3-3-1
1 Apply the parking brake, put the transmission in
neutral and stop the engine.
3 - 23
Section 3 - Maintenance
Routine Maintenance
Engine Air Filter
2 Open the right side engine cover.
3 If changing the inner element, disconnect the filter
induction hose H to prevent dust getting into the
engine. Cover the hose to prevent rain and dirt getting
into the engine.
4 Release the end cover spring clips 1 and remove end
cover A. Pull out the outer element 2. Take care not
to tap or knock the element as you remove it. If
necessary, pull out the inner filter 3.
5 Clean inside housing 4 and dust valve 5.
6 Carefully insert the new elements into the canister.
Make sure that they are seated correctly.
7 Refit cover A and fasten the spring clips. Make sure
that dust valve 5 is at the bottom.
8 Connect the induction hose H. Make sure the air filter
blocked switch connector is fitted. Check all hoses for
condition and tightnessK Fig 23. ( T 3-23).
Fig 23.
550/43477/1 3 - 23
Section B

Body and Framework

Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering

Publication No.
550/43477/1

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section B - Body and Framework

Notes:

B-0 550/43477/1 B-0

 Section B - Body and Framework

Contents Page No.

Body & Framework
Cab ........................................................................................................... B-1
Direct Glazing ....................................................................................... B-1
Cab ....................................................................................................... B-2
Centre Pivot .......................................................................................... B-3
Cooling Pack ........................................................................................ B-8
Replacement ...................................................................................... B-12

B-i B-i
 Section B - Body and Framework

Body & Framework

Cab
Direct Glazing
The following procedures explain how to correctly
removeand install panes of glass that are directly bonded
to the cabframe apertures. When carrying out the
procedures, relevantsafety precautions must be taken :
1 Always wear safety glasses during both removal and
replacemen
2 Use protective gloves - heavy duty leather gauntlet
type gloves when cutting out the broken glass;
‘nonslip’ type gloves when handling/moving panes of
glass; surgical type gloves when using the
polyurethane adhesives.
glass depends upon which type it is. See WARNING
below.
!MWARNING
Always wear safety glasses when removing or
installing screen glass. Never use a power operated
knife when removing the sealant around a toughened
glass screen. The action of the knife could cause
particles of glass to be thrown with sufficient force to
cause serious injury, even when safety glasses are
being worn. Use only hand operated tools when
working with toughened glass.
BF-2-3_1

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 (see Service Tools,
Section 1).

Several special tools are required to successfully

complete the removal and replacement procedures.
Reference is made to the tools in the text. The
majority of these tools can be obtained locally and the
remainder from JCB Service (see Service Tools,
Section 1).

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°F).

Removing the Broken Glass and Old Sealant

Note: The front screen glass is laminated, the other glass

is toughened. If a laminated pane breaks it will stay in one
piece even though the glass is cracked. A toughened pane
will shatter and fall apart. The method of removal of the

B-1 550/43477/1 B-1

 Section B - Body and Framework
Body & Framework
Cab

Cab

ROP/FOPS Structure
Checking

!MCAUTION
The machine is fitted with a Roll Over Protection
Structure (ROPS) and a Falling Objects Protection
Structure (FOPS). You could be killed or seriously
injured if you operate the machine with a damaged or
missing ROPS/FOPS. If the ROPS/FOPS 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 certification.
IND-005

1 Check the structure for damage.

2 Make sure that all the ROPS/FOPS mounting bolts A

are in place and undamaged K Fig 1. ( T B-2).

3 Make sure that the ROPS/FOPS mounting bolts A

are tightened to the correct torque setting. This
should be 330 Nm (243 lbf ft).

Fig 1.

B-2 550/43477/1 B-2

 Section B - Body and Framework
Body & Framework
Cab

Centre Pivot
K Fig 2. ( T B-3)

Fig 2.

B-3 550/43477/1 B-3


Removal and Replacement
Removal
Park the machine in the straight-ahead position on firm,
level ground. Lower the shovel flat onto sliders resting on
the ground. Apply the parking brake. Select neutral and
switch off the engine. Operate the hydraulic controls to
vent system pressure.
1 Securely block all wheels on both sides.
2 Remove the cab, refer to Cab Removal and
Replacement, this section.
3 Remove the pin from each steering ram rod end.
Move the steering rams clear of the front chassis.
4 Disconnect the driveshaft at the brake disc flange.
Mark the flanges to ensure correct re-assembly.
5 Separate the two halves of the hydraulic pipe clamp
to release the hydraulic pipework.
Note: There should be sufficient slack in the hydraulic
pipework to allow the front and rear chassis to be
separated without the pipework having to be disconnected.
When sep-aratingthe chassis, take care not to put undue
strain on the hydraulic pipework.
6 Using suitable blocks, support the rear chassis at
front and rear.
7 Place a trolley jack under the lower pivot flange of the
front chassis after putting a piece of timber between
the contact points.
8 Remove the lower pivot pin as follows :
a Remove screw 3, washer 4 and spacer 31.
b Drive out pivot pin 2, taking care to retain shims 30
and bearing 20. Discard seals 6.
9 Remove the upper pivot as follows:
a Remove split pin 22 and castellated nut 21 then
withdraw bolt 17 complete with washers 28.
b Remove bolts 23 and washers 24 and remove
end caps 5.
B-4 550/43477/1
Section B - Body and Framework
Body & Framework
Cab
c Drive out pivot pin 1, taking care to retain shims 9
to 14 and washers 26.
d Remove and discard bearings 18. Remove and
dis-card lip seals 7.
10 Remove the blocks from under the front wheels.
11 Release the parking brake and manually separate the
front and rear chassis just sufficiently to enable work
to be carried out on the centre pivot.
Replacement
Fit new bearings 18 during reassembly. This will
necessitate setting up shims 9 to 14 using a dummy boss
and bearing locator, see Service Tools in General
Information section, to give correct clearance. Proceed as
follows
1 Grease the face of the bottom end cap 5. Assemble
the bottom bearing cup to the rear chassis bearing
housing and secure using bolts 23 and washers 24.
Torque tight-en bolts.
2 Pack the bottom bearing with grease and fit into the
new bearing cup.
Note: Ensure that the bearing is completely filled with
grease.
3 Position dummy boss A into bottom bearing.
4 Position the top bearing on top of dummy boss A.
Holding the top bearing, rotate the dummy boss three
or four times to seat the rollers.
5 Position bearing locator B into top bearing
6 Measure gap d between the top of bearing locator B
and face X.
7 Add dimension d to dimension t which is stamped on
the front module. This dimension (d + t) equals the
shims required to give the correct clearance.
8 Select shims from the table corresponding to
dimension (d + t) and insert underneath bearing
locator B.
Note: If no dimension t is stamped, read dimension t as
zero
B-4
 Section B - Body and Framework
Body & Framework
Cab
9 Bearing locator B should now project above face X by The remainder of the procedure is a reversal of the
an amount equivalent to dimension t ± 0.025 mm.
removal procedure.
10 Remove bearing locator B, shim pack, top bearing Torque Settings
and dummy boss A.
Table 1.
11 Fit new lip seals 7 over the large diameter portion of Item Nm Kgf m lbf ft
the front chassis pivot boss, or alternatively rolled
3 244 24.9 180
inside out to protect the seal lips during chassis
mating. 21 68 6.9 50
23 98 10.0 72
12 Position the top bearing cone on pivot pin 1 to
dimension Y (178 mm) as shown.

13 Smear the bottom portion of the rear chassis bearing

housing with locking fluid.

14 Remove bottom end cap 5, fit washer 26 and replace

the bottom end cap. Torque tighten bolts 23.

15 Carefully mate the front and rear chassis.

16 Assemble the lower pivot pin 2 together with shims

30,bearing 20 and new seals 6. Retain with spacer
31, washer 4 and screw 3. Torque tighten screw.

17 Smear locking fluid onto the top portion of pivot pin 1

and assemble through rear chassis bearing housing
and front chassis pivot boss.

18 Pack the top bearing with grease and fit the bearing
cup.

Note: Ensure that that the bearing is completely filled with

grease.

19 Fit the shim pack and washer 26.

20 Grease the face of the top end cap 5 then secure with
washers 24 and bolts 23. Torque tighten bolts.

21 Fit bolt 17, washers 28 and castellated nut 21. Torque

tighten nut then fit new split pin 22.

Note: If necessary, the castellated nut can be further

tightened until the next castellation lines up with the split in
drilling in the bolt.

22 Manoeuvre lip seals 7 into position.

23 Apply grease through each of the nipples until it is

emitted through the lip seals.

B-5 550/43477/1 B-5

 Section B - Body and Framework
Body & Framework
Cab

Dimension (d + t) Shims mm (in) mm (in) Rivet Nuts

0.83 - 0.87 (0.033 - 0.034) D+B
Fitting Procedure
0.88 - 0.92 (0.035 - 0.036) E
0.93 - 0.97 (0.037 - 0.038) F+B A ‘Rivet Nut’ is a one piece fastener installed ‘blind’ from
one side of the machine body/framework. The rivet nut is
0.98 - 1.02 (0.039 - 0.040) A
compressed so that a section of its shank forms an ‘upset’
1.03 - 1.07 (0.040 - 0.042) E+C against the machine body/framework, leaving a durable
1.08 - 1.12 (0.042 - 0.044) D+2xB thread (see illustrations) K Fig 3. ( T B-6).
1.13 - 1.17 (0.044 - 0.046) A+C
1.18 - 1.22 (0.046 - 0.048) 2xD
1.23 - 1.27 (0.048 - 0.050) A+B
1.28 - 1.32 (0.050 - 0.052) D+F
1.33 - 1.37 (0.052 - 0.054) 2xD+C
1.38 - 1.42 (0.054 - 0.056) 2xF
1.43 - 1.47 (0.056 - 0.058) F+D+C
1.48 - 1.52 (0.058 - 0.060) D+E
1.53 - 1.57 (0.060 - 0.062) 2xF+C
1.58 - 1.62 (0.062 - 0.064) A+D
1.63 - 1.67 (0.064 - 0.066) D+E+C
1.68 - 1.72 (0.066 - 0.068) A+F
1.73 - 1.77 (0.068 - 0.070) E+F+C
1.78 - 1.82 (0.070 - 0.072) 2xE Fig 3.
1.83 - 1.87 (0.072 - 0.074) B+E+F Rivet nuts are fitted to various parts of the machine body
1.88 - 1.92 (0.074 - 0.076) A+E and framework. They are used in a number of applications,
1.93 - 1.97 (0.076 - 0.078) A+B+F for instance, hose clamp and cab floor plate retention etc.

1.98 - 2.02 (0.078 - 0.079) 2xA Various sized rivet nuts are available, see the table below
2.03 - 2.07 (0.080 - 0.081) A+C+E to
2.08 - 2.12 (0.082 - 0.083) 2xD+E
determine the size of rivet nut to be used for particular
2.13 - 2.17 (0.084 - 0.085) 2xA+C applications.
2.18 - 2.22 (0.086 - 0.087) D+E+F
2.23 - 2.27 (0.088 - 0.089) 2xA+B
2.28 - 2.32 (0.090 - 0.091) 2xF+E

B-6 550/43477/1 B-6

 Section B - Body and Framework
Body & Framework
Cab

Fig 4.
Fig 5.
If for any reason a new rivet nut requires fitting, then the
correct installation procedure must be followed : Diameter Diameter
M5 7 0.25 - 3.00 14.00 7.10
1 Drill a hole in the machine body/framework where the
rivet nut is to be fitted. De-burr hole edges. 3.00 - 5.50 17.00
M6 9 0.50 - 3.00 16.00 9.10
2 Screw the rivet nut onto the mandrel of the installation 3.00 - 5.50 19.00
tool. The bottom of the mandrel should be in line with
the bottom of the rivet nut, shown at A. M8 11 0.50 - 3.00 18.00 11.10
3.00 - 5.50 21.00
3 Wind the body of the installation tool down
M10 13 1.00 - 3.50 23.00 13.10
thethreaded mandrel until it touches the head of the
rivet nut, shown at B K Fig 4. ( T B-7). 3.50 - 6.00 26.00

4 Insert the rivet nut (assembled to the tool) into the Note: In an emergency, and if no installation tool is
hole drilled in step 1. available, it is possible to fit a rivet nut by using a nut and
bolt the same thread diameter as the rivet nut being
5 Hold handle C and at the same time draw the mandrel installed. However, this is not the recommended method.
into the installation tool by turning nut D. The rivet nut
will contract in length and form an ‘upset’ (smooth
bulge) seating itself against the body/framework (see
inset E) K Fig 5. ( T B-7).

Note: The thread of the rivet nut must not be stripped, take
care when ‘upsetting’ the rivet nut.

6 Remove the installation tool.

Specifications (all dimensions in mm)

Rivet Nut Rivet Nut Material Rivet Drill Thread Outside

Thickness Length Hole Diameter Diameter

B-7 550/43477/1 B-7

 Section B - Body and Framework
Body & Framework
Cab

Cooling Pack
Introduction
This cooling pack is a combination pack. It provides all the
necessary cooling activities for the machine’s components
with the exception of the Air Conditioning. (It should be
noted that whilst most machines are fitted with air
conditioning, it is an optional fitment. Its fitment or not
makes no difference to the main cooling pack’s function.)

When viewed from the the engine side A, the individual

sections of the cooling pack are: 1 Hydraulic oil cooling 2
Engine Coolant Radiator 3. K Fig 6. ( T B-8)Transmission
Oil Cooling.

The cooling pack sections are held together by top and

bottom holding plates. By removing the section securing
bolts, it is possible to remove and replace a single section.

It is intended that to replace a single section the complete

pack will need to be removed from the machine.

Key Fig 6.
7 Coolant drain plug.
8 The cooling packs lower mounting points. Removal and Replacement

Removal
The cooling pack is a combination unit that cools water, air,
transmission and hydraulic oils. Before attempting to work
onthe cooling pack unit, all appropriate safety measures
must be taken.

1 Park the machine on firm level ground and lower the

loader arms. Engage the parking brake. Put the
transmission in neutral and chock both sides of all
four wheels. Stop the engine and let it cool down.
Operate the hydraulic control levers to release
pressure trapped in the hoses then remove the
hydraulic tank filler cap. Refit the cap once any
residual pressure has been released.

B-8 550/43477/1 B-8

 Section B - Body and Framework
Body & Framework
Cab

!MCAUTION 3 Remove drain plug 2 from the radiator section of the

cooling pack and drain the coolant. Renew the drain
Hydraulic Pressure Hydraulic fluid at system pressure plug aluminium washer, refit the drain plug and torque
can injure you. Before disconnecting or connecting tighten. See Torque Settings K Fig 8. ( T B-9)
hydraulic hoses, stop the engine and operate the
controls to release pressure trapped in the hoses.
Remove tank filler cap to release any residual
pressure in the tank. Make sure the engine cannot be
started while the hoses are open.
IND-006

!MCAUTION
Batteries
To prevent the engine being started, disconnect the
battery while working on the cooling pack.
0109

!MWARNING
Hot Coolant
Fig 8.
The cooling system is pressurised when the engine is
hot. Hot coolant can spray out when you remove the
filler cap. Let the system cool before removing the
filler cap. To remove the cap; turn it to the first notch
and let the system pressure escape, then remove the
cap.
INT-3-2-9_1

2 Carefully loosen cap 1. Let any pressure escape.

Remove the cap. (Access to the cap is through the
opening cut into the top of the engine cover) K Fig
7. ( T B-9).

Fig 9.

4 Arrange slings from the four points in the engine

cover to an overhead crane. (Eye bolts can be
securely crewed into the four threaded lifting point
holes. The holes are plugged with plastic bungs.)
K Fig 9. ( T B-9)

5 Remove the exhaust silencer at its connection where

it comes through the engine cover.

6 Remove the air cleaner induction hose at its

Fig 7.
connection to the filter housing. (Cap the open end of
the hose to prevent dirt entering the intake). Also

B-9 550/43477/1 B-9

 Section B - Body and Framework
Body & Framework
Cab
remove the electrical connector from the vacuum
switch in the induction pipe. (The air cleaner
assembly can be left attached to the engine cover.)

7 Remove the hose connections to the header tank.

(The tank can be left in position on the engine cover.)

8 Remove the two bolts 5 securing the fuel sedimenter

bowl to the engine cover. (Secure the fuel sedimenter
to a suitable place on the engine whilst adrift from its
mounting point. Take care not to kink the fuel pipes by
allowing the sedimenter to hang loose.) K Fig
10. ( T B-10)

Fig 11.

12 Remove the six front retaining bolts 7. (Three from

each side in the engine cover.) K Fig 12. ( T B-10)

Fig 10.

9 Disconnect the wiring harness to the reverse alarm

and the rear worklights and release it from its
fastenings to the right hand engine cover.

10 Remove the two bolts securing the battery isolator

switch to the right hand side engine cowl. Fig 12.

11 Remove the four rear retaining bolts 6. (Two from 13 Remove the cooling pack to engine cowl upper
each side in the engine cover.) K Fig 11. ( T B-10) mounting bolts 8 K Fig 13. ( T B-11).

B - 10 550/43477/1 B - 10
 Section B - Body and Framework
Body & Framework
Cab

Fig 14.
Fig 13.
19 Disconnect the top and bottom hydraulic hoses at the
14 Using the overhead crane lift the engine cover from cooling pack by removing the four Allen screws 10. If
the machine. there are no tags on the hoses, tie on your own to aid
correct refitment. Cap the open hoses and ports
15 Using the overhead crane lift the engine cover from K Fig 15. ( T B-11).
the machine.

16 Lower the assembly to the ground and secure.

17 Disconnect the top and bottom coolant hoses.

18 Disconnect the top and bottom turbo intercooler

hoses 9 from the cooling pack. Cap the ends of the
hoses and the ports to the cooling pack K Fig
14. ( T B-11)

!MWARNING
Take care when disconnecting hydraulic hoses and
fittings as the oil will be HOT.
TRANS-1-2
Fig 15.

20 Disconnect the top and bottom transmission hoses at

the cooling pack by removing the four Allen screws as
for step 22. If there are no tags on the hoses, tie on
your own to aid correct refitment. Cap the open hoses
and ports.

21 Remove the engine cooling fan.

22 Arrange slings from the cooling pack lifting eyes

(welded into the top mounting plate) to the overhead
crane.

B - 11 550/43477/1 B - 11
 Section B - Body and Framework
Body & Framework
Cab
Note: Do not lift the cooling pack by attaching lifting hooks
or eyes to the cooling packs top mounting points. The pack
!MWARNING
sides can be distorted leading to a failure of the packs Antifreeze can be harmful. Obey the manufacturer's
section instructions when handling full strength or diluted
antifreeze.
23 Disconnect the two lower cooling pack retaining bolts 7-3-4-4_1
11 from the brackets to the chassis K Fig
16. ( T B-12). 3 When refitting the batteries, make sure they are
connected in the correct manner by connecting the
earth lead last.

Torque Settings:

Table 2.
Item Nm Kgf m lbf ft
2 55 5.6 40
10 25 2.5 18

Dismantling
1 Remove the upper section securing bolts A and the
lower securing bolts B, that hold the required
indivdual section to the upper and lower mounting
plates.
Fig 16.
2 Slide the section from the pack.
24 Using the overhead crane lift the cooling pack from
Note: Do not use excessive force to remove the section, or
the machine.
use a pry bar against the upper or lower section securing
plate. If necessary slacken the other sections upper and
Replacement lower securing bolts to relieve the pressure on the section
to be removed.
Replacement is the reverse of removal but note the
following:
Assembly
1 All hydraulic hose sealing ‘O’ rings are to be replaced.
Assembly is the reverse of removal but note the following
Do not overtighten Allen screws 10 see Torque
Settings.
1 Keep all ports covered until the relevent connection
are to be made, to keep dirt and debris from entering
2 The correct concentration of coolant antifreeze is to
the pack sections.
be added to the cooling system. A 50% antifreeze
mixture should be used even if frost protection is not
2 Refit the pack sections using the correct length bolts
needed. This gives protection against corrosion and
(the pack section could be severely damaged by
raises the coolant’s boiling point.
inserting bolts of a incorrect length.

Note: It is recommended that the cooling system be filled
at a maximum rate of 10 litres per minute. If the fill rate is
any higher than this there is a possibility of air becoming
trapped in the system.
3 If the engine coolant section is being replaced ensure
that the drain plug 2 is installed using a new
aluminium washer and that it is tightened to the
correct torque. (See Torque Settings.)

B - 12 550/43477/1 B - 12
Section E

Hydraulics
Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering

Publication No.
550/43477/1

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section E - Hydraulics

Notes:

E-0 550/43477/1 E-0

 Section E - Hydraulics

Contents Page No.

Basic System Operation
Introduction to Hydraulic Schematic Symbols .......................................... E-1
General (Basic and Functional Symbols) ............................................. E-1
Control Valves ...................................................................................... E-6
Example of Schematic Circuit .............................................................. E-7

Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7 E-9
Guideline for acceptable wear .............................................................. E-9
Disassembly ......................................................................................... E-9
Assembly ............................................................................................ E-13
Recommended Start-Up ......................................................................... E-19
Procedure For New or Rebuilt Pump ................................................. E-19
PRESSURE TESTING ....................................................................... E-20
DESCRIPTION OF HYDRAULIC SYSTEM ....................................... E-22
OPERATION – BUCKET CROWD ..................................................... E-24

Hydraulics
Hydraulic Contamination ........................................................................ E-31
Hydraulic Fluid Quality ....................................................................... E-31
Venting the Hydraulic Pressure .............................................................. E-33
Automatic Carry Control System Venting ........................................... E-33
Connecting and Disconnecting Hydraulic Hoses .................................... E-34
Connecting the Hoses ........................................................................ E-34
Fitting Procedure ................................................................................ E-34
Cooling Fan Motor .................................................................................. E-37
Removal and Replacement ................................................................ E-37
Dismantling, Inspection and Assembly ............................................... E-37
Cooling Fan Motor Components ........................................................ E-41
Removal ............................................................................................. E-42
Replacement ...................................................................................... E-43
Dismantling, Inspection and Assembly ............................................... E-43
Dismantling ......................................................................................... E-43
Bi-Directional Motor ............................................................................ E-46
Ram ........................................................................................................ E-49
Maintenance of Cylinders ................................................................... E-49
Storage of Cylinders ........................................................................... E-49
Loader Lift Cylinder ............................................................................ E-51
Steering Cylinder .................................................................................... E-53
Dismantling of Steering Cylinder ........................................................ E-53
Steering Cylinder .................................................................................... E-54

Hydraulics
Fault Finding ........................................................................................... E-55

E-i E-i
 Section E - Hydraulics

Basic System Operation

Introduction to Hydraulic Schematic Symbols
TE-001

General (Basic and Functional Symbols)

Complex hydraulic components and circuits can be Variable control
described to the engineer by using graphical symbols. The
following pages illustrate and give a brief description for
some of the more common symbols used.
Table 2. Rams
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 Single acting
principles explained here. If more detailed information is
required you are recommended to obtain a copy of
BS2917 or IS01219.
Double acting
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.
Double ended
Table 1. General

Spring
Double acting with damping
at rod area end
Flow restriction affected
by viscosity
Table 3. Pumps and Motors

Direction of flow
Variable capacity pump two
directions of flow

Indication of rotation

Fixed capacity motor one

direction of flow
Indication of direction and
paths of flow

E-1 550/43477/1 E-1

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols

Non-return valve with

back pressure spring
Fixed capacity motor two
directions of flow

Pilot operated non-

return valve

Variable capacity motor one

direction of flow
One way restrictor

High pressure selector

Variable capacity motor two
(shuttle valve)
directions of flow

Throttling orifice -
Table 4. Control Valves
normally closed

Used to enclose several

valves indicating they
are supplied as one unit Throttling orifice -
normally open

3-Position, 4-port spring

centered pilot operated
valve
Relief valve

3-position, 6-port spring

centered pilot operated
valve

3-Position, 4-port spring Variable restrictor

centered solenoid &
pilot pressure operated
valve

3-Position, 4-port spring

centered detent hand
operated valve

Non-return valve

E-2 550/43477/1 E-2

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Table 5. Energy Transmissions and Conditioning

Working line, return or feed Reservoir - return line above

fluid level

Pilot control

Reservoir - return line below

Drain lines fluid level

Flexible pipe
Header tank

Line junction
Pressure sealed tank

Accumulator
Crossing lines

Filter or strainer
Air bleed

Line plugged, also pressure

Water trap
test point

Line plugged with take off line Cooler - with no indication of

coolant flow

Quick release couplings -

connected
Cooler - indicating direction of
coolant flow

Quick release couplings -

disconnected
Heater

E-3 550/43477/1 E-3

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols
Table 6. Control Mechanisms

Rotating shaft - one Stem operated

direction

Rotating shaft - two

directions Spring operated

Detent
Roller operated

Locking device
Roller trip operated (one
directional)

Over centre device

Solenoid one winding

Simple linkage
Solenoid two windings

General control
Electric motor operated

Push button operated

Internal pressure pilot
operated

Lever operated

External pressure pilot

operated
Pedal operated

E-4 550/43477/1 E-4

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols

Pressure operated
spring release

Pilot operated by
solenoid pilot valve

Pilot operated by a
solenoid or seperate
pilot valve

Pressure guage

Pressure switch

E-5 550/43477/1 E-5

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols

Control Valves
Control valves are usually represented by one or more
square boxes.

K Fig 1. ( T E-6) shows a control valve represented by

three boxes. The number of boxes indicates the number of
possible valve operating positions, (3 boxes - 3 positions
etc).

Fig 4.

Fig 1.
K Fig 2. ( T E-6) - In circuit diagrams the pipework is
usually shown connected to the box which represents the
unoperated condition. (Hydraulic circuit diagrams are
usually shown in the unoperated condition).
It must be noted that not all spools are of the same type.
Their operating designs can be seen by following the path
the flow arrows take in their respective operating squares.
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. K Fig 5. ( T E-6) shows a 'D' type spool.

K Fig 6. ( T E-6) - 'F' spools are often shown as four

position spools with the three normal positions for neutral
and service control; and the forth position, which has a
Fig 2. detent, connects both sides of the ram together to allow the
service to 'float'.
K Fig 3. ( T E-6) shows a valve described as a 3-position,
4-port control valve. Port describes the openings to and
from the valve by which the hydraulic fluid enters or leaves.
In the fig shown, Position 2 indicates that in an unoperated
condition all 4 ports are blocked.

Fig 5.

K Fig 6. ( T E-6) - 'N' spools are sometimes used to

control hydraulic motors, and it can be seen from the flow
arrows, that in neutral position both service ports are
connected to the exhaust oil port
Fig 3.

If the valve spool was moved to Position 1, movement of

the spool would connect Port P1 to Port P2, and Port P3 to
Port P4. K Fig 4. ( T E-6).

If the valve spool was moved to Position 3, movement of

the spool would connect Port P1 to Port P4, and Port P3 to
Port P2. K Fig 4. ( T E-6). Fig 6.

E-6 550/43477/1 E-6

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols

Example of Schematic Circuit

Fig 7.

Some of the symbols described on the preceding pages side of hydraulic ram G. Notice that the fluid must first open
have been arranged into a simple schematic circuit. K Fig one way valve F. before flowing to the ram.
7. ( T E-7).
Example Circuit Key
Hydraulic tank A. is a pressurised tank with an internally
mounted strainer B. on the suction line to the fixed Table 7.
displacement pump C. System pressure is limited to the A Hydraulic Tank
setting of relief valve D.
B Strainer
Valve spool E is an open-centre spool that is in neutral C Fixed Displacement Pump
position; flow from the pump passes through the spool and D Relief Valve
returns to the hydraulic tank.
E Spool
If the lever operated spool is moved away from neutral F One Way Valve
position hydraulic fluid is directed to either head side or rod G Double Acting Hydraulic Ram

E-7 550/43477/1 E-7

 Section E - Hydraulics
Basic System Operation
Introduction to Hydraulic Schematic Symbols

Page left intentionally blank

E-8 550/43477/1 E-8


Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7
Guideline for acceptable wear
Gear Housings
Wear in excess of .007” cut-out necessitates replacement
of the gear housing. Place a straight-edge across bore. If
you can slip a .007 feeler gage under the straight-edge in
the cut-out area, replace the gear housing.
Pressure pushes the gear against the housing on the low
pressure side. As the hubs and bushings wear, the cut-out
becomes more pronounced. Excessive cutout in ashort
period of time indicates excessive pressure or oil
contamination. If the relief valve settings are within
prescribed limits, check for shock pressures of tampering.
When the cut-out is moderate, .007” or less, the gear
housing is in good condition and may be reused.
Gear
Any scoring on gear hubs necessitates replacement.
scoring, grooving or burring of the outside diameter of the
teeth requires replacement. Nicking, grooving. or fretting of
teeth surfaces also necessitates replacement.
Drive Shafts
Replace if there is any wear detectable by touch in the seal
area or at the drive coupling. The maximum allowable
wear .007”
Wear in the shaft seal area indicates oil contamination.
Wear or damage to spline, keys, or keyways necessitates
replacement.
Thrust Plates
The thrust plates seal the gear section at the sides of the
gears. Wear here will allow internal slippage, that is, oil will
bypass within the pump.
A maximum of .002” wear is allowable. Replace thrust
plates if they are scored, eroded or pitted. Check center of
thrust plates where the gears mesh. Erosion here indicates
oil contamination. Pitted thrust plates indicate cavitation or
E-9 550/43477/1
Section E - Hydraulics
Hydraulics
oil aeration. Discolored thrust plates indicate overheating,
likely due to insufficient oil.
Dowel Pins
If either the dowel or dowel hole is damaged, the dowel or
machined casting, or both, must be replaced.
If more than reasonable force is required to seat dowels,
the cause may be poorly deburred or dirty parts; cooking of
the dowel in the hole or improper pin-to-hole fit.
Bushings
If gears are replaced, bushings must be replaced.
Bushings should fit into the bore with a heavy press fit.
Seal and Gaskets
Replace all rubber and polymer seals, including all “O”
rings thrust plate channel seals, shaft seal and gasket
seals.
Plugs
Examine the plugs in the shaft end port proper position and
tight. The PGP/PGM315 and PGPPGM 330 should have
two plugs in both the shaft end and port end in tandem
units only.
The PGP/PGP350 nad PGP/PGM365 have one plug in
their shaft and port ends high pressure side only.
Disassembly
1 Place the pump in a vise with the with the dirve shaft
pointing down. Caution : DO NOT GRIP ON OR
NEAR ANY MACHINED SURFACES DURING
ASSEMBLY OR DISASSEMBLY Match-mark all
sections. Be sure to align these marks when
reassembling K Fig 8. ( T E-10)
E-9
 Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7

Fig 8. Fig 10.

2 Use a socket wrench to remove the 4 cap screws on 4 Remove the thrust plate. Examine and replace if
single units or the 4 hex nuts, studs and washers of necessary. See Wear Guide K Fig 11. ( T E-10).
multiple units K Fig 9. ( T E-10).

Fig 9. Fig 11.

3 Lift off the port end cover. If prying is necessary, be
careful not to damage the machined surfaces. Dowel
pins will remain in either the port end cover or the ear
housing K Fig 10. ( T E-10).
5 Carefully remove the drive and driven gears. Avoid
tapping the gear teeth together or agaisnt othe
hardened surfaces. Keep these gears together
because they are a matched set. Examine and
replace if necessary. See Wear GuideK Fig
12. ( T E-11).

For multiple assemblies only

E - 10 550/43477/1 E - 10
 Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7
remain in either the bearing carrier or the gear
housing K Fig 14. ( T E-11).

Fig 12. Fig 14.

6 Lift the gear housing from the bearing carrier. If prying
is necessary, take care not to damage machined
surfaces. Examine and replace if necessary. See
Wear Guide K Fig 13. ( T E-11).
For multiple assemblies only
8 Remove the connecting shaft. Remove the thrust
plate. Examine and replace if necessary (See Wear
Guide) Remove the driven gear and the integral gear
and drive shaft. Keep these together as they are a
matched set. Examine & replace if necessary (See
Wear Guide). Be careful not to damage the machined
surfaces of the gears K Fig 15. ( T E-11).

Fig 15.
Fig 13.
9 Lift of pry off the first section gear housing. Be careful
7 Carefully lift or pry off the bearing carrier to prevent not to damage machined surfaces. Examine and
damage to contact face and edges. Dowell pins will

E - 11 550/43477/1 E - 11
 Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7
replace if necessary (See Wear Guide) K Fig
16. ( T E-12).

Fig 18.

12 Use a bearing puller to remove the outboard bearing

Fig 16.
K Fig 19. ( T E-12).
10 Inspect all bushings for scoring or discoloration and
replace if necessary. Use a bushing puller as shown
in the tool list to remove bushingsK Fig 17. ( T E-12)

Fig 17. Fig 19.

11 If the pump is equipped with an outboard bearing,
place the shaft end cover in the vise with the
mounting face up. Remove the snap ring with snap
ring pliers. If a unit is equipped with a spiral/-lock
retaining ring, remove with a samll screwdriver /or awl
K Fig 18. ( T E-12).
13 Grip the shaft end cover in a vise with the mounting
face down. Remover double lip seal by inserting the
special seal removal tool (see Tool list) into the notch
between the double lip seal and the shaft end cover.
Tap the seal out and discard. Remove and discard all
rubber and polymer seals .

E - 12 550/43477/1 E - 12
 Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7

Assembly end covers. PGP/PGM350 and 365 have one plug on

the outlet side of their shaft end and por/t end covers
1 Stone all machined surfaces with a medium grit
4 New plugs should be screwed in tightly. Stake the
carborundum stone K Fig 20. ( T E-13).
plug with a prick punch at both ends of the screwdrive
slot and around edges. Peen the edge of the hole 1/
32” to 1/16” with a 1-1/2” diameter steel ball. K Fig
22. ( T E-13) Note : If new plug or plugs are being
installed, coat threads with Loctite thread sealant.

Fig 20.

2 If the bushings have been removed, deburr the

bushing bores with an emery cloth. Rinse parts in a
solvent. Air blast all the parts and wipe with a clean,
lintless cloth before starting assembly K Fig
21. ( T E-13).
Fig 22.

Note: Assembly steps 5, 6, 7, & 8, apply to shaft end cover,

bearing carrier and portend cover. Any bushings removed
from the shaft end cover, portend cover or bearing carrier
should be assembled in the drive bores with the groove to
the top of unit (12 o’clock). Assemble the bushings in the
driven bores with the groove to the bottom of the unit
(6o’clock). The PGP/PGM315 does not have grooved
bushings, therefore the bushing seeams shold be placed
at the 12 and 6 o’clock positions.

5 Bushings should be pressed into the bores, one at a

time, using the special installation tool and and arbor
press. Be sure the that the grooves (or seams) are
positioned as stated in Step #5. The bushings must
be pressed into the bores flush with the casting face.
Be sure to support the castings so that they are
Fig 21. square and level K Fig 23. ( T E-14).

3 Grip shaft end cover in vise with mounting face down

Examine plug or plugs* to be sure they’re tightly in
place. Replacement is necessary only if parts are
damaged. Remove with screwdriver. * PGP/PGM315
and 330 have two plugs in both the shaft end and port

E - 13 550/43477/1 E - 13
 Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7

Fig 25.

8 If the unit is equipped with an outboard bearing, guide

Fig 23. the bearing into its recess in the shaff end cover. This
is a ligh press fit. It may be necesary to lightly tap the
6 Repeat Steps 1 and 2, stone and rinse parts K Fig bearing into the bore K Fig 26. ( T E-14).
24. ( T E-14)

Fig 26.

9 Install the snap ring in the groove to retain the

outboard bearing K Fig 27. ( T E-15)
Fig 24.

7 See that dowel pins are in place in any new castings.

Examine all oa the dowels. Before inserting, make
certain that the hole is clean and free from burrs.
Gently start the pin straight into the hole and tap
lightly with a soft hammer K Fig 25. ( T E-14).

E - 14 550/43477/1 E - 14
 Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7

Fig 27.
Fig 29.
10 Grease the new gasket seals and insert them into the
grooves in both sides of all gear housings. Position
12 Assemble the channel seals into the grooves in the
the first gear housing over the shaft end cover and
thrust plates with the flat side of the seal facing away
dowels. Tap it with a soft hammer until it rests tightly
from the thrust plate as shown below K Fig
against the shaft end cover. Be careful not to pinch
30. ( T E-15).
the gasket seal. Also be sure that hte large rounded
core in on the inlet side K Fig 28. ( T E-15).

Fig 30.

13 Gently slip the thrust plate through the gear housing

Fig 28. and into place on the shaft end cover. The channel
seal from Step # 13 should face the shaft end cover.
11 Grease the new gasket seals and insert them into the The relief groove in the plate should face the outlet
grooves in both sides of all gear housings. Position side of the pumpK Fig 31. ( T E-16)
the first gear housing over the shaft end cover and
dowels. Tap it with a soft hammer until it rests tightly
against the shaft end cover. Be careful not to pinch
the gasket seal. Also be sure that hte large rounded
core in on the inlet side K Fig 29. ( T E-15).

E - 15 550/43477/1 E - 15
 Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7

Fig 31.
Fig 33.
14 Slide the driven gear through the housing and into the
bushing in the shaft end cover. Coat the steel sleeve
16 Place the bearing carrier onto the journals of he drive
tool with grease. Place the lightly-greased drive shaft
and driven gears. Be sure to line up the dowel holes
inside the sleeve and slide both through the shaft end
over the dowel pins. When the parts are parallel,
cover with a twisting motion, until the integral gear
squeeze them together or alternately tap over each
rests Avoid damaging the double lip seal. Remove the
dowel until the parts are together K Fig 33. ( T E-16).
steel sleeve. Squirt clean oil over the gears K Fig
32. ( T E-16).

Fig 32. Fig 34.

15 Slip the thrust plate with the seal over the gear 17 Insert the connecting shaft into the spline of the drive
journals and into the housing bore. The flat side of the gear. Position and place the second gear housing on
seal should face up with the relief groove facing the the bearing carrier as outlined in K Fig 34. ( T E-16)
outlet side. ( For single pump assemblies go directly Step # 12.
to Step # 21)
18 For multiple assemblies only.

19 Place the thrust plate in the gear housing per Step #

14. Insert the drive and driven gears of the second

E - 16 550/43477/1 E - 16
 Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7
section in their respective bearings. Make certain the
gears are in contact with the thrust plate face. Place
the port end cover plate in the housing per Step #
K Fig 35. ( T E-17) 16. For multiple assemblies only

Fig 37.

21 Place the port end cover over the gear journals. Align
Fig 35. the dowels with the holes in the mating casting. K Fig
37. ( T E-17)Being careful not to pinch the gasket-
20 Check the plug or plugs in the port end cover to be seal. tap the port end cover lightly in the centre
sure that they are tight. Follow the procedure outlined between bearing bores to engage the dowels and to
in Step #4 for new plugs. K Fig 36. ( T E-17) For move parts together in the final seating K Fig
multiple assemblies only. 38. ( T E-17).

Fig 36.
Fig 38.

22 Thread the fasteners into the shaft end cover and

tighten altermately of cross corner. Rotate the drive
shaft with a 6” wrench to check for binding. If there is

E - 17 550/43477/1 E - 17
 Section E - Hydraulics
Hydraulics
Service Procedure Hydraulic Pump : PARKER PGP365A198*EVAB15-7
no internal binding, torque diagonally opposed
fasterners to 200 ft. lbs. (2400 in. lbs.); 141 ft. lbs.
(1700 in. lbs.) for PGP/PGM315 models; 450 ft. lbs.
(5400 in lbs.) for PGP/PGM 365 K Fig 39. ( T E-18).

Fig 39.

E - 18 550/43477/1 E - 18

Recommended Start-Up
Procedure For New or Rebuilt Pump
Before installing a new or rebuilt pump. back of the
mainrelief valve until the spring tension on the adjusting
screw is relieved. This will avoid the possibility of
immediate damage to the replacement unit in the event
that the relief valve setting had been increased beyond the
recommended operating pressure, prior to removing the
old unit.
Before connecting any lines to the pump, fill all ports with
clean oil to provide initial lubrication. This is particularly
important if the unit is located above the oil reservoir.
After connecting the lines and mounting the replacement
unit, operate the pump at least two minutes at no load and
at low rpm (400 min.) During this break-in period, the unit
should run free and not develop an excessive amount of
heat. If the unit operates properly, speed and pressure can
then be increased to normal operating settings.
Reset the main relief valve to Ist proper setting while the
pump is running at maximum operating engine speed for
the vehicle.
ALWAYS USE AN ACCURATE GAUGE WHEN
ADJUSTING THE RELIEF VALVE PRESSURE
SETTING.
Make certain that there is an adequate supply of oil for the
pump; at least one gallon of oil for each gpm of pump
capacity.
If one section of a tandem pump is being tested. make sure
that all other sections not being tested are adequeately
suppled with oil. If any of the other section run dry, or if
plugs are left in ports, serious and permanent damage will
result.
Use only Genuine JCB Hydraulic Oil.
The feed line must be of adequate size with no more than
5” mercury vacuum adjacent to the pump inlet. As a rule,
the feed line must provide a feed flow velocity not in excess
of 8 feet per second.
Feeding hot oil into a cold pump may cause the pump to
seize. Jog the pump by momentarily starting and stopping
E - 19 550/43477/1
Section E - Hydraulics
Hydraulics
Recommended Start-Up
repeatedly the driving engine or motor to gradually
equalize pump and oil temperatures.
Run the pump at least two minutes at no load and
moderate speed (not over 1500 rmp). If the pump
becomes excessively hot, shut down immediately and
locate the problem source.
Gradually increase pressure on pump, in 500 psi
increments until the desired test pressure has been
reached. This should take about five minutes.
Delivery should run close to rated catalog performance
figures, which are averaged from testing several pumps. A
5% lower reading may be used as rated minimum if new or
relativelly new parts have been used. When rebuilding the
pump with parts from the original pump, which while worn,
appear safisfactory for reuse, a 10% or 15% lower reading
may be permitted, depending on the performance
expeceted from the equipment. One’s own experience will
prove the best guide here.
Many repairmen measure the output at normal operating
speed and at zero pressure. Then again at 1000 psi (or the
operating pressure of the equipment) and allow a volume
decrease approximating the listing below. It is a suggested
reference only which makes allowance for reused parts.
At test speeds other than 1800 rpm, gpm delivery will vary
almost proportionately. but the same (drop-off) figures
should be used.
Be sure to run the pump in the direction for which it was
designed and built. Driving the pump in the wrong direction
will build up pressure behind the shaft seal. damaging it
and necessitating replacemnt.
After completing testing procedures, the pump is ready for
installation and immediate duty operation on equipment.
Again, it must be remembered that to prevent seizure, hot
oil must not be fed into a cold pump.
GPM
Delivery 1000 psi/70 2000 psi/140 3000 psi/
bar bar 210bar
at 1800
rpm 100
psi
E - 19
 Section E - Hydraulics
Hydraulics
Recommended Start-Up

10-30 1/21 -3 2-31/2 21/2-4

30-50 2 -3 2 -4 3-41/2
50-70 2 -3 2-5 31/2-51/2

Pump Pressure Testing

!MWARNING
A raised body might drop suddenly and cause serious
injury. Before working under a raised body, install the
body safety strut.
7-1-1-7

!MWARNING Fig 40.

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.
4-3-5-7

PRESSURE TESTING

Main Relief Valve

Connect a 0-400 bar (0-6000 lbf/in2) pressure gauge to

snap connector A to the pump outlet K Fig 40. ( T E-20).

Run engine at maximum speed, fully raise the lift arms and
hold while checking the maximum gauge reading which
should equal the M.R.V. pressure shown in Technical Data.

If necessary, adjust the pressure setting as follows.

1 Open the cover of the relief, there will be an Allen Fig 41.
screw.

2 Turn clockwise to increase the pressure setting and

anti-clockwise to decrease the pressure setting.
Please see technical data.

3 Use a 0-600 bar K Fig 41. ( T E-20) pressure gauge

to check the pressure.

E - 20 550/43477/1 E - 20
 Section E - Hydraulics
Hydraulics
Recommended Start-Up

Fig 42.

E - 21 550/43477/1 E - 21

DESCRIPTION OF HYDRAULIC SYSTEM
WITH HYDROCONTROL COMPONENTS
This sketch shows the connection of all the hydraulic
components on the machine K Fig 42. ( T E-21).
CONTROL VALVE OIL FLOW PATH
The oil enters the valve through the inlet port of the valve
and passes through the neutral gallery and comes out of
E - 22
Section E - Hydraulics
Hydraulics
Recommended Start-Up
The main pump flow is connected to the inlet port of the
valve. The main pump flow is also tapped out through the
pilot supply unit and the pressure is reduced (35 bar preset
pressure) and then fed to the joystick. The pilot unit has an
accumulator to supply oil to joystick to bring the machine
to stand-by position, when pump is not running.
Fig 43.
the valve through the outlet port in neutral condition when
the joystick is not operated K Fig 43. ( T E-22).
550/43477/1 E - 22
 Section E - Hydraulics
Hydraulics
Recommended Start-Up

Fig 44.

INLET SECTION
The inlet port is at the side of the section shown with a
green colorK Fig 44. ( T E-23).

The cross-section of the main relief is also shown for

reference.

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 Section E - Hydraulics
Hydraulics
Recommended Start-Up
from the head side enters the valve through port A1 and
flows to tank K Fig 45. ( T E-24).

Fig 45.

OPERATION – BUCKET CROWD

When the joystick is moved to crowd position the
pilot port no.2 of the valve is pressurized and the spool is
moved. The oil is transferred from the neutral passage to
the service port B1. Then the oil passes in to the rod side
of the cylinder and the bucket crowd is operated. The oil

E - 24 550/43477/1 E - 24
 Section E - Hydraulics
Hydraulics
Recommended Start-Up

Fig 46.

OPERATION - BUCKET CROWD OPERATION BUCKET - DUMP

This sketch shows the oil flow path in the entire valve.
K Fig 46. ( T E-25) The red chambers are pressurized
when the bucket crowd is operated, and the blue
chambers are not pressurized.
When the joystick is moved to dump position the pilot port
no.4 of the valve is pressurized and the spool is moved.
The oil is transferred from the neutral passage to the
service port A1. Then the oil passes in to the head side of
the cylinder and the bucket dump is operated. The oil from
the rod side enters the valve through port B1 and flows
to tank K Fig 47. ( T E-26).

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 Section E - Hydraulics
Hydraulics
Recommended Start-Up

Fig 48.

OPERATION – LOADER UP
When the joystick is moved to boom up position the pilot
port no.1 of the valve is pressurized and the spool is
moved. The oil is transferred from the neutral passage to
the service port A2. Then the oil passes in to the head side
of the cylinder and the boom up is operated. The oil from
the rod side enters the valve through port B2 and flows
to tank K Fig 49. ( T E-27).

Fig 47.

OPERATION – BUCKET DUMP

This sketch shows the oil flow path in the entire valve. The
red chambers are pressurized when the bucket crowd is
operated, and the blue chambers are not pressurized
K Fig 48. ( T E-26).

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 Section E - Hydraulics
Hydraulics
Recommended Start-Up

Fig 49. Fig 50.

OPERATION – LOADER DOWN

When the joystick is moved to boom down position the pilot
port no.3 of the valve is pressurized and the spool is
moved. The oil is transferred from the neutral passage to
the service port B2. Then the oil passes in to the rod side
of the cylinder and the boom down is operated. The oil
from the head side enters the valve through port A2 and
flows to tank K Fig 50. ( T E-27).

E - 27 550/43477/1 E - 27
 Section E - Hydraulics
Hydraulics
Recommended Start-Up

Fig 51.

OPERATION –LOADER DOWN

This sketch shows the oil flow path in the entire valve. The
red chambers are pressurized when the boom down is
operated, and the blue chambers are not pressurized.

LOADER FLOAT
When the joystick is moved to float position the pilot port
no.3 of the valve is pressurized and the spool is moved to
the float position. In this position of the main spool the ports
A2 & B2 are connected to tank. Hence the boom floats and
follows the terrain, to do dozing operation K Fig
51. ( T E-28).

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 Section E - Hydraulics
Hydraulics
Recommended Start-Up

Fig 53.

LOADER FLOAT

This sketch shows the oil flow path in the entire valve. The
red chambers are pressurized when the float is operated,
and the blue chambers are not pressurized. Oil does not
flow to any service portsK Fig 53. ( T E-29) .

OUT LET SECTION

The sketch shows the cross-section of the outlet
section. The oil flows out from the valve through the outlet
port of the valve to the tank K Fig 54. ( T E-30) .

Fig 52.

E - 29 550/43477/1 E - 29
 Section E - Hydraulics
Hydraulics
Recommended Start-Up

Fig 54.

E - 30 550/43477/1 E - 30
 Section E - Hydraulics

Hydraulics
Hydraulic Contamination

Hydraulic Fluid Quality Cleaning Operation

Construction machinery 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.
The purpose of cleaning oil is to remove contaminants of
all types and sludge by filtering hydraulic fluid through a
cleaning unit. General Bulletin 011 also refers.
Procedure
Connect the cleaning unit in place of the hydraulic filter.
Run the system for sufficient time to pump all the hydraulic
fluid through the unit. Disconnect the cleaning unit and
reconnect the filter. Top up the system with clean hydraulic
fluid as required K Fig 55. ( T E-31).

Effects of Contamination
Once inside the system, hydraulic circuit contaminants
greatly effect 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:

1 Solid Particles

Sand, fibres, metallic particles, welding scale, sealing

materials and wear particles etc.

2 Liquid

usually water and incompatible oils and greases.

Fig 55. Cleaning Unit
3 Gases
Contaminant Standards
Air, sulphur dioxide etc. which can create corrosive
compounds if dissolved in the fluid. Dirt that damages your system is in many cases too small
to be seen with the eye. The particle size is measured in
These contaminants can appear during manufacture, microns.
assembly and operation.
1 micron = 0.001 mm (0.0000394 in).

E - 31 550/43477/1 E - 31
 Section E - Hydraulics
Hydraulics
Hydraulic Contamination
– Dirt that damages your system is in many cases too
small to be seen with the eye. The particle size is
measured in microns. micron = 0.001 mm (0.0000394
in).
– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)
– Human Hair = 70 microns (0.07 mm, 0.00275 in)
– Grain of Salt = 100 microns (0.1 mm, 0.00394 in)

Smallest particle visible to the naked eye is 40 microns

(0.00157) approximately.

Standards will often be quoted to ISO (International

Standards Organisation) for which literature can be
obtained.

Filters

The filter assembly fitted to all product ranges is designed

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

To ensure optimum performance and reliability it is

important that the machines hydraulic system is serviced
periodically in accordance with the manufacturers
requirements.

E - 32 550/43477/1 E - 32

Venting the Hydraulic Pressure
!MWARNING
Hydraulic Pressure (Servo Machines)
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses,
stop the engine. When the engine has stopped, turn
the starter switch to on. Operate the controls to
release pressure trapped in the hoses. Turn the starter
switch to off. Make sure the engine cannot be started
while the hoses are open.
5-1-7-1
Machines from the serial number given above are fitted
with a new generation loader control valve. A feature of this
new valve is that when the ignition is turned off, the servo
control is disconnected from its pressure accumulator.
This can falsely give the impression should the control
lever be operated, that there is no residual pressure in the
system. To prevent the hydraulic system being opened
whilst there is still residual pressure present, the following
venting procedure MUST be carried out
1 Park the machine on firm level ground. Lower the
attachments to the ground, apply the park brake and
set the transmission to neutral K Fig 56. ( T E-33).
2 Switch the engine OFF.
3 Turn the ignition ON, but DO NOT start the engine.
4 Ensured the loader isolation switch in the right hand
side cab switch bank is turned ON. (The switch will be
illuminated when ON.)
Fig 56.
E - 33 550/43477/1
Section E - Hydraulics
Hydraulics
Venting the Hydraulic Pressure
5 Operate the loader control lever repeatedly to vent
any residual pressure.
6 Turn OFF the ignition and disconnect the batteries to
ensure the machine cannot be started while the
hydraulic system is open.
Automatic Carry Control System Venting
Before attempting any maintenance work on the load
suspension hydraulic system, the isolating ball valve must
be OPEN.
The isolating ball valve is normally CLOSED for ACCS to
be operative K Fig 57. ( T E-33).
!MWARNING
The loader arms will fall to the ground if they are not
on the ground or securely supported before the
isolating ball valve is opened. Ensure isolating ball
valve is open before attempting any maintenance work
on the load suspension hydraulic circuit. The isolating
ball valve is closed for normal system operation.
0106
Fig 57.
E - 33

Connecting and Disconnecting Hydraulic Hoses
The following paragraphs describe how to connect and
disconnect hydraulic hoses safely.
Connecting the Hoses
Connect the hoses. Where the connection is of the quick
release type, see section A, contents. For all other hose
connections, use correct tools and ensure that
connections are not crossthreaded.Support the weight of
the hose until theconnection is made. Do not exceed the
recommended torque loading.
!MWARNING
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 protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2
7 Check for leaks as follows
a Start the engine.
b Operate the controls to pressurise the required
hose.
c Switch off the engine. Remove the starter key.
Check for signs of leakage at the
hoseconnections.
Disconnecting the Hoses
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5
1 Vent the hydraulic pressure as described.
E - 34 550/43477/1
Section E - Hydraulics
Hydraulics
Connecting and Disconnecting Hydraulic Hoses
2 Disconnect the hoses. Where the connection is of the
quick release type, see Section A, contents. For all
other hose connections, plug both sides of the
connection to prevent loss of fluid.
Fitting Procedure
On a typical machine, some hydraulic components may
utilise ‘Positional Type’ SAE Hydraulic Adaptors. When
fitting ‘Positional Type’ Hydraulic Adaptors it is important to
adopt the following procedure. If this procedure is not
followed correctly, damage to the ‘O’ ring seal A can occur
resulting in oil leaks.
1 Ensure the locknut B is screwed back onto the body
of the adaptor as far as possible as shown.
2 Check the ‘O’ ring backing washer C 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 the ‘O’ ring A is fitted and that it is free from
damage or nicks. Before fitting the adaptor, smear the
‘O’ ring with clean hydraulic fluid.
Note: : The dimensions and shore hardness of the ‘O’ ring
is critical. Should it become necessary to replace the ‘O’
ring, ensure that only JCB Genuine Parts are used.
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 is correctly seated against the
sealing face.
5 Set the angular position of the adaptor as required,
then secure by tightening the locknut B. Note: When
fitted correctly no more than one thread should be
visible at Z as shown.
6 Torque tighten the locknut to 81 Nm (60 lbf ft) K Fig
58. ( T E-35).
E - 34

Fig 58.
Pressure Testing the Loader Valve A.R.V.’s
Using a Hand Pump
!MWARNING
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).
13-2-3-7
E - 35 550/43477/1
Section E - Hydraulics
Hydraulics
Connecting and Disconnecting Hydraulic Hoses
To pressure test and re-set the loader auxiliary relief
valves (A.R.V.), the following equipment must be used:
892/00340 Test Block Body
892/00223 Hand Pump
892/00279 Pressure Gauge 0 - 400 bar
1 Remove the loader valve A.R.V.’s from the loader
valve block. Note their positions for correct
reassembly.
2 Install the first A.R.V. assembly in the test block at the
port marked ‘RV’ K Fig 59. ( T E-35) (relief valve).
Fig 59.
3 Connect a hydraulic hand pump to port ‘P’ (pump) of
the test block. Make sure that the hand pump is filled
with JCB Hydraulic Fluid.
4 Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure
test gauge to port ‘G’ (gauge) of the test block.
5 Port ‘T’ (tank) can be left open when using a hydraulic
hand pump.
6 Raise the pressure at the valve inlet using the
hydraulic hand pump, when the A.R.V. ‘cracks’ and
oil escapes from the port marked ‘T’ the pressure
gauge will indicate the A.R.V. setting.
7 If the A.R.V. setting is correct as stated in release the
pressure in the test block and remove the A.R.V.
assembly. Refit the A.R.V. in the loader valve block.
8 If the A.R.V. setting needs to be adjusted release
locknut and adjust screw, using a 5 mm Allen Key and
repeat the test until the correct pressure is obtained.
E - 35

Tighten the locking nut to preserve the setting. If the
specified pressure is higher than the maximum
achievable by adjustment, additional shims will need
to be fitted.
9 When the correct A.R.V. setting has been attained,
release the pressure in the test block. Remove the
A.R.V. assembly and refit it to its correct position in
the loader valve block.
10 Repeat the procedure for the other A.R.V.’s.
!MDANGER
Make sure the articulation safety lock is fitted before
transporting the machine. The articulation safety lock
must also be fitted if you are carrying out daily checks
or doing any maintenance work in the articulation
danger zone.
Section E - Hydraulics
Hydraulics
Connecting and Disconnecting Hydraulic Hoses
4 Check fan reaches its recommended speed as
detailed in.
Adjusting the Fan Speed
1 On the right hand side of the machine, slacken the
locknut A on the fan motor and adjust to achieve the
recommended speed K Fig 60. ( T E-36).
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.

If the articulation lock is not fitted you could be

crushed between the two parts of the chassis.
GEN-3-1_1

!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in Fig 60.
accordance with the instructions given in this
publication. Note: Screw the adjuster in to increase fan speed and
HYD-1-5 pressure, out to decrease.

!MWARNING 2 Tighten the locknut and recheck the fan speed.

When working close to the machine with the engine

running, protective clothing must be worn, ie. Safety
glasses, ear protection, gloves etc.
GEN-4-3

Fan Drive Without Reversing Facility

1 Attach tacho-reflective tape to the fan hub (rather
than to the fan blades).

2 Warm up the hydraulic system until 4 or 5 segments

show on the hydraulic temperature gauge.

3 Hold the engine at Max specified revs. Check max

engine revs in.

E - 36 550/43477/1 E - 36
 Section E - Hydraulics
Hydraulics
Cooling Fan Motor

Cooling Fan Motor

Removal and Replacement 9 Remove the bolts 3 securing the fan blades to the
motor and remove the fan blades.
Removal
10 Remove the bolts 4 securing the fan motor its
framework and remove the fan motor.
1 Park the machine on firm level ground and lower the
loader arms. Engage the parking brake. Put the
transmission into neutral and chock both sides of all Replacement
four wheels. Stop the engine and let it cool down.
Operate the hydraulic control levers to release any Replacement is the reverse of removal.
pressure trapped in the hoses. Slowly remove the
hydraulic tank filler cap to vent any residual pressure.
Refit the filler cap.

2 Open the rear grille and remove the reverse alarm

from its mounting by removing the two securing bolts.

3 Open the left hand and right hand rear side access
panels. Remove the bolts securing the rear fibreglass
bodywork pod to the rear of the engine cover.

4 Secure slings to the rear pod and using the overhead

crane lift the pod away from the machine.

!MWARNING Fig 61.

Hydraulic fluid at system pressure can injure you.

Before disconnecting or connecting hydraulic hoses,
select float on the relevant external hydraulics control
with engiine running, then switch off the engine. Make
sure the engine cannot be started while hoses are
open.
13-3-2-14
5 Disconnect the hydraulic hoses to the fan motor. If
there are no tags on the hoses tie on your own to aid
refitment. Cap the open ports and hoses.
6 Remove the bolts 1 securing the fan guards to the
cooling pack cowl and to the motor framework.
Remove the fan guards.
7 Remove the bolts 2 securing the fan motor framework
to the cooling pack cowl.
8 Lift the framework complete with the fan motor and
blades from the machine K Fig 61. ( T E-37).
Dismantling, Inspection and Assembly
General
The pumps can be either uni-directional (this can be
clockwise or counter-clockwise) or bi-directional as used
with the reversing fan option.
The pumps cam be supplied with either one (in the case of
uni-directional) or two (as with bi-directional) pressure
relief valves located in the end cover. These relief valves
are used to set the operating speed of the motor. details of
the correct setting procedure can be found elsewhere in
this section. Each motor comprises and end cover, body,
bush/ gear assembly and a mounting flange held together
by through bolts. The gear/bush assembly consists of a
pair of matched drive gears supported by plain bearing
bushes. The drive gear journal extends through a rotary
shaft seal in the mounting flange to form the driveshaft.
Rubber O-rings, bush seals and nylon back-up seals act
as sealing devices within the unit. Internal leakage is
directed back to low pressure by means of an external
drain connection and internal drilling.

E - 37 550/43477/1 E - 37

Routine Maintenance
No maintenance is necessary other than periodic checks
for tightness of the mounting bolts and visual; inspections
for oil leakage. The unit should be kept clean, especially in
the area of the shaft seals as dirt can accelerate seal wear
and cause leakage. The motor must only be used with the
recommended JCBhydraulic fluid, details of which can be
found in Section
3 - Routine Maintenance.
Direction of Rotation
The manufactured direction of rotation is indicated by an
arrow and the word ‘Rotate’ on the motor body. The first
letter of the code reference following the number stamped
on the body also denotes the direction of rotation, ‘A’ =
Anti-clockwise (counter-clockwise), ‘C’ = clockwise or ‘R’ =
bi-rotational.
Important: Rotation is always specified as viewed on the
end of the driveshaft.
Note: For identification purposes, the inlet port is arrowed
or stamped with the word ‘HP INLET’ (HP = High
Pressure).
Dismantling
For components see K
Before dismantling, ensure the work area, work bench,
tools and the unit itself are thoroughly clean.
1 Withdraw the drive coupling using a suitable puller
Note: The coupling must not be levered or hammered off
the shaft as this will result in internal damage.
2 Remove the Woodruff key 12 from the driveshaft 11.
3 Lightly mark the end cover 3, body 9 and mounting
flange 15 to ensure correct alignment and take a note
of the motors direction of rotation.
4 Remove the bolts 1.
5 Remove the end cover 3 and lift off the back-up seal
5, bush seals 6 and the body O-ring 4.
6 At the other end of the motor, after making sure that
there are no burrs on the shaft, lightly tap the
E - 38 550/43477/1
Section E - Hydraulics
Hydraulics
Cooling Fan Motor
mounting flange to disengage it from the locating
dowels in the body and slide it squarely off the shaft.
7 Remove the circlip 17 and push the shaft seal 16
squarely out of the mounting flange, taking care not to
damage any sealing surfaces.
8 Remove the back-up seal 5, bush seals 6 and body
O-ring 4.
9 Before removing internal components the bushes 7
and 8 must be marked to identify their position within
the body. On the surface of the bush which will not
affect the sealing, lightly mark as follows:
‘FD’ Flange Driveshaft Bush
‘FI Flange Driven (idler) Gear Bush
‘CI’ Cover Driven (Idler) Gear Bush
‘CD’ Cover Driveshaft Bush
With the unit lying on its side, pull the driveshaft 11
squarely out of the body bringing the bushes with it.
10 Remove the driven gear 10 and the two remaining
bushes. Inspection Assessment Each component
should be thoroughly cleaned, carefully examined
and assessed for re-use. Following is a guide for
inspecting the various components. Should any
component not be suitable for further use, the pump
should be replaced.
Body
Inspect the body bore cut-in on the inlet side where the
gears wipe the body.
The body can only be re-used if the cut-in is bright and
polished in appearance and the depth does not exceed
0.08 mm. The body should not be scored, have a ‘matt’
appearance or show signs that the tip of the gears have
dug in and torn away the surface material.
The body should be inspected to ensure that there is no
superficial damage, which may adversely affect
performance or sealing. Pay particular attention to the port
threads and body O-ring seal recesses.
E - 38

Mounting Flange and End Cover
The inner surfaces should be inspected to ensure that
there is no unusual wear or scoring in the regions 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. replacement shaft
seals can be refitted with Loctite hydraulic sealant to
overcome slight damage in this area.
Bushes
The side faces, which abut the gears, should be perfectly
flat, showing no 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 providing that they are not
scored, have bronze appearing through the grey surface or
show any prominent signs of wear.
Gears
ensure that there are no signs of scuffing or pitting on the
involute face. The Journal bearing surfaces should be
completely free from scoring or bruising. The surface
should appear highly polished and smooth to the touch.
Examine the area where the shaft seal lips run on the
driveshaft, this shows up as a polished ring or rings. If a
noticeable groove can be felt or there is scoring the shaft
is unserviceable. Provided the driveshaft is not damaged
from the drive coupling and the gears have not been
harmed as described above, then the gears can be re-
used. As a matter of good practice, when motors are
dismantled, all the seals should be replaced. It is most
important that genuine JCB parts are used.
Assembly
For components see K Fig 101. Ensure all parts are
perfectly clean and lubricate the bushes and gears with
clean hydraulic fluid (ensure O-ring recesses and end
faces of the body remain dry). This will assist assembly of
the components into the body bores. A light smear of
petroleum jelly may be applied to the body seals 4 to help
keep them in place during assembly.
E - 39 550/43477/1
Section E - Hydraulics
Hydraulics
Cooling Fan Motor
1 Refit the cover driveshaft bush ‘CD’ and cover bush
‘CI’ (7 and 8) into the un-dowelled end of the body.
2 Place the cover 3 against the body 9 and position the
assembly so that the dowels are facing upwards.
3 Fit the driveshaft 11 and the driven gear 10 back into
their original positions in the body.
4 Refit the flange drive bush 7 and the flange driven
bush 8 into their original bores.
5 Fit a new body O-ring 4, bush seals 6 and backup
seals 5 into the bushes ensuring that the flat face of
the back-up seal will be against the mounting flange.
6 Push the shaft seal 16 squarely into the recess in the
mounting flange, remembering that if the seal recess
was scored from the removal of the original seal, then
a thin coat of Loctite hydraulic sealant must be
applied to the outside diameter of the replacement
seal to prevent possible leakage. Fit the seal retaining
circlip 17 and apply a light coat of high melting point
grease to the seal lips.
7 Fit the assembly sleeve 20 (supplied with the seal kit)
to the driveshaft and carefully refit the mounting
flange 15, sliding it over the assembly sleeve and
fitting it squarely to the dowels and the body. Remove
the assembly sleeve.
8 Holding the whole unit together, carefully invert the it,
making sure that the assembly is supported on the
mounting flange not the driveshaft.
9 Remove the end cover 3 and fit a new body Oring 4,
bush seals 5 and back-up seals 6 to the end cover as
before.
10 Fit the end cover 3 ensuring that the drain hole in the
cover lines up with the driven gear in externally
drained motors and that the drain runs to the outlet
side in inter drained motors.
Refit the bolts 1 and torque tighten to the required
specification. See Torque Settings
11 Pour a small amount of clean filtered JCB hydraulic oil
into the port and check that the shaft can be rotated
without undue force.
E - 39
 Section E - Hydraulics
Hydraulics
Cooling Fan Motor
Torque Settings

Item Nm lbf-ft
1 43.5 - 51.5 32 - 38
19 28 + 5 21 + 3.7

E - 40 550/43477/1 E - 40
 Section E - Hydraulics
Hydraulics
Cooling Fan Motor

Cooling Fan Motor Components

K Fig 62. ( T E-41)

Component Key
1 Bolt
2 Spring Washer
3 End Cover
4 O-ring
5 Back-up Seal
6a Bush Seal
6b Bush Seal
7 Bush
8 Bush
9 Body
10 Driven Gear
11 Driveshaft
12 Woodruff Key
13 Not Used
14 Not Used
15 Mounting Flange
16 Shaft Oil Seal
17 Circlip
18 Tab Washer
19 Nut
20 Sleeve (assembly tool)

Fig 62.

E - 41 550/43477/1 E - 41
 Section E - Hydraulics
Hydraulics
Cooling Fan Motor

Removal
Note: The following procedure’s illustrations depict a Uni-
Directional Motor; the Bi-Directional motor has an
additional hose. In all other aspects the procedures are the
same.
1 Park the machine on firm level ground, lower the
attachments to the ground, apply the park brake and
set the transmission to neutral. Stop the engine.
Block both sides of all four wheels.
Important: The procedure detailed below must be
followed to correctly vent the residual hydraulic pressure.
2 Vent the hydraulic pressure as detailed in K Venting
the Hydraulic Pressure .
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses,
stop the engine and carry out the full venting
procedure. Make sure the engine cannot be started
while the hoses are open.
INT-3-1-18
7 Label and disconnect the hoses A and B to the
cooling fan motor. plug the hoses and cap the K Fig
64. ( T E-42)open motor ports to prevent the ingress
of dirt or debris. Connecting and Disconnecting
Hydraulic Hoses.

3 Disconnect the batteries to prevent the engine being

started whilst carrying out this procedure.

4 Disconnect the batteries to prevent the engine being

started whilst carrying out this procedure.

5 Open the left and right-hand side engine covers.

From inside the right-hand side cover pull the release
cable A to unlatch the rear fan housing assembly
K Fig 63. ( T E-42).

Fig 64.

8 Open the fan housing and remove the four bolts A

securing the inner guard to the housing and remove
the guard K Fig 65. ( T E-43). A B A.

Fig 63.

6 Remove the six bolts securing the fan grille to the fan
housing. (The lower three are fitted on the under side
of the grille.)

E - 42 550/43477/1 E - 42

Fig 65.
9 Remove the four bolts B securing the fan blades to
the motor hub and remove the fan. Store the fan
carefully so as not to damage the blades. (Do not refit
a fan with damaged blades.)
10 Lower the fan housing to the closed position and
remove the two Allen bolts A securing the fan motor
to the spider and remove the motor K Fig
66. ( T E-43).
Fig 66.
E - 43
Section E - Hydraulics
Hydraulics
Cooling Fan Motor
Replacement
Replacement is the reverse of the removal procedure,
however note the following.
!MWARNING
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 protective glasses. Hold a piece of
cardboard close to suspected leaks and then inspect
the cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
INT-3-1-10_2
1 Take care to secure the hydraulic hoses inside the fan
housing to prevent possible contact with the fan.
2 Top up the hydraulic fluid as necessary with the
correct grade of fluid. Refer to Section 3 - Routine
Maintenance.
Uni-Directional Motor
General
Note: Before removing or dismantling the motor, check that
its performance is as specified in Technical Data. If the
performance is below that specified, the motor should be
renewed. Renewal of components such as gears, bearings
and housing will not effect a permanent cure. if a motor’s
output is satisfactory but there is evidence of external
leakage, it should be dismantled for re-sealing only. Before
dismantling make sure the motor’s external body and the
work area are thoroughly cleaned and are
Dismantling, Inspection and Assembly
For motor components,.
Dismantling
Note: It is very important to work in a clean environment
when repairing hydraulic motors. Plug all ports and wash
the exterior of the motor with a proper cleaning solvent
before stripping the motors.
1 Remove the port plugs and ensure all oil is drained
from the motor.
550/43477/1 E - 43

2 Prior to dismantling the motor, mark the motor body 9
and flanges 3 and 16 with a permanent marker pen to
ensure correct alignment when assembling.
3 Mount the motor vertically in a vice (use vice softjaws
to protect the motor mounting flange) by the mounting
flange, with the driveshaft pointing downwards and
slacken the bolts 23.
4 Remove the bolts 23, washers 22 and the rear
housing 16.
5 Carefully remove the gear housing 9 and place on a
clean work bench. Ensure the rear bearing block 13
stays in place on the driveshaft gear 12 and idler gear
11.
6 Remove the rear bearing block 13, remove the idler
shaft 11 and the driveshaft gear 12. 7 Remove the
front bearing block 6.
7 Turn the mounting flange over, with the shaft seal
uppermost, and remove the retaining circlip 1 and the
seal 2.
8 Clean all sealant from mating surfaces, discard the
seal and O-rings
Inspection
1 Clean and dry all parts thoroughly prior to inspection.
(It is not necessary to check the seals as all seals
need to be replaced). Inspect all Oring grooves and
shaft seal recesses, make sure there are no burrs.
2 Check the driveshaft for damage. Check for marks or
grooves on the driveshaft in the area of the seal.
Slight discolouration of the shaft is allowable.
3 Inspect the faces of the gears for scoring or excessive
wear. If the face of the gear is sharp, it could mill into
the bearing block. If wear is evident then the parts
must be replaced.
4 Inspect the bearing blocks for excessive wear or
scoring on the surfaces that are in contact with the
gears. Also inspect the bearing for excessive wear or
damage.
5 Inspect the area inside the gear housings. It is normal
for the surface inside the gear housing to show a
E - 44 550/43477/1
Section E - Hydraulics
Hydraulics
Cooling Fan Motor
clean “wipe” on the surface of the intake side. There
should however be no excessive wear or scoring.
The motor must be renewed if any of the following
defects are found:
i The gear cut-in track in the body low pressure
side is deeper than 0.08 mm or has a scarred
and matt appearance.
ii The PTFE coated bearings in the body or
flanges are worn through so that the bronze
base is visible.
iii The gear side faces or bearing blocks are
scarred.
iv The driveshaft has a wear groove where the
shaft seal lips run.
Assembly
Wash all components in a suitable aromatic solvent. When
dry apply hydraulic fluid immediately to prevent moisture
collecting.
1 Install a new shaft seal 2 into the mounting flange 3,
with the part number of the seal facing outwards.
Press the new seal into its bore until fully seated.
Install the circlip 1 into its groove in the mounting
flange 3.
2 Place the front 6 and rear 13 bearing blocks on a
clean work bench with the E-seal grooves facing
upwards. Apply a coating of petroleum jelly to the
grooves. Apply a coating of petroleum jelly to the E-
seals and back-up seals. (This will help keep the
seals in place during assembly.)
3 Place the E-seals 5 and 14, flat side outwards, into
the bearing blocks 6 and 13. Carefully place the back-
up seals 4 and 15, with the flat side outwards, in the
respective groove made by the E-seal and the groove
in the bearing block.
Note: In the centre of the back-up seal and the Eseal there
is a “notch”. Make sure these notches line up, so that the
back-up seal sits flush with the E- seal.
4 Place the mounting flange 3, with the seal side facing
downwards on a clean flat surface.
E - 44
 Section E - Hydraulics
Hydraulics
Cooling Fan Motor
5 Apply a light coating of petroleum jelly to the exposed casings prior to dismantling and press home using
face of the front bearing block 6. hand pressure only.

6 Insert the drive end of the driveshaft 12 through the 15 Install the four bolts 23 with their respective washers
bearing block 6 with the seal side down, and the open 22 and hand tighten.
side of the E-seal pointing to the intake side of the
motor. 16 Place the assembled motors into a vice (using soft
jaws to protect the mounting flange) and alternately
7 Install a sleeve over the driveshaft threads to protect tighten the bolts 23 to the torque specified in • See
the seal 2 and carefully slide the driveshaft through Torque Settings.
the seal 2. Remove the sleeve from the driveshaft.
17 Remove the motor assembly from the vice.
8 Install the idler gear shaft 11 into the remaining
position in the bearing block. Apply a light coat of 18 Place a small amount of clean hydraulic oil in the inlet
clean hydraulic oil to the face of the driveshaft and of the motors and rotate the driveshaft away from the
idler gears. inlet by one revolution. If the driveshaft binds,
disassemble the motor and check for assembly
9 Pick up the rear bearing block 13, with the seals problems. Rectify the problems and reassemble the
facing upwards and the open ends of the E-seals motor.
facing the intake side of the motor, and place over the
driveshaft and idler gear shafts.
Item Nm Kgf m lbf ft
10 Ensure the dowel pins 8 are in place in the housing 9. 17 40 4.08 29.5
23 56 5.71 41.3
Note: On later housings there are two long dowels through
the housing that locate in the front mounting flange and the
rear cover. These replace the four short dowels item 8.

11 Apply a coating of petroleum jelly to the seal grooves

in both sides of the housing 9. Apply a light coating of
petroleum jelly to the O-rings (7 and 10) and install
them in their grooves.

12 Gently slide the gear housing 9 over the rear bearing

block 14. Slide the housing down until the housing
dowel pins come into contact with their respective
bores in the mounting flange 3. Press the housing
home firmly with your hands, do not force or use any
kind of tool. Make sure that the intake port in the
housing is on the same side as the open end of the E-
seal 14 and that the marks made on the casings prior
to dismantling are in alignment.

13 The surface of the rear bearing block 13 should be

slightly below the face of the gear housing 9. If the
bearing block sits higher than the rear face of the
housing then the E-seal or O-ring may have become
detached from its seat and be trapped. Remove the
housing and check the seals for correct installation.

14 Install the rear housing 16 onto the dowels in the

housing 9, taking care to align the marks made on the

E - 45 550/43477/1 E - 45
 Section E - Hydraulics
Hydraulics
Cooling Fan Motor

Component Key
K Fig 67. ( T E-46)

1 Circlip
2 Seal
3 Front housing
4 Back-up seal
5 E-seal
6 Front bearing block
7 O-ring
8 Locating dowels
9 Gear housing
10 O-ring
11 Idler gear
12 Driveshaft gear
13 Rear bearing block
14 E-seal
15 Back-up seal
16 Rear housing
17 Proportional relief valve cartridge
18 Measuring coupling
19 Spring
20 Ball
21 Valve seat
22 Washer
23 Bolt

Fig 67.

Bi-Directional Motor
General

Note: Before removing or dismantling the pump, check

that its performance is as specified in Technical Data. If
the performance is below that specified, the motor should
be renewed. Renewal of components such as gears,
bearings and housing will not effect a permanent cure. If a
motor’s output is satisfactory but there is evidence of
external leakage, it should be dismantled for re-sealing
only. Before dismantling make sure the motor’s external

E - 46 550/43477/1 E - 46

body and the work area are thoroughly cleaned and are 11
free from possible causes of contamination.
Dismantling, Inspection and Assembly
For motor components, K. 12
Dismantling
Note: It is very important to work in a clean environment
when repairing hydraulic motors. Plug all ports and wash
the exterior of the motor with a proper cleaning solvent
before stripping the motors.
13
1 Remove the port plugs and ensure all oil is drained
from the pump.
2 Prior to dismantling the motor, mark the motor body
7, flange 3 and the solenoid operated control valve 14
with a permanent marker pen to ensure correct
alignment when assembling. 14
3 Mount the motor vertically in a vice (use vice softjaws
to protect the motor mounting flange) by the mounting
flange 3 with the driveshaft pointing downwards and
slacken the bolts 16. 15
4 Remove the bolts 16, washers 17 and the solenoid
operated control valve 14. 16
5 Carefully remove the gear housing 7 and place on a
clean work bench. Ensure the rear bearing block 12
stays in place on the driveshaft and idler gears, items
11 and 10. 17
6 Remove the rear bearing block 12, remove the 18
driveshaft 11 and the idler gear 10.
7 Remove the front bearing block 5.
8 Turn the mounting flange over, with the shaft seal
uppermost, and remove the retaining circlip 1 and the
seal 2.
Item
9 Clean all sealant from mating surfaces, discard all
15
seals and “O” rings.
16
10 Ensure the dowel pins 8 are in place in the housing 7.
Component Key
Note: On later housings there are two long dowels through
the housing that locate in the front mounting flange and the
K Fig 68. ( T E-48)
rear cover. These replace the four short dowels item 8.
E - 47 550/43477/1
Section E - Hydraulics
Hydraulics
Cooling Fan Motor
Apply a coating of petroleum jelly to the seal grooves
in both sides of the housing 7. Apply a light coating of
petroleum jelly to the O-rings (6 and 9) and install
them in their grooves.
Gently slide the gear housing 7 over the rear bearing
block 12. Slide the housing down until the housing
dowel pins come into contact with their respective
bores in the mounting flange 3. Press the housing
home firmly with your hands, do not force or use any
kind of tool. Make sure that the marks made on the
casings prior to dismantling are in alignment.
The surface of the rear bearing block 12 should be
slightly below the face of the gear housing 7. If the
bearing block sits higher than the rear face of the
housing then the seal or O-ring may have become
detached from its seat and be trapped. Remove the
housing and check the seals for correct installation.
Install the solenoid operated control valve 14 onto the
dowels in the housing 7, taking care to align the
marks made on the casings prior to dismantling and
press home using hand pressure only.
Install the four bolts 16 with their respective washers
17 and hand tighten.
Place the assembled motor into a vice (using soft
jaws to protect the mounting flange) and alternately
tighten the bolts 16 to the torque specified in K See
Torque Settings.
Remove the motor assembly from the vice.
Place 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 reassemble the
motor.
Table 8.
Nm Kgf m lbf ft
40 4.08 29.5
56 5.71 41.3
E - 47
 Section E - Hydraulics
Hydraulics
Cooling Fan Motor

1 Circlip
2 Seal
3 Front housing
4 Seal
5 Front bearing block
6 O-ring
7 Gear housing
8 Locating dowels
9 O-ring
10 Idler gear
11 Driveshaft gear
12 Rear bearing block
13 Seal
14 Solenoid operated control valve
15 Proportional relief valve cartridge
16 Bolt
17 Washer

Fig 68.

E - 48 550/43477/1 E - 48
 Section E - Hydraulics
Hydraulics
Ram

Ram
Maintenance of Cylinders 3 Take out the piston rod sub assembly.

Open the cylinder in a clean dust free location 4 Lock Rod eye mounting with a bar.

Ensure all the tools are in good condition. 5 Unscrew the Piston with help of right spanner.

Ensure the pressure in the system is relieved before 6 Take out the Head end cover by sliding on piston rod.
opening.
7 Inspect all components and seals for any damages
Ensure the oil is in cold condition before opening cylinder and replace damaged parts.

Ensure proper lifting tackles (Rope, Belts) while handling Assembly of Cylinder
cylinder.
1 Clean all components of cylinder thoroughly.
Ensure that the working area is clean and oil is not spilled
around the floor 2 Assemble seals on piston and Head end cover as
shown in drawing.
Storage of Cylinders
3 Slide head end cover on piston rod.
If cylinder stored for more than 12 months without oil filled
4 Screw piston on piston rod and tighten to required
and 18 months with oil cylinders needs to be revalidated
torque.
K Fig 69. ( T E-49).
5 Assemble Piston Rod sub assembly into tube sub
Cylinders stored should not be kept in an open yard.
assembly with out damaging the piston seal.

6 Tighten the Head end cover K Fig 70. ( T E-50).

7 Apply thread locker wherever required as

recommended in drawings.

8 Mount cylinder and test cylinder in low idle for air

bleeding.

Fig 69.

Dismantling of Cylinders

1 Place cylinder on V-blocks and lock Cap end cover

mounting .

2 Open the Head End Cover Locking and unscrew the

head end cover using tool recommended in Assembly
drawing.

E - 49 550/43477/1 E - 49
 Section E - Hydraulics
Hydraulics
Ram

Fig 70.

CYLINDER SPECIFICATION H210 120X080 NC

CM+RE 820 DA
WIPRO DRAWING NUMBER : P6457
CUSTOMER JCB INDIA

Tools Recommended
Part No Tools Size Torque
4 Spanner 95 mm A/F 245-270 kgf-m
5 Hook Spanner Standard Manual
6 Ellen key 5 mm Manual

Note: Apply - Anabond 115 for piston rod threads

Anabond 132 on set screw threads ( item no 6 )

E - 50 550/43477/1 E - 50
 Section E - Hydraulics
Hydraulics
Ram

Loader Lift Cylinder SL. NO DESCRIPTION QTY

12 Back up ring 1
SL. NO DESCRIPTION QTY 13 Standard O-ring 1
1 Tube S/A 1 14 Back up ring 1
2 Piston Rod S/A 1 15 Rod Seal 1
3 H.E.Cover 1 16 Wiper Guard 1
4 Piston 1 17 Wiper 1
5 Nyloc nut 1 18 Snap Ring 1
6 Bush 2 19 Wiper 4
7 Conical head grease nipple 3 20 Grease Nipple Protection Cover 4
8 Piston bearing 21 Bimetal bush 1
9 Piston Seal 1 22 Protection Cap 3
10 Standard O-ring 1 23 Sealing washer 3
11 Standard O-Ring 1
K Fig 71. ( T E-51)

Fig 71.
Tools Recommended 4 Piston 1

Part No Tools Size Torque 5 H.E.Cover 1

4 Spanner 95 mm A/F 400-440 kgf-m 6 Stop Tube 1

5 Hook Spanner Standard Manual 7 Set Screw 1

7 Allen key 5 mm Manual 8 Snap Ring 1

9 Conical head grease 2
Note: 10 Snap Ring 1
11 Piston Seal 1
– Apply - Anabond 115 for piston rod threads
– Anabond 132 on set screw threads ( item no 6 ) 12 O-ring 1
13 Piston Bearing 2
SL. NO DESCRIPTION QTY
14 Back up ring 1
1 Piston Rod S/A 1
15 Standard O-ring 1
2 Tube S/A 1
16 Back-up ring 1
3 Bush 2
17 Rod seal 1

E - 51 550/43477/1 E - 51
 Section E - Hydraulics
Hydraulics
Ram

18 Wiper 1
19 O-ring 2
20 Wiper 4
21 Grease Nipple Prote 2
22 Wiper Guard 1
23 Bimetal bush 1
24 Protection Cap 2
25 Sealing washer 2

E - 52 550/43477/1 E - 52
 Section E - Hydraulics
Hydraulics
Steering Cylinder

Steering Cylinder
Dismantling of Steering Cylinder 6 Assemble Piston Rod sub assembly into tube sub
assembly with out damaging the piston seal.
1 Place cylinder on V-block and lock Cap end cover
mounting . 7 Tighten the Head end cover.

2 Open the Head End Cover Locking and unscrew the 8 Apply thread locker wherever required as
head end cover using tool recommended in Assembly recommended in drawings.
drawing.
9 Mount cylinder and test cylinder in low idle for air
3 Take out the piston rod sub assembly. bleeding.

4 Lock Rod eye mounting with a bar.

5 Unscrew the Piston nyloc nut with help of right size

spanner.

6 Slide out the piston.

7 Take out the Head end cover by sliding on piston rod.

8 Inspect all components and seals for any damages

and replace damaged parts.

Tools
Recommend
ed
Part No Tools Size Torque
3 Hook Standard Manual
Spanner
5 Spanner 50 50-55 kgf-km

Note: Apply loctite 242/ Anabond 118 on piston rod

threads.

Assembly of Steering Cylinder

1 Clean all components of cylinder thoroughly

2 Assemble seals on Piston and Head end cover as

shown in drawing.

3 Slide head end cover on piston rod.

4 Slide Piston on Piston rod end step.

5 Screw in Nyloc Nut on piston rod to recommended

torque.

E - 53 550/43477/1 E - 53
 Section E - Hydraulics
Hydraulics
Steering Cylinder

Steering Cylinder

Sr. NO DESCRIPTION QTY

1 Piston Rod S/A 1
2 Tube S/A 1
3 Bush 1
4 Piston 1
5 H E Cover 1
6 Set Screw 1
7 Snap Ring 1
8 Grease Nipple 1
9 Snap Ring 1
10 Piston seal 1
11 Standard O-ring 1
12 Piston Bearing 2
13 Back- up ring 1
14 Standard O-ring 1
15 Back- up ring 1
16 Road seal 1
17 Wiper 2
18 Satndard O-ring 1
19 Wiper 2
20 Grease Nipple Protection Cap 1
21 Protection Cap, 3/4" BSP 2
22 Wiper Guard 1
23 Bimetal Bush 1
24 Sealing Washer 2

E - 54 550/43477/1 E - 54

To use this section, look for the fault in the list below and refer
to the probable causes and actions required listed against
the fault.
Fault
1 Lack of power in all
hydraulic functions.
2 One hydraulic service
fails to operate or is
slow to operate.
3 The engine tends to
stall when hydraulics
are under load.
4 Ram creep.
E - 55
Section E - Hydraulics
Hydraulics
Fault Finding
Hydraulics
Fault Finding
Remember safety must always be the first priority, refer to the
‘Care and Safety’ section for a reminder on safety practices.
Table 9.
Probable Cause Action
Insufficient hydraulic fluid. Check for leaks and top up as
required.
Hydraulic leaks in system.
Check hoses, replace as required.
Engine performance.
Check engine performance.
Pump control setting incorrect.
Check and adjust as required.
Low pump flow.
Check for external leaks, replace
Priority valve sticking. seals.
Check priority valve.
Associated service pipe lines Check hoses, replace as required.
leaking,damaged, trapped or
kinked. Replace seals.
Replace seals. Check and adjust as required.
A.R.V. setting incorrect. Check for leaks, rectify as required.
Associated valve block section Check that the control lever is
leaking or not operating. operating
Associated check valve not the spool, rectify as required.
opening to allow return of oil to
tank. Check and rectify as required.
Diverter not opening. Check electrical power supply and
valve operation, rectify as required.
Pump control setting incorrect. Check and adjust as required.
Engine performance. Check engine performance.
Ram seals. Check and rectify as required.
A.R.V.
550/43477/1 E - 55
Section F

Transmission
Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering

Publication No.
550/43477/1

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section F - Transmission

Notes:

F-0 550/43477/1 F-0

 Section F - Transmission
Contents

Contents Page No.

Axles
GENERAL INSTRUCTIONS ..................................................................... F-1
SHIMS ...................................................................................................F-1
SEALS FOR REVOLVING SHAFTS .....................................................F-1
Storage and Service Instruction ................................................................ F-2
FRONT AXLE PERIODIC SERVICING .................................................F-3
Axle case ...............................................................................................F-3
Final Drives ...........................................................................................F-3
FINAL DRIVE SECTION .......................................................................F-5
FRONT DIFFERENTIAL AXLE SECTION ............................................F-6
Parking Brake Calipers wear check and replacement ...........................F-7
Calipers replacement ............................................................................F-7
FRONT AXLE DISASSEMBLING, OVERHAULING AND RE-ASSEM-
BLING ....................................................................................................F-9
Calipers replacement ............................................................................F-9
FRONT AXLE DISASSEMBLING, OVERHAULING AND RE-ASSEM-
BLING ..................................................................................................F-11
Parking Brake group dismantling ........................................................F-16
Front Axle Differential Unit overhauling: dismantling ...........................F-16
Front Axle Differential Unit Re-assembling -Bevel pinion positioning ..F-19
Computing of Brake Disk Pack of Rear Axle Final Drive .....................F-28
Computing clearance for making up Brake Disk .................................F-28
Second system to determine lug brake disks shim .............................F-31
MAX-TRAC .............................................................................................. F-34
MAX-TRAC SECTION .........................................................................F-34
Differential Unit overhauling : Re-assembling .....................................F-35
SUPER MAX-TRAC Differential disassembling, overhauling and re-as-
sembling ..............................................................................................F-36
TROUBLESHOOTING ............................................................................ F-41

Transmission
Technical Data ......................................................................................... F-43
(ZF 4WG - 160 Powershift Transmission) ...........................................F-43

Transmission Fault Codes

Fault Codes ............................................................................................. F-45
Propshafts ...........................................................................................F-55
Display Panel ........................................................................................... F-56
Warning Lights .....................................................................................F-56

Transmission
Technical Data ......................................................................................... F-59
(ZF 4WG - 160 Powershift Transmission) ...........................................F-59

F-i F-i
 Section F - Transmission
Contents

Contents Page No.

F-ii F-ii
 Section F - Transmission
Axles
GENERAL INSTRUCTIONS

Axles
GENERAL INSTRUCTIONS

SHIMS RTV SILMATE, RHODORSIL CAF 1 or LOCTITE PLASTIC

All adjustments shall be carried out after all adjustment shims
have been selected measuring them one by one with a
micrometer gauge and, then, summing up all values
measured; don’t trust incorrect measurement of pack as a unit
or sum of nominal value printed on each shim.
SEALS FOR REVOLVING SHAFTS
GASKET.
Clean matching surface as follows prior, smearing compound:
– Remove old deposits using a metal brush.
– Degrease surfaces by one the following cleaners:
trichloroethylene, kerosene or a warm water and soda
solution

1 Proceed as follows for proper fitting of captioned seals BEARINGS

2 Prior assembly, seals should be kept, for at least half an
hour, in a bath with the same oil to be sealed;
3 Clean thoroughly shaft and make that working surface be
not damaged
When assembling them it is advisable to proceed as follows:
– Heat them with 80 to 90 °C before fitting on relevant
shafts;
– Cool them before inserting in relevant external seats

4 Position sealing lip against the fluid to be sealed; in case

SPRING PINS
of hydrodynamic lip lines should be oriented so as that,
considering direction of revolving shaft, they lead fluid
When using split pins be sure that lengthwise cleft be
inside of sealing means.
posiioned toward stress on pin. Coil pins don’t require specific
position.
5 Smear sealing lip with a film of lubricant (oil is better than
grease) and fill up with grease the space between
IMPORTANT : Dispose of worn and replaced materials has to
sealing lip and dust shield lip, if using double sealing lip
follow local regulation.
type seals.

6 Press seal in relevant seat or use a proper fitter with flat

contact surface; never use ham-mer or mallet to mount
seal.

7 When press fitting seal make sure that it be correctly

driven in relevant seat, i.e., perpendi-cular with respect
to its seat, as fitting is completed make sure, if required,
that seal itself be in contact with relevant shoulder.

8 To prevent damage of seal lip when inserting shaft, duly

protect component during assembly.

O-RING SEALS
Lubricate O-RING seals at assembly to prevent twisting that
would impair correct sealing.

SEALING COMPOUNDS
For matching surfaces identified by X use one of following
compounds:

F-1 550/43477/1 F-1

 Section F - Transmission
Axles
Storage and Service Instruction

Storage and Service Instruction

In order to assure the right preservation, handling and
utilization of the product, must be paying attention to the
following instruction

Temprature Comditions

Storage - 40 + 70° C
Working 30 + 60° C

During the handling of the product avoid any collision for

not to damage the external and internal components.

In case of long time standing of the product, before the

installation or the starting, must be sure that the product
have not suffered any damage.

Not submit the electrical components to incompatible

tension.

Never use petrol, solvents or other inflammable fluids, use

approved commercial solvents that are both
noninflammable and not-toxic.

In case of stopping and before living the vehicle, make

sure the parking brake is engaged.

Failing to follow these instructions or an unproper use of

the product may result in harm to persons and objects
damages.

F-2 550/43477/1 F-2

 Section F - Transmission
Axles
Storage and Service Instruction

FRONT AXLE PERIODIC SERVICING

K Fig 1. ( T F-3)

Fig 1.

Keep adequate containers corresponding to drain plugs.

Axle case
Remove oil filling and level plug (1).

Remove drain plug (2) and drain the oil.

Refit the drain plug (2).

Final Drives
Place plugs (3) of the final drives to have “DRAIN”
writinghorizontal, remove the plug, drain oil K Fig
2. ( T F-3).

Refit the plugs (3). Fig 2.

Fill up to have oil overflowing from the level hole (1). Refit
the level and filling plug (1) K Fig 3. ( T F-4).

F-3 550/43477/1 F-3

 Section F - Transmission
Axles
Storage and Service Instruction

Fig 3.

Place the oil level plug (3) by rotating drive unit of 90° so to
position “OIL LEVEL” writing horizontal and fill up to have
oil overflowing, refit plug K Fig 4. ( T F-4)

Fig 4.

Important: Dispose of used oil in accordance with specific

local regulation.

F-4 550/43477/1 F-4

 Section F - Transmission
Axles
Storage and Service Instruction

FINAL DRIVE SECTION

K Fig 5. ( T F-5)

Fig 5.

Table 1. 13 Brake Drive Piston

1 Sun gear
14 Lug disk
2 Side gear
15 Brake disk
3 Side gear carrier pins
16 Piston Return Spring
4 Final Drive Cover
17 Retaining Spring Ring
5 Side gears carrier Support
18 Ring nut
6 Wheel Hub
19 Disks carrier Hub
7 Bevel gear
8 Pressure plate
9 Bevel gear Support
10 Pins
11 Spindle
12 Half shaft

F-5 550/43477/1 F-5

 Section F - Transmission
Axles
Storage and Service Instruction

FRONT DIFFERENTIAL AXLE SECTION

K Fig 6. ( T F-6)

Fig 6.

F-6 550/43477/1 F-6

 Section F - Transmission
Axles
Storage and Service Instruction

Parking Brake Calipers wear check and

replacement
This check have to be made sometimes, by thickness
gauge recording of play between caliper and brake disk,
this play must not be bigger than 5 mm K Fig 7. ( T F-7).

Fig 9.

If dimension recorded is bigger than 5 mm, replace the

calipers as described in procedure, Page 22.

Calipers replacement
Fig 7.
Note: Lock machine by proper K Fig 10. ( T F-7) blocks
If the dimension recorded isn’t within this play, undo the wo or similar equipment
screws and remove the cover K Fig 8. ( T F-7).

Fig 8. Fig 10.

Work on adjusting (see figure) till to obtain a value of 0.8 ÷
1 mm K Fig 9. ( T F-7).
– Unlock parking brake;
– Undo the two screws and remove cover K Fig
11. ( T F-8);
– Remove the split pin (4a) and the pin (4b).
– Remove brake inner calipers and the outer

F-7 550/43477/1 F-7

 Section F - Transmission
Axles
Storage and Service Instruction
Measure by thickness gauge and work onadjusting (see
figure), till to obtain 0.8 ÷ 1 mm K Fig 14. ( T F-8).

Fig 11.

Release adjusting nut in order to obtain the maximum

opening of gripper K Fig 12. ( T F-8).
Fig 14.

Check O-Ring seal on the cover and, if worn, replace.

Screw in the two locking screws of cover K Fig
15. ( T F-8).

Fig 12.

Assemble the new brake calipers, by inser-ting the inner

caliper (5a) and than the outer one (5b) K Fig 13. ( T F-8).
Fig 15.

Fig 13.

F-8 550/43477/1 F-8

 Section F - Transmission
Axles
Storage and Service Instruction

FRONT AXLE DISASSEMBLING, OVERHAULING

AND RE-ASSEMBLING

This check have to be made sometimes, by thickness

gauge recording of play between caliper and brake disk,
this play must not be bigger than 5 mm K Fig 16. ( T F-9).

Fig 18.

If dimension recorded is bigger than 5 mm, replace the

Fig 16. calipers as described in procedure,Page 22.

If the dimension recorded isn’t within this play, undo the wo Calipers replacement
screws and remove the cover K Fig 17. ( T F-9).
– Unlock parking brake;

Undo the two screws and remove cover;

Remove the split pin (4a) and the pin (4b) .

Remove the split pin (4a) and the pin (4b).

Note: Lock machine by proper blocks or similar equipment

K Fig 19. ( T F-9) and K Fig 20. ( T F-10)

Fig 17.

Work on adjusting (see figure) till to obtain a value of 0.8 ÷

1 mm K Fig 18. ( T F-9).

Fig 19.

F-9 550/43477/1 F-9

 Section F - Transmission
Axles
Storage and Service Instruction
Insert the locking calipers pin (6a) and lock by the split pin
(6b), by folding it.K Fig 23. ( T F-10) and K Fig 23.
( T F-10)

Fig 20.

Release adjusting nut in order to obtain the maximum

opening of gripper.

Assemble the new brake calipers, by inser-ting the inner Fig 23.
caliper (5a) and than the outer one (5b) K Fig
22. ( T F-10).

Fig 24.

Measure by thickness gauge and work on adjusting (see

Fig 21.
figure), till to obtain 0.8 ÷ 1 mm K Fig 25. ( T F-11) and
K Fig 26. ( T F-11).

Fig 22.

F - 10 550/43477/1 F - 10
 Section F - Transmission
Axles
Storage and Service Instruction

Fig 25.
Fig 27.

Final Drives dismantling

Note: In case of intervent on the brake disks, cover

dismantling isn’t advised, not to prejudice adjusting of side
gears carrier pins. Avoid steps K Fig 28. ( T F-11),K Fig
29. ( T F-11) and K Fig 30. ( T F-12).

Fig 26.
Fig 28.
FRONT AXLE DISASSEMBLING, OVERHAULING
AND RE-ASSEMBLING Remove O-Ring seal.

Note: Lift and handle each particular by a lifting tool with

proper capacity. Make sure that groups or particulars are
suitabled by proper hooks K Fig 27. ( T F-11)

Fig 29.
Remove wheel shaft check plate, by inserting a M8 screw
in revelent hole.

F - 11 550/43477/1 F - 11
 Section F - Transmission
Axles
Storage and Service Instruction
Pull out complete side gear carrier K Fig 33. ( T F-12).

Fig 30.

Undo screws securing side gear carrier to wheel hub Fig 33.
K Fig 31. ( T F-12).
Pull out wheel shaft with sun gear, disks car-rier hub and
thrust plate K Fig 34. ( T F-12).

Fig 31.

Suitably support side gears carrier, use a lever inserted Fig 34.
inproper recesses, separate from wheel hub K Fig 32.
( T F-12). Remove brake disk pack K Fig 35. ( T F-12).

Fig 32. Fig 35.

F - 12 550/43477/1 F - 12
 Section F - Transmission
Axles
Storage and Service Instruction
Remove lock ring nut locks K Fig 36. ( T F-13) Support wheel hub. Undo and release ring gear by proper
tool (Draw. 4903367) from hub spindle K Fig 39.
( T F-13).

Fig 36.

Remove lockK Fig 37. ( T F-13)s .

Fig 39.

Remove pressure plate assy, return spring and

compression tool K Fig 40. ( T F-13).

Fig 37.

Screw in proper tool (Draw. 4903355) on pressure plate to

compress piston return spring K Fig 38. ( T F-13).

Fig 40.

Note: Remove ring gear, relevant support and pins K Fig

41. ( T F-14).

Fig 38.

F - 13 550/43477/1 F - 13
 Section F - Transmission
Axles
Storage and Service Instruction

Fig 41.

Pry off lock ring from ring gear by a screw-driver K Fig 42. Fig 43.
( T F-14). Should inner race (of wheel outer bearing) be replaced, it
has to be removed by a puller or remover.

Re-assemble by an heating equipment or proper tool

K Fig 44. ( T F-14).

Fig 42.

Remove ring gear support K Fig 43. ( T F-14).

Fig 44.
Remove piston; it’s easier by blowing com-pressed air in
brake oil delivery ducting K Fig 45. ( T F-15).

F - 14 550/43477/1 F - 14
 Section F - Transmission
Axles
Storage and Service Instruction

Should hub spindle result damaged, disas-semble it by

removing fixing screws.

At re-assembling, smear sealing compound on flange

joining to axle case at re-assemble and tighten lock screws
with a torque of 59 ÷ 63 daNm K Fig 48. ( T F-15).

Note: Place hub spindle so to have drain plug positioned

on the highest position and that the oil recirculation duct be
fitted into relevant hole.

Fig 45.

Remove wheel hub assy K Fig 46. ( T F-15).

Fig 48.

Fig 46.

Pry off wheel hub seal and remove inner race with roller
cage of wheel inside bearing. By using a punch remove
from wheel hub outer races of inner and outer wheel
bearings K Fig 47. ( T F-15).

Fig 47.

F - 15 550/43477/1 F - 15
 Section F - Transmission
Axles
Storage and Service Instruction

Parking Brake group dismantling

Insert through oil adding hole of gripper a pressure of 100
bar, in order to obtain cali-pers release.

Unlock and unscrew the two nuts from sup-porting pins of

parking brake gripper K Fig 49. ( T F-16).

Fig 51.

Unlock and undo fixing screws and remove parking brake

gripper support K Fig 52. ( T F-16).

Fig 49.

Release pins and remove brake gripper K Fig 50.

( T F-16).

Fig 52.

Front Axle Differential Unit overhauling:

dismantling
Before differential unit dismantlig, dismantle gear carrier
supports and remove the two half shafts as described
Fig 50. before.

Release and remove fixing screws securing brake disk to Release and remove screw securing diffe-rential-and
P.T.O. flange. Remove brake disk K Fig 51. ( T F-16). support assy, remove unit from axle case K Fig 53.
( T F-17).

Place and block suitably the unit and start stripping down.

F - 16 550/43477/1 F - 16
 Section F - Transmission
Axles
Storage and Service Instruction
Unlock and remove caps and support fixing screws K Fig
56. ( T F-17).

Fig 53.

Loosen the screws of the bevel gear K Fig 54. ( T F-17). Fig 56.

Remove lock pin of threaded ring, remove caps K Fig 57.

( T F-17).

Fig 54.

Lock differential unit upside down; mark caps to match

parts at re-assembling K Fig 55. ( T F-17). Fig 57.

Unscrew and remove deflection pin of bevel gear K Fig

58. ( T F-18).

Fig 55.

F - 17 550/43477/1 F - 17
 Section F - Transmission
Axles
Storage and Service Instruction

Fig 58.
Fig 60.
Note: Lift up differential from support, by a lifting tool with
proper capacity; at the same time, remove the bearing Undo nut and remove P.T.O. flange from pinion K Fig 60.
support by extraction screws K Fig 59. ( T F-18). ( T F-18).

Differential overhauling: Remove bevel pinion from differential sup-port, hammer

pinion shank by a proper tool,taking care not to damage
thread K Fig 61. ( T F-18)

Fig 59.
Fig 61.
Straighten notches on pinion nut, then posi-tion reaction
tool on P.T.O. flange to unlock pinion nutK Fig 59. Pry off seal from P.T.O. flange K Fig 62. ( T F-19).
( T F-18) .

F - 18 550/43477/1 F - 18
 Section F - Transmission
Axles
Storage and Service Instruction

Fig 62.

Remove outer races of outer and inner pinion bearings;

save shim for axial position of pinion K Fig 63. ( T F-19)
,K Fig 64. ( T F-19) and K Fig 65. ( T F-19).

Fig 65.

Remove the retaining pin and then replace the pinion head
bearing on the connecting frame K Fig 66. ( T F-19).

Fig 63.

Fig 66.

Front Axle Differential Unit Re-assembling -

Bevel pinion positioning

Prior re-assembling of bevel pinion on diffe-rentialsupport

Fig 64. it is necessary to record some dimensions to compute

F - 19 550/43477/1 F - 19
 Section F - Transmission
Axles
Storage and Service Instruction
hickness of spacer to be interposed between pinion under PR10: B 168.50 - 0.10 168.40 mm.
head bearing and shoulder on relevant differential seat.
Furthermore, measure pinion head height from bearing
Record dimension from ring gear axis to seating surface of seating face to outer edge and mark as H K Fig 68.
pinion under head bea-ring, it will be identified as A, to this ( T F-20):
end a cylinder is to be positioned on caps, then probe the
exact available space, now add differential bearing radius
K Fig 67. ( T F-20).

Fig 68.
PR12: H 82.00 mm
PR10: H 78.50 mm.

Measure and record dimension relevant to width of pinion

under head bearing asK Fig 69. ( T F-20)
Fig 67.
PR12 B.O.:
PR12: D = 37.00 mm
A= probed dimension +62.5 mm in our case:
PR10: D = 34.10 mm.
A= A = 162.6 + 62.5 = 225.1 mm

PR10 B.O.:
A= probed dimension +62.5 mm in our case:
A= 144.1 + 62.5 = 206.6 mm.

Each bevel pinion head face is marked with a number

having (±) sign.

Said number, expressed in millimetre tenth, shows

displacement from the theoretical dimension from pinion
under head to ring gear axis.

e.g.:-1 = 0.10 mm Fig 69.

Theoretical pinion dimension=184.00mm PR10: Determine shim S thickness for correct axial position of
theoretical pinion dimension = 168.50 mm Therefore, the bevel pinion
true dimension, identified as B, will be: B = theoretical
pinion dimension ± displacement, S=A-B-D

In our case In our case:

PR12:B 184.00 - 0.10 183.90 mm PR12: S = 225.1 - 183.9 - 37.00 4.2 mm

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 Section F - Transmission
Axles
Storage and Service Instruction

PR10: S = 206.6 - 168.4 - 34.1 4.1 mm.

Add 0.05 mm to theoretical computed thickness to

compensate the following bearing pre-load. K Fig 70.
( T F-21) Round up or down to the nearest tenth of
millimetre the computed thickness.

4.02 rounded down to 4 mm

3.88 rounded up to 3.9 mm.

Fit in the inner race of head pinion bearing and make three
caulking holder with ~ 120°.
Fig 71.

Insert adjustment shim for axial position of pinion. Its value

was computed previously; also, fit outer races of pinion
under head and shank bearings K Fig 72. ( T F-21).

Fig 72.

Fig 70. To avoid a complete differential assembly and, then, note

Fit in pinion shank inner race of under head bearing, heat
or press-in part by installer K Fig 71. ( T F-21).
an axial position error of pinion (and consequent
disassembly to resto-re dimension), it is advisable to
position pinion in its seat and the reference cylinder on
caps and measure said space, identified as E, K Fig 73.
( T F-22) that has to result

E = B - 62.5 - H

In our case:

E = 168.4 - 62.5 - 78.50 = 27.40 mm.

At this point, dimension E (as practically measured) has to

result 0.05 mm lower than the theoretical computation
because there is no bearing pre-load. On the contrary
thickness value has to be corrected as required.

F - 21 550/43477/1 F - 21
 Section F - Transmission
Axles
Storage and Service Instruction

Fig 75.
Fig 73.
– Position bevel pinion in its seat on differen-tial Re-assemble components and check correct bearing
support; preload, that has to correspond to a rotating torque (no
– Fit spacer and bearing pre-load shims, e.g. a shim of seal fitted) of 0.2 ÷ 0.4 daNm. As bearing pre-load has
– 1.5 mm; been determined, remove drive flange and fit lip seal in
relevant seat.
– Fit inner race of pinion shank bearing.
Re-mount flange and lock up definitively K Fig 76.
At this point, dimension E (as practically measured) ( T F-22)
has to result 0.05 mm lower than the theoretical
computation because there is no bearing pre-load.
On the contrary thickness value has to be corrected
as required K Fig 74. ( T F-22).

Fig 76.

Important: Mount differential assy on support. Insert

support while differential is lowered.
Fig 74.
Install caps, care not to reverse position and lock fixing
Mount drive flange on pinion, position proper reaction tool
screws of caps and support with a torque of 31.5 ÷ 34.5
and lock the nut with a torque of 57 ÷ 63 daNm.
daNm K Fig 77. ( T F-23).
Check by a dial gauge end play of pinion; then
disassemble and change adjustment shims to eliminate all
end play up to reach a pre-load K Fig 75. ( T F-22).

F - 22 550/43477/1 F - 22
 Section F - Transmission
Axles
Storage and Service Instruction
Position a dial gauge perpendicular than ring gear tooth
and check, with pinion steady, backlash that has to be of
0.18 ÷ 0.23 mm K Fig 80. ( T F-23).

Fig 77.

Check by a dial gauge end play of differen-tial unit. Screw

in a threaded ring so to have a notch aligned against spring
lock pin and actuate the opposite one up to K Fig 78.
( T F-23) eliminate end play.
Fig 80.

Otherwise rotate both ring nuts, by displa-cing them of the

same number of notches and nearing ring gear to pinion if
backlash is excessive, by moving away on the contrary
K Fig 81. ( T F-23).

Brush red lead on some ring gear tooth, rotate to mesh

pinion and ring gear repea-tedly, so to make evident tooth
contact. Proper and correct tooth contact marks are visible
on a new bevel gear set as a result of an optimum contact
approached on the tester, consequently, a proper axial
position of pinion against ring gear will emphasise
Fig 78. remarking of previous tester contact markings.

As such a condition has been reached, go on with bearing

pre-load by screwing in ring nut further one more notch
K Fig 79. ( T F-23).

Fig 81.

Fit spring pins locking threaded rings of diffe-rential unit

K Fig 82. ( T F-24).
Fig 79.

F - 23 550/43477/1 F - 23

Fig 82.
Lock fixing screws to bevel gear with a tor-que of 31.5 ÷
34.5 kgm K Fig 83. ( T F-24).
Fig 83.
Apply sealing compound on deflection pin of bevel gear,
screw in till bevel crown contact; unscrew with ~ 60° to
create the play reque-sted and fix the lock nut with screw
in position K Fig 84. ( T F-24).
F - 24 550/43477/1
Section F - Transmission
Axles
Storage and Service Instruction
Fig 84.
Perform the two securing notches on pinionnut. Clean
throughly contact surfaces, apply hard locking compound
and then install differen-tial unit on axle case. Lock the
connecting screws with a torque of21 ÷ 23 daNm K Fig 85.
( T F-24).
Fig 85.
Rear Axle Final Drive overhauling and
re- assembling
Refit wheel hub, fit wheel bearing outer races, make sure
of their proper seating; then position wheel bearing inner
race with roller cage prior press fitting lip seal.
Note: Smear Loctite 573 or equivalent sea-lant on outer
diameter surface.
Remove and replace O-Ring seals on piston K Fig 86.
( T F-25).
F - 24
 Section F - Transmission
Axles
Storage and Service Instruction
Press fully down and insert retaining screws.

Support suitably wheel hub while assembling parts to

prevent damage of seal; then go on by fitting wheel bearing
on hub spindleK Fig 89. ( T F-25).

Fig 86.

Insert ring gear support into ring gear, then assemble

spring ring retaining axle K Fig 87. ( T F-25).

Fig 89.

Insert piston full travel down on hub spindle .

Mount on hub spindle the complete ring gear unit K Fig

90. ( T F-25).

Fig 87.

Mount on pressure plate: return spring, retai-ning cup and

compression tool K Fig 88. ( T F-25).

Fig 90.

Insert into relevant holes the six pins that, for proper
operation of whole system, have to be of the same lenght
and, however, in accordance with relevant drawing K Fig
91. ( T F-26).

Fig 88.

F - 25 550/43477/1 F - 25

Fig 91.
Insert into relevant holes the six pins that, for proper
operation of whole system, have to be of the same lenght
and, however, in accordance with relevant drawing K Fig
92. ( T F-26).
Fig 92.
By proper wrench (Draw. 4903367) lock ring so to reach
the specified wheel bearing pre-load corresponding to a
rotation torque of 2.5 ÷ 3.5 daNm and a rope pull strength
on studs included between 13 and 16 Kg K Fig 93.
( T F-26).
Note: to prevent wrong torque recording, it is advisable to
set bearings, by various wheel revolutions, prior
performing the check.
F - 26 550/43477/1
Section F - Transmission
Axles
Storage and Service Instruction
Fig 93.
Insert ring nut locks: if slots aren’t aligned, tighten nut
furtherly up to reach proper posi-tion to allow insertion of
locks themselves; secure by lock ring, remove spring
compres-sion tool K Fig 94. ( T F-26).
Fig 94.
Arrange side gear carrier on blocks made of wood and
remove pins.
Save needle rollers of filling bearing casings. It is important
to keep needle rollers joined with relevant pin for
allowance question of pins themselves.
Remove side gears and relevant thrust washers; no gear
has to be removed prior all of them are free K Fig 95.
( T F-27).
Remove side gears and relevant thrust washers; no gear
has to be removed prior all of them are free.
F - 26
 Section F - Transmission
Axles
Storage and Service Instruction

Fig 95.

Arrange all the three side gears into relevant seats of side
gear carrier, position inner thru-st washers and align holes
K Fig 96. ( T F-27).

Fig 97.

Insert the complete pins, taking care to avoid any bump,

cause of needle rollers fall K Fig 98. ( T F-27).

Fig 96.

Mount on pins the two needle roller casings. Insert outer

thrust washers, grease lower half of pin (head side) and
position the first needle roller row, insert spacer and
position the second row K Fig 97. ( T F-27).
Fig 98.
Note: In case of needle roller replace-ment, use needle
rollers of the same selec-tion class for the two rows of each
side gear.

F - 27 550/43477/1 F - 27
 Section F - Transmission
Axles
Storage and Service Instruction

Computing of Brake Disk Pack of Rear Axle Final Drive

K Fig 99. ( T F-28)

Fig 99.

To assemble lug brake disks pack, it’s possible to use a
standard pack, that avoid to do the various measurings
and calculates.
The total pack of standard lug disks usually is 18 ÷ 0.25
mm. Then it’s possible to use :
4 lug disks of 4.5 mm or : 2 lug disks of 4 mm
2 lug disks of 5 mm.
However, it’s recommended to perform measurings and
following procedure.
Computing clearance for making up Brake Disk
Record distance from rest face of side gears carrier on
wheel hub to ring gear outer edge, identify this value as A
K Fig 100. ( T F-29).

F - 28 550/43477/1 F - 28
 Section F - Transmission
Axles
Storage and Service Instruction

Brake Disk Pack computing

To determine thickness of disk pack (disks and lug disks)
from previously computed value X, it is necessary to
deduct disk clea-rance (1 mm per each brake disk) and the
total thickness of brake disks, remaining space has to be
filled with disks provided with lugs on outer diameter and
having pro-per thickness with a tolerance of ± 0.25 mm.

A 137.8 mm
B 114 mm
C 75.9 mm
Fig 100. D 12 mm

Record distance from outer edge of ring gear to face of X=A-B-C+D

pressure plate, identify as B K Fig 101. ( T F-29).
X = 137.8 - 114 - 75.9 + 12 = 40.1 mm.

In our case we have four brake disks and deem advisable

a 4 mm clearance:

40.1 - 4 = 36.1 mm.

Brake disk thickness = 4.5 mm

4.5 x 4 18 mm
36.1 - 18 18.1 mm.

This is the space to be filled with disks provi-ded of lugs on

outer diameter K Fig 103. ( T F-30):
Fig 101.

Record distance from disks reaction face to outer edge of

side gears carrier, identify as C K Fig 102. ( T F-29).

Fig 102.

F - 29 550/43477/1 F - 29
 Section F - Transmission
Axles
Storage and Service Instruction

Fig 104.

Fig 103.

18.1 = 4.5 + 4.5 + 4.5 + 4.5

Four outer diameter lug disks 4.5 mm thick K Fig 104.

( T F-30) .

F - 30 550/43477/1 F - 30

Second system to determine lug
brake disks shim
K Fig 105. ( T F-31)
Fig 105.
This procedure has to be followed with disks carrier hub
K Fig 106. ( T F-32) (a) and relevant thrust washer (b)
K Fig 107. ( T F-32)assembled .
– Insert a brake disks pack-base, as step 182;
– Add two lug disks (c) of 4 mm K Fig 108. ( T F-32).
F - 31 550/43477/1
Section F - Transmission
Axles
Storage and Service Instruction
Note: These two disks (c) are requi-red to simulate brake
disks stroke and they have to be removed after determined
shim of the four lug disks.
– Mount gear carrier support (d), screw in the four
locking screws till to have the right parallelism
between hub and side gears car-riers support ;
– Test by thickness gauge in the two points with 180°;
e.g.:
– If dimension recorded is 4.30 mm, remove a lug disk
of 4.50 mm (from brake disks pack-base) and replace
with one of 4.25 mm ;
– If dimension recorded is 3.70 mm, remove a lug disk
of 4.00 mm (from brake disks pack-base) and replace
with one of 4.25 mm;
F - 31

Fig 106.
Insert wheel shaft on which sequentially mount: the thrust
washer, disks carrier hub, sun gear and lock ring; then
push all compo-nents fully down against hub spindle.
Fig 107.
Note: In case of inverting of brake disks posi-tions, the
reduction case gets damaged.
F - 32 550/43477/1
Section F - Transmission
Axles
Storage and Service Instruction
Fig 108.
Insert an inner lug brake disk, go on fitting alternatively an
outer lug disk and an inner lug disk up to complete the pack
assy.
From now AVOID to move back wheel shaft to prevent
dropping of inner brake disk from hub.
Insert an inner lug brake disk, go on fitting alternatively an
outer lug disk and an inner lug disk up to complete the pack
assy K Fig 109. ( T F-32).
Fig 109.
From now AVOID to move back wheel shaft to prevent
dropping of inner brake disk from hub.
F - 32
 Section F - Transmission
Axles
Storage and Service Instruction

Fig 112.
Fig 110.

Fit on O-Ring seal and mount the complete side carrier

assy.

Care to avoid removal of side gear locks while the whole

unit is fitting in.

Lock wheel hub screws with a torque of 6,1 ÷ 6,9 daNm.

Fig 113.

Fit wheel shaft check plate.

Fit O-Ring seal on outer side.

Mount side cover on final drive.

Fig 111. Smear locking screws with sealing compound,

Fit on O-Ring seal and mount the complete side carrier then lock with a torque of 3.3 ÷ 3.7 daNm.
assy.

Care to avoid removal of side gear locks while the whole

unit is fitting in.

Lock wheel hub screws with a torque of 6,1 ÷ 6,9 daNm.

F - 33 550/43477/1 F - 33
 Section F - Transmission
Axles
MAX-TRAC

MAX-TRAC
MAX-TRAC SECTION

1 Half case

2 Thrust washer of planetary gear

3 Planetary gear

4 Bevel thrust washer of side gear

5 Side gear

6 Half case
Fig 115.
7 Spider
Mark the two half-cases, the spider and open it K Fig
116. ( T F-34).

Fig 116.

Remove spider with the four side gears and relevant

thrust washers K Fig 117. ( T F-35)
Fig 114.

Release the bolts of the two half cases K Fig 115.

( T F-34).

F - 34 550/43477/1 F - 34
 Section F - Transmission
Axles
MAX-TRAC

Fig 117.
Fig 119.
Remove the planetary gears with relevant thrust
washers K Fig 118. ( T F-35).
Differential Unit overhauling : Re-assembling

Have a visual and dimensional check of wear on side

gears, planetary gears and relevant thrust washers and
spider and all components of differential group.

Replace, if necessary, the bearings with heating

equipment (120° C) or proper installer K Fig
120. ( T F-35).

Fig 118.

Should bevel gear set be renewed, release fixing

screws and remove ring gear K Fig 119. ( T F-35).

At re-assembling, screw in screws.

Note: Screws have to be locked after diffe-rential

assembling, see step 70 (page 43) for front differential and
step 164 (page 77) for rear differential.
Fig 120.

Re-assemble differential components in rele-vant seats

K Fig 121. ( T F-36).

F - 35 550/43477/1 F - 35
 Section F - Transmission
Axles
MAX-TRAC

6 Bevel thrust washer of side gear

7 Side gear
8 Half case
9 Spider

Should bevel gear set be renewed, undo bevel gear fixing

screws and remove.

Replace, if required, the bearings, by remo-ving them with

a puller and re-assemble them with an heating equipment
with 120° K Fig 122. ( T F-37).

Fig 121.

SUPER MAX-TRAC Differential disassembling,

overhauling and re-assembling

SUPER MAX-TRAC SECTION

1 Half case
2 Lug disks - q.ty 6
Available shims
for PR 12 Front Axle Differential
lug disk 3.00 mm
lug disk 3.10 mm
lug disk 3.20 mm
lug disk 3.30 mm
Available shims
for PR 10 Front Axle Differential
lug disk 2.50 mm
lug disk 2.60 mm
lug disk 2.70 mm
lug disk 2.80 mm
Available shims
for PR 12 / 10 Rear Axle Differential
lug disk 2.50 mm
lug disk 2.60 mm
lug disk 2.70 mm
lug disk 2.80 mm
3 Intermediate clutch disks - q.ty 4
4 Outer clutch disks - q.ty 2
5 Planetary gear

F - 36 550/43477/1 F - 36
 Section F - Transmission
Axles
MAX-TRAC

Fig 122.

F - 37 550/43477/1 F - 37
 Section F - Transmission
Axles
MAX-TRAC
Mark the two half cases, unscrew and remo-ve the screws Remove the planetary gear with relevant intermediate and
and open them K Fig 123. ( T F-38). shim disks and clutch disks, in half case on bevel gear side
K Fig 126. ( T F-38).

Fig 123.

Remove the planetary gear with relevant intermediate and Fig 126.
shim disks and clutch disks K Fig 124. ( T F-38) and
K Fig 125. ( T F-38). Remove spider with the four side gears and relevant bevel
thrust washers K Fig 127. ( T F-38).

Fig 124.
Fig 127.

Re-assembling
Before re-assembling, each smooth face have to be
lubricated with oil K Fig 128. ( T F-39).

– Insert a lug disk (a) (with outer lugs) into half case.
– Insert an intermediate disk (b) (with inner lugs), then
another disk (a), a disk (b), still lug disk (a).

Fig 125.

F - 38 550/43477/1 F - 38
 Section F - Transmission
Axles
MAX-TRAC
Note: Disks (b) are thin with lining on both faces, disk (c) – Position planetary gear.
is thick and lined on one face only. – Insert disk (c) with unlined face turned downward.
– Insert a lug disk (a).
– Insert a disk (c) with unlined face turned upward
– Insert in sequence a disk (b), a lug disk (a), a disk (b)
– Smear oil on planetary gear and insert taking care to
and a lug disk (a) K Fig 130. ( T F-39).
mesh shaft splines with inner lugs of clutch disks
K Fig 129. ( T F-39).

Fig 130.

Align in turn outer lugs of lug disks (a) K Fig

131. ( T F-39).
Fig 128.

Re-assemble side gears with relevant bevel thrust

washers on spider and position them on the half case
K Fig 130. ( T F-39).

Fig 131.

Mount the half case aligned against the lugs of lug disks,
taking care to align the referen-ce marked done before
disassembling; close the two half casings. Screw in fixing
screws and lock a torque of K Fig 132. ( T F-40):
Fig 129.

F - 39 550/43477/1 F - 39
 Section F - Transmission
Axles
MAX-TRAC

FRONT DIFFERENTIAL: 11.5 ÷ 12.5 kgm

REAR DIFFERENTIAL: 11.5 ÷ 12.5 kgm.

Fig 133.
Type Tubed 17.50×25-20 PR, Heat cut resistant
Max 5000 Kg. @58 PSI & 50 Kmph, 8250 Kg. @
Fig 132.
Load 83 PSI & 10 Kmph

CHECK Tyre Pressures

As assembling is done, play of each clutch pack have to be K Fig 134. ( T F-40)
included between 0.05 and 0.1 mm (as required for proper
operations of SUPER MAX-TRAC differential).
Front : 83 PSI
Check has to perform with 180° at the same time on both Rear 63 PSI
clutch packs to prevent that play between side gears and
spider would mislead reading.

Make sure of proper gear rotation.

If play value of clutches results different than specified one,

differential has to be disas-sembled again, rearrange
clutch pack again, select proper disk shims K Fig
133. ( T F-40).

Reassemble and check all over again.

Mount bevel gear and lock screws.

Note: Screws have to be locked after diffe-rential

assembling, see step 70 (page 43) for front differential and
step 164 (page 77) for rear differential.
Fig 134.

F - 40 550/43477/1 F - 40
 Section F - Transmission
Axles
TROUBLESHOOTING

TROUBLESHOOTING

FAULT CAUSE REMEDY

Oil leakage from final drive carrier Incorrect screws torque Check the torque.
Oil leakage from seals O-Ring damaged Replace O-Ring
Oil leakage from breather Incorrect installation Replace seals
Lubricant with excessive foam Seals damaged Replace seals
Oil leakage from brake gripper High oil level Check oil level
parking Incorrect lubricant • Replace the oil.
Seals damaged • Replace seals Kit.
Final drive noise Incorrect lubricant Replace the oil
Check oil level
Low oil level. Incorrect bearing adjustment Verify and adjust the bearing setting
Bearing damaged Verify and change the bearing
Gears damaged Verify and replace the gears.

Differential assy noise

Incorrect lubricant Replace the oil
Incorrect backlash Verify and adjust
Incorrect bearing preload Verify and adjust
Incorrect bevel pinion position Verify the pinion position
Side gears thrust washer Verify and replace.
damaged

F - 41 550/43477/1 F - 41
 Section F - Transmission
Axles
TROUBLESHOOTING

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F - 42 550/43477/1 F - 42
 Section F - Transmission
Transmission
Technical Data

Transmission

Technical Data

(ZF 4WG - 160 Powershift Transmission)

Table 2.
Pump Flow @ 2000 r.p.m. 80 l (17.6 UK gal, 21 US gal) 105 l (
System pressure 16+2 bar (232+29lb/in 2 )
Torque converter
input pressure (max) 9 bar (130 lb/in 2 ) 9
-output pressure (max) 3.5 bar (51 lb/in 2 )
output temperature (max)
-continuous 100°C (212 ° F)
-short duration 120°C (248°F)
Inductive transmitters (engine, turbine, central geartrain)
Resistance @ 20°C (68°F) 1050 ±105 ohms
Temperature range -40°C (-40°F) - 150°C (302°F)
Torque limit - securing bolts 30Nm (22lbf ft, 3 kgf m) 30Nm (22lbf ft, 3 kgf m)

Speed sensor output -40°C (-40°F) - 150°C (302°F)

Temperature range
Working range 2Hz - 5kHz
24V

Proportional valves in control valve

Resistance @ 20°C (68°F) 19 ±1.9 ohms
Current (mA) 100 - 500
Pressure range 0.8 - 8.3 bar (11.6 - 120lb/in 2)
Stall data
Engine idle 780 ±20 r.p.m.
Engine max no-load 2340±20 r.p.m.
Transmission 2200 r.p.m.
Hydraulic 2330 r.p.m
Combined - transmission/hydraulic 2180 r.p.m.

K Fig 135. ( T F-44)

F - 43 550/43477/1 F - 43
 Section F - Transmission
Transmission
Technical Data

Fig 135.

Table 3.
Key
1 Input drive plate
2 Torque converter
3 Converter bell housing
4 Breather
5 Cover - transmission case
6 Filter head
7 Filter
8 Parking brake caliper
9 Output drive flange/ brake disc to front axle
10 Magnetic oil drain plug
11 Output drive flange to rear axle
12 Transmission case
13 Lifting lugs
14 Hydraulic pump mounting
15 Electro- hydraulic control unit

F - 44 550/43477/1 F - 44
 Section F - Transmission

Transmission Fault Codes

Fault Codes

The Electronic Monitoring System (EMS) will display an

error code in the event of a fault developing in the
transmission system.

Table 4.
Fault Fault Detected Possible Causes Action
Code
12 Logical error at direction select Cable from shift lever to TCU is Check cables from TCU to shift lever.
signal broken.
Cable is defective and is contacted Check signal combinations of shift lever
to battery voltage or earth. F-N-R.
Shift lever is defective.
25 Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the sensor.
open circuit to transmission to battery voltage or earth.
sump temperature sensor input.
Cable has no connection to TCU. Check the connectors.
Temperature sensor has an Check the temperature sensor.
internal defect.
Connector pin is contacted to
battery voltage or is broken.
26 Short circuit to earth at Cable is defective and is contacted Check the cable from TCU to the sensor.
transmission sump temperature to vehicle earth.
sensor input.
Temperature sensor has an Check the connectors.
internal defect.
Connector pin is contacted to Check the temperature sensor.
vehicle earth.
27 Short circuit to battery voltage or Cable is defective and is contacted
open circuit at converter output to battery voltage.
temperature sensor input.
Cable has no connection to TCU. Check the cable from TCU to the sensor.
Temperature sensor has an Check the connectors.
internal defect.
Connector pin is contacted to Check the temperature sensor.
battery voltage or is broken.
28 Short circuit to earth at onverter Cable is defective and is contacted Check the cable from TCU to the sensor.
output temperature sensor nput. to vehicle earth.
Temperature sensor has an Check the connectors.
internal defect.

F - 45 550/43477/1 F - 45
 Section F - Transmission
Transmission Fault Codes
Fault Codes

Connector pin is contacted to Check the temperature sensor.

vehicle earth.
31 Short circuit battery voltage or Cable is defective and is contacted Check the cable from TCU to the sensor.
open circuit at engine speed to battery voltage.
input.
Cable has no connection to TCU. Check the connectors.
Connector pin is contacted to
battery voltage or is broken.
32 Short circuit to earth at engine Cable is defective and is contacted Check the cable from TCU to the sensor.
speed input. to vehicle earth.
Speed sensor has an internal Check the connectors.
defect.

33 Logical error at engine speed Cable/connector is defective and is Check the cable from TCU to the sensor.
input contacted to vehicle earth.
Speed sensor has an internal Check the speed sensor.
defect.
Sensor gap is the wrong size. Check the sensor gap.
35 Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the sensor.
open circuit at turbine speed to battery voltage.
input.
Check the connectors.
Short circuit to earth at turbine Cable/connector is defective and is Check the cable from TCU to the sensor.
speed input. contacted to vehicle earth.
Check the connectors.
Speed sensor has an internal Check the speed sensor.
defect.
36 Logical error at turbine speed Cable/connector is defective and is Check the cable from TCU to the sensor.
input. contacted to vehicle earth.
Speed sensor has an internal Check the speed sensor.
defect.
Sensor gap is the wrong size. Check the sensor gap.
37 Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the sensor.
open circuit at internal speed to battery voltage.
input.
Cable has no connection to TCU.
Speed sensor has an internal
defect.
Connector pin is contacted to
battery voltage or has no contact.
38 Short circuit to earth at internal Cable/connector is defective and is Check the cable from TCU to the sensor.
speed input. contacted to vehicle earth.
Speed sensor has an internal Check the connectors.
defect.

F - 46 550/43477/1 F - 46
 Section F - Transmission
Transmission Fault Codes
Fault Codes

Speed sensor has an internal Check the speed sensor.

defect.
39 Logical error at internal speed Cable/connector is defective and is Check the cable from TCU tothe sensor.
input. contacted to vehicle earth.
Speed sensor has an internal Check the connectors
defect.
Sensor gap is the wrong size. Check the speed sensor
3A Short circuit to battery voltage or Cable is defective and is contacted Check the cable from TCU to the sensor.
open circuit at output speed to battery voltage.
input.
Cable has no connection to TCU. Check the connectors.
Speed sensor has an internal Check the speed sensor.
defect.
Connector pin is contacted to Check the cable from TCU to the sensor.
battery voltage or has no contact.
3B Short circuit to earth at output Cable/connector is defective and is Check the connectors.
speed input. contacted to vehicle earth.
Speed sensor has an internal Check the speed sensor.
defect.
3C Logical error at output speed Cable/connector is defective and is Check the cable from TCU to the sensor.
input contacted to vehicle earth.
Speed sensor has an internal Check the connectors.
defect.
Sensor gap is the wrong size. Check the speed sensor.
Check the sensor gap
3E Output speed zero does not fit to Speed sensor has an internal Check the cable from TCU to the sensor.
other speed signals. defect.
Check the sensor signal of the output
speed sensor..
Check the sensor gap of the output speed
sensor.
54 EMS & ZF computer not Interference on CAN-Bus. Check cluster controller
communicating via the CAN-
Bus.
CAN wire/connector is broken. Check wire of CAN-Bus.
CAN wire/connector is defective Check cable to cluster controller.
and has contact with vehicle earth
or battery voltage.
71 Short circuit to battery voltage at Cable/connector is defective and is Check the cable from TCU to the gearbox.
clutch K1. contacted to battery voltage.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.

F - 47 550/43477/1 F - 47

72 Short circuit to earth at clutch K1 Cable/connector is defective and is Check the cable from TCU to the gearbox.
contacted to vehicle earth.
Regulator has an internal defect.
73 Open circuit at clutch K1. Cable/connector is defective and
has no contact to TCU
Regulator has an internal defect.
74 Short circuit to battery voltage at Cable/connector is defective and
clutch K2. has contact to battery voltage.
Cable/connector is defective and
has contact to another regulator
output of the TCU.
Regulator has an internal defect.
75 Short circuit to earth at clutch Cable/connector is defective and
K2. has contact to vehicle earth.
Regulator has an internal defect.
76 Open circuit at clutch K2. Cable/connector is defective and
has no contact to TCU.
Regulator has an internal defect.
77 Short circuit to battery voltage at Cable/connector is defective and
clutch K3. has contact to battery voltage.
Cable/connector is defective and
has contact to another regulator
output of the TCU.
Regulator has an internal defect.
F - 48 550/43477/1
Section F - Transmission
Transmission Fault Codes
Fault Codes
Check the internal wire harness of the
gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the regulator resistance..
Check the internal wire harness of the
gearbox
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
F - 48

78 Short circuit to earth at clutch Cable/connector is defective and is Check the cable from TCU to the gearbox.
K3. contacted to vehicle earth.
Regulator has an internal defect.
79 Regulator has an internal defect. Cable/connector is defective and
has no contact to TCU.
Regulator has an internal defect.
81 Short circuit to battery voltage at Cable/connector is defective and
clutch K4. has contact to battery voltage.
Cable/connector is defectiveand
has contact to another regulator
output of the TCU.
82 Short circuit to earth at clutch Regulator has an internal defect
K4.
Cable/connector is defective and is Check the connectors from TCU to the
contacted to vehicle earth.
Regulator has an internal defect.
83 Open circuit at clutch K4. Cable/connector is defective and
has no contact to TCU.
Regulator has an internal defect.
84 Short circuit to battery voltage at Cable/connector is defective and
clutch KV. has contact to battery voltage.
Cable/connector is defective and
has contact to another regulator
output of the TCU.
Regulator has an internal defect.
F - 49 550/43477/1
Section F - Transmission
Transmission Fault Codes
Fault Codes
Check the internal wire harness of the
gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
F - 49

85 Short circuit to earth at clutch Cable/connector is defective and is Check the cable from TCU to the gearbox
KV. contacted to vehicle earth.
Regulator has an internal defect.
86 Open circuit at clutch KV. Cable/connector is defective and
has no contact to TCU.
Regulator has an internal defect.
87 Short circuit to battery voltage at Cable/connector is defective and
clutch KR. has contact to battery voltage.
Cable/connector is defective and
has contact to another regulator
output of the TCU.
Regulator has an internal defect.
88 Short circuit to earth at clutch Cable/connector is defective and is Check the cable from TCU to the gearbox.
KR. contacted to vehicle earth.
Regulator has an internal defect.
89 Open circuit at clutch KR. Cable/connector is defective and
has no contact to TCU.
Regulator has an internal defect.
91 Short circuit to earth at the Cable is defective and is contacted Check the cable from TCU to the reverse
reverse warning alarm relay. to vehicle earth.
Reverse alarm device has an
internal defect.
Connector pin is connected to
vehicle earth.
F - 50 550/43477/1
Section F - Transmission
Transmission Fault Codes
Fault Codes
Check the internal wire harness of the
gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harnessof the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
Check the cable from TCU to the gearbox.
Check the connectors from TCU to the
gearbox.
Check the regulator resistance.
Check the internal wire harness of the
gearbox.
alarm device.
Check the connectors from reverse alarm
device to the TCU.
Check the resistance of the reverse alarm
device.
F - 50
 Section F - Transmission
Transmission Fault Codes
Fault Codes

92 Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the reverse
the alarm warning relay. to battery voltage. alarm device.
Reverse alarm device has an Check the connectors from reverse alarm
internal defect. device to the TCU.
Connector pin is connected to Check the resistance of the reverse alarm
battery voltage. device.
Open circuit at the reverse Cable is defective and has no Check the cable from TCU to the reverse
warning alarm relay. connection to the TCU. alarm device.
93 Reverse alarm device has an Check the connectors from reverse alarm
internal defect. device to the TCU.
Connector has no connection to Check the resistance of the reverse alarm
the TCU. device.
97 Short circuit to earth at park Cable is defective and is contacted Check the cable from TCU to the park
brake solenoid. to vehicle earth. brake solenoid.
Park brake solenoid has an internal Check the connectors from the park brake
defect. solenoid to the TCU.
Connector pin is connected to Check the resistance of the park brake
vehicle earth. solenoid.
Cable is defective and is contacted
to battery voltage.
98 Short circuit to battery voltage at Cable is defective and is contacted Check the cable from TCU to the park
park brake solenoid. to battery voltage. brake solenoid.
Park brake solenoid has an internal Check the connectors from the park brake
defect. solenoid to the TCU.
Connector pin is connected to Check the resistance of the park brake
battery voltage. solenoid.
99 Open circuit at park brake Cable is defective and has no Check the cable from TCU to the park
solenoid. connection to the TCU. brake solenoid.
Park brake solenoid has an internal Check the connectors from the park brake
defect. solenoid to the TCU.
Connector has no connection to Check the resistance of the park brake
the TCU. solenoid.
B1 Slippage at clutch K1. Low pressure at clutch K1. Check pressure at clutch K1.
Low main pressure Check main pressure in the system.
Wrong signal at internal speed Check sensor gap at internal speed
sensor. sensor.
Wrong signal at output speed Check sensor gap at output speed
sensor. sensor.
Wrong size of the sensor gap. Check signal at internal speed sensor.
Clutch is defective. Check signal at output speed sensor.
Replace clutch.
B2 Slippage at clutch K2. Low pressure at clutch K2. Check pressure at clutch K2.
Low main pressure. Check main pressure in the system.

F - 51 550/43477/1 F - 51

Wrong signal at internal speed
sensor.
Wrong signal at output speed
sensor.
Wrong size of the sensor gap.
Clutch is defective.
B3 Slippage at clutch K3.
Low pressure at clutch K3.
Low main pressure.
Wrong signal at internal speed
sensor.
Wrong signal at output speed
sensor.
Wrong size of the sensor gap.
B4 Slippage at clutch K4 Low pressure at clutch K4.
Low main pressure.
Wrong signal at internal speed
sensor.
Wrong signal at output speed
sensor.
Wrong size of the sensor gap.
Clutch is defective.
B5 Slippage at clutch KV. Low pressure at clutch KR.
Low main pressure.
Wrong signal at internal speed
sensor.
Wrong signal at turbine speed
sensor.
Wrong size of the sensor gap.
Clutch is defective.
Excessively hot sump. Measure temperature of oil in the
sump is above allowed maximum.
F - 52 550/43477/1
Section F - Transmission
Transmission Fault Codes
Fault Codes
Check sensor gap at internal speed
sensor.
Check sensor gap at output speed
sensor.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.
Check pressure at clutch K3.
Check main pressure in the system.
Check sensor gap at internal speed
sensor.
Check sensor gap at output speed
sensor.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.
Check pressure at clutch K4.
Check main pressure in the system.
Check sensor gap at internal speed
sensor.
Check sensor gap at output speed
sensor.
Check signal at internal speed sensor.
Check signal at output speed sensor.
Replace clutch.
Check pressure at clutch KR.
Check main pressure in the system.
Check sensor gap at internal speed
sensor.
Check sensor gap at turbine speed
sensor.
Check signal at internal speed sensor.
Check signal at turbine speed sensor.
Replace clutch.
Cool down machine.
Check oil level.
Check temperature sensor.
F - 52
 Section F - Transmission
Transmission Fault Codes
Fault Codes

B7 Excessively hot converter Measure temperature of the oil at Cool down machine.
output. the converter output is above
allowed maximum.
Check oil level.
Check temperature sensor.
Excessively hot converter Measure temperature of the oil at Cool down machine.
output. the converter output is above
allowed maximum.
Check oil level.
Check temperature sensor.
D1 Short circuit to battery voltage at The TCU measures more than 6V Check cables and connectors to sensors,
power supply for sensors. at the pin AU1 (5V sensor supply). which are supplied from AU1.
Check the power supply at the pin AU1
(should be approx.. 5V).
D2 Short circuit to earth at power The TCU measures less than 4V at Check cables and connectors to sensors,
supply for sensors. the pin AU1 (5V sensor supply). which are supplied from AU1.
Check the power supply at the pin AU1
(should be approx.. 5V).
D3 Low power at battery. Measured voltage at power supply Check power supply battery.
is less than 24V.
Check cables from batteries to TCU.
Check connectors from batteries to TCU.
D4 High power at battery Measured voltage at power supply Check power supply battery
is more than 24V.
Check cables from batteries to TCU.
Check connectors from batteries to TCU.
D5 Error at switch 1 for valve power Cable or connectors are defective Check fuse.
supply VPS1. and are contacted to battery
voltage.
Cable or connectors are defective Check cables from gearbox to TCU.
and are contacted to vehicle earth.
Permanent power supply KL30 Check connectors from gearbox to TCU.
missing.
Replace TCU.
D6 Error at switch 2 for valve power Cable or connectors are defective Check fuse.
supply VPS2. and are contacted to battery
voltage.
Cable or connectors are defective Check cables from gearbox to TCU.
and are contacted to vehicle earth.
Permanent power supply KL30 Check connectors from gearbox to TCU.
missing.
Replace TCU.

F - 53 550/43477/1 F - 53
 Section F - Transmission
Transmission Fault Codes
Fault Codes

E3 Short circuit to battery voltage at Cable or connectors are defective Check cables from TCU to the display.
display output. and are contacted to battery
voltage.
Check the connectors at the display.
Change display.
E4 Short circuit to earth at display Cable or connectors are defective Check cables from TCU to the display.
output. and are contacted to vehicle earth.
Display has an internal defect. Check the connectors at the display.
Change display.
F1 General EEPROM fault. TCU is defective. Replace TCU
F2 Configuration lost. Interference during saving data on Reprogramme the correct configuration
non volatile memory. for the vehicle (eg. with cluster controller).

F3 Application error. Something in the application is Replace TCU.

wrong.
F5 Clutch failure. One of the AEB values is out of Check clutch.
limit.
F6 Clutch adjustment data lost. Interference during saving data on Execute AEB.
non volatile memory.
TCU is brand new or from another
vehicle.

F - 54 550/43477/1 F - 54
 Section F - Transmission
Transmission Fault Codes
Fault Codes

Propshafts
Removing and Replacing

When Removing

Before removing propshafts always mark both companion

flanges and also mark the sliding joints prior to removal
K Fig 136. ( T F-55).

When Replacing

Upon reassembly, after lubricating sliding joints with JCB P

Grease, align the shafts against identification marks

previously made or, in the case of a shaft being renewed,
use the manufacturer’s alignment markings.

Apply JCB Lock and Seal to threads of all flange bolts.

Retaining straps B stretch with use, therefore these straps

must always be replaced with new ones. Fig 137.

Torque Settings

Item Nm kgf m lbf ft

A 75 - 85 7.7 - 8.7 55 - 63

Note: The rear propshaft is secured at the gearbox end by

flange bolts and nuts. These should be tightened to a
torque of 118 Nm (12 kgf m, 87 lbf ft).

Fig 136.

The propshafts must have both ends exactly on the same

plane as shown at X. The yokes must not be at right angles
as at Y or at an intermediate angle as at Z K Fig
137. ( T F-55).

F - 55 550/43477/1 F - 55
 Section F - Transmission
Transmission Fault Codes
Display Panel

Display Panel
Warning Lights Rear Work Lights On
Lights up when the rear work lights
Visual Warning Only are switched on.

Direction Indicators
Left or Right flashes with the
direction indicators. Both flash when
Hazard Warning Lights are on. Use Rear Fog Light On
the indicators to signal before Lights up when the rear fog light is
turning. switched on.

Hazard Warning
Flashes with the hazard warning
lights (even with the starter switch at
O). Switch the flashers on whenever
your machine is a possible hazard. Emergency Steer Pump
Lights up when the emergency
steering system is operating. ie.
Side Lights On When the machine is moving.
Lights up when the side lights are
switched on.

Parking Brake Engaged

Lights up when the parking brake is
engaged.
Main Beam On
Lights up when the headlight main
beams are switched on. Switch the
main beams off for on-coming
vehicles.

Battery Voltage Low

Dip Beam On
Lights up when the battery voltage is
Lights up when the headlight dipped low. “BATTERY LOW”
lights are switched on.

No Charge
Operates when the battery charging
Front Work Lights On
circuit fails while the engine is
Lights up when the front work lights running. The light should go out a
are switched on. few seconds after the engine is
started. “ALTERNATOR”
Engine Oil Pressure Low

F - 56 550/43477/1 F - 56
 Section F - Transmission
Transmission Fault Codes
Display Panel

Operates if the engine oil pressure Operates if the engine coolant

drops too far. The light should go out temperature rises too high.
when the engine is started. “ENG “COOLANT TEMP”
OIL PRESS”

Brake System Pressure Low

Air Filter Blocked
Lights up when the brake system
pressure is low. “BRAKE FAILURE” Operates if the engine air filter clogs
up. “AIR FLTER BLKD

Transmission Oil Pressure Low

Operates if the transmission oil
pressure drops too far. The light
should go out when the engine is
started. “TRANS OIL PRESS”

Note: Transmission Oil Pressure Low is

not applicable from Ser. No. 533692
Main Steer System (If fitted)
Lights up if the main hydraulic
system pressure fails. Stop the
machine as soon as it is safe to do
so and rectify the fault. “STEERING
PRESS”

Hydraulic Fluid Temperature High

Operates if the hydraulic fluid
temperature rises too high. “HYD
OIL TEMP”

Transmission Oil Temperature

High
Operates if the transmission oil
temperature rises too high. “TRANS
OIL TEMP”

Water Temperature High

F - 57 550/43477/1 F - 57
 Section F - Transmission
Transmission Fault Codes
Display Panel

Page left intentionally blank

F - 58 550/43477/1 F - 58
 Section F - Transmission
Transmission
Technical Data

Transmission

Technical Data

(ZF 4WG - 160 Powershift Transmission)

Table 5.
Pump Flow @ 2000 r.p.m. 80 l (17.6 UK gal, 21 US gal) 105 l (
System pressure 16+2 bar (232+29lb/in 2 )
Torque converter
input pressure (max) 9 bar (130 lb/in 2 ) 9
-output pressure (max) 3.5 bar (51 lb/in 2 )
output temperature (max)
-continuous 100°C (212 ° F)
-short duration 120°C (248°F)
Inductive transmitters (engine, turbine, central geartrain)
Resistance @ 20°C (68°F) 1050 ±105 ohms
Temperature range -40°C (-40°F) - 150°C (302°F)
Torque limit - securing bolts 30Nm (22lbf ft, 3 kgf m) 30Nm (22lbf ft, 3 kgf m)

Speed sensor output -40°C (-40°F) - 150°C (302°F)

Temperature range
Working range 2Hz - 5kHz
24V

Proportional valves in control valve

Resistance @ 20°C (68°F) 19 ±1.9 ohms
Current (mA) 100 - 500
Pressure range 0.8 - 8.3 bar (11.6 - 120lb/in 2)
Stall data
Engine idle 780 ±20 r.p.m.
Engine max no-load 2340±20 r.p.m.
Transmission 2200 r.p.m.
Hydraulic 2330 r.p.m
Combined - transmission/hydraulic 2180 r.p.m.

K Fig 138. ( T F-60)

F - 59 550/43477/1 F - 59
 Section F - Transmission
Transmission
Technical Data

Fig 138.

Table 6.
Key
1 Input drive plate
2 Torque converter
3 Converter bell housing
4 Breather
5 Cover - transmission case
6 Filter head
7 Filter
8 Parking brake caliper
9 Output drive flange/ brake disc to front axle
10 Magnetic oil drain plug
11 Output drive flange to rear axle
12 Transmission case
13 Lifting lugs
14 Hydraulic pump mounting
15 Electro- hydraulic control unit

F - 60 550/43477/1 F - 60
Section G

Brakes
Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering

Publication No.
550/43477/1

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section G - Brakes

Notes:

G-0 550/43477/1 G-0

 Section G - Brakes

Contents Page No.

Brake
Brake Circuits, Valves and Pedals ............................................................ G-1
Removal and Replacement .................................................................. G-1
Brake Valve .......................................................................................... G-2
Parking Brake ........................................................................................... G-6
Adjusting the Cable Slack .................................................................... G-6
Renewing the Brake Pads .................................................................... G-8
Testing the Parking Brake .................................................................... G-9
Parking Brake Transmission Disconnect .............................................. G-9
Charging the Accumulators ................................................................ G-10
Charging the Accumulators ................................................................ G-11
Brake System ..................................................................................... G-12

Brake
Technical Data ........................................................................................ G-15
Service Brake ..................................................................................... G-15

G-i G-i
 Section G - Brakes
Brake
Brake Circuits, Valves and Pedals

Brake
Brake Circuits, Valves and Pedals
Removal and Replacement 2 When connecting the foot pedal linkage, adjust clevis
3 to take up any slack in the valve push rod.
Note: The articulation lock must be fitted before any
maintenance is done on the machine. This will prevent Note: If there are two holes in the brake pedal lever,
anyone getting crushed between the two parts of the connect the valve push rod to the upper hole.
chassis.
3 After refitting the valve, start the engine and wait for a
Removal few minutes until the accumulators are charged.
Bleed the service brakes as described in Bleeding the
1 Park the machine on firm, level ground. Apply the Brakes.
parking brake and stop the engine. Securely chock all
four wheels. Repeatedly apply and release the
service brakes and parking brake until all the
pressure in the accumulators is exhausted.

!MWARNING
Before disconnecting any part of the brake hydraulic
system, make sure that engine is switched off and
hydraulic pressure is fully discharged.
BRAK-3-1

!MWARNING
A minimum of 10 applications of the service brake is
possible from the stored accumulator pressure.
Disconnect service brake accumulator hoses with
extreme caution.
BRAK-3-2

2 Disconnect and blank all hydraulic hoses having first

identified them to ensure correct replacement.
Fig 1.
3 Identify then unplug the electrical connections from
the three pressure switches.

4 Remove the clip 1 from the foot brake push rod

assembly.

5 Remove cap screws 2 and remove the valve from the

bracket K Fig 1. ( T G-1).

Replacement
1 Refit the valve by reversing the removal sequence.

G-1 550/43477/1 G-1

 Section G - Brakes
Brake
Brake Circuits, Valves and Pedals

Brake Valve
Dismantling and Assembly
The valve may only be dismantled to renew seals. If any
other part fails the complete valve must be renewed.

Remove only sufficient components to gain access to the

seals. DO NOT dismantle further.

Two repair kits are available: one consists of all the seals
and the other is a repair kit for the brake linkages and
includes the necessary rubber gaiters.

Key
K Fig 2. ( T G-3)

Table 1.
1 Brake valve
2 Foot brake push rod assembly
3 Brake light switch
4 Transmission dump switch
5 Accumulator inlet adaptors (2 off)
6 Low pressure warning switch
7 Pilot valve adjuster
8 90° Adaptor (return to tank)
9 Tee adaptors (brake supply)
10 Adaptor (Pressure from pump)
11 Adaptor (Return to tank via loader valve)
12 Straight adaptors (2 off)
13 Seal washer (4 off)
14 Seal washer (M18)
15 Seal washer (5 off)
16 Adaptor (Return to tank)

G-2 550/43477/1 G-2

 Section G - Brakes
Brake
Brake Circuits, Valves and Pedals

Fig 2.

Brake Pressure Setting anyone getting crushed between the two parts of the
chassis.
Note: Use the following procedure to test and set the brake
pressure if the heat shrink sleeving A, B has been removed
K Fig 3. ( T G-4).

Note: The articulation lock must be fitted before any

maintenance is done on the machine. This will prevent

G-3 550/43477/1 G-3

 Section G - Brakes
Brake
Brake Circuits, Valves and Pedals

!MWARNING !MWARNING
Before disconnecting any part of the brake hydraulic A minimum of 10 applications of the service brake is
system, make sure that engine is switched off and possible from the stored accumulator pressure.
hydraulic pressure is fully discharged. Disconnect service brake accumulator hoses with
BRAK-3-1 extreme caution.
BRAK-3-2

Fig 3.

Adjusting the Parking Brake Note: If after completing the above steps, the parking
brake does not pass the testing procedure. See Adjusting
1 Disengage the parking brake (lever horizontal). the Cable Slack.

2 Turn adjuster X clockwise, half a turn K Fig

4. ( T G-5) and K Fig 5. ( T G-5).

3 Test the parking brake. See Testing the Parking

Brake

4 If the brake fails the test, repeat steps 1 to 3.

G-4 550/43477/1 G-4

 Section G - Brakes
Brake
Brake Circuits, Valves and Pedals

Fig 4.

Fig 5.

G-5 550/43477/1 G-5


Parking Brake
Adjusting the Cable Slack
1 Parking brake lever without safety catch (Fig. 1) Turn
adjuster X K Fig 6. ( T G-6) anti-clockwise to return
pin Y to the bottom of the slot.
Fig 6.
2 Parking brake lever with safety catch (Fig. 2) Turn
adjuster X anti-clockwise to return pin Y to the bottom
of the slot. Make sure that the lever is fully down
against its stop at Z K Fig 7. ( T G-6).
Fig 7.
3 Loosen locknut A and remove pin B (at either end of
the cable).
4 Screw in the clevis C only enough to remove the
cable slack.
G-6 550/43477/1
Section G - Brakes
Brake
Parking Brake
5 Refit pin B and tighten locknut A to 27 Nm (19.9 lbf ft).
5 Test the parking brake, see Testing the Parking
Brake page G/6-2.
6 If the brake fails the test, repeat steps 1 to 4.
Note: If the brake cannot be adjusted by adjusting the
cable slack, replace the brake pads and/or the brake
cable.
Note: Operating arm D has three machined holed to
accommodate pin B. It is MOST IMPORTANT that pin B is
fitted ONLY to the CENTRE HOLE.
Note: If the operating arm securing bolt E has to be
removed it is MOST IMPORTANT that prior to removing
the operating arm D its position on its splined shaft is
carefully marked.
The arm MUST be refitted in its ORIGINAL POSITION.
Under NO CIRCUMSTANCES must the arm’s position in
relation to its shaft be altered in an attempt to gain
additional movement, as this could cause damage to or
failure of the parking brake K Fig 8. ( T G-6).
Fig 8.
G-6
 Section G - Brakes
Brake
Parking Brake

Fig 9.

G-7 550/43477/1 G-7


Renewing the Brake Pads
Renew pads when thickness of friction material is 1mm
(0.039 in).
1 Release brake and disconnect actuator from brake
lever.
2 Slacken one and remove the other brake mounting
bolt 1, washer 2 and nut 3 position brake to expose
brake pads.
3 Use flat bladed screw driver to remove pads 4 and 5.
Note: Take care when removing pad from the plastic
actuator cover.
4 Place pads in position.
Note: Centre hole in lever side pad snaps over tabs on
actuator cover. Align pad with flat on rotor cover B. If tabs
are broken dab pad adhesive on the back edge of the pad
and press firmly into correct position.
5 Remove pad adhesive from pad compartment in pad
carrier plate A.
6 Apply adhesive along back edge of pad carrier plate
and press into place.
7 Push lever side pad as far as possible into the brake.
8 Position brake over disc, fit mounting bolt 1, washer 2
and nut 3 and torque both bolts to 119Nm (140 lb ft)>
9 Attach cable to lever.
9 Adjust pad gap.
Dismantling
1 Disconnect actuator cable and remove brake
2 Remove friction pads 27-4 and 27-5.
Note: Before dismantling, mark the relative position of the
lever 10 to the shaft. The lever MUST be refitted in the
same position.
3 Unbend anti-rotation clip 27-12, remove screw 27-13,
clip 27-12, washer 27-11, lever 27-10 and spring 27-
14.
G-8 550/43477/1
Section G - Brakes
Brake
Parking Brake
4 Push out rotor assembly 27-6 from casting 27-9.
5 Remove 3 ball bearings 27-8.
6 Only if shaft seal 27-15 requires replacement. Press
out plastic shaft seal from casting using steel spacer
7 Remove any plastic left in casting.
Note: Before assembly insure all parts are clean and
serviceable.
Assembly
1 Insert seal 27-15 into casting with extended smooth
surface first. Using an arbor press with protective
spacer block, gently press seal until it snaps into
groove.
2 Grease ball pockets in casting 27-9, shaft and ball
pockets of the rotor assembly 27-6.
3 Insert 3 ball bearings 27-8 and ball spacer 27-7 into
the pockets in the casting 27-9.
4 From the inside of the casting 27-9, slide the shaft of
the rotor assembly 27-6 through the shaft seal 27-15
and seat ball pockets against the ball bearings 27-8.
5 Place the spring 27-14 over the large diameter pilot
on the outside of the casting 27-9.
6 Install lever 27-10 making sure the small diameter of
the spring 27-14 is piloted on the outside of the four
pins in the lever.
7 Set the lever 27-10 in the 4 o’clock position.
8 Install washer 27-11 and anti rotation clip 27-12, with
its tab inserted into the lower hole in the lever.
9 Insert screw 27-13 into rotor assembly shaft 27-6 and
tighten to 12.4-15.8 Nm [110-140 in.lbs.], while
guiding lever 27-10 over rotor assembly spine.
10 Bend up tab on the anti-rotation clip 27-12.
11 Install the friction pads 27-4 and 27-5.
12 Stroke lever 27-10 in the correct direction. The lever
must rotate through 60 degrees of rotation. Return
lever to 4 o’clock position and make sure the lever
side friction pad 27-5, is fully returned.
G-8
 Section G - Brakes
Brake
Parking Brake
c Reduce the engine speed to idle and set the
Testing the Parking Brake
forward/ reverse lever (or switch) to neutral.

!MWARNING d Do not do this test for longer than 20 seconds.

Before testing the park brake make sure the area
around the machine is clear of people.
2-2-4-5
Test the brake on a level, dry surface. Make sure your seat
belt is securely fastened.
1 The attachment should be in the travelling position
e Press SETUP key again to select park brake test
off.
f Lower attachment and stop the engine.
Note: If the machine moved during the test, see Adjusting
the Parking Brake. Do not use the machine with faulty
brakes.

2 Make sure the parking brake is fully engaged If you have any queries concerning this test procedure or
parking brake adjustment, consult your local JCB dealer.
3 Switch off transmission dump

4 Switch off Auto/Manual switch !MWARNING

Non approved modifications to drive ratios, machine
a On the EMS press the two arrow keys and the
weight or wheel and tyre sizes may adversely affect
SETUP key at the same time, to select the AEB
the performance of the park brake.
setup menu.
3-2-3-11

b Use the UP or DOWN arrows to select the park

brake test menu. Parking Brake Transmission Disconnect

c Press SETUP key to select park brake test on. When fully engaged, the parking brake electrically
disconnects the transmission drive; this prevents the
a Select third gear/range (3). machine from being driven with the parking brake on.

b Push down hard on the brake pedal and select

forward drive.

Note: An audible alarm will sound and a warning light will

show when the parking brake is engaged with the machine
in forward (F) drive. The alarm will stop when neutral (N)
drive is selected.

!MWARNING
If the machine starts to move during the following test,
immediately apply the foot brake and reduce the
engine speed.
2-2-5-1

a Release the brake pedal.

b If the machine has not moved, use the accelerator

pedal to gradually increase the engine speed to
1500rpm. The machine should not move.

G-9 550/43477/1 G-9


Charging the Accumulators
Charging the Accumulators
Note: The articulation lock must be fitted before any
maintenance is done on the machine. This will prevent
anyone getting crushed between the two parts of the
chassis.
1 Park the machine on level ground, lower the loader
arm, switch off the engine and chock all four wheels.
Release all hydraulic pressure in the accumulators by
repeatedly applying the foot brakes (engine stopped).
Fig 10.
5 Close vent valve C then press down and turn tee
handle D K Fig 10. ( T G-10) anticlockwise to
unscrew the accumulator plug.
6 Slowly release hand valve B on the nitrogen bottle
until the pressure gauge reading rises to the required
charge pressure, (see Technical Data) then close
the hand valve.
G - 10 550/43477/1
Section G - Brakes
Brake
Parking Brake
2 Connect charging tool A892/00239 (see Service
Tools) to a bottle of compressed nitrogen gas using
hand valve B.
Note: If the machine is fitted with Piston Type
Accumulators, service kit 892/00948 will be required to
connect to the accumulator charge point.
3 Using an Allen key, “crack” open the plug of the
accumulator being charged to allow later removal.
Note: DO NOT unscrew the accumulator plug at this stage
as any gas within the accumulator will be released.
4 Fit the charging tool to the accumulator and fully
tighten the retaining nut.
7 Press down and turn tee handle D clockwise to
tighten the accumulator plug.
8 Open vent valve C to release pressure in the hose,
then remove the tool from the accumulator.
9 Fully tighten the accumulator plug.
10 Repeat steps 2 - 9 for subsequent accumulators.
G - 10

Charging the Accumulators
K Fig 11. ( T G-11)
System Testing
!MWARNING
Before working on the brake system make sure the
machine is on level ground and chock all four wheels.
BRAK-1-4
Note: The articulation lock must be fitted before any
maintenance is done on the machine. This will prevent
anyone getting crushed between the two parts of the
chassis.
!MWARNING
Before disconnecting any part of the brake hydraulic
system, make sure that engine is switched off and
hydraulic pressure is fully discharged.
BRAK-3-1
Fig 11.
1 Switch off the engine and operate the brake pedal
repeatedly to make sure that all hydraulic pressure
stored in the accumulators is discharged.
G - 11 550/43477/1
Section G - Brakes
Brake
Parking Brake
2 Disconnect one of the service brake accumulator
hoses from the brake valve. Make up an adaptor to
connect Pressure Test Gauge Kit 892/00253
between the valve and the accumulator hose.
3 Switch on the engine and check the gauge reading
which should rise to the Pressure Regulator Cut-out
Pressure. (See Technical Data.) Operate the service
brake pedal repeatedly with the engine running and
check that the gauge reading does not fall below the
Pressure Regulator Cut-in Pressure. (See Technical
Data.)
4 Switch on the engine and check the gauge reading
which should rise to the Pressure Regulator Cut-out
Pressure. (See Technical Data.) Operate the service
brake pedal repeatedly with the engine running and
check that the gauge reading does not fall below the
Pressure Regulator Cut-in Pressure. (See Technical
Data.)
Stop the engine and operate the service brake pedal
a few times. The accumulator pressure should fall
only slightly with each brake application. If the
pressure falls drastically, it is likely that the
accumulators need recharging with nitrogen gas.
Repeat this test for the other brake circuit.
Note: The pressure differential cannot be adjusted
Testing the System Pressure (Remote
Test Point)
1 Switch off the engine and operate the brake pedal
repeatedly to make sure that all hydraulic pressure
stored in the accumulators is discharged.
2 Connect Pressure Test Gauge Kit 892/00253 to the
remote test point beneath the engine cover.
3 Switch on the engine and check the gauge reading
which should rise to the Pressure Regulator Cut-Out
pressure. (See Technical Data) As soon as this
pressure is reached, the gauge reading will fall to
zero. Record the maximum pressure obtained.
Note: Provided there are no leaks on the system and the
brake pedal is not applied the gauge reading will remain at
zero. Once the system’s maximum pressure has been
G - 11
 Section G - Brakes
Brake
Parking Brake
obtained the pressure regulator valve will discharge the
pump pressure back to the tank.

The charged lines between the brake valve and the

accumulators will still be at full charge pressure.
Before attempting to disconnect any part of the brake
system, make sure the engine is switched off and all
the hydraulic pressure is discharged by repeatedly
pressing the brake pedal.

Brake System
4 Operate the brake pedal a number of times to use the
pressure stored at the accumulators, until the
pressure has dropped sufficiently for the regulator
valve to cut in K Fig 12. ( T G-12).

5 As the valve cuts in the pressure reading on the

gauge will jump to show the retained system
pressure. Record this pressure.The pressure will
continue to rise until the maximum pressure is
obtained, at which point, the reading on the gauge will
Fig 12.
again fall to zero as the regulator valve cuts out.

Note: The pressure reading at step 5 will be the Pressure
Regulator Cut-in pressure. It must not be lower than the
minimum figure given in Technical Data.
Note: The pressure differential cannot be adjusted
Note: This method of testing the system will not show the
actual pressure drop per application of the brake. If you
suspect the depletion of the systems pressure is too rapid,
carry out the Testing the System Pressure (Stored
Accumulator Pressure) procedure.
Brake System
!MWARNING
Before working on the brake system make sure the
machine is on level ground and chock all four wheels.
BRAK-1-4
Note: The articulation lock must be fitted before any
maintenance is done on the machine. This will prevent
anyone getting crushed between the two parts of the
chassis.

!MWARNING
Before disconnecting any part of the brake hydraulic
system, make sure that engine is switched off and
hydraulic pressure is fully discharged.
BRAK-3-1

KEY:

A Brake Test Point

B Hydraulic Engine Fan Test Point
C Low Pressure Switch

G - 12 550/43477/1 G - 12

Fig 13.
Testing the System Pressure
1 Switch off the engine and operate the brake pedal
repeatedly to make sure that all the hydraulic
pressure stored in the accumulators is discharged.
2 Connect a 400 bar test gauge to the test point A on
the combined engine driven gear pump and charge
valve K Fig 13. ( T G-13).
3 Switch on the engine and check that the gauge
reading rises to the Charge Valve Cut-out Pressure.
(See Technical Data.)
4 With the engine running and the maximum charge
pressure obtained, repeatedly operate the brake
pedal. Check that the pressure is recharged to its
maximum pressure as each stoke of the brake pedal
is applied.
Note: There is no noticeable successive reduction in the
system pressure (with each stoke of the brake pedal)
untilthe Cut-in pressure is reached. The system will start to
recharge after the first full stroke of the pedal.
5 Fully charge the system
6 Switch off the engine. Switch the ignition ON. Slowly
and repeatedly operate the brake pedal (apply full
pedal stokes) until the low brake pressure warning
lamp illuminates. Check the pressure reading on the
gauge. (See Technical Data for Low Pressure Switch
perating Pressure)
G - 13 550/43477/1
Section G - Brakes
Brake
Parking Brake
7 Continue to operate the brake pedal until the
pressure drop-off point is reached.There must be a
Minimum of 5 Full Pressure Strokes Before the
pressure drop off point is reached.
Note: As the brake pedal is repeatedly applied (engine
switched OFF) the stored accumulator pressure is
gradually depleted At a pressure normally below 80 bar,
the stored pressure will be exhausted. At this point the
pressure gauge reading will fall to zero.
Note: The system charge pressures (cut-in, cut-out
pressures) are pre-set and non-adjustable. If the
pressures are found to be outside the given parameters,
the charge valve will need to be replaced.
Note: If you suspect the pressure depletion per full stoke
of the brake pedal is excessive, or the minimum number of
strokes before drop-off are not obtained, check the
accumulator charge pressures and where necessary
correct, (See Charging the Accumulators) before retesting
the brake system.
!MWARNING
Before proceeding with the bleeding procedure it is
important to ensure that the park brake is engaged and
that one pair of wheels is blocked on both sides.
BRAK-1-2
Note: The braking systems are fed from the main hydraulic
system and incorporate brake accumulators. These allow
approximately nine applications of the brakes with the
engine stopped.
Bleed each axle separately as follows:
Attach a tube to the brake bleed screw, located near the
axle centre. Ensure that the free end of the tube is
immersed in fluid contained in a suitable container.
Open the brake bleed screw and fully depress the brake
pedal. Hold the pedal fully depressed until air free fluid flow
from the bleed screw.
Close the brake bleed screw with the pedal fully
depressed.
Repeat the procedure for the rear axle.
Check the hydraulic fluid level.
G - 13
 Section G - Brakes
Brake
Parking Brake

Page left intentionally blank

G - 14 550/43477/1 G - 14
 Section G - Brakes

Brake
Technical Data
Service Brake
Table 2.
Type Oil-Immersed Multi-Plate Disc Actuation
Actuation Dual Circuit, Full Hydraulic with compact
valve and pressure accumulators
Location Front and Rear Axle (4 plates per hub)

Control Valve Type

K Fig 14. ( T G-16)

Table 3.
Pressure Regulator Setting
Cut-in Pressure 164 bar 2378 lbf/in 2
Cut-out Pressure 200 bar 2900 lbf/in 2
Maximum Pressure Differential 36 bar 522 lbf/in²
Service Brake Operating 65 - 70 1015 lbf/in 2
Pressure bar
Pressure Switch Operating 105 bar 1523 lbf/in 2
Pressure
Low Pressure Waring on

Accumulator
Capacity (per circuit) 0.75 litre 1.3 pint
Number (fitted) 2
Accumulator Gas Nitrogen
Pre-charge 57 bar 826 lbf/in 2

Parking Brake
Type Manually adjusted
disc, cable operated
Location Front face of
transmission

G - 15 550/43477/1 G - 15
 Section G - Brakes
Brake
Technical Data

Fig 14.

Component Key

Table 4.
1 Suction Strainer
2 Engine Driven Gear Pump
3 Brake Valve
4 Accumulators
5 Front Axle Brakes
6 Rear Axle Brakes
7 Oil Cooler
8 Return Filter/Diffuser
9 Filler Breather

G - 16 550/43477/1 G - 16
Section H

Steering
Service Manual - WLS 432ZX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body and Framework
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering

Publication No.
550/43477/1

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section H - Steering

Notes:

H-0 550/43477/1 H-0

 Section H - Steering

Contents Page No.

Hydraulic Steering
Technical Data .......................................................................................... H-1
Pump .................................................................................................... H-1
Steering Valve ...................................................................................... H-1
Steering Valve - Operation ................................................................... H-1
Tools ..................................................................................................... H-6
Dismantling ........................................................................................... H-7
Dismantling the Pressure Relief Valve (Cartridge) for OSPC LS / OSPC
LSR .................................................................................................... H-13
Assembling ......................................................................................... H-15
Assembling spool and sleeve. ............................................................ H-15
Assembling ......................................................................................... H-16
Assembly pattern for standard bearing ............................................... H-17
Installation Instruction for Lip Seal ..................................................... H-19
Assambly of the Shock Valves ........................................................... H-24

H-i H-i
 Section H - Steering

Hydraulic Steering
Technical Data
Pump A gear box driven emergency steer pump provides
pressure for steering in the event of hydraulic pump or
Supply from hydraulic system. Refer to Section E. engine failure. Instructions for removal and refitting of this
pump are given in Section F (Transmission).
Steering Valve
Steering Valve - Operation
K Table 1. ( T H-1)
Fitted as an extension of the steering column, the steering
Table 1. valve SV comprises a housing SV1 incorporating a sleeve
Type Saver Danfoss SV2 that contains a spool SV3. Attached beneath the
housing is a metering unit SV4. Within the metering unit is
a lobed rotor SV5 that is attached to the spool and driven
Relief valve operating Pressure by it inside a stator SV6 formed by the unit casing K Fig
1. ( T H-2).
K Table 2. ( T H-1)
Pressure oil is supplied to the steering valve by way of the
Table 2. steering priority valve PV. With the wheel stationary the
bar kgf/cm2 Ibf/in2 spool is held in a closed centre position within the sleeve
Shock valve 176 180 2550 by spring action. Output from the pump is 'dead ended' and
the load sensing port to the priority valve is connected to
exhaust.
K Table 3. ( T H-1)
When actuated by the steering column, the spool turns
Table 3.
within the sleeve, oil galleries are aligned and a demand
Ram Dimensions mm in
pressure signal is sent to the priority valve. Pressure oil
Bore 80 3.1 directed to the steering valve is routed through the sleeve
Rod Dia. 50 2.0 and spool to the metering unit. The rotor is also being
turned by the steering column and interaction between
Stroke 312.1 2.3 rotor and stator lobes pumps oil out to the steering rams to
achieve steering action.
General Description
With the engine stopped, (pump inoperative and no oil
Hydraulic oil is delivered from the pump via a steering supply available), the supply line is closed by a spring
priority valve to the steering valve. When the steering valve assisted non-return valve. Turning the steering wheel
is turned the steering valve is actuated and a pump rotates the spool further until the sleeve is mechanically
demand signal is sent to the priority valve spool. The spool engaged. The sleeve is turned and routes oil to the meter
moves and directs pressurised oil from the pump to the unit which is also being turned, this pumps oil to the rams
steering valve and then to the steering ramsK Steering under manual pressure. Manual operation is
Valve - Operation ( T H-1). supplemented by oil exhausted from the opposite side of
the rams which now has sufficient pressure to lift the non-
Pressurised oil enters the ram cylinders (rod side first ram return valve and cross connect the pressure and exhaust
and head side second ram) and causes the rams to extend systems.
or retract to turn the machine in the required direction.

A pressure relief valve is fitted to guard against shock

steering loads.

H-1 550/43477/1 H-1

 Section H - Steering
Hydraulic Steering
Technical Data

Fig 1.

Description K Fig 2. ( T H-2)

Fig 2.

H-2 550/43477/1 H-2


Emergency Steering Operation
Under normal conditions, the flow from the main pump 1
goes to the priority valve 2 via a check valve 3. If a
steerting demand is present, the priority valve directs the
steering valve SV; otherwise, the goes to the loader valve
LV.
Flow from the emergency steering pump 4 goes to the
emergency steering valve 5. Providing pilot pressure from
the main pump is present, the emergency steering valve
returns the flow directly back to the hydraulic tank T so
Fig 3.
K Table 4. ( T H-4)
H-3 550/43477/1
Section H - Steering
Hydraulic Steering
Technical Data
causing minimum loading on the emergency steering
pump.
If the pilot pressure is lost but the machine is still moving,
the emergency steering valve spool 6 moves over, closing
the neutral circuit. The flow from the emergency steer
pump is now, via check valve 7, to the priority valve and
from there to the steering valve. This ensures that the
machine may be brought to rest safety.
The check valves 3, 7 prevent cross flow occuring. A relief
valve 8 in the emergency steering valve operates at 175
bar when there is no steering demand, allowing flow to
return to the hydraulic tank K Fig 3. ( T H-3).
H-3
 Section H - Steering
Hydraulic Steering
Technical Data
Table 4.
1 Dust seal ring
2 Housing + spool + sleeve
3 Ball 8.5 mm [0.33 in]
4 Thread bushing
5 O-ring with kin-ring or Roto Glyd
6 Bearing assembly
7 Ring for springs
8 Cross pin 6 • 41 mm [0.24 • 1.61 in]
9 Neutral position springs
10 Cardan shaft
11 Spacer
12 O-ring 80,5 • 1,5 mm [3.17 • 0.06 in]
13 Distributor plate
14 Gearwheel
15 O-ring 75.92 • 1,78 mm [2.99 • 0.07 in]
16 End cover
17 Washer 8.2 • 11,9 • 1.0 mm [0.32 • 0.47 • 0.04 in]
18 Washer 8.2 • 11,9 • 1.0 mm [0.32 • 0.47 • 0.04 in]
19 Special screw
20 Screw
21 Name label
22 Spacer

H-4 550/43477/1 H-4

 Section H - Steering
Hydraulic Steering
Technical Data

Fig 4.

K Table 5. ( T H-5) 7 Bearing assembly

Table 5. 8 Ring
1 Dust seal ring 9 Cross pin
2 Housing, spool and sleeve. 10 Spacer
Check valve and the seats for relief and shock 11 Cardan shaft
valves are locktited. 12 Set of springs
3 Ball 8.5 mm [0.33 in] 13 O-ring
4 Thread bushing 14 Distributor plate
5 O-ring used with kin-ring (item 6) 15 Gearwheel set
6 Kin-ring 16 O-ring

H-5 550/43477/1 H-5

 Section H - Steering
Hydraulic Steering
Technical Data

17 End cover Guide ring Code number: SJ 150-9000-16 K Fig

6. ( T H-6)
18 Washer
19 Special screw
20 Screw
21 Name plate
22 Complete relief valve
23 Spring wire
24 Complete shock valve
25 Ball 3/16 in
26 Spring
27 Rolled pin
28 Bushing
29 Ball
30 Kin ring
Fig 6.
31 O-ring
Assembly tool for O-ring and kin-ring / Roto Glyd
Tools
Code number: SJ 150-9000-11, Code number: SJ
Holding tool Code number: SJ 150-9000-255 K Fig 150N4014-1 K Fig 7. ( T H-6)
5. ( T H-6)

Fig 7.

Assembly tool for lip seal Code number: SJ 150-9000-

17 K Fig 10. ( T H-7)

Fig 5.

H-6 550/43477/1 H-6

 Section H - Steering
Hydraulic Steering
Technical Data
5 2 mm [0.08 in] screwdriver.

6 13 mm ring spanner.

7 6.8 and 12 mm socket spanners.

8 Plastic hammer.

9 Tweezers.

The tools are not available from Sauer-Danfoss.

Fig 8.

Assempbly tool for cardan shaft. Code number: SJ 150-

9000-3 K Fig 9. ( T H-7)

Fig 9.

Assembly tool for dust seal. Code number: SJ 150-

9000-22 K Fig 10. ( T H-7) Fig 11.

Dismantling

Dismantle steering column from steering unit and place the

steering unit in the holding tool.

Screw out the screws in the end cover (6-off plus one
special screw).K Fig 12. ( T H-7)

Fig 10.

K Fig 11. ( T H-7)

1 Torque wrench 0 - 70 N.m.

2 13 mm socket spanner.

3 6.8 and 12 mm sockets.

4 12 mm screwdriver. Fig 12.

H-7 550/43477/1 H-7

 Section H - Steering
Hydraulic Steering
Technical Data
Remove the end cover, sideways. K Fig 13. ( T H-8)

Fig 15.

Fig 13. Remove distributor plate. K Fig 16. ( T H-8)

Lift the gearwheel set (with spacer if fitted) off the unit. Take
aut the two O-rings. K Fig 14. ( T H-8)

Fig 16.

Screw out the threaded bush over the check valve. K Fig
17. ( T H-9)
Fig 14.

Remove the cardan shaft. K Fig 15. ( T H-8)

H-8 550/43477/1 H-8

 Section H - Steering
Hydraulic Steering
Technical Data

Fig 17. Fig 19.

Remove O-ring K Fig 18. ( T H-9) Take care to keep the cross pin in the sleeve and spool
horizontal. The pin can be seen through the open end of
the spool. Press the spool inwards and the sleeve, ring,
bearing races and needle bearing will be pushed out of the
housing together. K Fig 20. ( T H-9)

Fig 18.

K Fig 19. ( T H-9)

OSPB, OSPB LS, OSPBX LS: Fig 20.

Shake out the check valve ball (.8 mm) Take ring, bearing races and needle bearing from sleeve
and spool. The outer (thin) bearing race can sometimes
OSPC LS, OSPC LSR: “stick” in the housing, therefore check that it has come out.
K Fig 21. ( T H-10)
Shake out the check valve ball and suction valve pins and
balls.

On some pins in the OSPC there are two springs (see

page 4, pos. 38). Replace this pins prior to the reassembly!

H-9 550/43477/1 H-9

 Section H - Steering
Hydraulic Steering
Technical Data

Fig 21. Fig 23.

Press out the cross pin. Use the special screw from the Carefully press the spool out of the sleeve. K Fig
end cover. K Fig 22. ( T H-10) 24. ( T H-10)

Note next point/paragraph!

Fig 24.

Fig 22.
Press the neutral position springs out of their slots in
the spool. K Fig 25. ( T H-11)
OSPB CN and OSPC CN

A small mark has been made with a pumice stone on both

spool and sleeve close to one of the slots for the neutral
position springs. K Fig 23. ( T H-10)

If the mark is not visible, remember to leave a mark of your

own on sleeve and spool before the neutral position
springs are dismantled.

For OSPF both marks should be placed opposite each

other!

H - 10 550/43477/1 H - 10
 Section H - Steering
Hydraulic Steering
Technical Data

Fig 25. Fig 27.

Remove dust seal and O-ring / Kin-ring / Roto Glyd. K Fig Remove seal washers (2-off). K Fig 28. ( T H-11)
26. ( T H-11)

Fig 28.
Fig 26.
Unscrew the setting screws using a 6 mm hexagon socket
Remove plugs from shock valves using a 6 mm hexagon spanner.
socket spanner. K Fig 27. ( T H-11)

H - 11 550/43477/1 H - 11
 Section H - Steering
Hydraulic Steering
Technical Data
Screw out the plug using and 8 mm hexagon socket
spanner. Remove seal washers. K Fig 31. ( T H-12)

Shake out the two springs and two valve balls into your
hand. The valve seats are bonded into the housing and
Fig 31.
cannot be removed. K Fig 29. ( T H-12)
Unscrew the setting screw using an 8 mm hexagon socket
spanner.K Fig 32. ( T H-12)

Fig 29.

The shock valves are now dismantled. K Fig 30. ( T H-12)

Fig 32.

Shake out spring and piston. The valve seat is bonded into
the housing and cannot be removed. K Fig 33. ( T H-13)

Fig 30.

H - 12 550/43477/1 H - 12
 Section H - Steering
Hydraulic Steering
Technical Data

Fig 35.

Fig 33. The pressure relief valve is now dismantled. K Fig

36. ( T H-13)
The pressure relief valve is now dismantled. K Fig
34. ( T H-13)

Fig 36.

Fig 34. The steering unit OSPB is now completely dismantled.

K Fig 37. ( T H-13)
Dismantling the Pressure Relief Valve
(Cartridge) for OSPC LS / OSPC LSR
Screw out the pressure relief valve using and 8 mm
Ihexagon socket spanner. Remove the seal ring. If the
valve is defective it must be replaced. K Fig 35. ( T H-13)

Fig 37.

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 Section H - Steering
Hydraulic Steering
Technical Data
The steering unit OSPB LS is now completely dismantled.
K Fig 38. ( T H-14)

Fig 40.

The steering unit OSPC LS is now completely dismantled.

Replace pins no. 2 prior to the reassembly! K Fig
41. ( T H-14)

Fig 38.

The steering unit OSPC is now completely dismantled.

Replace this pins prior to the reassembly! K Fig
39. ( T H-14)

Fig 41.

Cleaning: Clean all parts carefully in Shellsol K or the like.

Inspection and replacement: Replace all seals and

washers. Check all parts carefully and make any
Fig 39. replacements necessary.
The steering unit OSPC LS is now completely dismantled.
Lubrication: Before assembly, lubricate all parts with
Replace pins no. 1 prior to the reassembly! K Fig
hydraulic oil.
40. ( T H-14)

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 Section H - Steering
Hydraulic Steering
Technical Data

Assembling
Place the two flat neutral position springs in the slot. Place
the curved springs between the flat ones and press them
into place. K Fig 42. ( T H-15)

Fig 44.

Guide the spool into the sleeve. Make sure that spool and
sleeve for OSPB LS, OSPBX LS, OSPC LS, OSPC LSR
and OSPF are placed correctly in relation to each other
Fig 42. (see page 3).K Fig 45. ( T H-15)

Fig 43.
Fig 45.
Line up the spring set. K Fig 44. ( T H-15)
Assembling spool and sleeve.

OSPB LS, OSPBX LS, OSPC LS, OSPC LSR and OSPF

When assembling spool and sleeveonly one of two

possible ways of positioning the spring slots is correct.
There are three slots in the spool and three holes in the
sleeve in the end of the spool/sleeve opposite to the end
with spring slots. Place the slots and holes opposite each
other so that parts of the holes in the sleeve are visible
through the slots in the spool.

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 Section H - Steering
Hydraulic Steering
Technical Data

Fig 46.
Fig 48.
OSPB CN and OSPC CN
Line up the springs and centre them.
Assemble the spool/sleeve and make sure the marks on
spool and sleeve are opposite each other (see drawing
page 10).

Fig 49.

Assembling
Guide the ring down over the sleeve.

The ring should be able to move - free of springs

Fig 47.

Press the springs together and push the neutral position

springs into place in the slave.

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 Section H - Steering
Hydraulic Steering
Technical Data

Fig 50. Fig 52.

Fit the cross pin into the spool/sleeve. Assembly pattern for standard bearing
1 Outer bearing race

2 Needlebearing

3 Inner bearing race

4 Spool

5 Sleeve

Fig 51.

Fit bearing races and needle bearings as shown on the

drawing next page.

Fig 53.

H - 17 550/43477/1 H - 17
 Section H - Steering
Hydraulic Steering
Technical Data
Assembly pattern for double bearing

1 Washer for axial bearing

2 Outer needlebearing

3 Outer bearing race

4 Spool

5 Sleeve

6 Inner needlebearing

7 Inner bearing race Fig 55.

Grease o-ring and king-ring/roto Glyd with hydraulic oil and

place them on the tool.

Fig 56.

Hold the outer part of the assembly tool in the bottom of the
steering unit housing and guide the inner part of the tool
right to the bottom.

Fig 54.

Installation Instruction for O-ring /

Turn the steering unit until the bore is horizontal. Guide the
outer part of the assembly tool into the bore for the spool/
sleeve.

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 Section H - Steering
Hydraulic Steering
Technical Data

Fig 59.

Guide the assembly tool right to the bottom.

Fig 57.

Press and turn the o-ring/kin-ring into position in the

housing.

Draw the inner and outer parts of the assembly tool out of
the steering unit bore, leaving the guide from the inner part
in the bore.

Fig 60.

Press and turn the lip seal into place in the housing.

Fig 58.

Installation Instruction for Lip Seal

Lubricate the lip seal with hydraulic oil and place it on the
assembly tool.

Fig 61.

With a light turning movement, guide the spool and sleeve

into the bore.

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 Section H - Steering
Hydraulic Steering
Technical Data

Fig 62. Fig 64.

Fit the spool set holding the cross pin horizontal. Screw the threaded bush lightly into the check valve bore.
The top of the bush must lie just below the surface of the
The spool set will push out the assembly tool guide. The o- housing.
ring and kin-ring/roto Glyd are now in position.

Fig 65.
Fig 63.
Place a ball in the two holes indicated by the arrows
Turn the stearing unit until the bore is vertical again. Put
the check valve ball into the hole indicated by the arrow.

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 Section H - Steering
Hydraulic Steering
Technical Data

Fig 68.
Fig 66.
In some cases a spring has to be fitted (see page 4 pos.
Place a new pin in the same two holes. 38) on the pin before it is placed in the housing.

Fig 69.

Grease the o-ring with mineral oil approx. viscosity 500

Fig 67. mm2/s [SUS] at 20°C [68 °F].
Place a new pin in the same two holes.

Fig 70.

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 Section H - Steering
Hydraulic Steering
Technical Data
Place the distributor plate so that the channel holes match
the holes in the housing.

Fig 73.
Fig 71.
Fit the special screw with washer and place it in the hole
Fit the spacer, if any. shown.

Fig 72.
Fig 74.
Place the end cover in position.
Fit the six screws with washers and insert them. Cross-
tighten all the screws and the rolled pin with a torque of Ċ
30 +/-6 N.m [265.5 +/- 53 lbf.in]. The OSPB, OSPB LS and
OSPBX LS can now be function tested.

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 Section H - Steering
Hydraulic Steering
Technical Data
Screw in the setting screw with an 8 mm hexagon socket
spanner. Make the pressure setting on a panel or the
vehicle.

Fig 75.

Fit the piston.

Fig 78.

Screw plug with dust seal into the housing using an 8 mm

Ihexagon socket spanner. Tightening torque: Ċ65 +/-5
N.m. [575.3 +/- 44.2 lbf.in]

Fig 76.

Fit the spring

Fig 79.

Fig 77.

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 Section H - Steering
Hydraulic Steering
Technical Data

Assambly of the Shock Valves

Put a ball in the two holes indicated by the arrows.

Fig 82.

Screw plug with seal ring into the two shock valves and
tighten them with a torque of : . 30 +10 N.m [265.5 + 88.5
Fig 80.
lbf.in] using a 6 mm Ihexagon socket spanner. Steering
unit type OSPC, OSPC LS or OSPC LSR is now
Place springs and valve cones over the two balls.
assembled.
The blue spring applies to setting range 90-180 bar [1305-
2610 psi]. The untreated spring applies to setting range
170-260 bar [2465-3770 psi]

Fig 83.

Place the dust seal ring in the housing. With the OSPC,
OSPC LS and OSPC LSR the dust seal ring must be
Fig 81.
placed only after the pressure relief valve and shock valves
have been fitted.
Screw in the two setting screws using a 6 mm Ihexagon
socket spanner. Make the pressure setting on a panel or
the vehicle.

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 Section H - Steering
Hydraulic Steering
Technical Data

Fig 84.

Fit the dust seal ring in the housing using special tool SJ
150-9000-22 (see page 5) and a plastic hammer.

Fig 85.

Press the plastic plugs into the connection ports. Do not

use a hammer!

Fig 86.

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 Section H - Steering
Hydraulic Steering
Technical Data
Maximum Tightening Torque and Hydraulic
connections

T: Tank
L: Left port
P: Pump
R Right port

Fig 87.

Screwed connection Maximum tightening torque N.m [lbf.in]

With cutting edge With cooper washer With aluminium washer With O_]ring
G 1/4 35 [309] 35 [309] 35 [309] -
G 3/8 70 [619] 45 [398] 50 [442] -
G 1/2 100 [885] 55 [486] 80 [708] -
7/16 _]20 UNF - - - 20 [177]
3/4 _]16 UNF - - - 60 [531]
M 12 1.5" 30 [265] 20 [177] 30 [265] 25 [221]
M18 1.5" 80 [708] 55 [486] 70 [619] 50 [442]
M22 1.5" 100 [885] 65 [575] 80 [708] 60 [531]

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