Service Manual: Foreword

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

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

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

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

VARIABLE REACH TRUCK) Contents
506-36, 507-42, 509-42, 510-56, 512-56
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
EN - 9823/1700 - ISSUE 1 - 07/2018
25 - Steering System
27 - Driveline
30 - Hydraulic System
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
Copyright 2018 Â© JCB SERVICE

78 - After Sales
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Notes:
9823/1700-1
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
506-36, 507-42, 506-36, 507-42,

509-42, 510-56, 512-56 509-42, 510-56, 512-56
EN 9823/1700 EN 9823/1700
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
506-36, 507-42, 506-36, 507-42,

509-42, 510-56, 512-56 509-42, 510-56, 512-56
EN 9823/1700 EN 9823/1700
9823/1700-1
Notes:
9823/1700-1
01 - Machine
Contents Page No.
Acronyms Glossary .................................................................................................................................... 01-2
01-03 Safety
01-03-03 Safety - Yours and Others ............................................................................................... 01-3
01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-11
01-03-24 Risk Assessment ............................................................................................................ 01-12
01-03-27 Maintenance Positions ................................................................................................... 01-13
01-06 About this Manual
01-06-00 General ........................................................................................................................... 01-17
01-06-03 Model and Serial Number .............................................................................................. 01-18
01-06-06 Using the Manual ........................................................................................................... 01-19
01-09 Description
01-09-00 General ........................................................................................................................... 01-21
01-09-03 Log Moving/Object Handling .......................................................................................... 01-23
01-09-06 Optional Equipment and Attachments ........................................................................... 01-24
01-09-12 Main Component Locations ........................................................................................... 01-25
01-09-15 Service Point Locations ................................................................................................. 01-26
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-31
9823/1700-1
2018-07-16
Acronyms Glossary
FOPS Falling Object Protective Structure

PIL Parts Identification List
ROPS Roll-Over Protective Structure
9823/1700-1
2018-07-16
01 - Machine
03 - Safety
03 - Safety
Contents Page No.
01-03-03 Safety - Yours and Others ............................................................................................... 01-3

01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-11
01-03-24 Risk Assessment ............................................................................................................ 01-12
01-03-27 Maintenance Positions ................................................................................................... 01-13
01 - 1 9823/1700-1 01 - 1
Notes:
01 - 2 9823/1700-1 01 - 2
01 - Machine
03 - Safety
03 - Safety - Yours and Others
03 - Safety - Yours and Others
Introduction
All machinery can be hazardous. When a machine

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

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

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

the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
01 - 3 9823/1700-1 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
In this manual there are safety notices. Each notice

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

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

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

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

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

to identify important safety messages in this manual.
When you see this symbol your safety is involved,
carefully read the message that follows.
Figure 1. The safety alert system symbol
01 - 4 9823/1700-1 01 - 4
01 - Machine
03 - Safety
09 - General Safety
09 - General Safety Lifting Equipment

You can be injured if you use incorrect or faulty lifting
Introduction equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
Training equipment is in good condition and complies with all
To operate the machine safely you must know the local regulations.
machine and have the skill to use it. You must abide Raised Equipment
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The Never walk or work under raised equipment unless
operator's manual instructs you on the machine, its it is supported by a mechanical device. Equipment
controls and its safe operation; it is not a training which is supported only by a hydraulic device can
manual. Ensure that you receive the correct training drop and injure you if the hydraulic system fails
before operating any machinery. Failing to do so will or if the control is operated (even with the engine
result in incorrect operation of the machine and you stopped).
will be putting yourself and others at risk. In some Make sure that no-one goes near the machine while
markets, and for work on certain jobsites, you may you install or remove the mechanical device.
be required to have been trained and assessed in
accordance with an operator competence scheme. Raised Machine
Make sure that you and your machine comply with Never position yourself or any part of your body
relevant local laws and jobsite requirements – it is under a raised machine which is not correctly
your responsibility. supported. If the machine moves unexpectedly you
Care and Alertness could become trapped and suffer serious injury or be
killed.
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always Lightning
be alert for hazards. Lightning can kill you. Do not use the machine if there
Clothing is lightning in your area.
You can be injured if you do not wear the correct Machine Modifications
clothing. Loose clothing can get caught in the This machine is manufactured in compliance with
machinery. Keep cuffs fastened. Do not wear a prevailing legislative requirements. It must not be
necktie or scarf. Keep long hair restrained. Remove altered in any way which could affect or invalidate its
rings, watches and personal jewellery. compliance. For advice consult your JCB dealer.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
01 - 5 9823/1700-1 01 - 5
01 - Machine
03 - Safety
12 - Maintenance Safety
12 - Maintenance Safety Hydraulic Pressure

Hydraulic fluid at system pressure can injure you.
Introduction Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
Raised Machine service line has been vented before connecting or
Never position yourself or any part of your body removing hoses. Make sure the engine cannot be
under a raised machine which is not correctly started while the hoses are open.
supported. If the machine moves unexpectedly you 'O' rings, Seals and Gaskets
could become trapped and suffer serious injury or be
killed. Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
Air Conditioning Maintenance accidents. Renew whenever disturbed unless
The air conditioning system is a closed loop system otherwise instructed. Do not use Triochloroethane or
and contains pressurised refrigerant. No part of the paint thinners near 'O' rings and seals.
system should be disconnected until the system Arc Welding
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely To prevent the possibility of damage to electronic
frostbitten or injured by escaping refrigerant. components, disconnect the battery and the
alternator before arc-welding on the machine or
Compressed Air attached implements.
Compressed air is dangerous. Wear personal If the machine is equipped with sensitive electrical
protective equipment. Never point a compressed air equipment, i.e. amplifier drivers, electronic control
jet at yourself or others. units (ECUs), monitor displays, etc., then disconnect
Springs them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Always wear personal protective equipment when
irreparable damage to these components.
dismantling assemblies containing components
under pressure from springs. This will protect against Parts of the machine are made from cast iron, welds
eye injury from components accidentally flying out. on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
Metal Splinters
or apply any weld to any part of the engine.
You can be injured by flying metal splinters when
Always connect the welder earth (ground) cable to
driving metal pins in or out. Use a soft faced hammer
the same component that is being welded to avoid
or copper drift to remove and install metal pins.
damage to pivot pins, bearings and bushes. Attach
Always wear personal protective equipment.
the welder earth (ground) cable a distance from the
Communications part being welded no more than 0.6 m.
Bad communications can cause accidents. If two Counterweights
or more people are working on the machine, make
Your machine may be installed with counterweights.
sure each is aware of what the others are doing.
They are extremely heavy. Do not attempt to remove
Before starting the engine make sure the others are
them.
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the Accumulators
attachments and linkages, and anywhere beneath or The accumulators contain hydraulic fluid and gas at
behind the machine. People can be killed or injured high pressure. Prior to any work being carried out
if these precautions are not taken. on systems incorporating accumulators, the system
Repairs pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
If your machine does not function correctly in
cause serious injury or death.
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect Hot Components
your health. Do not try to do repairs or any other Touching hot surfaces can burn skin. The engine and
type of maintenance work you do not understand. To machine components will be hot after the unit has
avoid injury and/or damage get the work done by a been running. Allow the engine and components to
specialist engineer. cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
01 - 6 9823/1700-1 01 - 6
01 - Machine
03 - Safety
12 - Maintenance Safety
Working Under the Machine

Make the machine safe before getting beneath it.
Make sure that any attachments on the machine are
correctly attached. Engage the park brake, remove
the ignition key, disconnect the battery. If the machine
has wheels use blocks to prevent unintentional
movement.
Lifting the Machine
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
Chemicals
Certain seals and gaskets (e.g. crankshaft oil
seal) on JCB machines contain fluoroelastomeric
materials such as Viton®, FluorelTM and
Technoflon®. Fluoroelastomeric materials subjected
to high temperatures can produce highly
corrosive hydrofluoric acid. This acid can severely
burn. New fluoroelastomeric components at
ambient temperature require no special safety
precautions. Used fluoroelastomeric components
whose temperatures have not exceeded 300 °C
( 571.6 °F) require no special safety precautions. If
evidence of decomposition (e.g. charring) is found,
refer to the next paragraph for safety instructions.
Do not touch component or surrounding area.
Used fluoroelastomeric components subjected to
temperatures greater than 300 °C ( 571.6 °F) (e.g.
engine fire) must be treated using the following
safety procedure. Make sure that heavy duty gloves
and special safety glasses are worn: Thoroughly
wash contaminated area with 10% calcium hydroxide
or other suitable alkali solution, if necessary use
wire wool to remove burnt remains. Thoroughly
wash contaminated area with detergent and water.
Contain all removed material, gloves etc. used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations. Do not
burn fluoroelastiometric materials.
Hydraulic Hoses
Never re-use hydraulic hose end crimps or use
reusable hose end crimps.
Personal Protective Equipment
Use the appropriate personal protective equipment
before performing maintenance on the machine,
otherwise you could be injured.
Working at Height
Use appropriate access equipment such as ladders
or a working platform if it is necessary to work at
height to perform maintenance tasks on the machine.
If you do not use suitable access equipment there is
a risk of falling, resulting in personal injury or death.
01 - 7 9823/1700-1 01 - 7
01 - Machine
03 - Safety
18 - Operating Safety
18 - Operating Safety exhaust extractor. If you begin to feel drowsy, stop

the machine at once and get into fresh air.
Introduction Worksites
Worksites can be hazardous. Examine the site
Training before working on it. You could be killed or injured
if the ground gives way under your machine or if
Make sure that you have had adequate training and piled material collapses onto it. Check for potholes
that you are confident in your ability to operate the and hidden debris, logs, ironwork etc. Any of these
machine safely before you use it. Practice using the could cause you to lose control of your machine.
machine and its attachments until you are completely Check for utilities such as electric cables (overhead
familiar with the controls and what they do. With and underground), gas and water pipes etc. Mark
a careful, well trained and experienced operator, the positions of the underground cables and pipes.
your machine is a safe and efficient machine. With Make sure that you have enough clearance beneath
an inexperienced or careless operator, it can be overhead cables and structures.
dangerous. Do not put your life, or the lives of others,
at risk by using the machine irresponsibly. Before you
start to work, tell your colleagues what you will be Communications
doing and where you will be working. On a busy site,
use a signalman. Before doing any job not covered Bad communications can cause accidents. Keep
in this manual, find out the correct procedure. Your people around you informed of what you will be
local JCB distributor will be glad to advise you. doing. If you will be working with other people,
make sure any hand signals that may be used are
understood by everybody. Worksites can be noisy, do
Fuel not rely on spoken commands.
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel Parking
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the An incorrectly parked machine can move without an
engine running. Completely wipe off any spilt fuel operator. Follow the instructions in the Operator's
which could cause a fire. There could be a fire and Manual to park the machine correctly.
injury if you do not follow these precautions.
Banks and Trenches
Machine Condition
Banked material and trenches can collapse. Do not
A defective machine can injure you or others. Do not work or drive too close to banks and trenches where
operate a machine which is defective or has missing there is danger of collapse.
parts. Make sure the maintenance procedures in this
manual are completed before using the machine. Safety Barriers
Machine Limits Unguarded machines in public places can be

dangerous. In public places, or where your visibility
Operating the machine beyond its design limits can is reduced, place barriers around the work area to
damage the machine, it can also be dangerous. keep people away.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with Sparks
unapproved modifications or additional equipment.
Explosions and fire can be caused by sparks from
Engine/Steering Failure the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
If the engine or steering fails, stop the machine as material, vapour or dust.
quickly as possible. Do not operate the machine until
the fault has been corrected. Hazardous Atmospheres
Exhaust Gases This machine is designed for use in normal out

door atmospheric conditions. It must not be used
Machine exhaust gases can harm and possibly kill in an enclosed area without adequate ventilation.
you or bystanders if they are inhaled. Do not operate Do not use the machine in a potentially explosive
the machine in closed spaces without making sure atmosphere, i.e. combustible vapours, gas or dust,
there is good ventilation. If possible, install an without first consulting your JCB dealer.
01 - 8 9823/1700-1 01 - 8
01 - Machine
03 - Safety
Regulations clearly. Modification of the machine's configuration

by the user (e.g. the fitting of large and non-
Obey all laws, worksite and local regulations which approved attachments) may result in a restriction of
affect you and your machine. the machine visibility.
Electrical Power Cables Hands and Feet

You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. When
the machine or its attachments too close to electrical using the machine, keep your hands and feet clear
power cables. You are strongly advised to make of moving parts. Keep your hands and feet within the
sure that the safety arrangements on site comply operator compartment while the vehicle is in motion.
with the local laws and regulations concerning work
near electric power lines. Before you start using the Controls
machine, check with your electricity supplier if there
are any buried power cables on the site. There is You or others can be killed or seriously injured
a minimum clearance required for working beneath if you operate the control levers from outside the
overhead power cables. You must obtain details from machine. Operate the control levers only when you
your local electricity supplier. are correctly seated.
Working Platform Passengers

Using the machine as a working platform is Passengers in or on the machine can cause
hazardous. You can fall off and be killed or injured. accidents. Do not carry passengers.
Never use the machine as a working platform
unless with approved man-basket or man-crate (if Fires
applicable).
If your machine is equipped with a fire extinguisher,
Machine Safety make sure it is checked regularly. Keep it in the
correct machine location until you need to use it. Do
Stop work at once if a fault develops. Abnormal not use water to put out a machine fire, you could
sounds and smells can be signs of trouble. Examine spread an oil fire or get a shock from an electrical
and repair before resuming work. fire. Use carbon dioxide, dry chemical or foam
extinguishers. Contact your nearest fire department
Hot Components as quickly as possible.
Touching hot surfaces can burn skin. The engine and Roll Over Protection
machine components will be hot after the unit has
been running. Allow the engine and components to If the machine starts to roll over, you can be crushed
cool before servicing the unit. if you try to leave the cab. If the machine starts to roll
over, do not try and jump from the cab. Stay in the
Travelling at High Speeds cab, with your seat belt fastened.
Travelling at high speeds can cause accidents. Confined Areas

Always travel at a safe speed to suit working
conditions. Pay extra attention to proximity hazards when
operating in confined areas. Proximity hazards
Hillsides include buildings, traffic and bystanders.
Operating the machine on hillsides can be Safe Working Loads

dangerous if the correct precautions are not taken.
Ground conditions can be changed by rain, snow, ice Overloading the machine can damage it and make it
etc. Check the site carefully. When applicable, keep unstable. Study the specifications in the Operator's
all attachments low to the ground. Manual before using the machine.
Visibility Lightning
Accidents can be caused by working in poor visibility. If you are inside the machine during a lightning storm
Use your lights to improve visibility. Keep the road stay in the machine until the storm has passed. If
lights, windows, mirrors and cameras clean (when you are outside of the machine during a lightning
fitted). Do not operate the machine if you cannot see storm stay away from the machine until the storm
01 - 9 9823/1700-1 01 - 9
01 - Machine
03 - Safety
has passed. Do not attempt to mount or enter the

machine. If the machine is struck by lightning do
not use the machine until it has been checked for
damage and malfunction by trained personnel.
01 - 10 9823/1700-1 01 - 10
01 - Machine
03 - Safety
21 - Worksite Safety
21 - Worksite Safety An applicable worksite organisation is required in

order to minimise hazards that are caused by
restricted visibility. The worksite organisation is a
Introduction collection of rules and procedures that coordinates
the machines and people that work together in
WARNING You or others can be killed or seriously the same area. Examples of worksite organisation
injured if you do unfamiliar operations without first include:
practising them. Practise away from the worksite
on a clear area. Keep other people away. Do not • Restricted areas
perform new operations until you are sure you can • Controlled patterns of machine movement
do them safely. • A system of communication.
WARNING There could be dangerous materials
such as asbestos, poisonous chemicals or other You and/or your company could be legally liable for
harmful substances buried on the site. If you any damage you may cause to public utilities. It is
uncover any containers or you see any signs of your responsibility to make sure that you know the
toxic waste, stop the machine and advise the site locations of any public utility cables or pipes on the
manager immediately. worksite which could be damaged by your machine.
WARNING Before you start using the machine,
check with your local gas company if there are
any buried gas pipes on the site.
If there are buried gas pipes we recommend that
you ask the gas company for any specific advice
regarding the way you must work on the site.
Some modern gas pipes cannot be detected by
metal detectors, so it is essential that an accurate
map of buried gas pipes is obtained before any
excavation work commences.
Hand dig trial holes to obtain precise pipe
locations. Any cast iron pipes found must be
assumed to be gas pipes until contrary evidence
is obtained.
Older gas pipes can be damaged by heavy
vehicles driving over the ground above them.
Leaking gas is highly explosive.
If a gas leak is suspected, contact the local gas
company immediately and warn all personnel on
the site. Ban smoking, make sure that all naked
lights are extinguished and switch off any engines
which may be running.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
gas pipes.
CAUTION Before you start using the machine,
check with your local public water supplier if there
are buried pipes and drains on the site. If there
are, obtain a map of their locations and follow the
advice given by the water supplier.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
pipes and drains.
CAUTION If you cut through a fibre optic cable,
Do not look into the end of it, your eyes could be
permanently damaged.
01 - 11 9823/1700-1 01 - 11
01 - Machine
03 - Safety
24 - Risk Assessment
24 - Risk Assessment Loading/Unloading Area

• Is it level? Any slope of more than 2.5% (1 in
Introduction 40) must be carefully considered.
• Is more than one direction of approach to the
load possible? Approaching across the slope
It is the responsibility of the competent people that must be avoided, if possible.
plan the work and operate the machine to make a • Is the ground solid? Will it support the weight of
judgement about the safe use of the machine, they the machine when loaded?
must take into account the specific application and • How rough is the ground? Are there any
conditions of use at the time. sharp projections which could cause damage,
particularly to the tyres?
It is essential that a risk assessment of the work to be • Are there any obstacles or hazards in the area,
done is completed and that the operator obeys any for example, debris, excavations, manhole
safety precautions that the assessment identifies. covers, power lines?
• Is the space sufficient for safe manoeuvring?
If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be
a specific task, contact your JCB dealer who will be in or to enter the area while operations are in
pleased to advise you. progress?
The following considerations are intended as
suggestions of some of the factors to be taken into The Route to be Travelled
account when a risk assessment is made. Other • How solid is the ground, will it provide sufficient
factors may need to be considered. traction and braking? Soft ground will affect the
stability of the machine and this must be taken
A good risk assessment depends on the training and into account.
experience of the operator. Do not put your life or the • How steep are any slopes, up/down/across?
lives of others at risk. A cross slope is particularly hazardous, is it
possible to detour to avoid them?
Personnel
• Are all persons who will take part in the Weather
operation sufficiently trained, experienced and • How windy is it? High wind will adversely affect
competent? Are they fit and sufficiently rested? the stability of a loaded machine, particularly if
A sick or tired operator is a dangerous operator. the load is bulky.
• Is supervision needed? Is the supervisor • Is it raining or is rain likely? The ground that
sufficiently trained and experienced? was solid and smooth when dry will become
• As well as the machine operator, are any uneven and slippery when wet, and it will not
assistants or lookouts needed? give the same conditions for traction, steering
or braking.
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres still at the correct pressure and
in good condition and is there sufficient fuel to
complete the job (if applicable)?
The Load
• How heavy is it? Is it within the capabilities of
the machine?
• How bulky is it? The greater the surface area,
the more affected it will be by wind speeds.
• Is it an awkward shape? How is the weight
distributed? Uneven loads are more difficult to
handle.
• Is there a possibility of the load shifting while
being moved?
01 - 12 9823/1700-1 01 - 12
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-13 You can complete most of the maintenance
Health and Safety .......................................... 01-14 procedures with the lift arm lowered. Unless a
maintenance procedure instructs you differently, you
must lower the lift arm.
Lift Arm Lowered

1. Park the machine on level, solid ground.
2. Make the machine safe.
Refer to: PIL 01-03.
3. Retract and lower the lift arm.
4. Put the attachment flat on the ground.
5. Release the hydraulic pressure.
6. Stop the engine and remove the ignition key. If
the keyless ignition option is installed stop the
engine and wait the specified time.
Duration: 15 s
7. Disconnect the battery to prevent accidental
operation of the engine.
8. Make sure there are no loose articles in the
enclosure.
9. If necessary, put blocks against the two ends of
the wheels before you get below the machine.
Figure 2.
A Lift arm lowered
Lift Arm Raised

1. Install the maintenance strut.
01 - 13 9823/1700-1 01 - 13
01 - Machine
03 - Safety
27 - Maintenance Positions
Health and Safety

WARNING Maintenance must be done only by
suitably qualified and competent persons.
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
the ignition key. Disconnect the battery (by means
of the battery isolator if installed) when you are
not using electrical power. If you do not take these
precautions you could be killed or injured.
WARNING Make the machine safe before getting
beneath it. Make sure that any attachments on
the machine are correctly attached. Engage the
park brake, remove the ignition key, disconnect
the battery.
01 - 14 9823/1700-1 01 - 14
01 - Machine
06 - About this Manual
Contents Page No.
01-06-00 General ........................................................................................................................... 01-17

01-06-03 Model and Serial Number .............................................................................................. 01-18
01-06-06 Using the Manual ........................................................................................................... 01-19
01 - 15 9823/1700-1 01 - 15
Notes:
01 - 16 9823/1700-1 01 - 16
01 - Machine
00 - General
00 - General
Introduction
This supplement must be used in conjunction with

the operator manual and service manual applicable
to this machine.
Study this supplement, the operator manual and

service manual before using the machine and
before carrying out any maintenance work on the
machine. You must always understand and observe
the relevant laws and regulations. If you are unsure
about anything, contact JCB.
This supplement is arranged to give you a good

understanding of the additional features and controls
of the machine and its safe operation. It also contains
specific data to the machine. Read this supplement
from front to back before using the machine for the
first time. Particular attention must be given to all
the safety aspects of operating and maintaining the
machine.
Do not operate the machine without this supplement.
Treat this supplement as part of the machine.

Keep it clean and in good condition. Replace this
supplement immediately if it is lost, damaged or
becomes unreadable.
If there is anything you are not sure about, ask your

JCB dealer or employer. Do not guess, you or others
could be killed or seriously injured.
The illustrations in this supplement are for guidance

only. Where the machines differ, the text and or the
illustration will specify.
The manufacturer's policy is one of continuous

improvement. The right to change the specification
of the machine without notice is reserved. No
responsibility will be accepted for discrepancies
which may occur between specifications of the
machine and the descriptions contained in this
publication.
01 - 17 9823/1700-1 01 - 17
01 - Machine
03 - Model and Serial Number
03 - Model and Serial Number
Introduction
This manual provides information for the following
model(s) in the JCB machine range:
Model From: To:
506-36 1402020
507-42 1402020
509-42 1402020
510-56 1402020
512-56 1402020
01 - 18 9823/1700-1 01 - 18
01 - Machine
06 - Using the Manual
06 - Using the Manual
Introduction
Information in this manual conforms to a standard List). These headings are assigned numerical
JCB service manual format. The format uses section identification references.
headings taken from a PIL (Parts Identification
Table 1.
Example Section Main Assembly / Head- Component / Sub-head-
ing ing
PIL reference 33 03 03
Heading Electrical System Battery Isolator Switch
Information within each PIL reference is included information is contained within another PIL reference
under a set of standard headings such as a cross reference is provided.
Introduction, Health and Safety, Technical Data and
Operation for example. Where additional relevant The main systems information is contained in the
manual as follows.
Table 2.
System PIL Reference Heading
Hydraulic System PIL 30-00-50 Schematic Circuit
Electrical System PIL 33-03-03 Battery - Isolator Switch
PIL 33-09-00 Power Distribution (including fuses
and relays)
PIL 33-00-50 Schematic Circuit
Electronic Diagnostic PIL 33-57-00 Electronic Diagnostic (including
Servicemaster)
Machine Variants • Use the applicable Servicemaster diagnostics

tools.
Where information is different depending on machine
variant, the applicable information sets are included Torque Tightening
within the same PIL reference. Headings are
included to identify which information is for which When you replace components, always tighten the
variant. Make sure you use the correct information. applicable fixings to the correct torque value. Use the
torque tightening values contained in the individual
Diagnostics procedures (Remove and Install, Disassemble and
Assemble etc.). If no torque values are specified, use
Information in this manual can help you diagnose the standard torque tightening values. For the torque
machine faults. setting to be effective, do the following before you
install the fixings. Refer to PIL 72-00-00.
Before attempting to diagnose possible faults check
the following. • Make sure that all the applicable component
assemblies are correct.
• Make sure that the operator understands the • Make sure that the applicable fixings are to the
machine controls, functions and use. Refer to correct specification. If necessary discard the
the applicable Operator Manual. original fixings and replace them with new ones.
• Check that the maintenance record complies The relevant procedures indicate when this is
with the applicable schedule for the operating necessary.
environment. • Make sure that the applicable fixings and
• Check that the fluids in use comply with the threaded holes are free from contamination.
standards specified. This includes dirt, debris, old sealants and
• Make sure that the machine electronic set-up compounds, fluids and lubricants.
is applicable. Use the applicable Servicemaster
vehicle set-up tool.
01 - 19 9823/1700-1 01 - 19
01 - Machine
09 - Description
09 - Description
Contents Page No.
01-09-00 General ........................................................................................................................... 01-21

01-09-03 Log Moving/Object Handling .......................................................................................... 01-23
01-09-06 Optional Equipment and Attachments ........................................................................... 01-24
01-09-12 Main Component Locations ........................................................................................... 01-25
01-09-15 Service Point Locations ................................................................................................. 01-26
01 - 20 9823/1700-1 01 - 20
01 - Machine
09 - Description
00 - General
00 - General Introduction
Introduction .................................................... 01-21 The JCB Loadall is a self propelled, seated operator,
Operation ....................................................... 01-22 wheeled machine for operation on unimproved
natural terrain and disturbed terrain.
A main structural support is designed to carry an

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

loads by extending/retracting, raising/lowering the
boom.
01 - 21 9823/1700-1 01 - 21
01 - Machine
09 - Description
00 - General
Operation
The machine is intended to be used in normal

conditions for the applications described in this
manual. If the machine is used for other applications
or in dangerous environments, for example in
a flammable atmosphere or in areas with dust
containing asbestos, special safety regulations must
be obeyed and the machine must be equipped for
use in these environments.
01 - 22 9823/1700-1 01 - 22
01 - Machine
09 - Description
03 - Log Moving/Object Handling
03 - Log Moving/Object Handling
Introduction
Do not use the machine to move or handle logs

unless sufficient log protection is installed. You could
cause serious injury to yourself and damage to the
machine. For more information, contact your JCB
dealer.
01 - 23 9823/1700-1 01 - 23
01 - Machine
09 - Description
06 - Optional Equipment and Attachments
06 - Optional Equipment and

Attachments
Introduction
A wide range of optional attachments are available

to increase the versatility of your machine. Only the
JCB approved attachments are recommended for
use with your machine. Contact your JCB dealer for
the full list of approved attachments available.
01 - 24 9823/1700-1 01 - 24
01 - Machine
09 - Description
12 - Main Component Locations
12 - Main Component Locations
Introduction
Figure 3.
A D
E F
C
B
A Lift arm B Carriage

C Battery D ROPS (Roll-Over Protective Structure)/FOPS
(Falling Object Protective Structure) cab
E Hydraulic tow hitch (Agricultural machines only) F Mechanical tow hitch
01 - 25 9823/1700-1 01 - 25
01 - Machine
09 - Description
15 - Service Point Locations
Lubricate
There are 29 grease points on this machine. Refer You must lubricate all these grease points at every
to Figure 4. 50 h of machine operation.
For 510-56 and 512-56 machines, there are an

additional 8 grease points. Refer to Figure 5.
01 - 26 9823/1700-1 01 - 26
01 - Machine
09 - Description
Figure 4.
9,10
6
11
12,13
2,3
4
14,15
16,17
28,29 18,19,20,21
26,27 22,23,24,25
01 - 27 9823/1700-1 01 - 27
01 - Machine
09 - Description
Figure 5.
29,30
31,32
33,34
35
01 - 28 9823/1700-1 01 - 28
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-31
01 - 29 9823/1700-1 01 - 29
Notes:
01 - 30 9823/1700-1 01 - 30
01 - Machine
33 - Cleaning
00 - General
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-31 or other chemicals, you must adhere to
Preparation .................................................... 01-32 the manufacturer's instructions and safety
precautions.
CAUTION To avoid burning, wear personal
protective equipment when handling hot
components. To protect your eyes, wear goggles
when using a brush to clean components.
Notice: Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
Notice: The efficiency of the rams will be affected
if they are not kept free of solidified dirt. Clean dirt
from around the rams regularly. When leaving or
parking the machine, close all rams if possible to
reduce the risk of weather corrosion.
Notice: Never use water or steam to clean inside
the operator station. The use of water or steam
could damage the machine electrics and render
the machine inoperable. Remove dirt using a
brush or damp cloth.
Clean the product with water and/or steam. Do not

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

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

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

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

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

CAUTION When using a steam cleaner, wear
safety glasses or a face shield as well as
protective clothing. Steam can cause personal
injury.
01 - 31 9823/1700-1 01 - 31
01 - Machine
33 - Cleaning
00 - General
Notice: The engine and other components could Preparation

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

after pressure washing or steam cleaning.
01 - 32 9823/1700-1 01 - 32
03 - Attachments, Couplings and Load Handling
Contents Page No.
03-00 Attachments
03-00-00 General ............................................................................................................................. 03-3
03-12 Hitch
03-12-12 Mechanical Tow ................................................................................................................ 03-7
03-33 Fork
03-33-00 General ............................................................................................................................. 03-9
03-82 Jib
03-82-00 General ........................................................................................................................... 03-13
03-82-06 Shackle ........................................................................................................................... 03-15
03-84 Hook
03-84-00 General ........................................................................................................................... 03-19
03-84-06 Snatch Block .................................................................................................................. 03-20
9823/1700-1
2017-07-27
Notes:
9823/1700-1
2017-07-27
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9823/1700-1 03 - 1
Notes:
03 - 2 9823/1700-1 03 - 2
00 - Attachments
00 - General
Introduction ...................................................... 03-3 A wide range of optional attachments are available
Health and Safety ........................................... 03-4 to increase the versatility of your machine. Only JCB
approved attachments are recommended for use
with your machine. Consult your JCB Distributor for
the full list of approved attachments available.
Some attachments are supplied complete with

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

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

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

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

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

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

until the machine hydraulic oil has reached its normal
working temperature.
03 - 3 9823/1700-1 03 - 3
00 - Attachments
00 - General
Health and Safety

Attachments
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or others.
The use of non-approved attachments could
invalidate your warranty and cause damage to both
machine and attachments.
Attachments
If you have an attachment which is not covered in the
Operator's Manual do not install it, use it or remove
it until you have obtained, read and understood the
pertinent information. Install attachments only on the
machines for which they were designed.
WARNING! Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
DANGER! Before lowering the attachments to the
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or
close to the machine could fall and be crushed by the
attachments, or get caught in the linkages.
DANGER! Using the forks alone as a working
platform is hazardous; you can fall off and be killed
or injured. Never use the forks as a working platform.
03 - 4 9823/1700-1 03 - 4
12 - Hitch
12 - Hitch
Contents Page No.
03-12-12 Mechanical Tow ................................................................................................................ 03-7
03 - 5 9823/1700-1 03 - 5
Notes:
03 - 6 9823/1700-1 03 - 6
12 - Hitch
12 - Mechanical Tow
12 - Mechanical Tow
Health and Safety

WARNING Examine the tow hitch and the trailer
draw bar towing ring for signs of wear before each
use. A badly installed or worn hitch or towing
ring could cause loss of the trailer and injury to
yourself or other people.
WARNING Do not exceed the permitted limits on
trailer gross weight or hitch load. The machine
may become unstable.
WARNING Make sure the trailer hitch has
correctly engaged and locked before driving off.
WARNING Make sure you never use this
component if any part of it is missing, defective
or damaged in any way. Always install a new
replacement component
WARNING Make sure you only tow when the
hitch and eye are fixed or one fixed and
one rotating. If both the hitch and eye are
allowed to rotate they will lock up during
reverse manoeuvres and both components will be
damaged due to reduced lateral articulation.
03 - 7 9823/1700-1 03 - 7
33 - Fork
33 - Fork
Contents Page No.
03-33-00 General ............................................................................................................................. 03-9
03 - 8 9823/1700-1 03 - 8
33 - Fork
00 - General
Introduction ...................................................... 03-9 Forks can be installed on many different types of
Health and Safety .......................................... 03-10 agricultural or construction machines. Forks can be
Adjust ............................................................ 03-10 directly mounted on to a lift arm or carriage or
mounted to a lift arm via a quickhitch assembly.
There are a vast amount and size of forks used for
numerous applications.
Forks can be used to lift, raise and carry heavy things

and stack them where required.
03 - 9 9823/1700-1 03 - 9
33 - Fork
00 - General
Health and Safety Adjust

DANGER Using the forks alone as a working WARNING Loads can fall off incorrectly spaced
platform is hazardous; you can fall off and be forks. Always space the forks correctly for the
killed or injured. Never use the forks as a working load. Make sure the forks are completely under
platform. the load before lifting.
WARNING Loads can fall off incorrectly spaced CAUTION To prevent unintentional detachment
forks. Always space the forks correctly for the of forks during travel or transportation, the forks
load. Make sure the forks are completely under must not overlap the lower removal notch or be
the load before lifting. secured in the central two positions on top of the
carriage.
WARNING If the fork/locking pin is not fully
engaged, the fork could become unintentionally CAUTION The forks are heavy. Make sure
disengeged. suitable lifting equipment is used to support and
transport them.
WARNING Do not try to correct the alignment
of the fork tips by bending the forks or adding WARNING If the fork/locking pin is not fully
shims. Never repair damaged forks by heating or engaged, the fork could become unintentionally
welding. Forks are made of special steel using disengeged.
special procedures. Always replace the damaged
forks.
Repositioning the Forks
WARNING Overloaded scaffolding can collapse.
Never load scaffolding beyond the regulation Industrial Carriage Fork Adjustment
capacity.
WARNING The forks project in front of the 1. Make the machine safe. Apply the park brake (if
machine. Make sure there is enough clearance installed).
for the forks when making turns.
2. Lower the forks as required to enable the use of
CAUTION A load lifted on one fork can slip off. suitable lifting equipment to move the forks.
Never lift a load with one fork.
3. Stop the engine. Remove the ignition key.
CAUTION Never unload the forks by stopping the
machine suddenly. Follow the procedures in the 4. Release the locking pins and slide the forks to the
Operator Manual for unloading. desired position using suitable lifting equipment.
CAUTION The forks are heavy. Make sure Your machine will have either 'twist and pull'
suitable lifting equipment is used to support and or 'pull' type fork locking pins. Forks must not
transport them. overlap the lower removal notch or be secured in
the central two positions on top of the carriage,
CAUTION Do not exceed the total rated load see shaded 'no fork' zone.
capacity of the forks being used. Forks can break
resulting in a loss of load and possible injury.
CAUTION Loads stacked on uneven ground can
topple. Never stack loads on uneven ground.
03 - 10 9823/1700-1 03 - 10
33 - Fork
00 - General
Figure 6.
A Locking pins
B Lower removal notch
C 'No fork' zone
5. Re-engage the locking pins. Make sure the pins
and forks are correctly located.
6. Remove the lifting equipment.
03 - 11 9823/1700-1 03 - 11
82 - Jib
82 - Jib
Contents Page No.
03-82-00 General ........................................................................................................................... 03-13

03-82-06 Shackle ........................................................................................................................... 03-15
03 - 12 9823/1700-1 03 - 12
82 - Jib
00 - General
Introduction .................................................... 03-13
Health and Safety .......................................... 03-14
Safety
Read and understand all the warning messages.
Follow all the safety instructions given in this
Operator Manual. Do not install/operate an
attachment until you are sure that you can operate it.
Use the attachment only if it carries up to date test

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

attachment, check the appropriate load chart in
the cab and understand the lift capacities.
• Make sure the machine is in a level position.
If necessary, reposition the machine using
chassis levelling control or stabilisers (if fitted).
• Use the lifting shackle which is suitable for the
job, in good condition and proof tested where
necessary.
• Always sling the load safely and in accordance
with any local regulations.
• Make sure that the hook safety catch is closed
correctly to prevent the sling(s) from slipping off
the hook.
• Always lift the load carefully, to avoid snatching
the sling(s).
• Keep yourself and other people clear of a
suspended load, especially from beneath the
load.
• Always remember that the effective length of
the boom is increased when an attachment is
installed. Before manoeuvring the machine with
an attachment make sure you have sufficient
clearance.
• You must be careful while carrying a suspended
load. Keep the load as low to the ground
as possible. If necessary, use guide ropes to
prevent the load from swinging.
• Always travel in 1st gear at walking speed when
carrying a suspended load. Wherever possible,
travel on firm, level ground. Avoid rough or
excessively uneven ground.
• Do not carry suspended loads on public roads.
• Always be aware of the affects of wind velocity
on the load being handled.
03 - 13 9823/1700-1 03 - 13
82 - Jib
00 - General
Health and Safety

WARNING This attachment has a maximum safe
working load. Do not exceed the safe working
load. Do not exceed the machine stability limits
shown on the load chart(s) in the cab.
WARNING Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
WARNING The attachment is heavy. Take care
when lifting and handling it. Use suitable lifting
equipment. Make sure the lifting equipment is in
good condition. Make sure the lifting equipment
complies with all pertinent regulations. Wear
gloves and safety shoes.
WARNING Refer to the load chart in the cab for
permissible loading for each position of the jib
extension.
03 - 14 9823/1700-1 03 - 14
82 - Jib
06 - Shackle
06 - Shackle
Introduction
This a Q-fit attachment. It gives your machine greater Figure 8.

reach and height. This attachment is supplied with
test certificates for its fabrication, its hook and its D
shackle. The safe working load is stamped on a plate
mounted on the attachment.
Figure 7.
A F
G
A Roof truss jib
B Hook B
Installing/Removing
A
The attachment is heavy. Take care when lifting
and handling it. Use suitable lifting equipment. Make
sure the lifting equipment is in good condition. Make C
sure the lifting equipment complies with all relevant
regulations. Wear gloves and safety shoes. A Skid
B Lynch pin
The installation will be easier if the attachment is C Pin
rested on wooden blocks. D Jib- fully extended
E Jib- extended position 1
Store the attachment carefully to prevent damage F Jib- extended position 2
and corrosion. G Jib- fully retracted
Extending the Jib 1. Remove the load and lower the jib to the ground.
2. Make sure the skid is supporting the weight of
The jib may be extended to one of four positions:
the jib.
3. Remove the lynch pin, then pin.
4. Move the jib extension to the required position;
fully extended or fully retracted.
5. Insert the pin and secure with lynch pin.
Changing the Jib Angle

The angle of the jib may be set in one of two
positions.
03 - 15 9823/1700-1 03 - 15
82 - Jib
06 - Shackle
• Placing position • Travel position
Figure 9.
A B
D F
C E
C
A Placing position B Travel position

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

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

2. Make sure the skid is supporting the weight of
the jib.
3. Remove the lynch pin, then pin.
4. Use the tilt control in the cab to rotate the carriage
until the holes align in the required position.
Stops will prevent excessive movement of the jib.
5. Insert the bar and secure with lynch pin.
03 - 16 9823/1700-1 03 - 16
84 - Hook
84 - Hook
Contents Page No.
03-84-00 General ........................................................................................................................... 03-19

03-84-06 Snatch Block .................................................................................................................. 03-20
03 - 17 9823/1700-1 03 - 17
Notes:
03 - 18 9823/1700-1 03 - 18
84 - Hook
00 - General
00 - General
Remove and Install
(For: 510-56 [T2/T3], 512-56 [T2/T3])

Special Tools
Description Part No. Qty.
Slide Hammer Kit 993/68100 1
Figure 10.
A
B C D C
A Bolt
B Pivot pin
C Spacers
D Hook
E Lock nut
Remove
1. Remove the pivot pin lock nut and retaining bolt.
2. Using the Slide Hammer Kit remove the pivot pin.
Refer to (PIL 06-30).
Special Tool: Slide Hammer Kit (Qty.: 1)
2.1. Make sure to retain the spacers.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Make sure to install the spacers in the correct
locations.
3. Tighten the lock nut to the correct torque value.
03 - 19 9823/1700-1 03 - 19
84 - Hook
06 - Snatch Block
06 - Snatch Block Introduction

Introduction .................................................... 03-20 The fork mounted hook allows the machine to carry
Remove and Install ....................................... 03-21 slung loads with safety. It incorporates a swivel hook
with a spring loaded safety catch. This attachment is
supplied with test certificates for its fabrication and
its hook. Its safe working load is stamped on a plate
mounted on the attachment.
03 - 20 9823/1700-1 03 - 20
84 - Hook
06 - Snatch Block
Remove and Install 3.4. Make sure that both mounting brackets are
installed securely.
Figure 11.
C A
A Mounting sockets
B Lynch pin
C Locking bar
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Lower the attachment so that it just clears the
ground.
3. Apply the park brake and stop the engine.
4. Remove the attachment.
4.1. Remove the lynch pin and locking bar.
4.2. Carefully slide the attachment off the forks.
4.3. Install the locking bar and secure with lynch
pin.
4.4. Store the attachment carefully to prevent
damage and corrosion.
Install
1. Space the forks, equally on either side of the
machine centreline, so that the mounting sockets
can be slid onto them.
2. Tighten the fork clamping screws to prevent
movement.
3. Install the attachment.
3.1. Remove the lynch pin and locking bar.
3.2. Slide attachment over the forks so that the
rear of the attachment butts against the
heels of the forks.
3.3. Install the locking bar and secure with lynch
pin.
03 - 21 9823/1700-1 03 - 21
Notes:
03 - 22 9823/1700-1 03 - 22
Contents Page No.
06-00 Body and Framework

06-00-00 General ............................................................................................................................. 06-3
06-03 Chassis
06-03-00 General ............................................................................................................................. 06-7
06-06 Moveable Panel and Cover
06-06-00 General ........................................................................................................................... 06-11
06-06-03 Battery Compartment ..................................................................................................... 06-12
06-06-06 Engine Compartment ..................................................................................................... 06-13
06-06-14 Rear Cover ..................................................................................................................... 06-16
06-06-15 Top Cover ....................................................................................................................... 06-17
06-06-30 Undershield .................................................................................................................... 06-18
06-06-33 Lift Arm ........................................................................................................................... 06-19
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-21
06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-64
06-12-18 Angle Indicator ............................................................................................................... 06-65
06-12-24 Shim ............................................................................................................................... 06-66
06-12-66 Chain .............................................................................................................................. 06-79
06-30 Pivot Pins
06-30-00 General ......................................................................................................................... 06-101
06-42 Stabiliser
06-42-00 General ......................................................................................................................... 06-105
06-42-03 Leg ............................................................................................................................... 06-110
06-57 Counterweight
06-57-00 General ......................................................................................................................... 06-115
06-63 Identification Label
06-63-00 General ......................................................................................................................... 06-117
06-63-03 Machine ........................................................................................................................ 06-118
06-63-06 Engine .......................................................................................................................... 06-120
06-63-09 Axle(s) .......................................................................................................................... 06-122
06-63-12 Gearbox ........................................................................................................................ 06-123
06-63-15 Operator Protective Structure ...................................................................................... 06-124
06-66 Tools
06-66-00 General ......................................................................................................................... 06-127
06-69 Maintenance Strut
06-69-00 General ......................................................................................................................... 06-129
06-69-03 Lift Arm ......................................................................................................................... 06-130
06-75 Fire Extinguisher
06-75-00 General ......................................................................................................................... 06-135
06-89 Window Guard
06-89-00 General ......................................................................................................................... 06-137
06-97 Platform
9823/1700-1
2018-06-29
06-97-00 General ......................................................................................................................... 06-139
9823/1700-1
2018-06-29
Acronyms Glossary
ARV Auxiliary Relief Valve

HBCV Hose Burst Check Valve
LLMC Longitudinal Load Moment Control
LOLER Lifting Operations and Lifting
Equipment Regulations
MEWP Mobile Elevating Work Platform
OECD Organization for Economic
Cooperation and Development
PIN Product Identification Number
9823/1700-1
2018-06-29
Notes:
9823/1700-1
2018-06-29
Contents Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1 9823/1700-1 06 - 1
Notes:
06 - 2 9823/1700-1 06 - 2
00 - General
CAUTION Waxoyl contains turpentine substitute
Introduction ...................................................... 06-3 which is flammable. Keep flames away when
Preparation ...................................................... 06-4 applying Waxoyl. Waxoyl can take a few weeks
Clean ............................................................... 06-4 to dry completely. Keep flames away during the
Check (Condition) ............................................ 06-5 drying period.
Do not weld near the affected area during the
drying period. Take the same precautions as for
oil to keep Waxoyl off your skin. Do not breathe
the fumes. Apply in a well-ventilated area.
You must grease the machine regularly to keep

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

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

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

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

mix different types of grease, keep them separate.
Attach the dust caps after greasing (if installed).
06 - 3 9823/1700-1 06 - 3
00 - General
Preparation Clean
WARNING You will be working close into the
machine for these jobs. Lower the attachments. Keep all intakes and grilles clear from snow, ice and
Remove ignition key and disconnect the battery. debris.
This will prevent the engine being started.
Debris can collect under the boom. Remove all
debris from under the boom.
Make the machine safe before you start a greasing
procedure. Thoroughly dry the piston rams and protect them with
clean transmission or hydraulic oil if necessary.
You can complete most of the greasing procedures
with the boom lowered. If you raise the boom
to get access for greasing, you must install the
maintenance strut on the boom.
06 - 4 9823/1700-1 06 - 4
00 - General
Check (Condition)
1. Make sure that all of the guards and protective
devices are in position, secured by their locking
devices and free from damage.
2. Inspect all of the steelwork for damage. Include
the following:
2.1. Examine all of the lifting point welds.
2.2. Examine all of the pivot point welds.
2.3. Examine the condition of all the pivot pins.
2.4. Check that the pivot pins are correctly
in position and secured by their locking
devices.
3. Check the steps and handrails are undamaged
and correctly attached.
4. Check for broken, cracked or crazed window
glass and mirrors. Replace the damaged items.
4.1. The right hand side cab glass is installed
for the operators protection. If the cab glass
becomes damaged, the machine should not
be operated until it has been replaced.
5. Check that the lamp lenses are undamaged.
6. Check that all of the attachment teeth are
undamaged and correctly attached.
7. Check that all of the safety and instructional
labels are undamaged and in position. Install new
labels where necessary.
8. Note any damaged paintwork for future repair.
9. Inspect the machine for broken or loose
fasteners.
06 - 5 9823/1700-1 06 - 5
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-7
06 - 6 9823/1700-1 06 - 6
03 - Chassis
00 - General
Introduction ...................................................... 06-7 The chassis is the underpart of the vehicle or
Health and Safety ........................................... 06-8 machine, consisting of the frame on which the body
or cab is mounted.
06 - 7 9823/1700-1 06 - 7
03 - Chassis
00 - General
Health and Safety

CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
06 - 8 9823/1700-1 06 - 8
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ........................................................................................................................... 06-11

06-06-03 Battery Compartment ..................................................................................................... 06-12
06-06-06 Engine Compartment ..................................................................................................... 06-13
06-06-14 Rear Cover ..................................................................................................................... 06-16
06-06-15 Top Cover ....................................................................................................................... 06-17
06-06-30 Undershield .................................................................................................................... 06-18
06-06-33 Lift Arm ........................................................................................................................... 06-19
06 - 9 9823/1700-1 06 - 9
Notes:
06 - 10 9823/1700-1 06 - 10
00 - General
00 - General
Introduction
When moved to their maintenance position, the

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

of the access panels are correctly in their closed or
installed positions.
06 - 11 9823/1700-1 06 - 11
03 - Battery Compartment
03 - Battery Compartment
Remove and Install
Single Step Installation Close
Open 1. Close the battery compartment cover.
1. Make the machine safe. 2. Make sure the battery compartment cover is
closed correctly.
Refer to: PIL 01-03-27.
3. Use the key to lock the battery compartment
2. Use the key to unlock the battery compartment cover.
cover.
3. Open the battery compartment cover. Twin Step Installation
Figure 12. Open

2. Remove the bolts (and washers).
3. Lift the battery compartment cover to a small
distance and allow the cover to pivot forward.
A Battery compartment cover
Figure 13.
A
A Bolts B Battery compartment cover
Close 2. Install the bolts.
1. Position the battery compartment cover. 3. Tighten the bolts to the correct torque value.
06 - 12 9823/1700-1 06 - 12
06 - Engine Compartment
Remove and Install
CAUTION Beware of the hot exhaust system 7. Remove the air filter.
even with the engine stopped. Refer to: PIL 15-24-00.
8. Loosen the clips on the pipes to the engine and
Remove pre-cleaner (if installed).
9. Install the bolt 2.
10. Remove the filter assembly.
2. Open the engine compartment cover.
11. Plug all the open ports and hoses to prevent
3. Support the engine compartment cover with contamination.
suitable lifting equipment.
12. Remove engine pod base.
4. Remove the gas strut from the radiator cover.
13. Support the pod.
5. Remove the bolt 1 from the hinges.
14. Remove the bolt 3 (x6).
6. Use the lifting equipment to move the engine
cover clear of the machine. 15. Lower the pod with guards to the ground.
06 - 13 9823/1700-1 06 - 13
Figure 14.
B
A G
G
G
G E
A Engine compartment cover B Bolt 1

C Gas strut D Clips
E Bolt 2 F Engine pod base
G Bolt 3
06 - 14 9823/1700-1 06 - 14
Install
removal procedure.
06 - 15 9823/1700-1 06 - 15
14 - Rear Cover
14 - Rear Cover
Remove and Install
Remove
Remove the rear boom cover to get access to the
wear pad runways and boom chains.
1. Make the machine safe with the boom lowered.

2. Hold the boom cover.
3. Remove the bolts.
4. Lower the cover.
Figure 15.
B
A Boom cover
B Bolts
Install
removal procedure.
06 - 16 9823/1700-1 06 - 16
15 - Top Cover
15 - Top Cover
Remove and Install

Figure 16.
E E
B
D D
A
D
F
C
A Panel 1
B Panel 2
C Panel 3
D Bolts 1
E Location spigots
F Bolts 2
Remove
1. Make the machine safe with the lift arm raised,
refer to PIL (01-03).
2. Install the maintenance strut, refer to (PIL 06-69).
3. Remove the bolts 1 and washers.
4. Remove panel 1 from the machine.
5. Lift panel 2 from the location spigots and remove
from the machine.
6. Remove the bolts 2 and washers.
7. Remove panel 3 from the machine.
Install
removal procedure.
06 - 17 9823/1700-1 06 - 17
30 - Undershield
30 - Undershield
Remove and Install

WARNING You will be working close into the
machine for these jobs. Lower the attachments if
possible. Remove the ignition key and disconnect
the battery. This will prevent the engine being
started. Make sure the park brake is engaged.
Block all four wheels before getting under the
machine.
Remove
When cleaning around the engine and radiator,
debris will be released more easily if the undershield
is removed.
1. Make the machine safe with the boom lowered.

2. Working under the engine compartment, support
the undershield.
4. Lower the undershield to the ground.
Figure 17.
B C
A Undershield
B Bolts
C Lips
Install
steps.
2. Install the undershield.
3. Make sure that the lips are located before you
install the bolts.
06 - 18 9823/1700-1 06 - 18
33 - Lift Arm
33 - Lift Arm
Remove and Install
Remove
Remove the rear lift arm cover to get access to the
wear pad runways and lift arm chains.

2. Hold the lift arm cover, then remove the bolts.
3. Lower the cover.
Figure 18.
B
A Cover
B Bolts
Install
step.
1.1. Tighten all fastenings to the correct torque
value.
06 - 19 9823/1700-1 06 - 19
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-21

06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-64
06-12-18 Angle Indicator ............................................................................................................... 06-65
06-12-24 Shim ............................................................................................................................... 06-66
06-12-66 Chain .............................................................................................................................. 06-79
06 - 20 9823/1700-1 06 - 20
12 - Lift Arm
00 - General
Introduction .................................................... 06-21
Health and Safety .......................................... 06-23
Hydraulic Ram and Chain Operated Lift
Arms
Technical Data ............................................... 06-24
Operation ....................................................... 06-26 Twin lift rams operate the lift arm raise and lower
Operation (Hydraulic) .................................... 06-30 function. A single displacement ram is hydraulically
Calibrate ........................................................ 06-37 connected to the tilt ram and operates a parallel lift
feature.
Lubricate ........................................................ 06-38
Remove and Install ....................................... 06-40 The telescopic lift arm function is actuated by a single
Disassemble and Assemble .......................... 06-42 hydraulic extension ram which extends or retracts
the 1st intermediate lift arm section. As the ram
moves the intermediate lift arm section a system of
chains extend or retract the inner lift arm section.
On 4 stage lift arm machines shown in this service

manual, there is an extra intermediate lift arm
section, also operated by chains. All the lift arm
sections extend/retract at the same time.
Clearance between the lift arm sections is

maintained by sets of wear pads and shims.
Refer to body and framework, lift arm, general,

component identification. Refer to: PIL 06-12-00.
All intermediate and inner lift arm sections slide

against adjustable / replaceable wear pads installed
in the lift arm sections. Refer to: PIL 06-12-00. Refer
to: PIL 06-12-24.
Table 3.
Machine Lift Arm
506-36 3 Section, 3 stage
Refer to body and framework, lift arm, general,

component identification. Refer to: PIL 06-12-00.
All lift arm sections are identified in a similar way

irrespective of the number of sections or method of
operation. Not all types of lift arm are installed on
the machines shown in this service manual. Refer to
Figure 19.
06 - 21 9823/1700-1 06 - 21
12 - Lift Arm
00 - General
Figure 19. Common Lift Arm Configurations

E
A
E
A B
A B C
A B D
C
A Outer lift arm section
B Intermediate lift arm section (identified as
intermediate section 1 on H and J)
C Intermediate lift arm section 2
D Intermediate lift arm section 3
E Inner lift arm section
F 2 Stage, 2 section lift arm
G 3 Stage, 3 section lift arm
H 4 Stage, 4 section lift arm
J 5 Stage, 5 section lift arm
06 - 22 9823/1700-1 06 - 22
12 - Lift Arm
00 - General
Health and Safety

Lifting Equipment
equipment. You must identify the weight of the item to
equipment is in good condition and complies with all
local regulations.
DANGER! Before removing the boom from the
machine, make sure that the counterweight is
adequately supported as in certain ground conditions
the machine could tip backwards. Never travel or
transport the machine with the boom removed.
CAUTION! Make sure you know the weight of the
load before trying to lift it. Raise the load only a
few centimetres at first, to check that the machine is
stable. Lower the load straight away if the machine
begins to feel unstable. Do not exceed the loading
limits shown on the Load Charts.
CAUTION! This component is heavy. It must only be
removed or handled using a suitable lifting method
and device.
WARNING! The limits shown on the load charts are
for a stationary, level machine. Do not raise or extend
the lift arm while the machine is moving. Retract the
lift arm fully and lower it as far as possible before you
travel with a load.
WARNING! Under no circumstances should
personnel be lifted into the air without using an
approved and properly secured platform. Failure to
follow this warning could result in death or serious
injury.
WARNING! Do not work under raised lift arms unless
they are adequately supported by stands and/or
slings.
WARNING! You could be killed or injured if the boom
drops while you are working under it. Install the
boom maintenance strut as instructed before doing
any maintenance work with the boom raised. Keep
people away from the machine while you install or
remove the boom maintenance strut.
WARNING! Make sure the machine cannot tip
over when this component (or components) is (are)
removed during this operation.
06 - 23 9823/1700-1 06 - 23
12 - Lift Arm
00 - General
Technical Data
Lift arm wear pad clearance Table 4. Lift arm (front and rear)
Measurement Location Maximum gap
3 Stage (3 section) Lift Arm A Vertical clear- 3 mm
Figure 20. ance- outer lift
arm to interme-
diate lift arm
A
B Vertical clear- 3 mm
ance- interme-
diate lift arm to
inner lift arm
B C Total side clear- 3 mm
D C ance- interme-
diate lift arm to
inner lift arm
D Total side clear- 3 mm
ance- outer lift
arm to interme-
diate lift arm
Contact your JCB distributor if the wear pad

clearances are more than the maximum specified
dimensions.
4 Stage (4 section) Lift Arm
Figure 21.
K
H
F
J
E G

G Total side clear- 3 mm
Table 5. Lift arm (front and rear)
ance- 2nd inter-
Measurement Location Maximum gap mediate lift arm
E Total side clear- 3 mm to intermediate
ance- 2nd inter- lift arm
mediate lift arm H Vertical clear- 3 mm
to inner lift arm ance- 2nd inter-
F Vertical clear- 3 mm mediate lift arm
ance- 2nd inter- to intermediate
mediate lift arm lift arm
to inner lift arm
06 - 24 9823/1700-1 06 - 24
12 - Lift Arm
00 - General

J Total side clear- 3 mm
ance- outer lift
arm to interme-
diate lift arm
K Vertical clear- 3 mm
ance- outer lift
arm to interme-
diate lift arm
Contact your JCB distributor if the wear pad

clearances are more than the maximum specified
dimensions.
06 - 25 9823/1700-1 06 - 25
12 - Lift Arm
00 - General
Operation
Telescopic Operation Introduction 1st intermediate lift arm section out from the outer lift
arm.
Refer to Lift Arm- Introduction (PIL 06-12-00).
At the same time the chain roller 1 attached to lift
Lift arm extend 4 stage (4 section) lift arm arm section, causes extension chain 2 to pull the 2nd
intermediate lift arm section out from lift arm the 1st
When the controls are moved to extend the lift arm, intermediate lift arm.
hydraulic ram extends. The piston rod pushes the
Figure 22.
G
F
H
E
D C B A
At the same time the chain roller 2 attached to

the 2nd intermediate lift arm section, causes the
Table 6. extension chain 1 to pull the inner lift arm out from
Item Description the 2nd intermediate lift arm.
A Outer lift arm
Lift arm retract 4 stage (4 section) lift arm
B 1st intermediate lift arm
C 2nd intermediate lift When the controls are moved to retract the lift arm,
arm
(1)
the hydraulic ram retracts. The piston rod pulls the
D Inner lift arm 1st intermediate lift arm section inside the inner lift
arm 1.
E Extension chain 1
F Extension chain 2 At the same time the chain roller 3 attached to the 1st
G Chain roller 1 intermediate lift arm section, causes the retraction
H Chain roller 2 chain 1 to pull the 2nd intermediate lift arm section
inside the 1st intermediate lift arm section.
J Piston rod
K Hydraulic ram
(1) 4 section lift arm only
06 - 26 9823/1700-1 06 - 26
12 - Lift Arm
00 - General
Figure 23.
D C B A
P M
N L
J
K
retraction chain 2 to pull the inner lift arm section

inside the 2nd intermediate lift arm section.
Table 7.
Item Description Hydraulic hoses and pipes 3 stage (3
A Outer lift arm section) lift arm
B 1st intermediate lift arm
When the lift arm extends and retracts, the hydraulic
C 2nd intermediate lift hoses and pipes connected to the tilt and auxiliary
arm
(1)
services extend and retract at the same time.
D Inner lift arm
J Piston rod Extend
K Hydraulic ram
When the lift arm extends the extend ram pulls the
L Chain roller 3 intermediate lift arm out from inside the outer lift arm.
M Retraction chain 1 At the same time the chain system extends the inner
N Chain roller 4 lift arm.
P Retraction chain 2
The hydraulic hoses are clamped to the outer lift arm
(1) 4 section lift arm only and inner lift arm sections and are pulled out with the
lift arm sections.
At the same time the chain roller 4 attached to
the 2nd intermediate lift arm section, causes the
Figure 24.
C B A
A Outer lift arm B Intermediate lift arm

C Inner lift arm K Hydraulic ram
Q Guide roller
06 - 27 9823/1700-1 06 - 27
12 - Lift Arm
00 - General
A guide roller is fixed to the intermediate lift arm. The The hydraulic hoses are clamped to the outer lift arm
guide roller controls the hoses as they transfer from and inner lift arm sections and are pulled out with the
inside the outer lift arm to inside the inner lift arm lift arm sections.
section.
Retract
When the lift arm retracts the extend ram pulls the
intermediate lift arm inside the outer lift arm. At the
same time the chain system retracts the inner lift arm.
Figure 25.
C B A
A Outer lift arm B Intermediate lift arm

C Inner lift arm K Hydraulic ram
Q Guide roller
A guide roller is fixed to the intermediate lift arm Extend

section. The guide roller controls the hoses as they
transfer from inside the inner lift arm section to the When the lift arm extends, the extend ram pulls the
outer lift arm. 1st intermediate lift arm out from the outer lift arm.
At the same time the chain system extends the 2nd
Hydraulic hoses and pipes 4 stage (4 intermediate lift arm and the inner lift arm.
section) lift arm The hydraulic hoses are pulled out with the lift arm
sections by the inner lift arm pipe assembly, which
When the lift arm extends and retracts, the hydraulic
is fixed to the rear of the 2nd intermediate lift arm.
hoses and pipes connected to the tilt and auxiliary
A guide bracket at the front of the pipe assembly
services extend and retract at the same time.
moves inside the inner lift arm as it extends. The
guide bracket is installed with nylon wear pads.
Figure 26.
D C B A
R
A Outer lift arm B 1st intermediate lift arm

C 2nd intermediate lift arm D Inner lift arm
K Hydraulic ram Q Guide roller
06 - 28 9823/1700-1 06 - 28
12 - Lift Arm
00 - General
R Inner lift arm pipe assembly
A guide roller is fixed to the 1st intermediate lift arm arm. At the same time the chain system retracts the
section. The guide roller controls the hoses as they 2nd intermediate lift arm section and the inner lift
transfer from inside the outer lift arm to inside the 1st arm.
intermediate lift arm section.
The hydraulic hoses are pulled in with the lift arm
Retract sections by the inner lift arm pipe assembly, which
is fixed to the rear of the 2nd intermediate lift arm
When the lift arm retracts, the extend ram pulls the section. The guide bracket at the front of the pipe
1st intermediate lift arm section inside the outer lift assembly moves inside the inner lift arm as it retracts.
The guide bracket is installed with nylon wear pads.
Figure 27.
R D C B A
A Outer lift arm B 1st intermediate lift arm

C 2nd intermediate lift arm D Inner lift arm
K Hydraulic ram Q Guide roller
R Inner lift arm pipe assembly
A guide roller is fixed to the 1st intermediate lift arm

section. The guide roller controls the hoses as they
transfer from inside of the 1st intermediate lift arm
section to inside the outer lift arm.
06 - 29 9823/1700-1 06 - 29
12 - Lift Arm
00 - General
Operation (Hydraulic)
Lift arm extend and retract operation Regeneration operation

The extension circuit has a regenerative and HBCV The illustration shows the lift arm extend service
(Hose Burst Check Valve). The valve is part of the selected at the control spool, oil is supplied to the
extension ram. extension cylinder through the combined load hold
check valve and the regenerative valve assembly.
Figure 28. The valve assembly accommodates the retract load
hold check valve, extend load hold check valve and
the regenerative check valve.
Oil is fed to the retract load hold check valve, the

pressurised oil opens the check valve for the oil to
act on the head side of the extension ram, to extend
the cylinder.
With the forks of the machine lightly loaded, the

pressure required to extend the lift arm remains
below the relief valve setting.
S
Oil displaced from rod side of extension cylinder
flows to the regenerative valve assembly.
The combined pilot pressure from V1 and C1 is

S HBCV felt under the piston of the relief valve 1. Because
passage back to the tank through the extension
On machines installed with a 4 section lift arm, the spool is blocked by the closed relief valve 2, the
regenerative valve/ HBCV is located in an alternative pressurised oil opens the regenerative check valve
position on the extension ram. to supplement pump flow in extending the extension
cylinder.
06 - 30 9823/1700-1 06 - 30
12 - Lift Arm
00 - General
Figure 29. Lift arm extend regenerative
2F Control spool 12 Extension cylinder

18 Regenerative valve assembly 18A Retract load hold check valve
18B Regenerative check valve 18C Extend load hold check valve
18D Relief valve 1 18E Relief valve 2
06 - 31 9823/1700-1 06 - 31
12 - Lift Arm
00 - General
lift arm extend high pressure operation displaced oil from the extension cylinder is diverted
back to tank via the control spool.
Should the pressure required to extend the lift arm
increase, the regenerative check valve is held on The relief valve 1 senses a pressure drop via pilot
its seat by the oil that flows to the head side of the galleries from return line port and closes, thus the
extension cylinder. passage of oil to the head side of the extension
cylinder is blocked.
The inlet pressure through the internal pilot galleries
from the inlet cavity opens the relief valve 2, the
Figure 30. Lift arm extend high pressure

18B Regenerative check valve 18D Relief valve 1
18E Relief valve 2 V1 Inlet cavity
C1 Return line port
06 - 32 9823/1700-1 06 - 32
12 - Lift Arm
00 - General
Lift arm retract operation pressure opens check valve 1 and oil flows to the rod
side of extension cylinder.
When lift arm retract is selected at the control spool,
system pressure enters the combined load hold Pressure is felt under piston of check valve 3 through
check valve and regenerative valve assembly, the pilot line from port and the check valve 2, check valve
3 opens and displaced oil from the extension cylinder
is diverted back to tank through the control spool.
Figure 31. Lift arm retract

18 Regenerative valve assembly 18C Check valve 1
18F Check valve 2 18G Check valve 3
06 - 33 9823/1700-1 06 - 33
12 - Lift Arm
00 - General
Lift arm extend- Hose burst operation will hold both the load hold and the regenerative
check valve firmly on their seat, thus trapping a
In the event of a hose burst or other leakage in the column of oil in the cylinder head side circuit which
feed to the head side of the cylinder, back pressure will prevent the load from retracting.
Figure 32.
12 Cylinder 18A Retract load hold check valve

18B Regenerative check valve
06 - 34 9823/1700-1 06 - 34
12 - Lift Arm
00 - General
Lift arm raise and lower operation direction of load hold check valves and the lift rams
raise the lift arm.
Lift arm raise cycle
When the lift spool is selected, oil feeds lift ram
load hold check valves. Oil flows through free flow
Figure 33.
2D Lift spool 2F Tilt spool

2H Valve 1 2J ARV (Auxiliary Relief Valve)
8 Lift ram 8A Lift ram load hold check valves
9 Displacement ram 10 Tilt ram
10A Tilt ram load hold check valve 20 Displacement/lift link valve
Oil is forced out of the rod side of the displacement Figure 34.
ram as the lift arm rises. The oil cannot flow past the
tilt spool, as the spool is not selected. Instead, it flows
to the rod side of the tilt ram. The pilot pressure in
the load hold check valve increases and the valve
opens. This allows oil to flow from the head side of
the tilt ram to the head side of the displacement ram. 8A
This has the effect of allowing the tilt ram to extend

in proportion to lift arm lift, keeping the forks parallel
with the ground.
Displacement / lift link valve is installed between the

lift spool and the tilt spool. The function of this valve
is to allow a restricted flow of oil into the tilt circuit 8A Lift ram load hold check valve
to increase the lift force available by utilising the
displacement ram. The ARV opens to protect the tilt ram from over
pressurisation. The anti-cavitation feature of valve 1
makes sure that, in these circumstances, the tilt and
displacement rams will not cavitate.
06 - 35 9823/1700-1 06 - 35
12 - Lift Arm
00 - General
Lift arm lower cycle side of the lift rams raises the pilot pressure in the
load hold check valves and allows oil out of the lift
When the raise or lower spool is selected, oil feeds rams back to tank, lowering the lift arm.
the rod side of lift rams. Oil displaced from the head
Figure 35.
2D Lift spool 2F Tilt spool

2H Valve 1 2J ARV
8 Lift ram 8A Lift ram load hold check valves
9 Displacement ram 10 Tilt ram
10A Tilt ram load hold check valve 20 Displacement/lift link valve
As the lift arm lowers, oil is forced from the head side Figure 36.
of the displacement ram. The oil cannot flow past the
tilt spool, as the spool is not selected. Instead, it flows
through the free flow direction of the load hold check
valve to the head side of the tilt ram.
As a result the tilt ram will retract in proportion to lift 8A

arm lower, make sure that the forks are parallel with
the ground.
Displaced oil from the displacement ram closes the

check valve in displacement or lift link valve.
8A Lift ram load hold check valve
The ARV opens to protect the tilt ram from over

pressurisation. The anti-cavitation feature of valve 1
makes sure that, in these circumstances, the tilt and
displacement rams will not cavitate.
06 - 36 9823/1700-1 06 - 36
12 - Lift Arm
00 - General
Calibrate 8. Make sure that the difference in shim thickness of

shim 1 and shim 2 does not exceed the specified
value.
When the boom is assembled, do a check of
Length/Dimension/Distance: 3.2 mm
the carriage alignment to make sure that the
measurement is accurate. 9. Make sure that the maximum wear pad clearance
does not exceed the specified value.
Length/Dimension/Distance: 3 mm
2. Make sure that the tyre pressures are correct.
Figure 39.
3. Make sure that the machine is parked on flat level
ground.
B
4. Check the inclinometer to make sure that the
chassis is level.
Figure 37.
A
A Inclinometer
5. Measure the left and right side carriage height
from the ground to the top of the carriage and C F
D E
note the dimensions.
B Maximum wear pad clearance
Figure 38. C Lower wear pad 1
D Lower wear pad 2
E Shim 1
F Shim 2
X Y
X Left side dimension

Y Right side dimension
6. If there is a difference between left and right side
dimension, the front lower wear pads 1 and wear
pads 2 can be shimmed.
7. Add or remove the shim 1 and shim 2 as
necessary to align the carriage. Refer to adjust
(PIL 06-12-30).
06 - 37 9823/1700-1 06 - 37
12 - Lift Arm
00 - General
Lubricate
Consumables 3. Apply the specified lubricant evenly over the lift

Description Part No. Size arm wear pad runways. Refer to Figure 41.
Waxoyl 4004/0501A 0.4 L Consumable: Waxoyl
4004/0502 5L
4. Apply suitable slide lubricant to the inner hoses
4004/0505 200 L and hose runs.
You must lubricate the lift arm at every 500 h of 5. Allow applied lubricant to dry for the specified
machine operation. duration before you retract the lift arm.
1. Extend the lift arm fully. Duration: 2 –3 h
2. Remove the lift arm rear cover.

Figure 40.
A Rear cover
B Wear pad runways
Figure 41.
B
B
B Wear pad runways
6. For machines with a 3 stage boom, there are 2

grease points. Refer to Figure 42.
06 - 38 9823/1700-1 06 - 38
12 - Lift Arm
00 - General
Figure 42.
7. For machines with a 4 stage boom, there are 4

grease points. Refer to Figure 43.
Figure 43.
3
4
06 - 39 9823/1700-1 06 - 39
12 - Lift Arm
00 - General
Remove and Install Special Tool: Slide Hammer Kit (Qty.: 1)

9.3. Lower the displacement ram onto suitable
Special Tools
packing material to protect the piston rod.
Slide Hammer Kit 993/68100 1 10. Disconnect the displacement ram from the lift
arm.
Before removal 10.1. Remove the bolt 2.
1. Make the machine safe. Refer to PIL (01-03). Figure 45.
2. Machines with lift arm angle proximity switches,
Remove the proximity switches before you
remove the lift arm. Refer to (PIL 06-12-21).
Proximity switches can be damaged by vibration D C

when you remove and install the lift arm pivot pin.
Remove
1. Remove any attachments on the machine.
2. Raise the lift arm to the horizontal position, then
retract the lift arm fully. Support the lift arm.
3. Discharge the hydraulic pressure. Refer to PIL
C Bolt2
(30-00).
D Pivot pin2
10.2. Use a slide hammer kit to remove the pivot
5. Support the lift arm with a suitable lifting pin 2. Refer to (PIL 06-30).
equipment. Special Tool: Slide Hammer Kit (Qty.: 1)
6. Disconnect hydraulic hoses from the lift arm to 10.3. Lower the displacement ram onto suitable
the base. Label the hoses for easy identification. packing material to protect the piston rod.
7. Disconnect the hydraulic hoses from the HBCV 11. Remove the bolt 3.
(Hose Burst Check Valve).
Figure 46.
8. Disconnect lift arm extend proximity switch
electrical connectors from chassis harness.
9. Disconnect the lift ram from the lift arm.
9.1. Remove the bolt 1.
Figure 44.
B
E F
A E Bolt 3
F Pivot pin 3
12. Use a slide hammer kit to remove the pivot pin 3.
A Bolt 1 13. Carefully remove the lift arm from the machine
B Pivot pin 1 with appropriate lifting equipment.
9.2. Use a slide hammer kit to remove the pivot
pin1. Refer to (PIL 06-30).
06 - 40 9823/1700-1 06 - 40
12 - Lift Arm
00 - General
14. If necessary, remove the hoses from the 4 stage

lift arm. Refer to PIL (30-93).
Install
removal procedure. Additionally do the followings
steps.
1.1. If necessary, install the shims on the lift arm.
Refer to PIL (06-12-30).
1.2. Before you install the pivot pins, apply
the correct grease on them. Refer to PIL
(75-06).
1.3. Check the hydraulic fluid level. Refer to (PIL
30-00).
06 - 41 9823/1700-1 06 - 41
12 - Lift Arm
00 - General
Disassemble and Assemble
For: 3 Stage (3 Section) ............ Page 06-42 7.11. Remove the auxiliary service hoses.
For: 4 Stage (4 Section) ............ Page 06-46 7.12. Pull out the hoses in the same way as the
tilt ram hoses. Refer to 7.6 and 7.7.
(For: 3 Stage (3 Section)) 7.13. Plug all the open ports and hoses to
prevent contamination.
Unless the lift arm fabrications are damaged there
is normally no requirement to separate the lift arm 7.14. Put a label on the inner extension ram
sections. The lift arm sections can be separated with hoses on the underside of the lift arm to
the lift arm assembly removed or installed to the help installation.
machine as required.
7.15. Remove the inner extension ram hoses
connected at the steel pipes.
Disassemble
7.16. Pull out the hoses through the apertures
1. Make the machine safe. Refer to (PIL 01-03). under the lift arm in the direction of the
arrow Y.
2. Discharge the hydraulic pressure. Refer to (PIL
30-00). 7.17. Plug all the open ports and hoses to
3. Remove the fork carriage. Refer to (PIL 03-33).
8. Remove the inner lift arm.
4. Remove the tilt ram. Refer to (PIL 30-15).
8.1. Remove the front wear pads from the
5. Remove the inner extension ram. Refer to (PIL intermediate lift arm.
30-15).
8.2. Make sure that the lift arm assembly is fully
6. Remove the outer extension ram. Refer to (PIL supported by the outer lift arm and then
30-15). remove the upper and side wear pads.
8.3. Lift the front of the inner lift arm clear of the
7. Remove the telescopic hydraulic service hoses. lower wear pads and then remove them.
To ensure that the hoses do not become
damaged or tangled they must be removed 8.4. Put a label on the wear pads and keep them
before attempting to separate the lift arm together with the shims.
sections. Remove the hoses as follows:
8.5. Support the front end of the inner lift arm
7.1. Remove the bolts 2 and remove the lift arm and pull it out from the intermediate section.
hose guide roller assembly. 8.6. Make sure that the intermediate section
7.2. Remove the bolts 1 and remove the hose does not move.
guide. 8.7. Before you pull out the inner lift
7.3. Put a label on the hoses at the steel pipes arm completely, attach suitable lifting
on the underside of the lift arm to help equipment.
installation. 8.8. Make sure that the section is fully supported
7.4. Disconnect the hoses at the steel pipes. by the lifting equipment and then pull it out
from the intermediate section.
7.5. Remove the tilt ram hoses.
9. If the lift arm assembly has been removed
7.6. Pull out the hoses from the rear in the from the machine, make sure that it is securely
direction of the arrow X. supported. When the inner lift arm sections is
7.7. Then pull out the hoses through the removed, forces may cause the whole assembly
apertures under the lift arm in the direction to move.
of arrow Y.
10. Remove the intermediate lift arm.
7.8. Plug all the open ports and hoses to prevent
contamination. 10.1. Remove the front wear pads from the outer
lift arm.
7.9. Put a label on the auxiliary service hoses on
the underside of the lift arm and at the front 10.2. Make sure that the lift arm assembly is fully
of the lift arm to help installation. supported by the outer lift arm and then
remove the upper and side wear pads.
7.10. Disconnect the auxiliary hoses connected
at the steel pipes.
06 - 42 9823/1700-1 06 - 42
12 - Lift Arm
00 - General
10.3. Lift the front of the intermediate lift clear 10.7. Make sure that the section is fully
of the lower wear pads and then remove supported by the lifting equipment and
them. then pull it out from the outer section.
10.4. Put label on the wear pads and keep them 11. If the lift arm assembly has been removed
together with the shims. from the machine, make sure that it is securely
10.5. Support the front end of the intermediate supported. When the intermediate lift arm section
lift arm and pull it out from the outer is removed, forces may cause the whole
section. assembly to move.
10.6. Before you pull out the intermediate lift
arm completely, attach suitable lifting
equipment.
06 - 43 9823/1700-1 06 - 43
12 - Lift Arm
00 - General
Figure 47. 3 Stage Lift Arm
H
H
B
N X
F G
E
L
H
D
G J
K J
H
C
U
T
G
A
H
H
J
Y G C
J
A Outer lift arm B Inner lift arm

C Intermediate lift arm D Inner extension ram
E Outer extension ram F Tilt ram
G Extension ram hoses H Auxiliary service hoses
J Tilt ram hoses K Hose guide
L Bolts 1 M Bolts 2
06 - 44 9823/1700-1 06 - 44
12 - Lift Arm
00 - General
N Guide roller assembly T Intermediate lift arm front wear pads

U Outer lift arm front wear pads X Arrow X
Y Arrow Y
06 - 45 9823/1700-1 06 - 45
12 - Lift Arm
00 - General
Assembly use excessive force when setting the roller

assembly.
1. The assembly procedure is the opposite of
the disassembly procedure. Additionally do the (For: 4 Stage (4 Section))
following steps.
Special Tools
1.1. Check the length of the hose pairs. The Description Part No. Qty.
hose lengths must be equal to within +/- Male Cone Blanking 816/00189A 1
1mm for each service pair (tilt ram pair, Cap 3/8 in BSP
inner extension ram pair and auxiliary
service pair). Female Blanking Cap 892/00056A 1
3/8 in BSP
1.2. Do not renew individual hoses. The hoses
can stretch over time. New hoses may Consumables
not be the same length. Renew all six Description Part No. Size
telescopic service hoses if any of the hoses
JCB Threadlocker 4101/0250 0.01 L
are damaged.
and Sealer (Medium 4101/0251 0.05 L
1.3. Assemble the lift arm sections so that the lift Strength)
arm is fully retracted. Install the extension Special HP Grease 4003/2020 0.5 kg
ram followed by the inner ram. Refer to (PIL 4003/2017 0.4 kg
30-00).
4003/2006 12.5 kg
1.4. To enable alignment of the rod end pivot 4003/2005 50 kg
of the inner ram, the hydraulic hoses must
be installed so that the lift arm can be
extended. The length of the inner and Disassemble
intermediate lift arm sections protruding WARNING Never position yourself or any part
from the outer section must be kept equal of your body under a raised machine which is
to avoid damage to the telescopic service not properly supported. If the machine moves
hoses. unexpectedly you could become trapped and
1.5. Make sure that the hose routing is correct. suffer serious injury or be killed.
Do not cross over any hose. The tilt ram and
auxiliary service hoses are routed through Remove primary external components
the hose guide and along the tray fitted to
the top of the inner extension ram. 1. Make the machine safe. Refer to (PIL 01-30).
1.6. Lubricate the lift arm hose runs. Refer to 2. Remove the fork carriage. Refer to (PIL 03-33).
(PIL 06-00).
1.7. Make sure that the lift arm wear pad 3. Discharge the hydraulic pressure. Refer to (PIL
shimming is correct. Refer to Technical 30-00).
Data (PIL 06-12). 4. Remove tilt ram. Refer to (PIL 30-15).
1.8. Pivot the hose guide roller assembly so
as to take up the hose slack. Do not 5. Remove the outer extension ram from the lift arm
assembly. Refer to (PIL 30-15-07).
06 - 46 9823/1700-1 06 - 46
12 - Lift Arm
00 - General
Figure 48. 4 Stage Lift Arm
8
6
5 Extension ram 6 Tilt ram

8 Lift arm assembly
06 - 47 9823/1700-1 06 - 47
12 - Lift Arm
00 - General
Disassemble the main lift arm assembly Figure 49.

CAUTION You can be injured if you use incorrect
or faulty lifting equipment. You must identify the
weight of the item to be lifted then choose lifting
equipment that is strong enough and suitable for Y
the job. Make sure that lifting equipment is in good
X
condition and complies with all local regulations.
WARNING Hydraulic fluid at system pressure
can injure you. Before connecting or removing
any hydraulic hose, residual hydraulic pressure
trapped in the service hose line must be vented.
Make sure the hose service line has been vented
before connecting or removing hoses. Do not start
the engine with loose or open hose connections. X Screws 1, washers 1 and locknuts 1
Y Tracking assembly
The following procedure describes the procedure
required to fully dismantle the lift arm assembly. 9. Remove the two bolts 2, the two washers 2 and
Make sure you only dismantle the lift arm as far as is the two nuts 2. Remove the main pipe assembly
required to complete the task in hand. support plate from the main pipe assembly.
10. Remove the main pipe assembly from the inner
Put a label on all the hoses and pipework that are
ram.
disconnected to help assembly.
11. If required, remove the two nuts 3, four washers
1. Make sure you use the correct tools to prevent 3 and the two bolts 3 and remove the wear blocks
the ingress of debris or moisture. Make sure all from the support ram.
hoses and pipes are capped.
Special Tool: Female Blanking Cap 3/8 in BSP 12. Remove the support arm only if absolutely
(Qty.: 1) necessary. Correct functioning of the assembled
Special Tool: Male Cone Blanking Cap 3/8 in BSP lift arm depends on careful and accurate
(Qty.: 1) assembly of its components. Misalignment of
pipework and/or hoses will result in malfunction
2. Remove the bolts 1 and washers 1 to release of the lift arm and damage to the hoses and/or lift
the main pipe assembly support plate from its arm structure.
location points on the first intermediate lift arm.
13. If required, remove the four nuts 4, four bolts 4
3. Put a labels on the six hoses to help installation. and the eight washers 4 and remove the support
arm from the main pipe assembly.
4. Disconnect the six hoses at the rear connection
points. 14. Remove the front wear pads 1 from the first
intermediate lift arm.
5. At the rear of the inner ram, identify and
disconnect the four hose connections at the inner 15. Remove the side and top wear pads 1 from the
lift arm pipe assembly. Also disconnect the two rear of the second intermediate lift arm. Do not
hose connections at the inner ram. remove the bottom wear pads 1.
6. Pull the main pipe assembly together with the 16. Remove the inner lift arm and the second
support ram rearwards until you can access the intermediate lift arm from the first intermediate lift
front connection block. arm. Remove the bottom wear pads 1 if required.
7. Put labels on the six hoses for correct installation. 17. Remove the front wear pads 2 from the outer lift
Disconnect the six hoses at the front connection arm.
block.
18. Remove the top and side wear pads 2 from
8. Remove the two screws 1, two washers 1 and the rear of the first intermediate lift arm. Do not
two locknuts 1, retaining hose and the tracking remove the bottom wear pads 2.
assembly. Move the hose and the tracking
assembly away from the work area. If required, 19. Remove the first intermediate lift arm from the
remove and replace any damaged hoses. outer lift arm. Remove the bottom wear pads 2
if required.
20. Put a label on the six connections 1 to help
installation at the underside of the outer lift arm
06 - 48 9823/1700-1 06 - 48
12 - Lift Arm
00 - General
where the main hose assembly joins the six 'U' ram connectors Refer to Figure 51. are free to
pipes. Disconnect the six connections 1. move in the head of the inner lift arm. Put a label
for correct installation and disconnect the two
21. If required, disconnect the six 'U' pipes from the auxiliary hoses from the auxiliary pipe assembly.
external pipe assembly.
33. Remove the two nuts 9, four washers 9 and two
22. Remove the main hose assembly through the bolts 9 and remove the auxiliary pipe assembly
rear of the outer lift arm. If required, remove the from the inner lift arm. Refer to Figure 50.
eight bolts 5 and remove the four sets of pipe
clips from the hose assembly. 34. At the inner ram location: Remove the nut 10 and
bolt 10 and remove the rear location pin and the
23. At the rear underside position of the outer lift arm, two spacers. Support the rear of the inner ram
disconnect the right hand external hoses and the with a block of wood or similar soft material.
left hand external hoses from the external pipe
assembly. 35. Remove the front wear pads 3 from the second
intermediate lift arm.
24. Disconnect the connections 2 and the
connections 3 and remove the auxiliary hoses. 36. Remove the top and side wear pads 3 from the
If required, remove two of the four circlips and rear of the inner lift arm.
remove the auxiliary couplings from the bracket.
37. Remove the top and the side wear pads 3 from
25. If required, remove the two nuts 5, four washer the rear of the inner lift arm. Do not remove the
5 and two bolts 5 and remove the bracket from bottom wear pads 3.
the outer lift arm.
38. Remove the inner lift arm from the second
26. Support the external pipe assembly and remove intermediate lift arm. Remove the bottom wear
the six bolts and six washers from the underside pads 3 if required.
of the outer lift arm. Remove the external pipe
assembly from the work area. Disassemble the 39. Remove the bolt 11 and plate and remove the
two sections of the assembly only if one part is front inner ram location pin.
defective.
40. Move the inner ram assembly rearwards until you
27. Put a label for correct installation and disconnect can access the tilt ram hoses and the auxiliary
the three right hand external hoses from the right hoses.
hand external pipes assembly. Remove the three
hoses from the work area. 41. Put label on the tilt ram hoses and the auxiliary
hoses for correct installation.
28. Put a label for correct installation and disconnect
the three left hand external hoses from the left 42. Disconnect the tilt ram hoses and the auxiliary
hand external pipes assembly. Remove the three hoses from the front end of the inner lift arm pipe
hoses from the work area. assembly. Carefully remove the tilt ram hoses
and the auxiliary hoses from the inner lift arm.
29. Support the right external pipes assembly and
remove the three bolts 7 and three washers 7. 43. Remove the inner ram assembly from the inner
Remove the pipes assembly from the work area. lift arm.
30. Support the right external pipes assembly and 44. Remove the five bolts 12 and the five washers
remove the three bolts 8 and three washers 8. 12 and remove the inner lift arm pipe assembly
Remove the pipes assembly from the work area. from the inner ram.
31. If required, disconnect the two tilt ram hoses from 45. Remove the two nuts 13, four washers 13 and
each of the external pipe assemblies. the two bolts 13 and remove the front wear pad
bracket from the inner ram.
32. On the second intermediate lift arm and inner lift
arm sub-assembly: Make sure that the two tilt 46. Remove the two countersunk screws and
remove the front wear pad 4 from its bracket.
06 - 49 9823/1700-1 06 - 49
12 - Lift Arm
00 - General
Figure 50. 4 Stage Lift Arm (1 of 2)
2 Inner lift arm 3 Second intermediate lift arm

4 First intermediate lift arm 5 Outer lift arm
29 'U' pipes 30 External pipe assembly
32 Pipe clips 33 Right hand external hoses
35 Left hand external hoses 36 Connections 2
37 Connections 3 38 Auxiliary hoses
39 Circlips 40 Auxiliary couplings
41 Bracket 42 Nuts 5
43 Washers 5 44 Bolts 5
46 Bolts 6 47 Washers 6
49 Right hand external pipe assembly 51 Left hand external pipe assembly
56 Tilt ram hoses 57 Nuts 9
59 Auxiliary pipe assembly 61 Washers 9
62 Bolts 9 63 Nut 10
64 Bolt 10 65 Rear location pin
66 Spacer 67 Bolt 11
68 Plate 69 Front inner ram location pin
A Front wear pads 1 B Top and side wear pads 1
C Bottom wear pads 1 D Front wear pads 2
E Top and side wear pads 2 F Bottom wear pads 2
G Front wear pads 3 H Top and side wear pads 3
J Bottom wear pads 3
06 - 50 9823/1700-1 06 - 50
12 - Lift Arm
00 - General
Figure 51. 4 Stage Lift Arm (2 of 2)
1 Inner ram 6 Support arm

7 Main pipe assembly 8 Inner lift arm pipe assembly
9 Main pipe assembly support plate 11 Main hose assembly
15 Rear connection points 16 Front connection block
21 Nuts 2 22 Nuts 3
25 Wear blocks 26 Nuts 4
31 Bolts 5 57 Tilt ram connectors
58 Auxiliary hoses 70 Tilt ram hoses
71 Auxiliary hoses 72 Bolts 12
73 Washers 12 74 Nuts 13
77 Front wear pads bracket 78 Countersunk screws
79 Front wear pad 4
Assemble WARNING Hydraulic fluid at system pressure

can injure you. Before connecting or removing
CAUTION You can be injured if you use incorrect any hydraulic hose, residual hydraulic pressure
or faulty lifting equipment. You must identify the trapped in the service hose line must be vented.
weight of the item to be lifted then choose lifting Make sure the hose service line has been vented
equipment that is strong enough and suitable for before connecting or removing hoses. Do not start
the job. Make sure that lifting equipment is in good the engine with loose or open hose connections.
WARNING Never position yourself or any part
of your body under a raised machine which is
06 - 51 9823/1700-1 06 - 51
12 - Lift Arm
00 - General
not properly supported. If the machine moves 2.3. Identify which end of the hose assembly
unexpectedly you could become trapped and will be the front end with regard to lift arm
suffer serious injury or be killed. position.
2.4. Arrange the two front connectors of the
These procedures refer to left and right, front central hose relative to the two shorter side
and rear positions. This assumes the operator is hoses to reflect the dimension recorded in
positioned at the base of the lift arm assembly looking the step 2.1.
towards the lift arm nose.
2.5. The hose connectors will now interface
Correct functioning of the assembled lift arm correctly with the six 'U' pipes on the
depends on careful and accurate assembly of its external pipe assembly.
components. Misalignment of pipework and/or hoses
will result in malfunction of the lift arm and damage
to the hoses and/or lift arm structure.
1. Check the twin hose assemblies:

Figure 52.
1.1. Before you assemble, make sure that in all

the twin hose assemblies, the hoses are
of equal length. Refer to Figure 52. Do not
use any hose pairs which are misaligned by
more than the specified value.
2. Outer lift arm hose assembly:
2.1. At the front end of the external pipe
assembly, measure and record the
horizontal distance. Refer to Figure 53.
Make sure that the measurement is of the
specified value.
Figure 53.
2.2. In a suitably clean area, arrange the three

hoses of the outer lift arm hose assembly
adjacent to each other as shown. Refer to
Figure 54.
06 - 52 9823/1700-1 06 - 52
12 - Lift Arm
00 - General
Figure 54. Outer Lift Arm Hose Assembly 2.6. Make sure that the hoses are not twisted.
2.7. Measure the specified length using a front
connector of the shorter length hoses as a
X datum.
2.8. Apply JCB sealant to the threads of the two
bolts and install the hose clip and two bolts
at this point to locate the three hoses in
position.
920 Consumable: JCB Threadlocker and Sealer
31 (Medium Strength)
2.9. Using the hose clip installed in the previous
step as a datum, install the remaining three
hose clips and six bolts at the specified
intervals along the hose assembly applying
32 JCB sealant to the threads of the bolts.
920 Consumable: JCB Threadlocker and Sealer
(Medium Strength)
3. Check the hose lengths. Refer to Figure 54.
4. Carry out the assembly of the main pipe
assembly and support arm on a flat level surface:
4.1. Assemble the support arm and the main
pipe assembly together using the nuts 4,
920 bolts 4 and the washers 4.
4.2. Apply JCB sealant and hand tighten.
11
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
4.3. If a suitable length of flat level surface is
available, put the assembly on the level
surface. Tighten the nuts to the specified
torque value.
920 Torque: 28 N·m
4.4. Make sure that the lower joint between
the pipe assembly and the support arm is
absolutely flat and level. Otherwise damage
will be caused to the hoses when the lift arm
is operated. Check both before and after
torque tightening the nuts.
4.5. If a suitable length of flat level surface is not
available, invert the assembly and place it
on best available flat surface.
L1 L2 L1
11 Main hose assembly

31 Bolts 5
32 Pipe clip
L1 Hose 1. ( 4,100 ± 20 mm)
L2 Hose 2. ( 4,300 ± 20 mm)
06 - 53 9823/1700-1 06 - 53
12 - Lift Arm
00 - General
Figure 55.
P Lower joint
4.6. Put a straight edge, e.g. a spirit level, across ensuring that the straight edge is in contact
the joint. Support the ends of the assembly with both parts of the pipe assembly along
at support point 1 and support point 2, its whole length.
Figure 56.
Q S P R
P Lower joint Q Support point 1

R Support point 2 S Joint between base and support arm
4.7. Tighten the nuts to the specified torque Figure 57.

value.
Torque: 28 N·m
4.8. Install the main pipe assembly support plate 7
to the rear of the main pipe assembly with
the two bolts 2, washers 2 and the nuts 2.
4.9. Tighten the bolts 2 to the specified torque
value.
Torque: 28 N·m
19
4.10. Make sure that the main pipe assembly
support plate is installed correctly. 20
Otherwise damage to the assembly will
occur.
21 9
7 Main pipe assembly

9 Main pipe assembly support plate
19 Bolts 2
20 Washers 2
21 Nuts 2
4.11. Apply JCB sealant to the threads of the two
bolts 2.
Consumable: JCB Threadlocker and
Sealer (Medium Strength)
4.12. Install the two wear blocks to the front of
the support arm with the two bolts 3, four
washers 3 and the two nuts 3.
06 - 54 9823/1700-1 06 - 54
12 - Lift Arm
00 - General
4.13. Tighten the two nuts 3 to the specified 5.1. In a suitably clean area, clip mounting
torque value. bracket in place onto hose chain tracking.
Torque: 28 N·m 5.2. Slide the two right hand hoses of the
specified length through the tracking.
Figure 58.
Length/Dimension/Distance: 2,360 mm
5.3. Slide two left hand hoses of the specified
length on each side of the hoses.
Length/Dimension/Distance: 2,400 mm
5.4. Put the hoses and the tracking on to the
pipe assembly. Connect the hoses to the
24 steels of the pipe assembly.
6 5.5. Tighten it to the specified torque value.
23
Torque: 33 N·m
25 5.6. Attach the bracket to the pipe assembly with
23 22 screws 1, washers 1 and the locknuts 1.
6 Support arm 6. Inner lift arm assembly:

22 Nuts 3
6.1. Install the front wear pad 4 to the front
23 Washers 3
wear pad bracket with the two countersunk
24 Bolts 3
screws.
25 Wear blocks
6.2. Tighten the two countersunk screws to the
5. Inner lift arm hose assembly: specified torque value.
Figure 59. Torque: 28 N·m
U Z 6.3. Install the front wear pad bracket to the front
of the inner ram. Install the five bolts 12 with
five washers 12 to locate it in position.
Y
V X value.
Torque: 28 N·m
6.5. Connect the twin tilt ram hose assembly
at point A1 and the twin auxiliary hose
assembly at the point B1, working from the
U inner connection points outwards.
6.6. Tighten the connections to the specified
torque value.
U Left hand hoses
V Pipe assembly Torque: 33 N·m
X Mounting bracket 6.7. Make sure that the twin hoses are not
Y Hose chain tracking twisted after tightening.
Z Right hand hoses
06 - 55 9823/1700-1 06 - 55
12 - Lift Arm
00 - General
Figure 60. Inner Ram Assembly- 1

72
73
72
73
8
1
72
73
77 74
75 75
76 79
78
1 Inner ram 8 Inner lift arm pipe assembly

74 Nuts 13 75 Washers 13
76 Bolts 13 77 Front wear pad bracket
78 Countersunk screw 79 Front wear pad 4
06 - 56 9823/1700-1 06 - 56
12 - Lift Arm
00 - General
Figure 61. Inner ram assembly- 2
C1
70
A1
70
B1
71
8 Inner lift arm pipe assembly 70 Tilt ram hoses

71 Auxiliary hoses A1 Point A1
B1 Point A2 C1 Slide plate
6.8. Install the top and side wear pads 3 and the making sure each pair locates in the guide
bottom pads 3 (if removed) to the inner lift channels approximately half way along
arm. the bottom surface of the inner lift arm.
Continue to insert the tilt ram hoses and
Figure 62. the auxiliary hoses until they appear at the
H openings in the front end of the inner lift
arm.
2 6.12. Pull the tilt ram hoses and the auxiliary
hoses a little way out of the lift arm.
6.13. Connect the twin hoses to the auxiliary
pipe assembly. The hose end of the outer
hose assembly attaches to the upper pipe
J of the auxiliary pipe assembly and the
hose end of the inner hose assembly
attaches to the lower pipe of the assembly.
2 Inner lift arm

H Top and side wear pads 3
J Bottom pads
6.9. Put grease on the twin hose assemblies and
to the slide plate of the inner ram. Refer to
Figure 62.
Consumable: Special HP Grease
6.10. Install the inner ram assembly to the rear
of the inner lift arm.
6.11. Carefully insert the tilt ram hoses and
the auxiliary hoses into the inner lift arm,
06 - 57 9823/1700-1 06 - 57
12 - Lift Arm
00 - General
Figure 63. Figure 64.

70
68
69
70a
67
70b
71
71b
71a
71a
62 59
71b
70 Tilt ram hoses
71 Auxiliary hoses
70a Outer tilt ram hose end 61
70b Inner tilt ram hose end
71a Outer auxiliary hose end
71b Inner tilt ram hose end 61 60
6.14. Tighten these two hoses to the specified

torque value.
Torque: 33 N·m
6.15. Install the auxiliary pipe assembly to the
59 Auxiliary pipe assembly
left side of the inner lift arm with nuts
60 Nuts 9
9, washers 9 and the bolts 9, carefully
61 Washers 9
pushing any spare hose back into the lift
62 Bolts 9
arm.
67 Bolt 11
6.16. Tighten the two nuts 9 to the specified 68 Plate
torque value. 69 Front inner ram location pin
Torque: 28 N·m 7. Second intermediate lift arm assembly:
6.17. Twin tilt ram hoses connects to the tilt
ram, when installed. The outermost hose 7.1. Install the wear block (if removed during
attaches to the head end of the tilt ram and disassembly) into the second intermediate
the inner hose attaches to the rod end. lift arm.
6.18. Carefully install the inner ram assembly

into the inner lift arm.
6.19. Apply grease to the front inner ram
location pin.
6.20. Align the front end of the inner ram and
install the front inner ram location pin with
the plate and bolt 11.
06 - 58 9823/1700-1 06 - 58
12 - Lift Arm
00 - General
Figure 65. 8.6. Install the auxiliary hoses to the connectors

3 and the external pipe assembly.
8.7. Tighten the connections 2 and the
connections 4 to the specified torque value.
3
Torque: 58 N·m
8.8. Apply grease to the main hose assembly.
8.9. From the rear of the outer lift arm, feed the
front end of the main hose assembly into
the outer lift arm with the heads of the pipe
80 clip bolts 5 upwards. Do this until the hose
connectors appear through the exit holes in
the front underside of the outer lift arm.
8.10. Make sure that the main hose assembly is
3 Second intermediate lift arm
positioned flat on the lower inside surface
80 Wear block
of the outer lift arm.
7.2. Insert the assembled inner lift arm into the 8.11. At the front underside position on the outer
second intermediate lift arm. lift arm, install six 'U' pipes to the six hoses
7.3. Shim the top and the side wear pads 3 of the of the main hose assembly.
inner lift arm. Refer to body and framework- 8.12. Connect the unions at the same time,
lift arm, refer to (PIL 06-12).Refer to Figure rotating each union a small amount at a
62. time to prevent the hoses from twisting.
7.4. Apply grease to the inner ram rear location 8.13. Push the main hose assembly back into
pin. the outer lift arm slightly and connect the
Consumable: Special HP Grease 'U' pipes to the external pipe assembly.
7.5. Align the rear end of the inner ram and 8.14. Connect the unions at the same time,
install the inner ram rear location pin with rotating each union a small amount at a
the two spacers, bolt 10, washer 10 and the time to prevent the hoses from twisting.
nut 10. 8.15. Make sure that the six 'U' pipes are vertical
7.6. Tighten the nut 10 to the specified torque before you torque tighten the connectors
value. at both the ends of the 'U' pipes. Torque
tighten to the specified torque value.
Torque: 98 N·m
Torque: 33 N·m
7.7. Shim the front wear pads of the second
intermediate lift arm. Refer to body and 8.16. At the top right rear position of the outer lift
framework- lift arm, refer to (PIL 06-12). arm, install the right hand external pipes
assembly to the outer lift arm with the three
8. Outer lift arm assembly: bolts 7 and three washers 7.
8.1. Install the external pipe assembly to the 8.17. Tighten the three bolts 7 to the specified
underside of the outer lift arm with the six torque value.
bolts 6 and the six washers 6. Torque: 28 N·m
8.2. Tighten the bolts to the specified torque 8.18. On the right rear side of the outer lift
value. arm, connect the three right hand external
Torque: 28 N·m hoses to their three related connectors at
the external pipe assembly and the right
8.3. Install the bracket to the outer lift arm with hand external pipes assembly.
the two bolts 5, four washers 5 and two nuts
5. 8.19. Tighten each end of the bottom hose 2 to
the specified torque value.
8.4. Tighten the two nuts 5 to the specified
torque value. Torque: 44 N·m
Torque: 56 N·m 8.20. Tighten the four remaining connections to
8.5. If applicable, install two couplings to the
bracket with the circlips. Torque: 33 N·m
06 - 59 9823/1700-1 06 - 59
12 - Lift Arm
00 - General
8.21. At the top left rear position on the outer 8.29. Install the front wear pads 1 and the
lift arm, install the left hand external pipes top and side wear pads 2 to the
assembly to the outer lift arm with the three first intermediate lift arm. Tighten the
bolts 8 and three washers 8. bottom wear pads 2. Refer to body and
framework- lift arm, refer to (PIL 06-12).
8.22. Tighten the three bolts 8 to the specified
torque value. Figure 66.
Torque: 33 N·m
E
8.23. On the left rear side of the outer lift arm,
connect the three left hand external hoses
to their three related connectors at the 4
external pipe assembly and the left hand
external pipes assembly.
8.24. Tighten each end of the bottom hose 1 to
Torque: 44 N·m
8.25. Tighten the four remaining connections to F
Torque: 33 N·m
8.26. Connect the two tilt ram hoses to their
connections on the right and left hand A
external pipe assemblies.
8.27. Tighten the connection to the right hand 4 First intermediate lift arm
external pipe assembly to the specified A Front wear pads
torque value. E Top and side wear pads 2
Torque: 115 N·m F Bottom wear pads 2
8.28. Tighten the connection to the left hand 8.30. Insert the first intermediate lift arm
external pipe assembly to the specified assembly into the outer lift arm assembly.
torque value. 8.31. Shim the applicable wear pads. Refer to
Torque: 58 N·m body and framework- lift arm, refer to (PIL
06-12).
06 - 60 9823/1700-1 06 - 60
12 - Lift Arm
00 - General
Figure 67.
81
5 Outer lift arm 11 Main hose assembly

29 'U' pipes 30 External pipe assembly
31 Bolts 5 33 Right hand external hoses
35 Left hand external hoses 36 Connections 2
37 Connections 3 38 Auxiliary hoses
39 Circlips 41 Bracket
42 Nuts 5 43 Washers 5
44 Bolts 5 46 Bolts 6
47 Washers 6 49 Right hand external pipes assembly
51 Left hand external pipes assembly 52 Bolts 7
06 - 61 9823/1700-1 06 - 61
12 - Lift Arm
00 - General
55 Washers 8 56 Tilt ram hoses

79 Front wear pad 4 D Front wear pads 2
K Connections 1 W Connection to the right hand external pipe
assembly
X Bottom hose 1 Y Bottom hose 2
Z Connection to the left hand external pipe
assembly
9. Lift arm final assembly: 9.9. Connect the six connectors of the main
hose assembly, working from the inside
9.1. Insert the second intermediate lift arm / outwards, to their related connectors at the
inner lift arm assembly into the first rear connection points of the main pipe
intermediate lift arm / outer lift arm assembly.
assembly.
9.10. Make sure that the hoses do not twist
9.2. Shim the remaining wear pads. Refer to during this step.
(PIL 06-12).
Figure 69.
9.3. Place hoses and tracking on to the pipe
assembly. Connect the hoses to the steels
on the pipe assembly. Tighten to the
specified torque value.
Torque: 33 N·m
9.4. Pull the loose hose ends of the inner lift arm
hose assembly out of the back of the inner
lift arm (where they were stowed for safety
during Inner lift arm Assembly) and position
them up and over the top of the outer lift
arm.
9.5. Carefully insert the main pipe assembly and
support arm into the inner lift arm.
9.6. Make sure that the slots on the insides of
the support arm wear blocks engage with
the slide plate on the bottom of the inner
ram.
9.7. Continue to push the assembly in, until it 7 Main pipe assembly
is approximately half way in to the inner lift 11 Main hose assembly
arm. 13 Bolts 1
14 Washers 1
9.8. Make sure the pipe and support arm sub- 15 Rear connection points
assembly is adequately supported.
9.11. Connect the six hoses of the inner lift arm
Figure 68. hose assembly to the two hose connection
points on the inner ram and the four hose
25 connection points on the inner lift arm
pipe assembly, working from the inner
connection point onwards.
1 9.12. Tighten the six connections to the
Torque: 33 N·m
25 9.13. Push the main pipe assembly fully in until
the bolt holes in the main pipe assembly
support plate align with their location holes
in the first intermediate boom.
S1
9.14. Apply JCB sealant to the threads of the
1 Inner ram bolts.
25 Wear blocks Consumable: JCB Threadlocker and
S1 Slide plate Sealer (Medium Strength)
06 - 62 9823/1700-1 06 - 62
12 - Lift Arm
00 - General
9.15. Early machines have two fixing bolts. Later Table 8. Torque Values
machines have a different support plate
Item Description Nm
with four fixing bolts.
13 Bolts 1 28
9.16. Install the bolts 1 together with washers 19 Bolts 2 28
1 to secure the main pipe assembly in
position. 22 Nuts 3 28
26 Nuts 4 28
value. 31 Bolts 5 11
36 Connections 2 58
Torque: 28 N·m
42 Nuts 5 56
9.18. Tighten the six hose connections at the 46 Bolts 6 28
rear connection points to the specified
52 Bolts 7 28
torque value.
54 Bolts 8 28
Torque: 33 N·m
60 Nuts 9 28
9.19. Install the primary external components. 63 Nut 10 98
9.20. The installation of the primary components 72 Bolts 12 28
is the opposite of the removal procedure. 74 Nuts 13 28
9.21. Lubricate the lift arm hose runs. Refer to 78 Countersunk screws 28
(PIL 06-00). 81 Connections 4 58
9.22. Put grease on all the pivot pins. W Connection to the right hand 115
external pipe assembly
X Bottom hose 1 44
Figure 70. Y Bottom hose 2 44
Z Connection to the left hand 58
external pipe assembly
10
13
14
9
7
7 Main pipe assembly
8 Inner lift arm pipe assembly
9 Main pipe assembly support plate
10 Inner lift arm hose assembly
13 Bolts 1
14 Washers 1
Unless specified, torque hose connections to 33

N·m.
06 - 63 9823/1700-1 06 - 63
12 - Lift Arm
12 - Pivot Link Lever (Upper)
12 - Pivot Link Lever (Upper)
Adjust
The figure (Refer to Figure 71. ) shows the lift arm 4. If the gap is more than the specified value, add
viewed from the rear of the machine. the correct quantity of shims to get the correct
measurement. Add the shims equally at the two
1. Measure the gap 1 and the gap 2 as shown in the sides to make sure that the lift arm is at the centre
figure. Refer to Figure 71. of the pivot.
2. Add the values of gap 1 and the gap 2. Total gap Length/Dimension/Distance: 3 mm
= gap 1 + gap 2.
4.1. Later shims do not have handles.
3. Make sure that the total gap is not more than the
5. When the total gap is of the correct value, if the
specified value.
shim has handles, snap the handle from the shim
Length/Dimension/Distance: 3 mm at the crease.
Figure 71.
X Y
X Gap 1 Y Gap 2
Figure 72.
B
A Handled shim (earlier type)

B Crease
C Handle
06 - 64 9823/1700-1 06 - 64
12 - Lift Arm
18 - Angle Indicator
18 - Angle Indicator
Remove and Install
Angle Indicator
Remove
2. Remove the locknuts.
3. Remove the bolt 1 and the pointer arm.
4. Remove the bolts 2 to remove the dial.
Figure 73.
B C
A Locknuts
B Bolt 1
C Pointer arm
D Bolts 2
E Dial
F Decal
Install
steps.
1.1. If the scale is worn then remove the decal
and install a new decal.
1.2. Apply grease to the bolt 1, to make sure of
a smooth operation of the pointer arm.
06 - 65 9823/1700-1 06 - 65
12 - Lift Arm
24 - Shim
24 - Shim Technical Data

Technical Data ............................................... 06-66
Adjust ............................................................ 06-71
3 Stage (3 Section) Lift Arm
Calibrate ........................................................ 06-78 Adding washers
Figure 74. Typical Installation
2
1
E Wear pad bolt

F Shim
G Washer
1 Wear pad
2 Threaded insert
Table 9. Intermediate to Outer Lift Arm

Detail (Refer to Figure 75. ) Shim thickness Number of washers
L 0 to 1.7 3
1.7 to 4.2 2
4.2 to 6.7 1
6.7 to 9.3 0
K, H, N 0 to 1.5 3
1.5 to 4.0 2
4.0 to 6.5 1
6.5 to 9.0 0
J 0 to 2.0 4
2.0 to 4.5 3
4.5 to 7.0 2
7.0 to 9.5 1
Table 10. Inner to Intermediate Lift Arm

K, M, R 0 to 1.5 3
1.5 to 4.0 2
4.0 to 6.5 1
6.5 to 9.0 0
G, J, P 0 to 2.0 4
2.0 to 4.5 3
4.5 to 7.0 2
7.0 to 9.5 1
06 - 66 9823/1700-1 06 - 66
12 - Lift Arm
24 - Shim
Figure 75. 3 Stage (3 Section) Lift Arm Shimming
FRONT REAR
SECTION C-C SECTION D-D
SECTION B-B SECTION A-A
06 - 67 9823/1700-1 06 - 67
12 - Lift Arm
24 - Shim
4 Stage (4 Section) Lift Arm

Table 11. Torque Values
Adding washers
Item Nm
E 98 Figure 76. Typical Installation
2
1
E Wear pad bolt

F Shim
G Washer
1 Wear pad
2 Threaded insert
Table 12. Intermediate to Outer Lift Arm

G 0 –1 4
1 –3 3
3 –5 2
5 –7 1
H 0 –1 3
1 –3 2
3 –5 1
5 –7 0
K 0 –3 5
3 –6 4
6 –9 3
9 –12 2
L 0 –3 6
3 –6 5
6 –9 4
9 –12 3
N 0 –1 4
1 –3 3
3 –5 2
5 –7 1
S 0 –1 4
1 –3 3
3 –5 2
5 –7 1
Table 13. Inner to Intermediate Lift Arm

J 0 –1 4
1 –3 3
3 –5 2
06 - 68 9823/1700-1 06 - 68
12 - Lift Arm
24 - Shim

5 –7 1
M 0 –2.5 4
2.5 –5.5 3
5.5 –8.5 2
8.5 –11.5 1
N 0 –1 4
1 –3 3
3 –5 2
5 –7 1
P 0 –1 3
1 –4 2
4 –7 1
7 –9 0
R 0 –2 3
2 –5 2
5 –8 1
8 –11 0
T 0 –1 4
1 –3 3
3 –5 2
5 –7 1
U 0 –1 3
1 –3 2
3 –5 1
5 –7 0
06 - 69 9823/1700-1 06 - 69
12 - Lift Arm
24 - Shim
Figure 77. 4 Stage (4 Section) Lift Arm Shimming
FRONT REAR
B-FR B-FR
A-RR A-RR
SECTION A-A SECTION B-B SECTION C-C
SECTION D-D SECTION E-E SECTION F-F
Wear pad fixings Table 14. Torque Values

Item Description Nm
Refer to Figure 77.
A Bolt M12 x 45 Tuf-Lok 83
B Bolt M12 x 60 83
C Bolt M12 x 40 Tuf-Lok 83
D Set Screw M10 x 45 47
E Set Screw M10 x 35 Tuf-Lok 47
F Set Screw M10 x 25 Tuf-Lok 47
W Bolt M12 x 50 Tuf-Lok 83
06 - 70 9823/1700-1 06 - 70
12 - Lift Arm
24 - Shim
Adjust
3 Stage (3 Section) Lift Arm Figure 79.

D
The shims are installed under the pads for the
adjustment of the lift arm clearance. Partly worn pads
may be shimmed to restore correct lift arm clearance.
Shim the intermediate lift arm to outer lift arm. Repeat

the procedure for inner lift arm to the intermediate lift
arm.
Make sure that the wear pads are installed in the D Chamfer depth
correct way to prevent fouling.
Figure 80.
Install new wear pads when the clearances are out 2
of specification. The clearances must be measured, 1
the chamfer is not a guide to the amount of wear
remaining.Refer to Figure 79. F
Make sure that the threaded insert remains a tight fit

in the wear pad and does not rotate when tightened. G
If the insert is loose in the wear pad, install a new
wear pad and threaded insert.
E
The wear pad bolts are not all the same. Make sure
you use the correct bolts for each wear pad. Refer to E Wear pad bolt
(PIL 06-12). F Shim
G Washer
The number of washers under the bolt changes 1 Wear pad
depending on the shim thickness. Make sure you 2 Threaded insert
install the correct number of washers for the
thickness of shims. Refer to (PIL 06-12). Lower wear pads- Shimming
Do not install spring washers. Front lower wear pads
Figure 78. 1. Make the machine safe. Refer to (PIL 01-03).
2. Follow all the safety procedures. Refer to (PIL
01-03).
3. Raise the lift arm slightly so that forks are just off
the ground.
B
4. Measure the distances between the lift arm lower
faces which must be in the limit given. Refer to
(PIL 06-12-00).
5. If this dimension is less than the limit, then install
shims under the lower wear pads to restore the
A
dimension.
6. Rest the forks on the ground so that there is no
C
weight on the lower wear pads.
7. Remove the wear pad bolts and add shims as
required.
A Intermediate lift arm
B Outer lift arm 8. Measure the total thickness of shims under each
C Inner lift arm pad.
9. Add or remove the correct number of plain
washers under the heads of the wear pad
06 - 71 9823/1700-1 06 - 71
12 - Lift Arm
24 - Shim
bolts. Make sure that the thread engages to the 10. Remove the wedges, install the shims again and
specified depth. Refer to (PIL 06-12). tighten the bolts to the specified torque value.
Length/Dimension/Distance: 8 –12 mm Torque: 98 N·m
10. Do not install spring washers. Figure 82.
2
11. Install the shims again and tighten the bolts to the 1
Torque: 98 N·m F
Figure 81.
2 G
1
F E
E Wear pad bolt

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

F Shim
G Washer The following procedure applies to both front and
1 Wear pad rear top wear pads.
2 Threaded insert
1. Raise the lift arm until the inner lift arm is resting
Rear lower wear pads on the lower wear pads.
1. Rest the forks on the ground. 2. Measure the distances between the lift arm upper
2. Remove the lift arm rear cover. Refer to (PIL (PIL 06-12).
06-06).
3. If this dimension is less than the limit, install
3. Measure the distances between lift arm lower shims under the top wear pads to restore the
faces which must be in the limit given. Refer to dimension.
Technical Data (PIL 06-12).
4. Install or remove shims to obtain the correct
4. If this dimension is less than the limit, then install vertical clearance.
dimension. 5. Measure the total thickness of shims under each
pad.
5. Raise the lift arm slightly so that forks are just off
the ground and place wedges under the inner lift 6. Add or remove the correct number of plain
arm. washers under the heads of wear pad bolts.
Make sure that the thread engages to the
6. Remove the wear pad bolts and add shims as specified depth. Refer to (PIL 06-12).
required.
Length/Dimension/Distance: 8 –12 mm
7. Measure the total thickness of shims under each
pad. 7. Do not install spring washers.
8. Add or remove plain washers under the heads 8. Install the shims again and tighten the bolts to the
of wear pad bolts. Make sure that the thread specified torque value.
engages to the specified depth. Refer to (PIL Torque: 98 N·m
06-12).
9. Do not install spring washers.
06 - 72 9823/1700-1 06 - 72
12 - Lift Arm
24 - Shim

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

F Shim F Shim
G Washer G Washer
1 Wear pad 1 Wear pad
2 Threaded insert 2 Threaded insert
Side wear pads- Shimming 4 Stage (4 Section) Lift Arm

The following procedure applies to both front and The shims are installed under the pads for the
rear side wear pads. adjustment of the lift arm clearance. Partly worn pads
may be shimmed to restore correct lift arm clearance.
1. Measure the distances between the lift arm side
faces which must be in the limit given. Refer to On 4 stage (4 section) machines, shim the 1st
Body and Framework- Lift Arm, Technical Data intermediate lift arm to the outer lift arm. Repeat the
(PIL 06-12). procedure for the 2nd intermediate lift arm to the 1st
intermediate lift arm and the inner lift arm to the 2nd
2. If this dimension is less than the limit, install intermediate lift arm.
shims under the side wear pads to restore the
dimension. Install new wear pads when the clearances are out
3. Slacken the side wear pad bolts and install shims of specification. The clearances must be measured,
as required. Divide number of shims equally each the chamfer is not a guide to the amount of wear
side to ensure that inner lift arm runs centrally remaining.Refer to Figure 85.
within the outer lift arm.
Make sure that the threaded insert remains a tight fit
4. Measure the total thickness of shims under each in the wear pad and does not rotate when tightened.
pad. If the insert is loose in the wear pad, install a new
wear pad and threaded insert.
washers under the heads of wear pad bolts. Make sure that the wear pads are fitted in the correct
Make sure that the thread engages to the way to prevent fouling.
specified depth. Refer to (PIL 06-12-00).
The wear pad bolts are not all the same. Make sure
Length/Dimension/Distance: 8 –12 mm to use the correct bolts for each wear pad. Refer to
Body and framework- lift arm, refer to (PIL 06-12).
7. Install the shims again and tighten the bolts to the The number of washers under the bolt changes
specified torque value. depending on the shim thickness. Make sure you fit
the correct number of washers for the thickness of
Torque: 98 N·m shims. Refer to (PIL 06-12).
Do not install spring washers.
06 - 73 9823/1700-1 06 - 73
12 - Lift Arm
24 - Shim

D 2
1
D Chamfer depth E
Figure 86. E Wear pad bolt
2 F Shim
1 G Washer
F Rear lower wear pads

1. Rest the forks on the ground.
G 2. Remove the lift arm rear cover. Refer to (PIL
06-06).
E 3. Measure distances between lift arm lower faces
which must be in the limit given. Refer to (PIL
E Wear pad bolt
06-12).
F Shim
G Washer 4. If this dimension is less than the limit, then install
Lower wear pads- Shimming dimension.
Front lower wear pads 5. Raise the lift arm slightly so that forks are just off
the ground and place wedges under the inner lift
1. Raise the lift arm slightly so that forks are just off arm.
the ground.
6. Remove the wear pad bolts and add shims as
2. Measure the distances between the lift arm lower required.
(PIL 06-12-00). 7. Measure the total thickness of shims under each
pad.
3. If this dimension is less than the limit, then install
shims under the lower wear pads to restore the 8. Add or remove plain washers under the heads
dimension. of wear pad bolts. Make sure that the thread
engages to the specified depth.
4. Rest the forks on the ground so that there is no
weight on the lower wear pads. Length/Dimension/Distance: 8 –12 mm
5. Remove the wear pad bolts and add shims as 9. Do not fit spring washers.
required.
10. Remove the wedges, install the shims again and
6. Measure the total thickness of shims under each tighten the bolts to the specified torque value.
pad. Refer to (PIL 06-12).

washers under the heads of wear pad bolts.
Make sure that the thread engages to the
specified depth.
9. Install the shims again and tighten the bolts to the
specified torque value. Refer to (PIL 06-12).
06 - 74 9823/1700-1 06 - 74
12 - Lift Arm
24 - Shim

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

F Shim F Shim
G Washer G Washer
Top wear pads- Shimming Side wear pads- Shimming

The following procedure applies to both front and The following procedure applies to both front and
rear top wear pads. rear top wear pads.
1. Raise the lift arm until the inner lift arm is resting 1. Measure the distances between the lift arm side
on the lower wear pads. faces which must be in the limit given. Refer to
Technical Data (PIL 06-12-00).
2. Measure the distances between the lift arm upper
faces which must be in the limit given. Refer to 2. If this dimension is less than the limit, install
(PIL 06-12-00). shims under the side wear pads to restore the
dimension.
3. If this dimension is less than the limit, install
shims under the top wear pads to restore the 3. Slacken the side wear pad bolts and install shims
dimension. as required. Divide number of shims equally each
side to ensure that inner lift arm runs centrally
4. Install or remove shims to obtain the correct within the outer lift arm.
vertical clearance.
4. Measure the total thickness of shims under each
5. Measure the total thickness of shims under each pad.
pad.
6. Add or remove the correct number of plain washers under the heads of wear pad bolts.
washers under the heads of wear pad bolts. Make sure that the thread engages to the
Make sure that the thread engages to the specified depth.
specified depth.
7. Install the shims again and tighten the bolts to the
8. Install the shims again and tighten the bolts to the specified torque value. Refer to Technical Data
specified torque value. Refer to (PIL 06-12). (PIL 06-12).
06 - 75 9823/1700-1 06 - 75
12 - Lift Arm
24 - Shim
Figure 90.
2
1
E Wear pad bolt

F Shim
G Washer
Wear pad fixings
Figure 91.
F A
D D
A A
E E E E F F
F F B B B - FR B - FR
A - RR A - RR
C C W W F F
F F F F
F F
C C
C C
F F
06 - 76 9823/1700-1 06 - 76
12 - Lift Arm
24 - Shim
A Bolt 1 B Bolt 2
C Bolt 3 D Setscrew 1
E Setscrew 2 F Setscrew 3
W Bolt 4 FR Towards lift arm front
RR Towards lift arm rear

Item Description Nm
A Bolt M12 x 45 Tuf-Lok 83
B Bolt M12 x 60 83
C Bolt M12 x 40 Tuf-Lok 83
D Setscrew M10 x 45 47
E Setscrew M10 x 35 Tuf-Lok 47
F Setscrew M10 x 25 Tuf-Lok 47
W Bolt M12 x 50 Tuf-Lok 83
06 - 77 9823/1700-1 06 - 77
12 - Lift Arm
24 - Shim
Calibrate 8. Make sure that the difference in shim thickness of

shim 1 and shim 2 does not exceed the specified
value.
When the boom is assembled, do a check of
the carriage alignment to make sure that the
measurement is accurate. 9. Make sure that the maximum wear pad clearance
does not exceed the specified value.
2. Make sure that the tyre pressures are correct.
Figure 94.
3. Make sure that the machine is parked on flat level
ground.
B
4. Check the inclinometer to make sure that the
chassis is level.
Figure 92.
A
A Inclinometer
5. Measure the left and right side carriage height
from the ground to the top of the carriage and C F
D E
note the dimensions.
B Maximum wear pad clearance
Figure 93. C Lower wear pad 1
D Lower wear pad 2
E Shim 1
F Shim 2
X Y
X Left side dimension

Y Right side dimension
6. If there is a difference between left and right side
dimension, the front lower wear pads 1 and wear
pads 2 can be shimmed.
7. Add or remove the shim 1 and shim 2 as
necessary to align the carriage. Refer to adjust
(PIL 06-12-30).
06 - 78 9823/1700-1 06 - 78
12 - Lift Arm
66 - Chain
66 - Chain Introduction
Introduction .................................................... 06-79 Inspect the chains at the correct intervals. Do
Health and Safety .......................................... 06-80 the chain maintenance procedures at the correct
Technical Data ............................................... 06-81 intervals. Refer to maintenance schedules (PIL
Clean ............................................................. 06-82 78-24).
Check (Condition) .......................................... 06-83 Once the lift arm has done a number of cycles with
Adjust ............................................................ 06-85 some weight involved, some ‘bedding in’ occurs and
Lubricate ........................................................ 06-88 the chains slacken off. Recheck and if necessary,
Remove and Install ....................................... 06-89 adjust using the adjustment procedure. Refer to
adjust (PIL 06-12-66).
06 - 79 9823/1700-1 06 - 79
12 - Lift Arm
66 - Chain
Health and Safety

WARNING The practice of joining chains is
not recommended and chains from different
manufacturers must not be used together on the
same application.
If a chain requires shortening, make sure that
the pin to be extracted has its head completely
removed and deburred to make sure the link bore
is not scored.
Chains should be renewed in pairs because in
the event of a single chain breakage, the stress
imposed at the time of breakage usually causes
the unbroken chain to stretch.
Because chains are made from heat treated steel,
they must not be annealed.
WARNING Renew defective chains and
associated components immediately. Do not use
the machine until the chains and components are
replaced with new ones. Make sure you follow the
correct procedures.
WARNING Renew defective chains and
correct procedures.
Notice: Carry out chain inspection and
maintenance procedures at more frequent
intervals when operating in extreme
environmental conditions or when the machine is
subjected to shock loads.
Notice: When a chain is removed for inspection,
it must be installed in exactly the same working
position.
Notice: Once the lift arm has done a number of
cycles with some weight involved, some ‘bedding
in’ occurs and the chains slacken off. Further
tightening using the adjustment procedure will be
required.
06 - 80 9823/1700-1 06 - 80
12 - Lift Arm
66 - Chain
Technical Data
Chain wear limits

Table 16. Wear limits
Nominal Pitch Minimum Plate Depth Maximum Length
(measure 25 links)
19
(1)
16.89 485
25.4
(2)
22.69 648
(1) Chains of the specified pitch are fitted to all the machines. 19 mm
(2) Chains of the specified pitch are fitted to 510-56, 512-56 and 514-56 machines only. 25.4 mm
If the wear limits exceed the specified value, install

a new chain.
Figure 95.
A
C
A Pitch
B Plate depth
C Length of 25 links
06 - 81 9823/1700-1 06 - 81
12 - Lift Arm
66 - Chain
Clean
CAUTION You must climb on the machine to
install or remove the central access panels. Take
care, especially if the machine is wet. Remove
mud and oil before you climb on the machine. Do
not put your body weight on the central access
panels.
CAUTION Make sure the steps, handrails, and
your footwear soles are clean and dry before
climbing onto the machine. Always face the
machine when climbing on and off it.
1. Make the machine safe with the boom raised.

2. Debris can collect under the boom. Remove all
combustible material.
3. Do not aim the jet wash directly at the boom
chains.
Figure 96.
06 - 82 9823/1700-1 06 - 82
12 - Lift Arm
66 - Chain
Check (Condition)
Notice: Before inspecting chain components it WARNING Do not attempt to repair defective
may be necessary to clean them. Make sure you chain components with components from another
only use paraffin or a paraffin derivative to clean chain.
the chain.
Make sure you do not use chemical solvents. Inspect the components for wear and defects listed
in the table.
Do not steam clean the chain.
Use of solvents or steam cleaning will remove
lubricant from the internal bearing surfaces and
seriously reduce the service life of the chain.
Table 17.
Inspection Action
Pitting due to rust and corrosion. Check the chain links and pins. If one or more component has pit-
ting on its surface, install a new
chain.
Tight chain joints Disconnect the chains from the If one or more joint is tight, install a
boom to inspect for tight chain new chain.
joints. Articulate each link, if it does
not pivot under its own weight the
joint is tight. Refer to Figure 97.
Missing link plates Refer to Figure 98. Do not attempt to replace missing
link plates. If one or more link plate
is missing, install a new chain.
Cracked or fractured link plates Small fatigue fractures and cracks If one or more link plate is defec-
are difficult to see. Make sure the tive, install a new chain.
chain is clean. Refer to Figure 99.
Loose pins with enlarged pin holes Refer to Figure 100. If one or more pin or link plate is
defective, install a new chain.
Protruding or rotated pins Refer to Figure 101. If one or more pin is defective, in-
stall a new chain.
Wear or damage to the outer faces Check for defects caused by im- If one or more pin or link plate is
of the link plates or pin heads pact with other components. Refer defective install a new chain. In-
to Figure 102. spect the machine for defects that
may be causing chain damage or
abnormal chain wear. Rectify as
applicable.
Wear on the link plate edges This wear is caused by the chain Check the chain, follow the correct
running over the chain guide rollers procedure. If one or more link ex-
and is normal over time. ceeds the wear limit, install a new
chain. For wear limits refer to (PIL
06-12-66).
Chain elongation Elongation is caused by wear be- Check the chain, follow the correct
tween the pins and plates and is procedure. If the chain exceeds the
normal over time. Make sure the wear limit, install a new chain. For
chain does not exceed the wear wear limits refer to (PIL 06-12-66).
limit.
Anchor locking integrity Check the anchor pin and the cle- If defective, install a new anchor
vis for wear damage and corrosion. pin or clevis. If the clevis is integral
Check the locking split pins.Refer with the chain, install a new chain.
to Figure 103. Replace damaged or missing split
pins.
Chain guide rollers Check the rollers for worn bear- If defective, install new compo-
ings and grooving caused by the nents as applicable.
chains.
06 - 83 9823/1700-1 06 - 83
12 - Lift Arm
66 - Chain

B
A
Figure 98.
C
A Anchor pin
B Clevis
C Split pin
Wear Limits
Figure 99. WARNING Renew defective chains and
correct procedures.
Measure the nominal chain pitch and read off the

corresponding wear limits from the table. Refer to
Figure 100. body and framework- lift arm, refer to technical data
(PIL 06-12-66).
Check that link plate depth is not less than the

specified value, particularly on the sections of the
chain which run over the pulleys.
Figure 101.
Examine the chain over its full length to find a
minimum of three sections having the most wear
(usually sections which run over a pulley). Put each
section on a flat surface and make sure that the chain
is in tension. Measure the length as shown in the
figure for 25 links. Refer to Figure 104.
Figure 104.
A
Figure 102. B
C
A Chain pitch
B Link plate depth
C Length of 25 links
06 - 84 9823/1700-1 06 - 84
12 - Lift Arm
66 - Chain
Adjust 9. Extend the lift arm fully and then retract by the
specified value.
Consumables Length/Dimension/Distance: 50 mm
Description Part No. Size
JCB Chain Lubricant 4004/0237A 0.3 L 10. Measure the gap 2 between the under side of the
extend chain and the top of the intermediate lift
This section contains information for 3 and 4 section arm at the mid-point of the chain length.
lift arms.
11. Make sure that the gap 2 is of the specified value
Table 18. Lift Arms for the machines given:
Machine Lift Arm Adjustment 11.1. 506-36 machines:
506-36 3 Section, 3 stage Length/Dimension/Distance: 56 –66 mm
11.2. 507-42 and 509-42 machines:
512-56 4 Section, 4 stage 12. If necessary, tighten the extend chains equally to
514-56 4 Section, 4 stage maintain same tension in both the chains with the
adjustment nut 1.
Adjustment- 3 Stage (3 Section) Lift Arm 13. If the end link threads or the nuts are damaged,
replace the complete end link.
If the extend or retract chains have been replaced,
you must Set the chain adjusters to the correct initial 14. After the correct measurement has been
dimensions before adjusting the chains. Refer to obtained, extend and retract the lift arm several
Body and Framework- Lift Arm (PIL 06-12). times and recheck the gap 2. Adjust the extend
chains as necessary.
15. Install new split pins if the old split pins are
2. Raise the lift arm to the horizontal position. Fully removed.
retract the lift arm.
3. Measure the gap 1 as shown in the figure.
3.1. 506-36 machines:
3.2. 507-42 and 509-42 machines:
4. If necessary, adjust the chains to obtain the
correct initial setting dimension:
4.1. If the dimension is too great, shorten the
retract chain with the adjustment nut 1.
4.2. If the dimension is too small, shorten the
extend chains with the adjustment nut 2.
5. Make sure to tighten the extend chains equally to
maintain same tension in both the chains.
6. Extend the lift arm.
7. Apply lubricant on the chains.
Consumable: JCB Chain Lubricant
8. Retract the lift arm and check the gap 1 again. If
necessary, do the step 4 again.
06 - 85 9823/1700-1 06 - 85
12 - Lift Arm
66 - Chain
Figure 105. 2. Raise the lift arm to the horizontal position. Fully
B retract the lift arm.
3. Make sure that the gap 1 between the front end of
B the inner lift arm and the front end of the second
intermediate lift arm is of the specified value.
as shown in the figure.
5. Remove the lift arm rear cover to access the
adjustment nuts.
6. If necessary, adjust the chains to obtain the
correct initial setting dimension:
6.1. If the dimension is too great, shorten the
retract chain with the adjustment nut 1.
6.2. If the dimension is too small, shorten the
extend chains with the adjustment nut 2.
7. Each lift arm section has two extend chains.
Make sure to tighten the extend chains equally to
maintain same tension in both the chains.
A 8. Extend the lift arm.

9. Apply lubricant on the chains.
X
10. Retract the lift arm and check the gap 1 and the
gap 2 again. If necessary, do the step 5 again.
11. Extend the lift arm fully and then retract by the
specified value.
A Adjustment nut 1 Length/Dimension/Distance: 50 mm
B Adjustment nut 2
X Gap 1 12. Measure the gap 3 between the under side of the
extend chains and the top of the intermediate lift
Figure 106. arms at the mid-point of the chain length.
for the first intermediate lift arm.
for the second intermediate lift arm.
Z Length/Dimension/Distance: 58 –68 mm
15. If necessary, adjust the extend chains equally
Z Gap 2
with the adjustment nut 2.
Adjustment- 4 Stage (4 Section) Lift Arm 16. If the end link threads or the nuts are damaged,
replace the complete end link.
If extend or retract chains have been replaced, set
the chain adjusters to the correct initial dimensions 17. After the correct measurement has been
before you adjust the chains. Refer to body and obtained, extend and retract the lift arm several
framework- lift arm, refer to (PIL 06-12). times and recheck the gap 3. Adjust the extend
chains as necessary.
06 - 86 9823/1700-1 06 - 86
12 - Lift Arm
66 - Chain
18. Install new adjuster split pins if the old split pins Figure 108.
are removed.
Figure 107.
B
B
B
B
Z
Z Gap 3
C
X
D
A Adjustment nut 1
B Adjustment nut 2
C First intermediate lift arm
D Second intermediate lift arm
X Gap 1
Y Gap 2
06 - 87 9823/1700-1 06 - 87
12 - Lift Arm
66 - Chain
Lubricate
Consumables Figure 109.

JCB Chain Lubricant 4004/0237A 0.3 L
A
You must lubricate the chains at regular intervals.
1. Spray the chain with an even coating, avoid over

oiling.
A Rear cover
B Chain
3. Extend the lift arm.
4. Apply the specified lubricant on the drive chains.
4.1. Apply lubricant evenly. Do not over oil.
5. Install the lift arm rear cover.
Figure 110.
B
B Chain
06 - 88 9823/1700-1 06 - 88
12 - Lift Arm
66 - Chain
Remove and Install
WARNING The practice of joining chains is 10. From the front of the machine pull the chains
not recommended and chains from different out of the lift arm. Make sure that the cords are
manufacturers must not be used together on the accessible at both ends of the lift arm.
same application.
11. Inspect chain components. Refer to (PIL
If a chain requires shortening, make sure that 06-12-66).
the pin to be extracted has its head completely
removed and deburred to make sure the link bore Install
is not scored.
Chains should be renewed in pairs because in 1. Keep chains clean. Do not let them drag on the
the event of a single chain breakage, the stress ground.
imposed at the time of breakage usually causes
2. With the cords used during removal, pull the
the unbroken chain to stretch.
chains from the front to the rear of the lift arm.
Because chains are made from heat treated steel,
they must not be annealed. 3. Do not reuse the nyloc nut type adjusters.
Notice: When a chain is removed for inspection, 4. Fasten the chains at the top front.
it must be installed in exactly the same working
position. 5. Install new adjuster nuts. Do not tighten now.
6. Remove cord and fasten the chains at the rear.
Extend Chains Remove and Install- 3
Stage (3 Section) Lift Arm 7. Install new adjuster nuts. Turn the adjuster nuts
to set the chains to the correct initial position.
Refer to Table 19.
Remove
8. Do the chain adjustment procedure. Refer to (PIL
1. Raise the lift arm to the horizontal position and 06-12-66).
fully retract the lift arm. Support the front end of
the lift arm. 9. Make sure that new split pins are installed when
the adjustment is completed.
3. Follow the general safety precautions. Refer to Table 19. Adjustment- Extend chains
(PIL 01-03). Extend chains, both Refer to Figure 111.
ends
4. Remove lift arm rear cover. 24 mm
5. Remove the split pins and the adjuster nuts from Figure 111.
the extend chains top front and inside the lift arm
24 mm
rear.
6. Do not reuse the nyloc nut type adjusters.
7. Tie strong cords of sufficient length to the rear of
the extend chains. The cords will be used during
installation. B A
A Split pin
8. Put wire through the hole in the chain adjuster in B Adjuster nut
place of the split pin.
9. Attach the cord to the wire. This will allow the cord
to pass through the chain adjuster brackets.
06 - 89 9823/1700-1 06 - 89
12 - Lift Arm
66 - Chain
Figure 112.
C
A A
B B
A
B A
A Split pin B Adjuster nut
06 - 90 9823/1700-1 06 - 90
12 - Lift Arm
66 - Chain
C Cord
Retract Chain Remove And Install- 3 2. With the cords used during removal, pull the
Stage (3 Section) Lift Arm chains from the rear to the front of the lift arm.
Remove
4. Fasten the chain at the rear. Install a new
1. Raise the lift arm to the horizontal position and adjuster nut.
the lift arm. 5. Remove the chord and fasten the chain at the
rear.
6. Install new adjuster nuts. Turn the adjuster nuts
3. Follow the general safety precautions. Refer to to set the chains to the correct initial position.
(PIL 01-03). Refer to Table 20.
4. Remove the split pins and the adjuster nuts from 7. Do the chain adjustment procedure. Refer to
the retract chain bottom front and inside the lift body and framework- lift arm, refer to (PIL
arm rear. 06-12-66).
5. Tie strong cords of sufficient length to the rear 8. Make sure that new split pins are installed when
of the retract drive chain. The cords will be used the adjustment is completed.
during installation.
Table 20. Adjustment- Retract chains
6. Put wire through the hole in the chain adjuster in
place of the split pin. Retract chains, both Refer to Figure 115.
ends
7. Attach the cord to the wire. This will allow the cord 20 mm
Figure 113.
8. From the rear of the machine pull the chains 20 mm
out of the lift arm. Make sure that the cords are
accessible at both ends of the lift arm.
06-12-66).
B A
Install A Split pin
1. Keep chains clean. Do not let them drag on the B Adjuster nut
ground.
06 - 91 9823/1700-1 06 - 91
12 - Lift Arm
66 - Chain
Figure 114.
B
A
B
A Split pin B Adjuster nut

C Cord
Extend Chains Remove And Install- 4 2. Make the machine safe. Refer to (PIL 01-03).
Stage (4 Section) Lift Arm 3. Follow the general safety precautions. Refer to
(PIL 01-03).
Remove
4. Remove lift arm rear cover.
1. Raise the lift arm to the horizontal position and
the lift arm.
06 - 92 9823/1700-1 06 - 92
12 - Lift Arm
66 - Chain
Inner extend chains Install

1. Remove the split pins 1 and the adjustment nut 1. Keep chains clean. Do not let them drag on the
1 from the inner extend chain 1 at the front of the ground.
first intermediate lift arm.
2. At the front of the lift arm, attach the chains to the
2. Repeat step 1 for the inner extend chain 2. cord used during removal.
3. Remove the split pins 1 and the adjustment nut 3. From the rear of the machine use the cords to
2 from the inner extend chain 1 at the rear of the pull the chains through the lift arm.
first intermediate lift arm.
4. Repeat step 3 for the inner extend chain 2.
Inner extend chains
5. Tie strong cord of sufficient length to the rear of
the chain 1 and chain 2. The cords will be used 1. Fasten the inner extend chain 1 at the front of the
during installation. first intermediate lift arm.
6. Put wire through the hole in the chain adjuster in 2. Put new adjustment nuts 1. Do not tighten now.
place of the split pin.
3. Repeat step 1 for the inner extend chain 2.
to pass through the chain adjuster brackets. 4. Remove the chord and fasten the inner extend
chain 1 at the rear of the first stage intermediate
8. From the front of the machine pull the chains lift arm.
out of the lift arm. Make sure that the cords are
accessible at both ends of the lift arm. 5. Install new adjustment nuts 2. Do not tighten now.
9. Inspect chain components. Refer to (PIL 6. Repeat step 4 for the inner extend chain 2.
06-12-66).
7. Turn the adjustment nuts 1 and the adjustment
Outer extend chains nuts 2 to set the chains to the correct initial
position.
1. Remove the split pins 2 and the adjustment nut
3 from the outer extend chain 1 at the front of the Outer extend chains
outer lift arm.
1. Fasten the outer extend chain 1 at the front of the
2. Repeat step 1 for the other outer extend chain 2. outer lift arm.
3. Remove the split pins 2 and the adjustment nut 2. Put new adjustment nuts 3. Do not tighten now.
4 from the outer extend chain 1 at the rear of the
outer lift arm. 3. Repeat step 1 for the outer extend chain 2.
4. Repeat step 3 for the other outer extend chain 2. 4. Remove the chord and fasten the outer extend
chain chain 1 at the rear of the outer lift arm.
5. Tie strong cord of sufficient length to the rear
of the outer extend chain 1 and the outer 5. Install new adjustment nuts 4. Do not tighten now.
extend chain 2. The cords will be used during 6. Repeat step 4 for the outer extend chain 2.
installation.
7. Turn the adjustment nuts 3 and the adjustment
6. Put wire through the hole in the chain adjuster in nuts 4 to set the chains to the correct initial
place of the split pin. position.
Initial chain setting
1. Set the chains to the correct initial position.
8. From the front of the machine pull the chains
out of the lift arm. Make sure that the cords are 2. Do the chain adjustment procedure. Refer to
accessible at both ends of the lift arm. body and framework- lift arm, refer to (PIL 06-12).
06-12-66). Table 21. Adjustment- Extend Chains
- Outer extend chain Refer to Figure 115.
rear anchors
40 mm
06 - 93 9823/1700-1 06 - 93
12 - Lift Arm
66 - Chain
– Inner extend chain Refer to Figure 116. Figure 115.

front anchors
24 mm 40 mm
– Inner extend chain Refer to Figure 116.
rear anchors
24 mm
– Outer extend chain Refer to Figure 116.
front anchors
24 mm Figure 116.
24 mm
06 - 94 9823/1700-1 06 - 94
12 - Lift Arm
66 - Chain
Figure 117.
F
E
D G
C
B
A
M H
N
L
A Inner extend chain 1 B Adjustment nuts 1

C Split pins 1 D Outer extend chain 1
E Adjustment nuts 3 F Split pins 2
G Outer lift arm H Outer extend chain 2
J First intermediate lift arm K Second intermediate lift arm
L Inner lift arm M Inner extend chain 2
N Adjustment nuts 4 P Adjustment nuts 2
06 - 95 9823/1700-1 06 - 95
12 - Lift Arm
66 - Chain
Retract Chains Remove And Install- 4 4. Put wire through the hole in the chain adjuster in
Stage (4 Section) Lift Arm place of the split pin 2.
Remove to pass through the chain adjuster brackets.
1. Raise the lift arm to the horizontal position and 6. From the rear of the machine pull the chain out of
fully retract the lift arm. Support the front end of the lift arm. Make sure that the cord is accessible
the lift arm. at both ends of the lift arm.
2. Make the machine safe. Refer to (PIL 01-03). 7. Inspect chain components. Refer to (PIL
06-12-66).
3. Follow the general safety precautions. Refer to
(PIL 01-03).
Install
4. Remove lift arm rear cover.
1. Keep chains clean. Do not let them drag on the
Inner retract chain ground.
1. Remove the split pin 1 and the adjustment nut 1 2. At the rear of the lift arm, attach the chains to the
from the inner retract chain at the rear of the lift cord used during removal.
arm.
3. From the front of the machine use the cords to
2. Remove the split pin 2 and the adjustment nut 2 pull the chains through the lift arm.
from the inner retract chain anchor at the front of
the first intermediate lift arm.
3. Tie strong cord of sufficient length to the front of Outer retract chain
the retract chain. The cord will be used during 1. Fasten the outer retract chain at the front of the
installation. outer lift arm.
4. Put wire through the hole in the chain adjuster in 2. Put new adjustment nuts 3. Do not tighten now.
place of the split pin 2.
3. Remove the cord, fasten the outer retract chain
5. Attach the cord to the wire. This will allow the cord at the rear of the lift arm and fit a new adjustment
to pass through the chain adjuster brackets. nut 1.
6. From the front of the machine pull the chain out of 4. Turn the nut to set the chain rear anchor to the
the lift arm. Make sure that the cord is accessible specified value. Refer to Table 22.
at both ends of the lift arm.
5. Turn the adjustment nut 3 to set the outer retract
7. Inspect chain components. Refer to (PIL chain anchor to the correct initial position.
06-12-66).
Inner retract chain
Outer retract chain
1. If chain roller has been removed, reinstall the
1. Remove the split pin 3 and the adjustment nut 1 roller and its pivot.
from the outer retract chain at the rear of the lift
arm. To get access to the adjustment nut 1 do the 2. Fasten the inner retract chain at the inner retract
following steps: chain anchor at the front of the first intermediate
lift arm.
1.1. Remove the split pin 1 and the adjustment
nut 2. 3. Put new adjustment nut 3. Do not tighten now.
1.2. Disconnect the inner retract chain. 4. Remove cord, fasten the inner retract chain at the
1.3. Remove the chain roller pivot and the roller. rear of the lift arm.
2. Remove the split pin 2 and the adjustment nut 3 5. Put new adjustment nut 2. Do not tighten now.
from the outer retract chain anchor at the front of
the outer lift arm. 6. Turn the adjustment nut 3 and the adjustment nut
2 to set the chain to the correct initial position.
3. Tie strong cord of sufficient length to the front of Refer to Table 22.
the retract chain. The cord will be used during
installation.
06 - 96 9823/1700-1 06 - 96
12 - Lift Arm
66 - Chain
Initial chain setting Figure 118.

1. Set the chains to the correct initial position. Refer 20 mm
to Table 22.
2. Do the adjustment procedure. Refer to body and
framework- lift arm, refer to (PIL 06-12).
Table 22. Adjustment- Retract Chains Figure 119.

Outer retract chain front Refer to Figure 118.
anchor 65 mm
20 mm
Inner retract chain front Refer to Figure 118.
anchor and rear anchor
20 mm
Outer retract chain rear Refer to Figure 119.
anchor
65 mm
06 - 97 9823/1700-1 06 - 97
12 - Lift Arm
66 - Chain
Figure 120.
L
C
A
F
M
E
D
G K
H
J
A Adjustment nut 1 B Outer retract chain

C Inner retract chain D Split pin 1
E Adjustment nut 2 F Split pin 3
G Inner retract chain anchor H Split pin 2
J Adjustment nut 3 K Outer retract chain anchor
L Chain rear anchor M Chain roller
06 - 98 9823/1700-1 06 - 98
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ......................................................................................................................... 06-101
06 - 99 9823/1700-1 06 - 99
Notes:
06 - 100 9823/1700-1 06 - 100

30 - Pivot Pins
00 - General
Introduction .................................................. 06-101 Pivot pins are a short shaft or pin that supports
Lubricate ...................................................... 06-102 something that turns. Pivot pins are installed in
Remove and Install ..................................... 06-102 numerous positions on the machine. There is usually
a greasing point associated with the pivot pin.
Make sure that the pivot points are greased at
regular intervals. Refer to the Machine Maintenance
Schedules. Refer to: PIL 78-24.
Slide Hammer Kit

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

thread at each end. One of the threads will always
be M20 size, this is to accommodate the end stops.
The other end of the adaptor will have varying thread
sizes to suit the different size of threads in the pivot
pins.
06 - 101 9823/1700-1 06 - 101

30 - Pivot Pins
00 - General
Lubricate Remove and Install

Special Tools
Extension Ram Pivot Pin Description Part No. Qty.
Use another pivot pin to support the ram while
greasing the other pivot pin. Make a note that the illustration shows a typical pivot
pin. The actual pivot pin installed on the machine may
1. Make the machine safe. Refer to (PIL 01-03). look different.
2. Follow the general health and safety procedures. 1. Prepare the pivot pin for removal, remove the
Refer to (PIL 01-03). locking device e.g. pivot pin retaining bolt.
3. Remove the inner extension ram pivot pin and 2. Prepare the slide hammer kit.
apply waxoyl. Refer to (PIL 06-30).
4. Install the inner extension ram pivot pin.
2.1. Install the slide hammer onto the slide bar.
5. Remove the tilt ram pivot pin and coat with
waxoyl. Refer to (PIL 06-30). 2.2. Determine the thread size of the pivot pin
and then install the appropriate adaptor.
6. Install the tilt ram pivot pin. Use the spanner flats to securely install the
adaptor.
Figure 121.
2.3. Install an end stop onto the other end of the
adaptor (M20 thread size), make sure that
the adaptor threads are fully engaged.
2.4. Install the slide bar into the end stop. Make
sure that the threads are fully engaged.
2.5. Finally install the other end stop at the end
of the slide bar. The slide hammer kit is now
ready to use.
A B 3. To extract the pivot pin, slide the hammer along
the bar until it contacts the end stop. Repeat this
step until the pivot pin is released.
4. To remove the slide hammer kit, reverse steps 2
to 3.
A Inner extension ram pivot pin

B Tilt ram pivot pin
06 - 102 9823/1700-1 06 - 102

30 - Pivot Pins
00 - General
Figure 122. Typical Machine
A Adaptor
B End stop
C End stop
D Spanner flats
E Slide bar
F Slide hammer
06 - 103 9823/1700-1 06 - 103

42 - Stabiliser
42 - Stabiliser
Contents Page No.
06-42-00 General ......................................................................................................................... 06-105

06-42-03 Leg ............................................................................................................................... 06-110
06 - 104 9823/1700-1 06 - 104

42 - Stabiliser
00 - General
Introduction .................................................. 06-105
Health and Safety ........................................ 06-106
(For: 510-56 [T2/T3], 512-56 [T2/T3])
Remove and Install ..................................... 06-107 The stabilisers are a safety device to stop the
machine tipping over when the lift arm is extended.
There are two stabiliser legs. The stabiliser legs

can be deployed by controls in the cab, to give
the machine added stability when the machine is
stationary.
06 - 105 9823/1700-1 06 - 105

42 - Stabiliser
00 - General
Health and Safety
(For: 510-56 [T2/T3], 512-56 [T2/T3])

WARNING The stability of the machine can
be reduced when you use the lift arm without
stabilisers. Before using the lift arm make sure the
stabilisers are set on stable ground.
WARNING You must be sitting in the operators
seat when operating the machines lift arm,
stabiliser or drive controls.
WARNING Bystanders could be crushed and
obstacles could be damaged if they are beneath
the stabilisers while they are being lowered.
Before lowering the stabilisers, make sure any
bystanders are clear of the machine. Also make
sure that there are no obstacles beneath the
stabilisers.
Notice: Before you extend the boom make sure
that the stabiliser legs are deployed to the ground
and the weight of the machine is supported.
06 - 106 9823/1700-1 06 - 106

42 - Stabiliser
00 - General
Remove and Install
(For: 510-56 [T2/T3], 512-56 [T2/T3]) 6. Remove the bolts.
Make sure you use the correct lifting equipment. The 7. Move the plate to get access to the electrical
stabiliser assembly weighs approximately 700 kg connector.
8. Disconnect the connector.
Remove
9. Label the hydraulic hoses and disconnect the
1. Lower the stabilisers but keep them clear of the hoses from the inside of bulkhead connectors.
ground.
10. Pull the hoses and electrical harness back
2. Make the machine safe with the lift arm raised. through the opening of the chassis.
11. Remove the frame to axle fasteners. Keep the
3. Install the maintenance strut. Refer to (PIL washers.
06-69).
12. Use the lifting equipment to pull the assembly
4. Put supports under the chassis on both sides of forward and disengage the pivot from the nose
the machine. fabrication.
5. Support the stabiliser frame with suitable lifting 13. Remove the spacer assemblies.
equipment.
06 - 107 9823/1700-1 06 - 107

42 - Stabiliser
00 - General
Figure 123.
J C
K E
C
E
B
H
A B
G
F
E
G A D
Table 23. Item Description

Item Description J Electrical connector
A Stabiliser frame K Washers
B Bolts
C Bulkhead connectors Install
D Opening of the chassis 1. The installation procedure is the opposite of the
E Axle fasteners removal procedure. Additionally do the following
F Pivot steps.
G Spacer assemblies 1.1. Check the condition of the pivot bush. If
H Plate necessary replace the bush with a new one.
06 - 108 9823/1700-1 06 - 108

42 - Stabiliser
00 - General
Figure 124.
L Pivot bush
1.2. Check the condition of the pivot pin. If

necessary replace the pin with a new one.
1.3. Correctly install the spacer assemblies.
1.4. Washers are hardened. You must use the
correct washers.
1.5. Tighten the fasteners of the specified length
to the correct torque value.
1.6. Grease the stabiliser frame pivot. Refer to
(PIL 01-03-27).
1.7. Check the operation of the stabilisers.
30-00).
06 - 109 9823/1700-1 06 - 109

42 - Stabiliser
03 - Leg
03 - Leg
Remove and Install
(For: 510-56 [T2/T3], 512-56 [T2/T3]) 6. Support the stabiliser leg.

Special Tools 7. Put a label on the hydraulic hoses to help
Description Part No. Qty. installation.
8. Disconnect the stabiliser ram hydraulic hoses.
Hydraulic Pressure 9. Remove the screws that secure the pressure
Hydraulic fluid at system pressure can injure you. switch cover.
Before connecting or removing any hydraulic hose,
10. Lift and move the pressure switch cover away
from the ram to get access to the pressure switch
harness connector.
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be 11. Disconnect the pressure switch harness
started while the hoses are open. connector.
CAUTION! This component is heavy. It must only be
removed or handled using a suitable lifting method 12. Remove the stabiliser harness.
and device. 12.1. Remove the securing nuts.
The illustration and procedure describes removal of 12.2. Slide the harness through the slot in the
one stabiliser leg The procedure for the second leg bracket.
is same.
13. Remove the nut 1 and the bolt 1 that secure the
The stabiliser feet are not the same, they are different ram pivot pin.
on each side. If you remove both feet, make sure you
put a mark on them to help identify which side of the 14. Use the slide hammer kit to remove the ram pivot
machine they belong to. pin.
Remove
15. Remove the nut 2 and the bolt 2 that secure the
1. Lower the lift arm and carriage to the ground. leg pivot pin joint.
2. Lower the stabilisers as far as possible, do not 16. Use the slide hammer kit to remove the leg pivot
allow them to support the machine. pin.
17. Remove the complete stabiliser leg and ram from
4. Follow all safety precautions.
the stabiliser frame.
30-00).
06 - 110 9823/1700-1 06 - 110

42 - Stabiliser
03 - Leg
Figure 125.
F
J
G
E
K
M
H
A A L
P
B
Item Description
Table 24. D Pressure switch cover
Item Description E Stabiliser harness secur-
ing nuts
A Stabiliser ram hydraulic
hoses F Electrical connector
B Pressure switch cover G Slot in bracket
securing screws H Bracket
C Pressure switch harness J Ram pivot pin securing
connector bolt
06 - 111 9823/1700-1 06 - 111

42 - Stabiliser
03 - Leg
Item Description
K Ram pivot pin
L Stabiliser frame
M Leg pivot pin securing
bolt
N Leg pivot pin
P Stabiliser leg
Install
steps.
1.1. Grease the ram and leg pivot pins. Refer to
(PIL 01-03-27).
30-00).
06 - 112 9823/1700-1 06 - 112

57 - Counterweight
57 - Counterweight
Contents Page No.
06-57-00 General ......................................................................................................................... 06-115
06 - 113 9823/1700-1 06 - 113

Notes:
06 - 114 9823/1700-1 06 - 114

57 - Counterweight
00 - General
00 - General
Health and Safety

method and device.
CAUTION You can be injured if you use incorrect
or faulty lifting equipment. You must identify the
weight of the item to be lifted then choose lifting
equipment that is strong enough and suitable for
the job. Make sure that lifting equipment is in good
WARNING Make sure the machine cannot be
used with the counterweight removed. Make sure
the ignition key is removed and the battery is
isolated.
WARNING Make sure the machine cannot tip
over when this component (or components) is
(are) removed during this operation.
06 - 115 9823/1700-1 06 - 115

63 - Identification Label
Contents Page No.
06-63-00 General ......................................................................................................................... 06-117

06-63-03 Machine ........................................................................................................................ 06-118
06-63-06 Engine .......................................................................................................................... 06-120
06-63-09 Axle(s) .......................................................................................................................... 06-122
06-63-12 Gearbox ........................................................................................................................ 06-123
06-63-15 Operator Protective Structure ...................................................................................... 06-124
06 - 116 9823/1700-1 06 - 116

00 - General
00 - General
Introduction
The machine has identification plates that contain

important information relating to the specific machine
details, for example VIN or PIN number and engine
serial number. These serial numbers can help you
identify exactly what equipment has been installed
on the machine.
06 - 117 9823/1700-1 06 - 117

03 - Machine
03 - Machine Digit 1 to 3 World Manufacturer

Identification
HAR Haryana, India
Component Identification
SOR Sorocaba, Brazil
GET Gatersleben, Germany
Machine Identification Plate PUN Pune, India
SHA Shanghai, China
Your machine has an identification plate mounted in
one of two positions as shown. The serial numbers JBP JCB Branded Products
of the machine and its major units are shown on the
plate.
Table 27.
The machine model and build specification is Digit 4 to 6 Machine Model
indicated by the PIN (Product Identification Number) 5AA 531-70
The serial number of each major unit is also shown 5AB 535-95
on the unit itself. If a major unit is replaced by a 5AC 536-60
new one, the serial number on the identification plate 5AD 541-70
will be wrong. Either get a replacement identification 5AF 540-170
plate from your JCB Dealer or simply remove the
old number. This will prevent the wrong unit number 5AG 550-140
being quoted when replacement parts are ordered. 5AH 533-105
The machine and engine serial numbers can help 5AJ 535-125
identify exactly the type of equipment you have. 5AK 535-140
Figure 126. 5AL 540-140
5AM 550-170
5AN 535-125 HiViz
5AP 535-140 HiViz
5AR 536-70
5AX 540-200
5A8 540-140 HiViz
5MA Work platform machines
5MF Work platform machines
5MN Work platform machines
5MX Work platform machines
5M8 Work platform machines
5RA 540-180 HiViz
5TA 531-70
5TB 541-70
5TC 536-70
5TD 535-95
Typical Product Identification Number 5TE 536-70
The machine model and build specification are
indicated by the PIN. The PIN has 17 digits and must Table 28.
be read from left to right.
Digit 7 Engine Type
Table 25. Typical PIN JCB Dieselmax (Tier 2):
JCB 5AA J E C G 1234567 J SA naturally aspirated
63 kW
K SB turbocharged 74 kW
Table 26.
L SC turbocharged and af-
Digit 1 to 3 World Manufacturer tercooled 93 kW
Identification JCB Dieselmax (Tier 3):
JCB United Kingdom T SD turbocharged 63 kW
GEO Georgia, US
06 - 118 9823/1700-1 06 - 118

03 - Machine
Digit 7 Engine Type

S SF turbocharged and af-
tercooled 74 kW
R SE turbocharged and af-
tercooled 97 kW
Table 29.
Digit 8 Gearbox Model
E 3 Speed (PS750)
F 3 Speed (PS760)
G 4 Speed (PS750)
H 4 Speed (PS760)
J 6 Speed (PS760)
M 4 Speed (SS700)
N 4 Speed (PS750)
Table 30.
Digit 9
Random check letter. The check letter is used to
verify the authenticity of a machine's PIN
Table 31.
Digit 10
Year of manufacture.
7 = 2007 D = 2013
8 = 2008 E = 2014
9 = 2009 F = 2015
A = 2010 G = 2016
B = 2011 H = 2017
C = 2012
Table 32.
Digit 11 to 17
Machine serial number. Each machine has a
unique serial number.
06 - 119 9823/1700-1 06 - 119

06 - Engine
06 - Engine
Introduction
The engine data labels are attached to the crankcase The data label includes the engine identification
and rocker cover (if installed) as shown. number.
Figure 127.
B
A Engine data label - crankcase

B Engine data label
Table 33. Example of the engine identification number

S A 320/40098 U 00001 04
Digit 1 2 3-10 11 12-16 17-18
06 - 120 9823/1700-1 06 - 120

06 - Engine
Table 34.
Digit 1 Engine Displacement
D 4.8
S 4.4
Table 35.
Digit 2 Type of Aspiration
Tier 2 engines
A Naturally aspirated
B Turbocharged
C Turbocharged with inter-
cooler
Tier 3 engines
D Turbocharged
E Electronic common rail
F Turbocharged with inter-
cooler
Table 36.
Digit Explanation
3-10 Engine part number
11 Country of manufacture.
U = United Kingdom
12-16 Engine serial number
17-18 Year of manufacture. 09
= 2009
The country of manufacturer, engine serial number

and year of manufacture of the engine are also
stamped on the crankcase Refer to Figure 127. .
06 - 121 9823/1700-1 06 - 121

09 - Axle(s)
09 - Axle(s)
The axles have a serial number stamped on a data

plate as shown.
Figure 128. Front axle
A Data plate - front axle

Figure 129. Rear axle
B Data plate - rear axle
06 - 122 9823/1700-1 06 - 122

12 - Gearbox
12 - Gearbox
The gearbox has a serial number stamped on a data

plate as shown.
Figure 130. Power-shift Transmission
A
A Data plate
06 - 123 9823/1700-1 06 - 123

15 - Operator Protective Structure
WARNING You could be killed or seriously Machines built to ROPS (Roll-Over Protective
injured if you operate a machine with a damaged Structure)/FOPS (Falling Object Protective
or missing ROPS/FOPS. If the ROPS/FOPS Structure) standards have identification label A fitted
has been in an accident, do not use the to the inside of the cab.
machine until the structure has been renewed.
Modifications and repairs that are not approved The FOPS structure provides Level II Impact
by the manufacturer may be dangerous and will Protection against falling objects (as defined in ISO
invalidate the ROPS/FOPS certification. 3449:2005).
Figure 131.
Data plate - ROPS/FOPS standards
06 - 124 9823/1700-1 06 - 124

66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ......................................................................................................................... 06-127
06 - 125 9823/1700-1 06 - 125

Notes:
06 - 126 9823/1700-1 06 - 126

66 - Tools
00 - General
00 - General
Introduction
All tools must be kept in the toolbox (if installed) when

not in use.
06 - 127 9823/1700-1 06 - 127

69 - Maintenance Strut
Contents Page No.
06-69-00 General ......................................................................................................................... 06-129

06-69-03 Lift Arm ......................................................................................................................... 06-130
06 - 128 9823/1700-1 06 - 128

00 - General
00 - General
Introduction
Before you start any service procedures on the

machine, make sure that the relevant maintenance
strut is installed in its correct position and secure.
06 - 129 9823/1700-1 06 - 129

03 - Lift Arm
03 - Lift Arm
Remove and Install
CAUTION You will have to climb onto the Figure 134.

machine to install or remove the strut. Take care, A
especially if the machine is wet. Remove mud and
oil before climbing onto the machine. Do not use
the exhaust as a handhold. It can burn you.
WARNING You could be killed or injured if the lift
arm drops while you are working under it. Install
the lift arm maintenance strut as instructed before
doing any maintenance work with the lift arm
raised. Keep people away from the machine while
you install or remove the lift arm maintenance
strut. A Lift arm raised
WARNING Make sure that you use the correct
JCB maintenance strut for the machine. Make Installing the Maintenance Strut
sure that the safety strut is only used with the
correct JCB retaining bolt or securing device.
Never substitute this bolt or securing device, 2. Follow all general health and safety procedures.
always use the correct JCB part. Refer to (PIL 01-03).
Make sure that the strut and bolt/securing device
is installed correctly. Never use a strut intended 3. Fully retract the lift arm.
for another machine. If in doubt, consult your JCB 4. Raise the lift arm just far enough to install the
dealer. strut.
If you raise the lift arm to get access for maintenance, 5. Stop the engine and remove the ignition key.
you must install the maintenance strut on the lift arm.
6. Use the steps for access to the strut. Undo the
Before you install the maintenance strut remove any
hand bolt and remove the strut from its stowage
load on the forks and empty shovels or attachments.
position. Some machines have two steps on the
chassis and no steps on the axle.
7. Lower the strut so that the cut-out locates with
the pipe on the lift ram. Place the strut around the
lift cylinder piston rod. Secure the strut in position
with hand bolt.
8. Lower the lift arm carefully onto the strut. Stop as
soon as the weight of the lift arm is on the strut.
06 - 130 9823/1700-1 06 - 130

03 - Lift Arm
Figure 135.
C
C
D
E
A
A X
A Steps B Bolt
C Strut D Lift cylinder piston rod
E Cut-out X Stowage position
Removing the Maintenance Strut

2. Follow all general health and safety procedures.
3. Raise the lift arm just enough to allow the strut
to be removed.
4. Stop the engine and remove the ignition key.
5. Use the steps for access and support the strut.
Undo the hand bolt and lift the strut clear of the
steel pipe on the lift ram. Some machines have
two steps on the chassis and no step on the axle.
6. Secure the strut with hand bolt in its stowage
position.
06 - 131 9823/1700-1 06 - 131

03 - Lift Arm
Figure 136.
C
B
A
A
A Steps
B Bolt
C Strut
X Stowage position
06 - 132 9823/1700-1 06 - 132

75 - Fire Extinguisher
Contents Page No.
06-75-00 General ......................................................................................................................... 06-135
06 - 133 9823/1700-1 06 - 133

Notes:
06 - 134 9823/1700-1 06 - 134

00 - General
00 - General
Check (Condition)
In addition to the operator check the extinguisher

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

leaks.
2. Make sure the fire extinguisher is correctly
attached.
3. Make sure that the gauge indicates that the
extinguisher is charged i.e. the needle is in the
green segment
3.1. If the needle is in or very near the red
segment at either end of the gauge, the
extinguisher must be serviced or replaced.
4. Make sure the safety pin is correctly installed.
Figure 137.
A Gauge
B Safety Pin
06 - 135 9823/1700-1 06 - 135

89 - Window Guard
89 - Window Guard
Contents Page No.
06-89-00 General ......................................................................................................................... 06-137
06 - 136 9823/1700-1 06 - 136

89 - Window Guard
00 - General
00 - General Figure 138. Front screen guard
Remove and Install A E
Screen Guard B
Remove C
D
2. Follow all general health and safety procedures. A
3. Support the guard.
4. Remove the upper nuts, bolts and washers.
5. Remove the lower nuts and washers.
6. Remove the guard from the machine.
Installation
removal procedure.
F
G
H F
A Screen guard
B Washer
C Bolts
D Nut
E Mounting lug
F Washer
G Washer
H Nut
06 - 137 9823/1700-1 06 - 137

97 - Platform
97 - Platform
Contents Page No.
06-97-00 General ......................................................................................................................... 06-139
06 - 138 9823/1700-1 06 - 138

97 - Platform
00 - General
Introduction .................................................. 06-139
Overview
Technical Data ............................................. 06-141 The JCB Work platform is installed to the machine
Component Identification ............................. 06-142 using the JCB Q-Fit design attachment. The machine
Operation ..................................................... 06-145 is then classed as a MEWP (Mobile Elevating Work
Platform) when this type of system is installed.
Operation (Hydraulic) .................................. 06-145
Check (Condition) ........................................ 06-146 The system enables safe access to elevated
Calibrate ...................................................... 06-147 positions during building / maintenance work.
Remove and Install ..................................... 06-155
Store and Recommission ............................ 06-155 Controls
Refer to Component Identification, (PIL 06-98-00).
Control of the lift arm is via a servo control lever in

the cab or a remote control unit from the JCB work
platform.
A safety key system prevents operation of the lift arm

by the cab control lever and remote control unit at
the same time. When the machine is operated from
the cab it is in cabin mode. When the machine is
operated from the remote control unit it is in remote
mode.
Remote Servo Control

The JCB work platform system enables remote
control of the lift arm lift / lower, extend / retract,
crowd / dump and engine speed functions by an
operator located in the JCB work platform. The
control of these functions is achieved through a
remote control unit and radio receiver.
When the system is operated in remote mode:
• The LLMC (Longitudinal Load Moment Control)

system is automatically engaged.
• All cab controls are isolated.
• A safety system monitors operation of the
remote control unit. If the unit is not operated
during the specified period of time, the engine
automatically stops. If necessary, the engine
can be re-started by use of the remote control
unit. The specified period of time is 15 min
Emergency Operation
In case of an emergency (for example, engine
failure), an independent electrically driven hydraulic
pump is provided. The pump allows the platform to
be lowered safely to the ground from the platform or
the cab.
Pressing the machine isolation push button stops

the engine and hydraulic system in an emergency.
06 - 139 9823/1700-1 06 - 139

97 - Platform
00 - General
The JCB work platform also has an emergency stop Health and Safety
(isolation) button next to the remote control unit.
Lift Arm / Machine Travel
Longitudinal Load Moment Control
Operating the lift arm while you travel can cause
(LLMC) System accidents. You will not have total control of the
machine. Do not operate the lift arm when you travel.
The LLMC System installed on this machine
operates in cabin mode, for more information on DANGER! Do not enter or exit the platform with the
the LLMC system refer to the relevant machine lift arm in the raised position.
operator’s manual.
DANGER! The machine must be in remote mode
During remote operation the LLMC remains in when using the platform. Do not use the platform
operation but increases the machine stability over when the remote control unit is in cab mode.
cabin mode. DANGER! Run flat inserts may be installed in
the rear wheels. These must remain installed to
the rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre. Make
sure that all tyres are inflated to the correct pressure
and have run flat inserts as required. Where run
flat inserts have been specified for use, ensure that
replacement wheels also have run flat inserts to
ensure the machine stability.
WARNING! Operating the boom while you travel can
cause accidents. You will not have total control of the
machine. Never operate the boom when you travel.
WARNING! Control lever/switch action may vary
on machines, instructional labels near the levers/
switches show by symbols, which levers/switches
cause what actions. Before operating control levers/
switches check the instructional label to make sure
you select the desired action.
WARNING! To operate the machine safely you must
know the machine and have the skill to use it.
You must abide by all relevant laws, health and
safety regulations that apply to the country you are
operating in. The operator's manual instructs you on
the machine, its controls and its safe operation; it
is not a training manual. Ensure that you receive
the correct training before operating any machinery.
Failing to do so will result in incorrect operation of
the machine and you will be putting yourself and
others at risk. In some markets, and for work on
certain jobsites, you may be required to have been
trained and assessed in accordance with an operator
competence scheme. Make sure that you and your
machine comply with relevant local laws and jobsite
requirements – it is your responsibility.
WARNING! Make sure it is clear overhead before
raising the boom. Keep an adequate safe distance
from all electrical power lines. Contact your local
power company for safety procedures.
WARNING! Notice boards or panels must not be
installed on the platform because they will increase
wind resistance.
WARNING! Do not use the platform as a crane.
WARNING! Do not extend the reach or height of the
platform by the use of ladders or other equipment.
06 - 140 9823/1700-1 06 - 140

97 - Platform
00 - General
WARNING! Do not use the platform when wind Technical Data

speeds exceed 12.5 m/s (41 ft/s)
WARNING! Do not allow the machine to come in to
contact with fixed objects, buildings etc. 500 kg Capacity Personnel Platform
WARNING! Do not allow the machine to come in to Unladen mass = 900 kg
contact with moving objects, vehicles, cranes etc.
WARNING! Do not exceed the maximum rated load Maximum Carrying capacity = 500 kg
stated on the platform.
WARNING! All operators must be adequately trained Inclines
and authorised to use the machine. 1. Maximum lateral incline
WARNING! All operators must make sure there is Angle: 0 ± 4 °
a restricted area under or around the platform to
safeguard against falling objects injuring bystanders 2. Make sure machine is level to
or colleagues.
Angle: 0 ± 1 °
WARNING! All operators must use the correct safety
harnesses when operating from the platform. Hard Figure 139.
hats with chin straps must also be worn.
WARNING! Do not lower a slewed platform to a
height below 2 metres (80 inches) from the ground
as the platform could hit the front of the machine.
WARNING! Under no circumstances should
personnel be lifted into the air without using an
approved and properly secured platform. Failure to
follow this warning could result in death or serious
injury.
WARNING! Do not operate the machine with
personnel in the platform, except when you need
to lower the platform in an emergency using the
procedure in the operators manual. If the platform
cannot be lowered by the use of the emergency
controls, personnel must be removed using other D
means. You must not work on the machine whilst
personnel are in the platform. D Inclinometer
WARNING! 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,
ECU (Electronic Control Unit), 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 and break the structure. 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 m from the part being welded.
06 - 141 9823/1700-1 06 - 141

97 - Platform
00 - General
Figure 140. Work Platform - Fixed Type (365 kg)

A B
B
A
D C
A Cradle- remote control B Cable reel

C Mounting assembly D Fork sleeves for (transportation when removed
from the machine)
06 - 142 9823/1700-1 06 - 142

97 - Platform
00 - General
Figure 141. Work Platform - Slew Type (500 kg and 1000 kg)
C
A
D
334/F6378-5
A Side extension (collapsed) B Side extension (extended)

C Cradle- remote control D Mounting assembly
E Pivot mechanism F Fork sleeves for (transportation when removed
from the machine)
The illustration(s) show a typical machine model;

your machine may look different from the model
shown.
06 - 143 9823/1700-1 06 - 143

97 - Platform
00 - General
Figure 142. Work Platform
6 7
1
8
1 Joystick Control Lever 2 Remote Control Unit

3 JCB Work Platform 4 Radio Receiver (behind cover)
5 Machine Isolation Button 6 Platform Emergency Stop Button
7 Stabiliser Control Levers 8 Safety Key Socket (Cab Mode)
06 - 144 9823/1700-1 06 - 144

97 - Platform
00 - General
Operation Operation (Hydraulic)
For emergency lowering procedures refer to Refer to: Refer to hydraulic system, general, general,
PIL 06-93-00. operation, (PIL 30-00-00).
06 - 145 9823/1700-1 06 - 145

97 - Platform
00 - General
Check (Condition) 5. Note damaged paintwork for future repair.
WARNING If one or more of these faults are Check the Electrical Circuits
found, make sure the machine is not used until
the fault has been correctly repaired or the 1. Inspect the electrical circuits regularly for:
component replaced.
1.1. Damaged connectors.
WARNING Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not 1.2. Loose connections.
use the machine if a hose or hose fixture is 1.3. Chafing on wiring harnesses.
damaged.
1.4. Corrosion.
Notice: These checks do not replace inspections
that are necessary to obey local or national 1.5. Missing insulation.
regulations applicable in your area.
1.6. Incorrect routing of harness.
Remote Mode Pre- Operation Checks 2. Do not use the machine if one or more of these
faults are found. You must make sure that the
Prior to commencing work from the platform, the electrical circuit is repaired immediately.
following functions must be checked (refer to the 3. Perform the daily checks as stated in the
Operators Manual): machine operator’s manual.
1. Machine isolation from the operator station.
2. Machine isolation from the platform.
3. Emergency Lowering.
Checking for Damage

1. These checks are not a substitute for inspections
to meet Lifting Operations and Lifting Equipment
Regulations 1998 (LOLER).
1.1. Platforms should be inspected daily prior
to use to ensure structural soundness and
correct operation.
1.2. Platforms should be inspected daily prior
to use to ensure structural soundness and
correct operation.
Check the Platform Structure

1. Inspect all steelwork for damage. Pay particular
attention to the following:
1.1. Inspect all lifting point welds.
1.2. Inspect all pivot point welds.
1.3. Inspect all lanyard anchor points.
1.4. Inspect the condition of all pivot pins.
1.5. Check pivot pins are correctly in place and
secured by their locking devices.
2. Check handrails and toeplates are undamaged
and secure.
3. Check gates are undamaged and secure.
4. Check all safety and instructional labels are in
place and undamaged. Install new labels where
necessary.
06 - 146 9823/1700-1 06 - 146

97 - Platform
00 - General
Calibrate
Load Calibration- Work Platform of other people before lowering the load. If you do
not follow these precautions you or others could
DANGER Do not stand underneath the raised be killed or seriously injured.
load during the lifting/lowering procedure. Stand
clear and to one side until the load has been
1. Loosen all the nuts and bolts in the location
safely lowered. Make sure that the area is clear
shown.
Figure 143.
C
C
D B E
E B
06 - 147 9823/1700-1 06 - 147

97 - Platform
00 - General
A Adjustment bolts (X8) B Stop bolts (X2)

C Micro-switch securing bolt (X2) D Springs (X8)
E Micro-switch (X2)
2. On the outer adjustment bolts: Figure 145.

2.1. Hold the outer adjustment bolt and tighten
the nut to eliminate any backlash. Make A
sure you do not load the spring.
2.2. Hold the existing nut and install a locknut.
Tighten to the correct torque.
3. On the inner six adjustment bolts:
3.1. Hold the adjustment bolt and tighten the nut
to eliminate any backlash. Make sure you
do not load the spring.
3.2. Hold the existing nut and install a locknut.
Tighten to the correct torque.
Figure 144.
A Adjustment bolt
A
4. Loosen the stop bolts until they make contact
with the basket support. Adjust the stop bolts to
leave a gap of the specified size between the
stop bolts and the drum.
4.1. Hold the stop bolts and tighten their
respective nuts.
A Adjustment bolt
06 - 148 9823/1700-1 06 - 148

97 - Platform
00 - General
Figure 146. Stop Bolt
B Stop bolts X Specified gap
5. Load a calibrated test weight on the platform. 5.2. For 365kg platform
Make sure it is placed in the middle of the Weight/Force: 402 kg
platform.
5.3. For 500kg platform
5.1. To make sure the calibration is done
correctly, the necessary calibrated test Weight/Force: 550 kg
weight is in excess of the nominal weight 5.4. For 1000kg platform
by 10%. The specified total calibrated test
weight necessary is: Weight/Force: 1,100 kg
06 - 149 9823/1700-1 06 - 149

97 - Platform
00 - General
Figure 147.
A Work platform Y Calibrated weight
6. Install the platform on to the machine.
Figure 148.
7. Lift the platform.
06 - 150 9823/1700-1 06 - 150

97 - Platform
00 - General
Figure 149.
8. Make the machine safe with the lift arm in the 9. Calibrate as follows:
necessary test position. Refer to (PIL 01-03).
06 - 151 9823/1700-1 06 - 151

97 - Platform
00 - General
Figure 150. Micro-switch Location
A Micro-switches
10. Loosen the right micro-switch securing bolt on 12. Test the correct calibration by weighing down the
the right side overload micro-switch. right side corner of the platform.
11. Slowly turn the right micro-switch securing bolt 12.1. Make sure the overload warning operates
until it stops the operation of the micro-switch. correctly before proceeding.
11.1. Tighten the bolt another 1/4 turn. Hold the
bolt and tighten the nut.
06 - 152 9823/1700-1 06 - 152

97 - Platform
00 - General
Figure 151. Right Side Micro-switch
C Right micro-switch securing bolt
Figure 152. Work Platform
C
A B
A Right side B Left side

C Work platform
13. Loosen the left micro-switch securing bolt on the 14.1. Tighten the bolt another 1/4 turn. Hold the
left side overload micro-switch. bolt and tighten the nut.
14. Slowly turn the left micro-switch securing bolt 15. Test the correct calibration by weighing down the
until it stops the operation of the micro-switch. left side corner of the platform.
06 - 153 9823/1700-1 06 - 153

97 - Platform
00 - General
Figure 153. Left Side Micro-switch
C Left Micro-switch securing bolt
15.1. Make sure the overload warning operates

correctly.
06 - 154 9823/1700-1 06 - 154

97 - Platform
00 - General
Remove and Install Store and Recommission
Refer to the personnel platform operators manual. General Maintenance- Work Platform
The machine must be serviced and maintained in
accordance with the machine manual.
Maintenance for the platform and associated

equipment consists mainly of repair or replacement
of any parts which are damaged or fail during use.
For maintenance of the vehicle, refer to the vehicle
manual.
No modifications are permitted to the platform

without the permission of the platform manufacturer.
For long-term parking of the Platform, it is

recommended that it is insulated from the floor to
avoid the possibility of corrosion.
The hydraulic cylinders must be fully retracted or

greased to avoid corrosion of the piston rods.
If the platform has been parked for long periods, it

must be checked for possible damage caused by
heat, cold, moisture, dust, etc.
There are eight lubricating points, four on the slewing

frames and one at each end of the slew rams, which
must be lubricated at the specified interval. The
specified interval is 50 h
All other movable joints must be lubricated as

required.
Check for oil leaks which may cause contamination.

Any leaks must be repaired.
Periodic inspection to check for structural defects

should be carried out in accordance with
theLOLER (Lifting Operations and Lifting Equipment
Regulations)1998.
Any major repair work must be re-certified to

EN280:2013. Major repair work or modifications
are those which could affect stability, strength or
performance.
When the machine is removed from service,

local regulations for machine decommissioning and
disposal will vary. Contact your nearest JCB dealer
for further information.
1. Preliminary checking of the platform before use

1.1. The operator who uses the machine must
check it by means of visual inspection
before using the equipment and connecting
it to the platform.
2. Plan for periodic maintenance to be carried out
on the platform.
06 - 155 9823/1700-1 06 - 155

97 - Platform
00 - General
2.1. The platform must be checked and

maintained by qualified personnel for
operation and compliance.
3. The periodic maintenance register must be filled
in correctly as proof of the inspections and
maintenance performed.
4. The register, in the following pages, can be
reproduced by the person in charge of the
platform maintenance to be used throughout the
life of the equipment.
5. The register covers a period of one year. The
register must be reproduced for the records of
the maintenance over the period of life of the
accessory.
Prolonged Shut-down of the Accessory

1. If the accessory is to remain unused for a long
period, certain important precautions must be
taken for its correct maintenance:
1.1. Store the accessory indoors or covered
with a water-proof sheet to protect it from
atmospheric agents;
1.2. Lubricate all joints or rotation points with
grease;
1.3. Protect the platform rotation transmission
chain and chrome-plated rods of the
hydraulic cylinders with lubricant;
1.4. Protect the platform rotation crown with
lubricant;
1.5. Touch up scratched parts with protective
paint;
1.6. Protect the hydraulic connectors.
Resuming Service after Shut-Down

1. Putting into service after prolonged disuse,
before resuming work after a long shut down:
1.1. Remove the grease applied before storage;
1.2. Clean the accessory thoroughly;
1.3. Check the working of the rotary parts with
pins and hinges;
1.4. Make a series of movements with the
accessory after connecting it to the vehicle.
06 - 156 9823/1700-1 06 - 156

Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-00-03 Cab Frame ....................................................................................................................... 09-5
09-00-06 Operator Protective Structure ........................................................................................ 09-10
09-09 Window
09-09-00 General ........................................................................................................................... 09-13
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-21
09-12-03 Seat Base ...................................................................................................................... 09-23
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-25
09-18 Door
09-18-00 General ........................................................................................................................... 09-29
09-18-12 Handle ............................................................................................................................ 09-32
09-27 Controls
09-27-00 General ........................................................................................................................... 09-35
09-27-36 Accelerator Pedal ........................................................................................................... 09-36
09-27-57 Park Brake ..................................................................................................................... 09-38
09-28 Cables and Fittings
09-30 Trim Panel
09-30-03 Roof Trim ....................................................................................................................... 09-47
09-30-09 Dashboard ...................................................................................................................... 09-48
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-53
09-36 Steering Wheel
09-36-00 General ........................................................................................................................... 09-57
09-44 Sunblind
09-44-00 General ........................................................................................................................... 09-59
09-48 Floor mat
09-48-03 Front Floor mat .............................................................................................................. 09-63
9823/1700-1
2018-06-14
Acronyms Glossary
ECU Electronic Control Unit

HVAC Heating Ventilation Air Conditioning
TXV Thermal Expansion Valve
9823/1700-1
2018-06-14
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3

09-00-03 Cab Frame ....................................................................................................................... 09-5
09-00-06 Operator Protective Structure ........................................................................................ 09-10
09 - 1 9823/1700-1 09 - 1
Notes:
09 - 2 9823/1700-1 09 - 2
00 - General
00 - General Health and Safety

Health and Safety ........................................... 09-3 Raised Equipment
Component Identification ................................. 09-4 Never walk or work under raised equipment unless
it is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails
or if the control is operated (even with the engine
stopped).
Make sure that no-one goes near the machine while
you install or remove the mechanical device.
Lifting Equipment
equipment is in good condition and complies with all
local regulations.
09 - 3 9823/1700-1 09 - 3
00 - General
Figure 154.
V X Q
E
D
W
F G
H
C S
J
B R
A K
T
P N M
L
A Hourmeter B Drive lever

C Console switches D Steering wheel
E Instrument panel F Steering column adjustment
G Multi-purpose switch H Instrument panel
J Ignition switch K Console switches
L Load Charts M Accelerator pedal
N Brake pedals P Park brake
Q Boom and carriage controls R Steer mode selector
S Chassis levelling controls T Stabilizer controls
U HVAC (Heating Ventilation Air Conditioning) V Inclinometer
W Auxiliary controls X Transmission dump switch
09 - 4 9823/1700-1 09 - 4
03 - Cab Frame
03 - Cab Frame
Remove and Install
Working Under the Machine 9. Disconnect the engine accelerator cable (if
installed).
Make sure that any attachments on the machine are 10. Disconnect the accelerator pedal electrical
correctly attached. Engage the park brake, remove connectors (if installed).
has wheels use blocks to prevent unintentional 11. Make sure that all wheels are blocked to prevent
movement. movement of the machine. Release the park
Air Conditioning Maintenance brake and disconnect the park brake cable.
The air conditioning system is a closed loop system 12. On machines with dual lever controls, disconnect
and contains pressurised refrigerant. No part of the the control levers from the control valve
system should be disconnected until the system connection rods.
or a suitably trained person. You can be severely 13. On machines with parallel servo control levers,
frostbitten or injured by escaping refrigerant. label and disconnect the hoses at the servo
control valves. Disconnect the control levers from
Notice: Make sure you label all hoses / pipes and the control valve connection rods.
electrical connectors (if installed) before removal to
aid identification during subsequent installation. 14. Disconnect the manual steer mode valve cable
(if installed) from the lever.
Cab
15. Disconnect the chassis electrical harness and
cab earth strap.
Remove
16. Undo the fuel filler hose clip. Loosen the fuel tank
1. Make the machine safe. filler hose on fuel tank filler neck so that the two
Refer to: PIL 01-03-27. separate later.
2. Install the safety strut. 17. Disconnect the braking system components.
Refer to: PIL 01-03-27. 17.1. 550-80 and 560-80 Machines- For details
of disconnecting the brake valve.
3. Discharge the hydraulic pressure.
Refer to: PIL 30-00-00. 17.2. On machines with cab mounted brake
servo, disconnect the brake pipe and
4. Remove the battery cover and disconnect the servo hose. Cap all open hoses and pipes
battery. to prevent fluid loss and ingress of dirt.
Refer to: PIL 33-03-00. 17.3. Disconnect brake pipe at the master
cylinder. Cap all open hoses and pipes to
5. Remove the bolts and remove the cab front prevent fluid loss and ingress of dirt.
cover.
18. Disconnect hitch cable (if installed).
19. For machines with manual transmission
6. Disconnect all hydraulic hoses from the steering disconnect the cables to the gear lever.
unit. Cap all open hoses and ports to prevent fluid
loss and ingress of dirt. 20. Unscrew and remove the cab mounting bolts.
7. Remove the heater cover (if installed). Undo the 21. Attach appropriate lifting equipment to the ROPS
hose clips and disconnect the heater hoses. (Roll-Over Protective Structure).
8. If applicable, once the system has been 22. Carefully lift the cab from the machine, make sure
discharged, disconnect the air conditioning that all connections have been released and are
hoses at the TXV (Thermal Expansion Valve). clear of any obstruction. Cap off fuel tank filler
Some machines are installed with a cab roof neck to prevent contamination.
mounted air conditioning condenser. Disconnect
the condenser hoses at the rear of the cab.
09 - 5 9823/1700-1 09 - 5
03 - Cab Frame
Install 1.5. If applicable, recharge the air conditioning

system.
removal procedure. Additionally do the following Refer to: PIL 12.
steps. 1.6. Check the hydraulic fluid level.
1.1. Tighten the cab mounting bolts to the Refer to: PIL 30-00-00.
correct torque value. 1.7. Make sure that all cables are connected and
1.2. Bleed the brakes. Refer to (PIL 24-00). correctly adjusted. Make sure that they are
routed and secured correctly.
1.3. Adjust the accelerator cable and pedal (if
installed). 1.8. Make sure that all electrical and hydraulic
services operate correctly.
1.4. Correctly connect and adjust the cables to
the gear lever (if installed).
Figure 155.
B
J B
G
B
C
D
E
F
B
A Park brake cable B Cab mounting bolts
09 - 6 9823/1700-1 09 - 6
03 - Cab Frame
C Cab front cover D Steering unit

E Cab earth strap F Chassis electrical harness
G Hitch cable H Fuel tank filler neck
J Filler hose clip
09 - 7 9823/1700-1 09 - 7
03 - Cab Frame
Figure 156.
K
K
R
Z
W
X
K Dual lever controls M Transmission gear lever
09 - 8 9823/1700-1 09 - 8
03 - Cab Frame
O Manual steer mode lever P Clip

R Heater cover (if installed) S Heater hose clips
T Air conditioning hoses at TXV U Servo hose clip
V Brake pipe W View- cab mounted servo
X View- master cylinder Y Brake pipe
Z Single lever control
09 - 9 9823/1700-1 09 - 9
Check (Condition)
WARNING You could be killed or seriously injured 1. Check condition of the structure for damage.
if you operate a machine with a damaged or
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/ 2. Make sure that all the ROPS (Roll-Over
FOGS has been in an accident, do not use the Protective Structure)/FOPS (Falling Object
machine until the structure has been renewed. Protective Structure) mounting bolts are in place
Modifications and repairs that are not approved and are undamaged.
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS/FOGS certification. 3. Make sure that the ROPS/FOPS mounting bolts
are tightened to the correct torque value.
Figure 157.
A
A Bolts

Item Nm
A 205
09 - 10 9823/1700-1 09 - 10
09 - Window
09 - Window
Contents Page No.
09-09-00 General ........................................................................................................................... 09-13
09 - 11 9823/1700-1 09 - 11
Notes:
09 - 12 9823/1700-1 09 - 12
09 - Window
00 - General
Introduction .................................................... 09-13 The service procedures, explain how to correctly
Health and Safety .......................................... 09-14 remove and install panes of glass that are directly
Preparation .................................................... 09-14 bonded to the cab frame apertures. When you carry
Remove and Install ....................................... 09-16 out any service procedure, you must always refer to
the relevant safety precautions, Health and Safety.
1. Always wear safety glasses during removal and

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

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

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

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

5 °C ( 41.0 °F).
09 - 13 9823/1700-1 09 - 13
09 - Window
00 - General
Health and Safety Preparation

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

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

otherwise they may be absorbed into the old sealant
and ultimately prevent the new glass from bonding.
New Glass
1. Make sure that the new glass correctly fits the
frame aperture.
1.1. Put two spacer blocks on to the bottom part
of the frame aperture.
Special Tool: Rubber Spacer Blocks (Qty.:
2)
1.2. Install the new glass on the spacer blocks
- Always use glass lifters. Check that there
is an equal sized gap all round the edge
of the glass. Note: The spacer blocks are
rectangular in section to give two common
gap widths. If necessary they can be
trimmed to a smaller size to give an equal
sized gap around the glass. Important: The
glass edges must not touch the frame,
otherwise movement of the frame will chip
and eventually break the newly installed
glass.
Special Tool: Glass Lifter (Qty.: 2)
09 - 14 9823/1700-1 09 - 14
09 - Window
00 - General
4. Clean the glass.

4.1. Use surface cleaner to thoroughly clean
and prime the black ceramic ink band
printed on the glass (see Note). Use a lint
A Frame aperture free cloth to apply the cleaner, allow to
B Spacer blocks dry. Important: Do not touch the glass after
C Glass lifters cleaning with the surface cleaner.
2. After checking for size, remove the new glass Duration: 5 min
and place it on a purpose made glass stand. Consumable: Surface Cleaning Fluid
Small panes of glass will need locating on a
600 x 700 mm x 15 to 19 mm thick plywood 4.2. If the glass does not have a black ceramic
board, sourced locally to fit the glass stand. It is ink band, paint a band on the glass using
recommended that an access hole is cut in the Black Primer. Make sure that the band
board to accommodate the glass lifter, making it measures the correct width and that the
easier and safer to handle small panes of glass. edge is a neat straight line.
The board should be covered with felt or carpet Dimension: 25 mm
to give an anti-scratch surface. Resting the glass Consumable: Black Primer/Activator
on four spacer blocks will ensure clearance of
the cartridge nozzle tip during application of the Figure 161.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 159.
5. Install the Ultra Fast Adhesive cartridge into a

suitable applicator gun:
Special Tool: Static Oven (240V) (Qty.: 1)
Special Tool: Mobile Oven (12V) (Qty.: 1)
Special Tool: Cartridge Gun (Qty.: 1)
Consumable: Polyurethane Adhesive
5.1. Remove the aluminium disc cover from
3. Make sure the glass is positioned on the stand the base of the cartridge and discard the
the correct way up (i.e. with the black ceramic dessicant capsule.
ink band upwards) ready for application of primer
etc. 5.2. Make sure that the rolled edge of the
cartridge is not damaged - if necessary, the
edges should be pressed flat, otherwise it
09 - 15 9823/1700-1 09 - 15
09 - Window
00 - General
will be difficult to remove the cartridge from Remove and Install

the applicator gun.
Special Tools
5.3. Pierce the front nozzle end of the cartridge
to its maximum diameter. Description Part No. Qty.
Glass Lifter 892/00842 2
5.4. Install the pre-cut nozzle.
Glass Extractor 892/00846 1
5.5. Install the cartridge in the applicator gun. (Handles Only)
Note: Cold material will be very difficult to Nylon Spatula 892/00847 1
extrude. The cartridges must be pre-heated
Wire Starter 892/00848 1
in a special oven for 1 hour to a temperature
of 80°C (176°F). Pre-heating the cartridges Braided Cutting Wire 892/00849 1
makes the adhesive more workable and Rubber Spacer Blocks 926/15500 2
also brings the curing time down to 30 Cut-Out Knife 992/12800 1
minutes. 'L' Blades 992/12801 1
Figure 162.
Consumables
Black Polyurethane 4102/2310 0.31 L
Sealant
A Black Primer/Activator 4104/2304 0.1 L
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
B JCB Glass Cleaner 4006/3175 0.75 L
Surface Cleaning Fluid 4103/1204 1L
A 12.5 mm
B 9 mm
Removal
6. Apply the pre-heated adhesive to the glass (do
not start in a corner). Keep the nozzle guide 1. Position the machine on level ground and apply
against the edge of the glass and make sure the park brake. Stop the engine. Put protective
that the adhesive forms a continuous pyramid' covers over the cab seat and control pedestals.
shape. Note: Once the pre-heated adhesive has
2. If a laminated pane breaks it will stay in one piece
been applied to the glass, install the glass in the
even though the glass is cracked. A toughened
aperture as soon as possible. If you wait too long
pane will shatter and fall apart. The method of
then the sealant will form a skin, this will prevent
removal of the glass depends upon which type
the glass from bonding.
it is.
Duration: 10 min
2.1. Laminated glass - leave installed until the
Figure 163. old sealant has been cut away, after which
it will be possible to lift the broken screen
away from its frame housing in one piece.
2.2. Toughened glass - remove as much of the
shattered glass as possible prior to cutting
out the old sealant.
3. Cut out the old sealant, leaving approximately 1
to 2 mm on the cab frame. There are several tools
and techniques for doing this:
3.1. Pneumatic Knife - This provides one of the
A Nozzle guide easiest methods of removing the sealant
7. After applying the adhesive, leave a small around laminated glass. The tool, powered
amount of sealant protruding from the nozzle. by compressed air, should be sourced
This will prevent any adhesive left in the cartridge locally. Press the handle to start the knife
from curing. blade oscillating. Important: This tool must
not be used on toughened glass. Insert the
knife blade into the sealant. Slowly move
the knife along the sealant with the blade
positioned as close to the glass as possible.
09 - 16 9823/1700-1 09 - 16
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 165.

the sealant will melt.
Figure 164.
3.2. Braided Cutting Wire and Handles - This

method uses a 3-core wire, a wire starter
tube and two handles. Insert the steel tube
into the old sealant on the inside of the
glass. Insert the braided cutting wire down
the centre of the steel tube. If necessary,
from the outside, cut out local sealant at the
point of the tube to gain access to the wire.
Using suitable pliers, pull the cutting wire
through the sealant to the outer side of the A Wire starter
glass. Secure the end of the braided cutting B Braided cutting wire
wire (found on the outer side of the glass) in C Glass extractor (handles)
the special handle. Slowly remove the steel D Glass extractor (handles)
tube. Secure the second end of the braided 3.3. Cut-out Knife - The cut-out knife can be
cutting wire in the special handle. Move the used as a left handed or right handed tool.
cutting wire backwards and forwards in a Insert the knife blade into the sealant. Make
sawing motion and at the same time gently sure that the blade of the knife is against the
push or pull the wire to cut through the old glass. Use the 'pull-handle' to pull the knife
sealant. along and cut out the old sealant.
Special Tool: Wire Starter (Qty.: 1) Special Tool: 'L' Blades (Qty.: 1)
Special Tool: Glass Extractor (Handles Special Tool: Cut-Out Knife (Qty.: 1)
Only) (Qty.: 1)
Special Tool: Braided Cutting Wire (Qty.: 1) Figure 166.
A Glass
3.4. Craft Knife - The blades are replaceable.
Insert the knife blade into the sealant. Pull
the knife along and cut out the old sealant.
09 - 17 9823/1700-1 09 - 17
09 - Window
00 - General
Figure 167. glass. Make sure the two spacer blocks are in
position. Refer to Preparation - New Glass
2. Install the glass in the frame aperture:
2.1. Always use the glass lifting tools when
moving the glass. Use a lifting strap to hold
large panes of glass in position.
Special Tool: Glass Lifter (Qty.: 2)
Figure 169. Typical Machine
A Blades
3.5. Glass Replacement Kit - This kit is
designed for removal of one pane of glass.
The kit comprises: Cartridge Polyurethane
Adhesive (310ml), Primer/Activator (10ml),
Surface Cleaner Wipe, Abrasive Pad,
Applicator Nozzle, Wool Dauber, Cutting
Wire, Rubber Blocks.
Consumable: Glass Replacement Kit
4. Laminated glass - lift out the broken pane using
glass lifters. Toughened glass - remove the cut off 2.2. Sit the bottom edge of the glass on the
sealant and all remaining particles of shattered spacer blocks.
glass. Special Tool: Rubber Spacer Blocks (Qty.:
2)
5. If necessary, trim off the remaining old sealant
to leave approximately 1 to 2 mm on the upright Figure 170.
face of the cab frame aperture.
Figure 168.
A 1.5 mm
6. Apply a coat of Black Primer to the paintwork if:
Consumable: Black Primer/Activator
6.1. Paintwork was damaged or scratched
during the glass/sealant removal
procedures. 2.3. Make sure that the glass is correctly
positioned, then gently press around the
6.2. The old sealant was inadvertently cut back edges of the glass and ensure full adhesive
to the cab frame during the glass/sealant contact is achieved. Do not press too hard
removal procedures. or too much adhesive will squeeze out.
Installing new Glass 3. Make the inside seal smooth:
1. If the internal trim strip is damaged, renew it (cut 3.1. Wearing surgical gloves, dip your finger in
to length as required) before installing the new a soapy water solution.
09 - 18 9823/1700-1 09 - 18
09 - Window
00 - General
3.2. Use your finger to make the inside seal

smooth.
4. All exposed edges must be sealed using Black
Polyurethane Sealant. Important: Use extreme
caution when wiping the inside of the new glass
- pushing too hard on the inside of the glass will
affect the integrity of the bonded seal.
Special Tool: Nylon Spatula (Qty.: 1)
Consumable: Black Polyurethane Sealant
5. Clean the glass after installation:
5.1. Small amounts of sealant can be cleaned
from the glass using the surface cleaner.
5.2. Large amounts of excess sealant should be
left to cure and then cut off with a sharp
knife. Note: On completion of the glass
replacement procedures, the sealant curing
time is 30 minutes. This means that the
machine can be driven and used after 30
minutes, but it must not be used during the
curing period of 30 minutes.
5.3. Clean the glass using a purpose made
glass cleaner.
Consumable: Hand Cleaner
Consumable: JCB Glass Cleaner
6. On completion of the glass installation
procedures tidy the work area:
6.1. Remove all broken glass from the cab area.
6.2. Remove the protective covers from the cab
seat and control pedestals.
6.3. Renew all safety and instructional labels so
that the new installation conforms with the
original cab installation.
09 - 19 9823/1700-1 09 - 19
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-21

09-12-03 Seat Base ...................................................................................................................... 09-23
09 - 20 9823/1700-1 09 - 20
12 - Operator Seat
00 - General
00 - General Check (Condition)

Check (Condition) .......................................... 09-21 1. Check that the seat adjustments operate
Remove and Install ....................................... 09-22 correctly.
2. Check the seat is undamaged.
3. Check the seat mounting bolts are undamaged,
correctly installed and tight.
4. Make sure the seat is clear from unwanted
materials and hazards at all times.
09 - 21 9823/1700-1 09 - 21
12 - Operator Seat
00 - General
Remove and Install 1.1. Tighten the bolts to the correct torque value.
Refer to: PIL 72.
(For: 510-56 [T2/T3])

method and device.
Remove
2. Disconnect the electrical connections to the seat.
3. Remove the bolts that attach the seat to the seat
base.
Figure 171.
A
A Bolt (x4)
4. Attach suitable lifting equipment to the seat.
5. Use the lifting equipment to remove the seat from
the machine.
Install
step.
09 - 22 9823/1700-1 09 - 22
12 - Operator Seat
03 - Seat Base
03 - Seat Base
Remove and Install
(For: 510-56 [T2/T3])
Remove
1. Make the machine.
2. Remove the seat.
3. Fully move the seat slide adjustment backward,
then remove the front fixing bolts from the slide
rails.
4. Fully move the seat slide adjustment forward and
remove the rear fixing bolts from the slide rails.
5. Remove the slide adjustment assembly.
Install
removal procedure.
09 - 23 9823/1700-1 09 - 23
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-25
09 - 24 9823/1700-1 09 - 24
15 - Seat Belt
00 - General
WARNING When a seat belt is installed on your
Introduction .................................................... 09-25 machine replace it with a new one if it is damaged,
Check (Condition) .......................................... 09-26 if the fabric is worn, or if the machine has been in
an accident.
The seat belt is to protect the operator if the machine

rolls over or is involved in an accident.
Some machines have a seat belt sensor installed

as part of the Green Beacon safety kit. The sensor
informs the Green Beacon ECU (Electronic Control
Unit) that the seat belt is correctly connected.
The Green Beacon ECU operates an external green

flashing beacon which informs observers that the
operator has correctly connected the seat belt.
09 - 25 9823/1700-1 09 - 25
15 - Seat Belt
00 - General
Check (Condition)
WARNING When a seat belt is installed on your
machine replace it with a new one if it is damaged,
if the fabric is worn, or if the machine has been in
an accident.
WARNING If the seat belt does not 'lock' when
you check if the seat belt is operating correctly, do
not drive the machine. Get the seat belt repaired
or replaced immediately.
1. Make sure the seat belt can be adjusted.

2. Examine the seat belt for signs of fraying and
stretching.
3. Check that the stitching is not loose or damaged.
4. Check that the belt mounting bolts are
undamaged, correctly installed and tight.
5. Check that the buckle assembly is undamaged
and operates correctly.
09 - 26 9823/1700-1 09 - 26
18 - Door
18 - Door
Contents Page No.
09-18-00 General ........................................................................................................................... 09-29

09-18-12 Handle ............................................................................................................................ 09-32
09 - 27 9823/1700-1 09 - 27
Notes:
09 - 28 9823/1700-1 09 - 28
18 - Door
00 - General
00 - General
Remove and Install
Consumables 5.1. Use a thin punch and hammer to tap the

Description Part No. Size securing pin from the hinge assembles.
Extreme Performance 4003/1327 0.4 kg 5.2. Remove the grub screw.
Moly Grease 4003/1326 12.5 kg
6. Use a thin punch and hammer to tap the hinge
pin from the hinge assembles.
Remove
7. Do steps 4 and 5 for all other hinges on the door.
8. Carefully remove the door from the hinge
2. Follow the general health and safety procedures. assembly.
9. If necessary, remove the hinge assembly by
3. Divide the doors by releasing the locking handle removing the nuts from inside the cab.
(Two piece doors only- if installed).
10. Do procedures 3 to 7 for the lower part of the
4. Make sure that the door upper is supported door. (Two piece doors only- if installed).
correctly.
11. If necessary the door catch assembly can be
5. To remove the hinge pin securing device, removed by removing the nuts, bolts and locking
depending on your machine, do one of the plate.
following actions:
09 - 29 9823/1700-1 09 - 29
18 - Door
00 - General
Figure 172. Two piece door assembly

C
F E
A Locking handle B Hinge assembly

C Hinge pin D Door- upper
E Door- lower F Door catch assembly
G Securing pin (or grub screw)
09 - 30 9823/1700-1 09 - 30
18 - Door
00 - General
Install
steps.
1.1. Lubricate the door hinge. Refer to (PIL
75-06).
Consumable: Extreme Performance Moly
Grease
09 - 31 9823/1700-1 09 - 31
18 - Door
12 - Handle
12 - Handle Figure 173.
Remove and Install A

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

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

lever.
5. Slightly tilt the handle unit to unhook the unit from
the door assembly. Retain the gasket and trim
plate.
E E
A Gasket
B Trim plate
C Latch assembly
D Handle- exterior
E Retaining screws
F Cover plate
Install
removal procedure.
09 - 32 9823/1700-1 09 - 32
27 - Controls
27 - Controls
Contents Page No.
09-27-00 General ........................................................................................................................... 09-35

09-27-57 Park Brake ..................................................................................................................... 09-38
09 - 33 9823/1700-1 09 - 33
Notes:
09 - 34 9823/1700-1 09 - 34
27 - Controls
00 - General
00 - General
Lubricate
1. Make the machine safe with the lift arm raised.
2. Remove the top cover.
3. Apply a thin layer of engine oil on the clevis end
of the control cables. Refer to Figure 174.
Figure 174.
C D
A Clevis end - Park brake cable
09 - 35 9823/1700-1 09 - 35
27 - Controls
36 - Accelerator Pedal
Remove and Install
(For: JCB 4.4 T2 Mech Nat Asp, JCB 4.4 F Bearing plate
T2 Mech Turbo, JCB 4.4 T3 Mech Turbo, G Bearing plate bolts
H Reaction bracket
JCB 4.4 T3 Mech Turbo and Aftercooled) J Spring
K Pivot pin
This procedure is for the Throttle Pedal assembly.
L Cable end
For details of the throttle control cable and M Split pin
adjustment refer to (PIL 09-28-06).
Remove
Throttle Pedal 1. Make the machine safe. Refer to (PIL 01-03).
Figure 175. 2. Open the engine compartment cover. Refer to
(PIL 06-06).
3. Remove the pad nut and bolt.
4. Remove the foot pad.
C
5. Remove the spring.
B
6. Remove the split pin and pivot pin to disconnect
A the throttle cable end.
E
7. Hold the pedal lever and throttle reaction bracket.
8. Remove the four bearing plate bolts and bearing
D plates.
9. Remove the pedal assembly from below the cab.
F Install
G 1. The installation procedure is the opposite of the
step.
2. Adjust the throttle control cable. Refer to (PIL
09-28-06).
K L M
A Foot pad bolt
B Foot pad
C Foot pad nut
D Pedal lever
E Bearing plate
09 - 36 9823/1700-1 09 - 36
27 - Controls
Throttle Pedal Switch (if installed)
Figure 176.
D
C
E
A
B
A Switch securing nuts B Switch

C Switch securing bolt D Bracket
E Bracket bolts F Electrical connector
Remove
2. Disconnect the switch electrical connector.
3. Hold the switch and remove switch securing nuts.
4. Remove the switch and bolts.
Install
step.
2. Make sure that the switch operates correctly.
Adjust
1. Operate the pedal and make sure that the switch
plunger moves down by the correct amount.
2. If the switch plunger does not move by the correct
amount loosen the bracket bolts and move the
bracket until the correct plunger movement is
obtained. When correct tighten the bracket bolts
and check plunger movement.
3. If necessary check the switch operation using a
multimeter at the electrical connector - the switch
is a normally closed type.
09 - 37 9823/1700-1 09 - 37
27 - Controls
57 - Park Brake
57 - Park Brake Adjust

WARNING The park brake must not be used to
Adjust ............................................................ 09-38 slow the machine from travelling speed, except
Remove and Install ....................................... 09-39 in an emergency, otherwise the efficiency of the
brake will be reduced. Whenever the park brake
has been used in an emergency the brake pack
must be renewed.
WARNING Make the machine safe before
working on it. Park the machine on level ground
and lower the loader arm. Stop the engine and
remove the ignition key. Make sure the park brake
is engaged. Disconnect the battery to prevent the
engine being started. Block all four wheels.
Notice: Over adjustment or failure to disengage
the park brake properly will cause excessive wear
of the park brake mechanism.
Before you try to adjust the park brake after an

emergency stop, remove and install new brake
friction components. Install other new components if
necessary.
The park brake must be engaged fully when the

lever is vertical. The park brake indicator light should
illuminate when the brake is engaged with the
forward and reverse lever away from neutral (starter
switch at IGN).
Do the park brake adjustment as follows:
1. Disengage the park brake (lever horizontal).

2. Pull and turn the handle grip clockwise, half a
turn.
3. Test the park brake. Refer to brakes- park brake,
refer to (PIL 24-18).
4. If the brake fails the test, repeat steps 1, 2 and 3.
5. If no more adjustment is possible and the pin is
at the end of its travel, then adjust the cable at
the calliper. Refer to brakes- service brake, refer
to (PIL 24-18).
09 - 38 9823/1700-1 09 - 38
27 - Controls
57 - Park Brake
Figure 177. Remove and Install

A
Removal
2. Put blocks under the wheels. Release the park
brake.
3. Remove the rubber gaiter.
B
4. Disconnect the electrical connector from the
switch connector.
5. Hold the switch and remove screw.
6. Remove the switch.
A Handle grip
B Pin Figure 178.
A Rubber gaiter
B Switch
C Electrical connector
D Switch connector
E Screw
F Switch location dowel
G Hole in mounting bracket
09 - 39 9823/1700-1 09 - 39
27 - Controls
57 - Park Brake
Installation
step.
1.1. To align the switch correctly, engage the
switch location dowel with the hole in the
mounting bracket.
09 - 40 9823/1700-1 09 - 40
28 - Cables and Fittings
Contents Page No.
09 - 41 9823/1700-1 09 - 41
Notes:
09 - 42 9823/1700-1 09 - 42
Remove and Install
(For: JCB 4.4 T2 Mech Nat Asp, JCB 4.4 For details of the throttle pedal refer to (PIL
T2 Mech Turbo, JCB 4.4 T3 Mech Turbo, 09-27-36).
JCB 4.4 T3 Mech Turbo and Aftercooled)
This procedure is for the Throttle cable assembly.
Figure 179.
B
C
G
F
H
J
A Pedal side lock nut B Split pin

C Pivot pin D Pump side lock nut
E Injection pump control lever F Pedal side lock nuts
G Pedal adjustment height H Stop adjustment nut
J Stop adjustment bolt
Remove 3. The pedal to cable clevis is located on the right

side of the cab on the outside (Adjacent to
1. Make the machine safe. Refer to (PIL 01-03). the HVAC (Heating Ventilation Air Conditioning)
unit).
2. Open the engine compartment cover. Refer to
(PIL 06-06). 4. Remove the split pin and withdraw pivot pin from
the pedal operating lever.
09 - 43 9823/1700-1 09 - 43
5. Loosen lock nuts on pedal side. 5. Press the throttle pedal to its maximum position.
Make sure that the fuel injection pump throttle
6. Screw the lock nut to the bottom of the threaded lever moves to the fully open position.
section on the outer cable.
7. Lift the outer cable through the bracket and pass
the inner cable through the slot in the front of the
bracket.
8. Working at the injection pump lever in the engine
compartment - loosen pump side lock nut and lift
the cable through the slot in the support bracket.
9. Disconnect the spring from the arm on the
injection pump and withdraw the cable.
Install
step.
2. Adjust the throttle control cable.
3. Adjust the throttle pedal stop.
Adjust
Throttle Pedal Stop
1. Slacken the stop adjustment lock nut.
2. Adjust the stop adjustment bolt until the threaded
end of the bolt is the correct measurement.
3. When correct tighten the adjustment nut.
4. Check the adjustment and repeat if necessary.
Throttle control cable

The cable can be adjusted at the fuel injection pump
and the throttle pedal.
When adjusting the cable make sure that the fuel

injection pump throttle lever returns to the closed
position when the throttle pedal is not pressed.
1. Slacken pump side lock nuts to adjust the cable

at the fuel injection pump.
2. Remove slack in the cable without moving
injection pump control lever from its closed
position.
3. Slacken the pedal side lock nuts to adjust the
cable at the throttle pedal.
4. Remove slack in the cable without moving
injection pump control lever from its closed
position.
09 - 44 9823/1700-1 09 - 44
30 - Trim Panel
30 - Trim Panel
Contents Page No.
09-30-03 Roof Trim ....................................................................................................................... 09-47

09-30-09 Dashboard ...................................................................................................................... 09-48
09 - 45 9823/1700-1 09 - 45
Notes:
09 - 46 9823/1700-1 09 - 46
30 - Trim Panel
03 - Roof Trim
03 - Roof Trim
Remove and Install

Notice: Take care during the removal and
replacement of the roof liner. Make sure your
hands and clothes are clean. The roof liner is
easily damaged.
Remove
2. With the aid of one more person hold the roof
liner and remove the screws.
3. Lower the liner to get access to the electrical
connectors at the interior lights and audio
speakers (if installed).
4. Disconnect the electrical connectors from the
interior lights and audio speakers.
5. Remove the roof liner.
6. Put the roof liner into a clean plastic bag and keep
it in a safe place. The roof liner is damaged easily.
Figure 180.
A A A A
C
C
D D
B
A A A
A Screws
B Roof liner
C Interior lights
D Audio speakers
Install
1. The installation procedure is the opposite of
step.
1.1. If seals are attached to the panel, make
sure they are in good condition. If damaged,
replace the seals.
09 - 47 9823/1700-1 09 - 47
30 - Trim Panel
09 - Dashboard
09 - Dashboard
Remove and Install
Remove 16. Remove the screw 7, screw 8 and screw 9.
1. Make the machine safe. 17. Remove the lower left hand panel.
Refer to: PIL 01-03. Figure 181.
2. Remove the steering wheel.
C C
3. Remove the two button head screws 1.
4. Remove the steering column lower surround.
5. Remove the two button head screws 2 and the
two screws 1. D B D
6. Remove the steering column upper surround. 9

12
7. Remove the two screws 2 that hold the centre

6
display panel in place, disconnect all connections

and remove the panel. 00: 00: 05
8. If the steer mode select switch has a lockable

surround, then remove it as follows.
8.1. Remove the two screws that secure the -
steer mode select switch panel.

8.2. Disconnect all connections and remove the A
panel.
A Button head screw 1
8.3. Remove the steer mode control knob.
B Button head screw 2
9. Remove the heater control panel. C Screw 1
D Screw 2
Figure 182.
10. Remove the radio (if installed).
11. Remove the right hand Instrument panel.
12. Remove the left hand switch panel.
13. Remove the centre display panel.
Refer to: PIL 33-24. E
14. Remove the screw 3, screw 4, screw 5 and screw

6 and then remove the upper right hand panel.
Take care not to damage the harness when you F
move it through the hole in the panel.
E Steer mode select switch panel
15. The screw 5 is removed from the front of the F Steer mode control switch
panel, i.e. the opposite side to that shown.
09 - 48 9823/1700-1 09 - 48
30 - Trim Panel
09 - Dashboard
Figure 183.
G Q H
M
N
G Screw 3 H Screw 4
J Screw 5 K Screw 6
L Screw 7 M Screw 8
N Screw 9 P Lower left hand panel
Q Upper right hand panel
09 - 49 9823/1700-1 09 - 49
30 - Trim Panel
09 - Dashboard
Install
removal procedure.
09 - 50 9823/1700-1 09 - 50
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-53
09 - 51 9823/1700-1 09 - 51
Notes:
09 - 52 9823/1700-1 09 - 52
00 - General
Introduction .................................................... 09-53 The safety labels are strategically placed around the
Health and Safety .......................................... 09-54 product to remind you of possible hazards.
If you need eye-glasses for reading, make sure you

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

Replace a lost or damaged safety label. Make
sure the replacement parts include the safety labels
where necessary. Each safety label has a part
number printed on it, use this number to order a new
safety label from your JCB dealer.
09 - 53 9823/1700-1 09 - 53
00 - General
Health and Safety

WARNING Safety labels on the machine warn
you of particular hazards. You can be injured if
you do not obey the safety instructions shown.
09 - 54 9823/1700-1 09 - 54
36 - Steering Wheel
36 - Steering Wheel
Contents Page No.
09-36-00 General ........................................................................................................................... 09-57
09 - 55 9823/1700-1 09 - 55
Notes:
09 - 56 9823/1700-1 09 - 56
36 - Steering Wheel
00 - General
00 - General 1.1. If the key becomes damaged during the

removal procedure, replace with a new key.
Remove and Install 1.2. Make sure that the steering wheel aligns
with the marks you made during removal.
1.3. If removed, install the foam collar. Attach
Remove the adhesive lined side to the column trim
panel before you install the steering wheel.
Refer to: PIL 01-03. Figure 185.
2. Mark the position of the steering wheel on the

splined shaft.
3. Take out the steering wheel centre cap from the
wheel.
G
4. Remove the steering wheel securing nut.
5. Remove the washer.
6. Remove the steering wheel away from the
splined shaft.
7. Make sure to retain the key.
8. Remove the foam collar (if installed).
Figure 184.
A
B
H
C
G Column trim panel
H Foam collar
D
A Steering wheel center cap

B Steering wheel securing nut
C Washer
D Key
E Steering wheel
F Shaft
Install
steps.
09 - 57 9823/1700-1 09 - 57
44 - Sunblind
44 - Sunblind
Contents Page No.
09-44-00 General ........................................................................................................................... 09-59
09 - 58 9823/1700-1 09 - 58
44 - Sunblind
00 - General
00 - General
Remove and Install
Roller Blind 3. Support the blinds.

4. Remove the trim panel screws from each end of
Remove the blind. Some machine variants only have 2
1. Make the machine safe. securing screws at each side of the blind.
Refer to: PIL 01-03. 5. Disconnect the trim panel to remove the blind
assembly.
2. Make sure that both blinds are fully retracted.
Figure 186.
A
A
A A
A Screws B Trim panel

C Blind assembly X Roller blind with two securing screws
09 - 59 9823/1700-1 09 - 59
44 - Sunblind
00 - General
Install
removal procedure.
09 - 60 9823/1700-1 09 - 60
48 - Floor mat
48 - Floor mat
Contents Page No.
09-48-03 Front Floor mat .............................................................................................................. 09-63
09 - 61 9823/1700-1 09 - 61
Notes:
09 - 62 9823/1700-1 09 - 62
48 - Floor mat
03 - Front Floor mat
03 - Front Floor mat
Remove and Install
Remove
2. Remove the nuts and remove the pedal pads
from the machine.
3. Remove the bolts and the retaining plate.
4. Remove the screws and the kick strips.
5. Remove the trim retainers from the front section
of the mat.
6. Remove the mat from the machine.
Figure 187.
A
D E
C F
G D
A Pedal pads
B Nuts
C Kick strips
D Screws
E Bolts
F Retaining plate
G Trim retainers
Install
removal procedure.
09 - 63 9823/1700-1 09 - 63
Notes:
09 - 64 9823/1700-1 09 - 64
12 - Heating, Ventilating and
Air-Conditioning (HVAC)
Contents Page No.
12-00 Heating, Ventilating and Air-Conditioning (HVAC)

12-00-00 General ............................................................................................................................. 12-3
12-03 HVAC Unit
12-03-00 General ........................................................................................................................... 12-27
12-03-03 Evaporator ...................................................................................................................... 12-35
12-03-06 Pressure Switch ............................................................................................................. 12-36
12-03-09 Expansion Valve ............................................................................................................. 12-38
12-03-12 Blower Motor .................................................................................................................. 12-39
12-03-15 Thermostat ..................................................................................................................... 12-40
12-03-18 Heater Coil ..................................................................................................................... 12-42
12-04 Heater Unit
12-04-00 General ........................................................................................................................... 12-45
12-04-18 Heater Coil ..................................................................................................................... 12-49
12-09 Compressor
12-09-00 General ........................................................................................................................... 12-51
12-12 Receiver Drier
12-12-00 General ........................................................................................................................... 12-55
12-15 Condenser
12-15-00 General ........................................................................................................................... 12-59
12-18 Filter
12-18-00 General ........................................................................................................................... 12-67
12-18-06 Fresh Air ........................................................................................................................ 12-68
12-21 Heater Valve
12-21-00 General ........................................................................................................................... 12-71
12-96 Pipe
12-96-00 General ........................................................................................................................... 12-75
9823/1700-1
2018-02-23
Acronyms Glossary
FEAD Front End Accessory Drive

PAG Polyalkyline Glycol
RPM Revolutions Per Minute
TXV Thermal Expansion Valve
9823/1700-1
2018-02-23
12 - Heating, Ventilating and Air-Conditioning (HVAC)
Contents Page No.
12-00-00 General ............................................................................................................................. 12-3
12 - 1 9823/1700-1 12 - 1
Notes:
12 - 2 9823/1700-1 12 - 2
00 - General
Introduction ...................................................... 12-3 To maintain optimum operator comfort in warm
Health and Safety ........................................... 12-4 climates or during seasons of high ambient
Technical Data ................................................. 12-5 temperature, the air conditioning system delivers
Component Identification ................................. 12-6 cool, dehumidified air into the cab. Cooling is
provided by passing the warm ambient air, together
Operation ......................................................... 12-9 with recirculated air, over an evaporator matrix in the
Diagram ......................................................... 12-12 air conditioning unit.
Fault-Finding .................................................. 12-13
Check (Condition) .......................................... 12-16 The air conditioning system is a closed circuit
through which the refrigerant is circulated, its state
Check (Leaks) ............................................... 12-20 changing from gas to liquid and back to gas again,
Check (Operation) ......................................... 12-20 as it is forced through the system. The major
Check (Pressure) .......................................... 12-21 components of the system are the:
Adjust ............................................................ 12-24
• Compressor
Lubricate ........................................................ 12-24 • Condenser matrix
• Receiver drier
• Expansion valve
• Evaporator matrix
12 - 3 9823/1700-1 12 - 3
00 - General
Health and Safety • DO NOT steam clean refrigerant system

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

is used and that charging is done only by
qualified personnel. It is illegal to discharge
the refrigerant into the atmosphere but as
a precaution in case of accidental leakage,
discharging and charging of the vehicle
refrigerant system must be conducted in a well-
ventilated area.
• Containers of refrigerant should be stored in a
cool environment away from direct sunlight.
• DO NOT perform welding operations close to
refrigerant hoses (maintain a distance of at least
0.5m from hoses).
12 - 4 9823/1700-1 12 - 4
00 - General
Technical Data
Table 38. Binary pressure switch settings

Item Specification
Low pressure 2 bar ( 29.0 psi)
High pressure 26 bar ( 376.8 psi)
Table 39. Thermostatic switch settings

Item Specification
Cut out 0.2 –1.4 °C ( 32.4 –34.5
°F)
Cut in 3.4 –4.8 °C ( 38.1 –40.6
°F)
Table 40. Refrigerant

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

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

(2) Systems with roof mounted condenser.
Table 41. Oil

Item Specification
Type PAG (Polyalkyline Gly-
col) oil
Charge amount
(3)
-
Complete system 0.0426 L
Condenser remove and 0.0284 L
install
Evaporator remove and 0.0568 L
install
Hoses remove and in- 0.0085 L
stall
Receiver drier remove 0.0142 L
and install
Compressor remove and None- pre charged
install
(3) The quantity of oil replaced should be the same
as that taken out during `Recovery' procedure.
12 - 5 9823/1700-1 12 - 5
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Heater Only
Figure 188.
E
D
D
D
C D
B
Item Description
D Cab heater vents
Table 42.
E Heater Control panel
(1)
Item Description
A Heater and ventilation (1) A typical heater control panel is shown. Refer to
unit (HV) the applicable Operator Manual for machine specific
controls.
B Heater valve
12 - 6 9823/1700-1 12 - 6
00 - General
Machines with Air Conditioning
Figure 189.
E
F
H F
A
B
C
D
Item Description
G Condenser (cooling
Table 43.
pack mounted)
Item Description H Condenser (roof mount-
A TXV (Thermal Expan- ed) (Available as an op-
sion Valve) tion on some machines).
B Evaporator matrix (1) Typical heater control panel shown. Refer to
C Compressor the correct operator manual for machine specific
D FEAD (Front End Acces- controls.
sory Drive)
Table 44. Component Locations
E Heater/air conditioning
control panel
(1)
HVAC System Location (All Ma-
F Heater/air conditioning chines)
vents HVAC (Heating Venti- Fixed to cab (RHS)
lation Air Conditioning)
unit
TXV Part of HVAC unit
12 - 7 9823/1700-1 12 - 7
00 - General
HVAC System Location (All Ma-

chines)
Evaporator matrix Part of HVAC unit
Compressor Fixed to engine (RHS)
Binary switch Fixed to pipe next to
compressor
Receiver drier Fixed to chassis inside
engine compartment
Condenser - cooling Part of machine cooling
pack mount pack inside engine com-
partment
Condenser - roof mount Fixed to a frame fixed at
the rear of the cab roof.
Includes electric cooling
fans
12 - 8 9823/1700-1 12 - 8
00 - General
Operation
Fresh air is supplied to the cab interior through the fan. In the condenser, the refrigerant changes state
cab air vents. The heater and ventilation unit (HV) to a high pressure, high temperature liquid but with
uses a blower fan to increase the air speed. The a lower heat content.
air can also be heated by the heat exchange matrix
housed within the HV unit. The refrigerant passes through the receiver drier,
which contains a desiccant to remove moisture from
On machines with air conditioning, the unit also the system. The receiver drier serves as a tank for
houses the air conditioning evaporator matrix to refrigerant and also includes a filter to remove foreign
become a combined HVAC (Heating Ventilation Air particles from the system.
Conditioning) unit. Refer to (PIL 12-03).
Figure 190.
The machine operator can control the air
temperature and speed from within the cab on the F
E
heater control panel. For operation of the heater
controls refer to the applicable Operator Manual.
The operator uses the fan speed switch to select

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

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

D
through which the refrigerant is circulated, its state
changing from gas to liquid and back to gas again, A Compressor
as it is forced through the system. B Condenser matrix
C Receiver drier
The major components of the system are as follows. D Binary pressure switch
E TXV
• Compressor F Evaporator matrix
• Condenser matrix
• Receiver drier The receiver drier can only hold a limited amount of
• Binary pressure switch moisture, additional moisture can lead to icing and
• TXV (Thermal Expansion Valve) ultimately blockage of the thermostatic expansion
• Evaporator matrix valve. If the air conditioning system has been left
open or has been leaking for a prolonged period of
Operate the air conditioning as described in the time, the desiccant will become saturated and the
operator manual. receiver drier will need to be replaced with new one.
Air conditioning system power is generated from The high temperature, high pressure refrigerant
the engine, through an electromagnetic clutch to is forced by compressor action into the TXV,
the compressor. Switches, connected in series, are which meters the amount of refrigerant entering
included in the clutch supply line, all must be closed the evaporator. In the TXV the refrigerant
for the clutch and therefore the air conditioning instantaneously expands to become a low pressure,
system to operate. low temperature liquid.
The compressor draws in low pressure refrigerant The refrigerant is drawn through the evaporator
gas from the suction line (evaporator to matrix by the suction of the compressor. The
compressor) and increases refrigerant pressure temperature of refrigerant is now considerably below
through compression. This process also increases that of the air being drawn across the evaporator
the refrigerant temperature. matrix by the blowers. Heat is transferred from the
ambient and re circulated air to the refrigerant,
High pressure refrigerant is forced from the causing the low pressure liquid to vaporise and
compressor to the condenser. Ambient air is drawn become a low pressure gas. Moisture in the air
across the condenser by the engine- driven cooling
12 - 9 9823/1700-1 12 - 9
00 - General
condenses on the evaporator matrix and is drained The low temperature, low pressure, high heat
away through condensate. content refrigerant gas, is now drawn by suction back
to the compressor, where the cycle is completed.
Cool de-humidified air is emitted through air vents
into the cab.
Figure 191.
X F Y
C E A
A Compressor B Condenser matrix

C Receiver drier D Binary pressure switch
E TXV F Evaporator matrix
X Refrigerant is in liquid state Y Refrigerant is in gas state
System control 2. The high and low level binary pressure switch
located in the pipework near to the compressor.
The system is a manual control type and is set to on This switch is not adjustable.
or off by switch. There is no automatic control of the
cab air temperature. 3. The freeze protection thermostat switch located
inside the HVAC unit. This switch is not
Refrigerated air will be heated by the heater matrix If adjustable.
the heater control is not set to ‘cold’.
When the air conditioning switch is set to on
You can control the system by activating and the refrigeration system is active. The system
deactivating the compressor electromagnetic clutch. operates within fixed temperature and pressure limits
When current is fed to the field coil of the compressor controlled by the freeze protection thermostat switch
clutch, a magnetic field develops between the field and the binary pressure switch. The system does not
coil and the armature which pulls the field coil, respond to changes in the cab air temperature.
complete with clutch assembly, onto the compressor
rotor. Since the clutch assembly is turned constantly If the compressor runs continuously condensate
by the crankshaft pulley drive belt, the compressor on the evaporator matrix will freeze and the
armature turns, starting the refrigeration cycle. system will not be effective. The freeze protection
thermostat switch has its sensor probe installed
Current is fed to the field coil through a series of in the evaporator matrix. When the temperature
switches. of the probe is near 0 °C ( 32.0 °F) the
thermostat switch contacts open. The compressor
1. The manual air conditioning on/off switch in the clutch disengages, closing down the refrigeration
control console. cycle. As the temperature of the probe increases the
12 - 10 9823/1700-1 12 - 10
00 - General
thermostat switch contacts close. The compressor

clutch engages and refrigeration re-starts.
Figure 192.
D Binary pressure switch G Manual air conditioning on/off switch

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

pressure limit or falls below the lower limit,
the contacts of the binary switch open and the
compressor clutch disengages, closing down the
refrigeration cycle.
12 - 11 9823/1700-1 12 - 11
00 - General
Diagram
Figure 193.
2A
3 B C
2B
L
M
1
R
H
2
3 M
1 4
5 F
6
4
5A
5B 1 2
1 Heater fan switch 2A Air conditioning switch A

2B Air conditioning switch B 3 Secondary fuse box A
4 Heater connector 5A Binary switch A
5B Binary switch B 6 Air conditioning compressor clutch solenoid
F Freeze protection thermostat M Blower motor
R Blower motor resistor
12 - 12 9823/1700-1 12 - 12
00 - General
Fault-Finding
Fault
Poor performance (For system diagnosis using test gauges, refer to Check Table 45. Page 12-13
Operation, PIL 12-03)
Warm air or slightly cool air emitted from unit Table 46. Page 12-13
Compressor clutch continually cuts out Table 47. Page 12-13
Poor performance- Compressor function tests Table 48. Page 12-14
Compressor not achieving 24 bar pressure Table 49. Page 12-14
No air conditioning Table 50. Page 12-14
Table 45. Poor performance (For system diagnosis using test gauges, refer to Check Operation, PIL
12-03)
Cause Remedy
Condenser matrix air flow restricted Remove debries from matrix using compressed air
HVAC (Heating Ventilation Air Conditioning) Unit air Refer to (PIL 12-18)
intake filter blocked
Compressor drive belt too slack Refer to (PIL 15-18)
Low system pressure Discharge and recharge the system
Table 46. Warm air or slightly cool air emitted from unit
Cause Remedy
Expansion valve stuck open or closed Renew expansion valve. Refer to (PIL 12-03)
Table 47. Compressor clutch continually cuts out

Cause Remedy
Condenser matrix blockage Remove debris from matrix or
Overcharging of refrigerant system Discharge and recharge the system. Refer to (PIL
12-00)
Blocked expansion valve or condenser Clear blocked component. Refer to (PIL 12-03)
Compressor fault Do compressor function tests. Refer to (PIL 12-03)
12 - 13 9823/1700-1 12 - 13
00 - General
Table 48. Poor performance- Compressor function tests

Cause Remedy
(1) Is the compressor rotation smooth? With the YES = Check (2), NO = Renew compressor
engine having been turned off for 5 minutes, turn
the compressor shaft by turning the armature plate
by hand. Check for smooth rotation. Grinding or
hanging during shaft rotation is caused by a broken
component within the compressor.
(2) Is the field coil receiving greater than 7.5 V? YES = Check (3), NO = Rectify electrical problem
This test should be conducted with the electrical
system on and clutch engaged. Unplug the electrical
connector and measure on the machine side.
(Reversing polarity will short diode resulting in blown
fuses).
(3) Is the field coil resistance between 3 and 4 ohms? YES = Check (4), NO = Renew compressor
Coil resistance out of this range will not engage
or will cause fused circuits to open. Unplug the
electrical connector, measure on compressor side.
(4) Is compressor capable of producing 24 bar or YES = Compressor is functioning correctly, No =
more? To check this do the pressure tests. Refer Follow the pressure fault finding table (Compressor
to (PIL 12-03). Excessive high pressure can be not achieving 24 bar pressure).
artificially produced by preventing air flow across
the condenser. Preventing air flow through the
condenser minimises heat removal from the system
resulting in high pressure.
Table 49. Compressor not achieving 24 bar pressure

Cause Remedy
Low refrigerant charge - possible leakage, suction TEST = Discharge and recharge the system,
and discharge pressure are low. ACTION = Repair leak & check system pressures
(Compressors with dirt/oil build up at hose
connections are most likely to have damaged 'O'
rings. Check for leaks and replace 'O' rings.
System high pressure side blockage - flow to the TEST = Check suction pressure is 0.35 bar or less,
compressor is stopped or limited. ACTION = Compressor is functioning correctly,
remove the system blockage.
Compressor failure - internal compressor damage. TEST = Suction pressure high, discharge pressure
low, do compressor function tests (See table 4),
Action = Renew compressor
Test performed below 10 ºC - Low ambient TEST = Move machine to area where temperature is
temperature limits pressure. higher, ACTION = Check system pressures
Table 50. No air conditioning

Cause Remedy
(1) Are the controls set correctly, i.e. air conditioning YES = Check (2), NO = Reset controls and retest
selected, heater control set to coldest position and
blower switched on?
(2) Is the air conditioning (evaporator) blower YES = Check (30), NO = Reset controls and retest
working?
(3) Is the compressor running (visual check of pulley/ YES = Check (10), NO = check (5)
clutch)?80 % or betetr
(4) Is the air conditioning fuse(s) blown? For details YES = Renew fuses and retest, NO = Check (9)
of the electrical circuit and connections, Refer to (PIL
33-00-50)
(5) Is there a 12V supply to the binary pressure YES = Check (6), NO = Check (7)
switch harness?
12 - 14 9823/1700-1 12 - 14
00 - General
Cause Remedy
(6) Does the compressor clutch engage with binary YES = Replace binary pressure switch assembly, NO
pressure switch assembly bypassed? = Check (8)
(7) Does the clutch engage with freeze thermostat YES = Renew freeze thermostat switch and retest,
switch bypassed? NO = Check all electrical connections.
(8) Is there a 12V supply at the compressor? YES = Renew the compressor clutch and re-test, NO
= Renew the compressor relay and re-test.
(9) Are blower switch and wiring OK? YES = Renew blower unit complete, NO = Renew
switch or wiring.
(10) Is the system correctly charged with refrigerant YES = Check (11), NO = Charge check required by
OK? refrigeration engineer or suitably trained person.
(11) Is condenser air flow blocked? YES = Clean condenser and radiator, NO = Check
(12).
(12) Is evaporator air flow blocked? YES = Clean/Replace HVAC Unit Air Intake filter.
Refer to (PIL 12-03), NO = If necessary replace the
evaporator. Call in refrigeration engineer or suitably
trained person.
12 - 15 9823/1700-1 12 - 15
00 - General
Check (Condition)
Attach the manifold gauge block to the service ports

to check the condition of the air conditioning system.
Figure 194. Typical Installation

F G
A Manifold gauge block B Service ports

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

components and ambient conditions. Make sure that
Table 51. Normally functioning air conditioning system gauge readings

Ambient tempera- Relative humidi- Suction pressure Discharge pres- Vent temperature
ture ty(%) (Low side) sure (High side)
18 °C ( 64.4 °F) 55 1.32 bar ( 19.1 psi) 8.76 bar ( 127.0 psi) 8 °C ( 46.4 °F)
25 °C ( 77.0 °F) 55 1.53 bar ( 22.2 psi) 10.8 bar ( 156.5 psi) 8.8 °C ( 47.8 °F)
12 - 16 9823/1700-1 12 - 16
00 - General
The pressures on the manifold at 25 °C ( 77.0 4. Operate system and check performance.
°F) and 55% relative humidity with the engine at
1500 RPM (Revolutions Per Minute), the blower No refrigerant circulation
on maximum, the heater turned off with the door
closed and 10 minallowed for stabilisation, should
be approximately 1.53 bar ( 22.2 psi) for the low side Table 54.
and 10.8 bar ( 156.5 psi) for the high side. Generally Gauge Pressure
the high pressure is 6 to 8 times more than the low
Low side (LS) Zero to negative ( -1 bar
pressure.
( -14.5 psi))
High side (HS) Low ( 5.4 bar ( 78.3 psi))
Low R-134a Charge
Other symptoms
Table 52.
Gauge Pressure Receiver Drier- Frost or moisture on tubes before
and after receiver-drier.
Low side (LS) Low ( 0.5 bar ( 7.2 psi))
High side (HS) Low ( 9.8 bar ( 142.0 Reason
psi))
Refrigerant flow obstructed by dirt, moisture or gas
Reason leakage from expansion valve heat sensing tube.
System slightly low on R-134a, due to leak or Remedy

incorrect charge.
1. Discharge the air conditioning system.
Remedy
2. Check heat sensing tube at expansion valve.
1. Leak test the system. Replace expansion valve if necessary.
2. Discharge the air conditioning system. 3. Remove expansion valve and try to remove dirt. If
dirt cannot be removed, replace expansion valve.
3. Repair system leaks.
4. Replace receiver drier.
4. Charge system with R-134a.
5. Operate system and check performance.
Poor refrigerant circulation
Insufficient cooling of condenser or
Table 53. refrigerant over charge
Gauge Pressure
Table 55.
Low side (LS) Zero to negative ( -1 bar
( -14.5 psi)) Gauge Pressure
High side (HS) Low ( 5.4 bar ( 78.3 psi)) Low side (LS) High ( 13 bar ( 188.4
psi))
Other symptoms High side (HS) High ( 22.1 bar ( 320.3
psi))
Receiver Drier- Frost on tubes from receiver-drier to
evaporator unit. Reason
Reason Refrigerant overcharge, condenser cooling fins
clogged with dirt or cooling fans malfunctioning.
Refrigerant flow blocked by dirt, receiver-drier
clogged. Remedy
Remedy 1. Clean the condenser cooling fins.
1. Discharge the air conditioning system. 2. Check the cooling fan operation.
2. Replace the receiver-drier. 3. Discharge the air conditioning system.
3. Charge system with R-134a. 4. Charge system with R-134a.
12 - 17 9823/1700-1 12 - 17
00 - General
5. Operate system and check performance. 4. Charge system with R-134a.

Air in system
Compressor malfunction
Table 56.
Table 58.
Gauge Pressure
Low side (LS) High ( 2.8 bar ( 40.6 Gauge Pressure
psi)) Low side (LS) High ( 4.9 bar ( 71.0
High side (HS) High ( 22.1 bar ( 320.3 psi))
psi)) High side (HS) High ( 8.3 bar ( 120.3
psi))
Other symptoms
Reason
Pipes- Low pressure pipes are hot to the touch.
Internal compressor leak or compressor
Reason mechanically broken.
Air is present in the system, possible from Remedy

inadequate discharge procedure.
Remedy 2. Repair or replace compressor.
1. Discharge the air conditioning system. 3. Charge system with R-134a.
2. Check compressor oil for contamination. Check 4. Operate system and check performance.
compressor for proper oil amount. Correct if
necessary.
Some moisture in the system
Table 59.
Gauge Pressure
Low side (LS) Normal, then sometimes
Expansion valve improperly mounted drops to below zero (
-2.1 bar ( -30.4 psi))
Table 57. High side (HS) Normal, then sometimes
goes high ( 14.8 bar
Gauge Pressure ( 214.5 psi))
Low side (LS) High ( 3.5 bar ( 50.7
psi)) Reason
High side (HS) High ( 22.1 bar ( 320.3
psi)) Moisture in system freezes, temporarily stopping
cycle, normal system operation returns when ice
Other symptoms melts.
Pipes- Large amount of frost on low side pipes. Remedy
Reason 1. Discharge the air conditioning system.
Excessive refrigerant in low side pipes possible from 2. Replace receiver-drier.

expansion valve being opened too wide. 3. Remove moisture by repeatedly evacuating
system.
Remedy
1. Leak test the system.
3. Repair system leaks.
12 - 18 9823/1700-1 12 - 18
00 - General
Table 60. Further diagnosis table

High pressure Low pressure Cycle Engage Disengage Possible cause
Too high Too low Compressor running continuously Condenser dirty
Too high Normal to too Compressor running continuously Engine over-
high heating
Normal to too Normal Compressor running continuously Air or foreign
high matter in system
or excess refrig-
erant.
Too high Too high Too fast Too short Normal Excess refriger-
ant
Normal to too Normal Too slow or too Too long or con- Normal or non- Dirt or excess
low low tinuously existent refrigerant oil in
circuit
Normal to too Too high Too fast Too short Normal Faulty thermo-
low stat
Normal to too Too high Compressor running continuously Compressor
low faulty
Normal to too Normal to too Compressor running continuously Low pressure
low high line blocked
Normal to too Normal Too fast Too short Normal Evaporator
low blocked
Normal to too Normal Too fast Too short Too short Insufficient re-
low frigerant
Normal to too Normal Too fast Too short Too long Evaporator feed
low line blocked
12 - 19 9823/1700-1 12 - 19
00 - General
Check (Leaks) Check (Operation)

The air conditioning system needs to be checked
The air conditioning system is a closed loop system regularly to make sure it operates efficiently and
and contains pressurised refrigerant. No part of the safely.
system should be disconnected until the system
has been discharged by a refrigeration engineer Before you do any service operation, carry out a
or a suitably trained person. You can be severely basic service check as described below.
frostbitten or injured by escaping refrigerant.
1. Start the engine and operate at fast idle speed of
WARNING! Leak testing of Air Conditioning systems 1000 RPM (Revolutions Per Minute).
should only be carried out in well ventilated areas.
2. Switch on the air conditioning and set to
The refrigerant is heavier than air and will leak maximum cooling.
downwards from the defective component. Check in
a well ventilated area. 3. The cab temperature should be above the
specified value.
Hose or pipe connections are likely leakage points of
Temperature: 20 °C ( 68.0 °F)
any refrigerant circuit.
4. At low ambient temperatures it may be necessary
It is essential that an electronic leak detector is used to operate the heating system to prevent the air
to locate leaks accurately. However, if a leak detector conditioning system switching off.
is not available, an approximate source can be found
by applying soap solution to the suspect area. 5. Operate the engine at operating temperature for
five to ten minutes.
To test for leaks in the high pressure side of
the system i.e. from the compressor output to the 6. Close the cab door and windows and allow the
expansion valve, run the air conditioning for a few internal temperature to stabilize.
minutes then switch off the engine and test for
leakage using an electronic leak detector or soapy 7. Measure the temperature at the evaporator
water. outlets. The temperature should change as the
compressor clutch cycles in and out.
To test for leakage in the low pressure side of the
system, switch off the air conditioning and leave for 8. The outlet temperature with the clutch engaged,
a new minutes before you do the test. should be significantly below the ambient
temperature (4°C to 10°C) which can raise upto
the specified value when the clutch disengages.
Tightening leaking hoses
Temperature: 6 –8 °C ( 42.8 –46.4 °F)
The refrigerant hoses have crimped ferrule end
fittings. The hose connectors have an O-ring seal 9. Stop the engine when the tests are complete.
which compresses when the connection is tight and
create an air tight seal. Off-Season Operation
Hoses are used to connect the inlets and outlets During the off-season, the air conditioning system
of the compressor, condenser, receiver drier and should be operated for at least five minutes every
expansion valve (the evaporator coil is connected to month to circulate the oil in the system to lubricate
the expansion valve within the air conditioning unit the fittings and seals.
using rigid pipes).
When you operate the system, make sure of the
If leakage is detected from a hose connector, either followings.
by means of an electronic leak detector or soapy
water, tighten the connector up and repeat the • Engine idle speed is more than 1000 RPM.
leakage test. If leakage is still evident, it will be • Ambient temperature is more than the specified
necessary to discharge the system and renew the value. 0 °C ( 32.0 °F)
connector O-ring seal. • Cab temperature is more than the specified
value. 20 °C ( 68.0 °F)
• The engine is at normal operating temperature.
12 - 20 9823/1700-1 12 - 20
00 - General
Check (Pressure) 10. Close the valves and remove all equipment.
Figure 195.
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
or a suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
Refer to the Health and Safety section. Refer to: PIL

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

purity.
The JCB recommended Javac unit only recovers

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

A Low pressure hose (blue)
2. Make sure that the engine is OFF and the engine B High pressure hose (red)
is cool. C Hose (yellow)
D Filter
3. Remove the ignition key. E Javac unit
F Empty receiver bottle
4. Connect the manifold to the system with the blue
hose connected to the system low pressure port.
Do not connect the red hose. Make sure that both Evacuate
valves are closed.
This procedure follows on from the Recovery
5. Connect the yellow hose to the Javac unit filter. process and is necessary to make sure that the
system is correctly refilled with refrigerant. To avoid
6. Connect the filter to the Javac unit. leakage in the vacuum system itself, Do not use
extensions to the yellow hose (use standard 2 metre
7. Connect the Javac unit to an empty receiver length).
bottle. Weigh the bottle before and after filling to
assess the system capacity. Note: Do not fill the 1. Recover all refrigerant from the system, refer to
receiver bottle to more than 80% by weight. refrigerant recovery.
8. Switch on Javac unit and open the low pressure 2. Close all valves and connect the manifold.
manifold valve. Note: If the high pressure Connect the blue hose to the system low
warning light on the Javac unit comes on, throttle pressure port and the red hose to the high
back the manifold low pressure valve to provide pressure port.
a restriction.
3. Connect the yellow hose to the vacuum pump.
9. The Javac unit will automatically switch off when Note: If the Electronic vacuum gauge is used
a pressure balance exists between the system connected as shown. Refer to Electronic Vacuum
and the receiver bottle. Switch off Javac unit at Gauge for further information.
main switch, but leave the system connected.
Switch on after the specified time and the Javac 4. Open the manifold valves.
unit will restart if residual pressure remains.
5. Switch on the vacuum pump until 740mm (29
Duration: 10 min in) mercury vacuum reads on both gauges.
12 - 21 9823/1700-1 12 - 21
00 - General
Note: achievable vacuum will vary with altitude. 6. Switch on the vacuum pump and open the high
Maximum gauge reading will be 25mm (1 in) less pressure side valve.
for every 305 metres (1000 feet) above sea level.
7. Unscrew the oil injector cap and add the specified
6. Maintain suction for approximately the specified quantity of refrigerant oil.
time. Note: If the vacuum falls rapidly the system
is leaking. Check all connections and reseal. If 8. When 740mm (29 in) mercury shows on the
the point of leakage is not obvious, recharge the vacuum gauge, open the oil injector valve to
system and test again. allow the oil into the system.
Duration: 30 min 9. If more oil is needed repeat the above procedure.
The quantity of oil should be the same as that
7. Close the valves and remove all equipment. taken out during the Recovery procedure. Note:
Figure 196. Use only PAG oil in R-134a systems.
Figure 197.

B High pressure hose (red)
C Hose (yellow) F
D Vacuum pump
E Electronic vacuum gauge
B High pressure hose (red)
Re-lubricate C Hose (yellow)
D Vacuum pump
Re-lubrication is essential after recovering the
E Oil injector
system refrigerant, vacuuming and component
F Low pressure point
flushing. The system should be evacuated to a
vacuum of 740mm (29 in) of mercury before re-
lubricating. Charge
1. Make sure that the engine is OFF and the engine This procedure is the industry recommended
is cool. practice for refilling air conditioning systems with
refrigerant. Evacuate the system beforehand to
2. Remove the ignition key. 740mm (29 in) of mercury.
3. Close all valves and connect the manifold as 1. Close all valves and connect the manifold
shown, with the blue hose connected to the oil as shown. Connect the blue hose to system
injector and the red hose to the system high low pressure and the red hose to system
pressure port. high pressure. Connect the yellow hose to the
refrigerant cylinder.
4. Connect the yellow hose to the vacuum pump.
2. Invert the single valve cylinder on the scales and
5. Connect the other end of the oil injector to the zero the scale reading. Note: Some refrigerant
system low pressure point. cylinders have separate valves for gas and liquid.
12 - 22 9823/1700-1 12 - 22
00 - General
Be sure to connect to the liquid port when Figure 199.

following the above procedure. Note: Refrigerant
can be used either in gas or liquid form. If
recharging with gas follow the manufacturers
instructions and recharge only via the low
pressure port. Do not use liquid refrigerant at the
low pressure port.
3. Slowly open the high pressure valve and allow
the vacuum to draw-in refrigerant to the specified
weight for the system. Refer to Technical
Data. Add refrigerant until the scales indicate
the specified weight for the system or the
weight obtained when the system refrigerant
was previously recovered. Note: To speed up
the process a thermostatically controlled thermal
blanket can be used around the replenishing
cylinder.
4. Close all valves and remove the equipment.
Figure 198.
A396790
Table 61.
Gauge Reading Description
ATM/BAT Normal atmospheric
pressure reading. Bat-
tery condition.
15"/510mbar 381mm (15 in)Hg. Par-
tial vacuum- Vacuum
system is operating.
29"/980mbar 736mm (29 in)Hg. No
vacuum drawn- Possible
system leakage.
8000 8.0mm (0.31 in)Hg. Par-
tial vacuum - If the read-
ing does not progress
the system may have a
slow leak.
1000 1.0mm (0.039 in)Hg.
A Low pressure hose (blue) Deeper vacuum.
B High pressure hose (red) 600 0.6mm (0.023 in)Hg.
C Hose (yellow) Deep vacuum.
D Refrigerant cylinder 400 0.4mm (0.015 in)Hg.
E Scales Deep vacuum.
F Thermal blanket
200 0.2mm (0.0078 in)Hg.
Deep vacuum.
Electronic Vacuum Gauge
25 0.025mm (0.00098
The CPS VG100 vacuum gauge is an electronic type in)Hg. Pump Test. Max-
using LED's to indicate various states of vacuum. It imum sustainable vacu-
is used in place of or to supplement the gauge on the um.
vacuum pump. Before connecting into the system,
switch on to check that the first LED lights to show
that the battery is in good condition.
Note: The indicator lights show pressure in inches of

mercury (Hg) and vacuum in microns (0.001mm Hg).
12 - 23 9823/1700-1 12 - 23
00 - General
Adjust Lubricate
For compressor drive belt adjustment, please see Refer to discharge and pressurise (PIL 12-03-00).
(PIL 15-18).
12 - 24 9823/1700-1 12 - 24
03 - HVAC Unit
03 - HVAC Unit
Contents Page No.
12-03-00 General ........................................................................................................................... 12-27

12-03-03 Evaporator ...................................................................................................................... 12-35
12-03-06 Pressure Switch ............................................................................................................. 12-36
12-03-09 Expansion Valve ............................................................................................................. 12-38
12-03-12 Blower Motor .................................................................................................................. 12-39
12-03-15 Thermostat ..................................................................................................................... 12-40
12-03-18 Heater Coil ..................................................................................................................... 12-42
12 - 25 9823/1700-1 12 - 25
Notes:
12 - 26 9823/1700-1 12 - 26
03 - HVAC Unit
00 - General
00 - General Component Identification

Component Identification ............................... 12-27
Operation (Electrical) ..................................... 12-28
Diagram ......................................................... 12-29
Remove and Install ....................................... 12-33
Figure 200.
C
A HVAC (Heating Ventilation Air Conditioning) unit B Blower fan motor

housing
C Removable cover D Heater control valve
E Electrical harness connector
12 - 27 9823/1700-1 12 - 27
03 - HVAC Unit
00 - General
Operation (Electrical)
Refer to Operation (PIL 12-03-00).
12 - 28 9823/1700-1 12 - 28
03 - HVAC Unit
00 - General
Diagram
Figure 201. Machines with SD engines and cooling pack mounted condensor
C
A
M
B
FT
E
J
F K
G H
12 - 29 9823/1700-1 12 - 29
03 - HVAC Unit
00 - General
Figure 202. Machines with SF engines and roof mounted condensor (single relay controlled)
C
A
M
B
FT
E
J
K
F H
P
U
W
A
N
Q
A
V
B
Q
12 - 30 9823/1700-1 12 - 30
03 - HVAC Unit
00 - General
Figure 203. Machines with SE engines and roof mounted condensor (twin relay controlled)
C
A
M
B
FT
E
J
K
F H
A
S
Q
A
V
B
Q
T
Table 62.
A Secondary fuse box
B Heater fan / air conditioning switch
C Air conditioning switch A
D Air conditioning switch B
E Heater harness electrical connector
FT Freeze protection thermostat
F Binary switch pin A
12 - 31 9823/1700-1 12 - 31
03 - HVAC Unit
00 - General
G Binary switch pin B

H Compressor clutch solenoid
J Earth point
K Earth point
M Fan blower motor
N Roof Air Conditioning Fans Relay (Single relay con-
trolled)
P Earth point
Q Earth point
R Fan motor resistor
S Roof Air Conditioning Fan 1 Relay (Twin relay con-
trolled)
T Roof Air Conditioning Fan 2 Relay (Twin relay con-
trolled)
U Roof fan A - positive
V Roof fan B - positive
W Roof fan A - earth
X Roof fan B - earth
12 - 32 9823/1700-1 12 - 32
03 - HVAC Unit
00 - General
Remove and Install Refer to: PIL 06-06-13.

10. Remove the bolt 1 and bolt 2 which secure the
Air Conditioning Maintenance HVAC unit to the machine.
and contains pressurised refrigerant. No part of the 11. Carefully remove the unit sufficiently to access
system should be disconnected until the system the electrical harness connector at the rear.
has been discharged by a refrigeration engineer 12. The electrical harness connector is located
or a suitably trained person. You can be severely behind the unit and cannot be disconnected until
frostbitten or injured by escaping refrigerant. the unit is pulled away from the machine.
The heating and ventilation unit (HV) contains a 13. Disconnect the electrical connector.
blower unit and heat exchanger matrix. It is located
under the right front side of the cab. 14. Remove the assembly from the machine.
The HVAC (Heating Ventilation Air Conditioning) unit Figure 204.

is the same as the HV unit but also contains an
evaporator matrix and thermostat.
F
Put labels on all the hoses before removal for easy
G
installation.
Remove
Get access to the TXV (Thermal Expansion Valve)
by lowering the unit without disconnecting the hoses.
In this case it is not necessary to discharge the
refrigerant.

2. Install the safety strut. E
3. To remove the HVAC unit it is necessary to A C B D
discharge the refrigerant from the system. A Heater valve
Refer to: PIL 12. B Heater matrix
C TXV (If installed)
4. Drain the cooling system. D Bolt 1
E Bolt 2
Refer to: PIL 21. F Clip
5. If installed, remove the cab side cover to get G Cable
access to the HVAC unit.
Install
6. Disconnect the heater hoses from the heater
valve and from the heater matrix. 1. The installation procedure is the opposite of the
7. Disconnect the HVAC hoses from the TXV (if steps.
installed).
1.1. Make sure that the TXV is installed correctly
8. Remove the clip and disconnect the cable from with the diaphragm, located below the
the heater valve. valve.
9. For 526-56 machines only:
9.1. Remove the cab frame from the machine.
9.2. Remove the chassis side cover from the
machine.
12 - 33 9823/1700-1 12 - 33
03 - HVAC Unit
00 - General
Figure 205.
C TXV
J Diaphragm
1.2. Charge the HVAC system and check for
leaks.
Refer to: PIL 12.
1.3. Fill the cooling system and check for leaks.
Refer to: PIL 21.
12 - 34 9823/1700-1 12 - 34
03 - HVAC Unit
03 - Evaporator
03 - Evaporator
Introduction
The evaporator works in the opposite way as the

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

Ventilation Air Conditioning) unit.
12 - 35 9823/1700-1 12 - 35
03 - HVAC Unit
06 - Pressure Switch
06 - Pressure Switch Introduction

Introduction .................................................... 12-36 The binary pressure switch assembly has a low and
Remove and Install ....................................... 12-37 high pressure switch designed to operate at specified
pressure values.
When the refrigerant pressure is within the specified

limits, the pressure switches will be closed and if the
thermostat and on/of switches are closed, current
will be supplied to the field coil of the clutch. Due
to the electromagnetic action the field coil clutch will
be pulled towards the compressor's clutch and the
refrigeration cycle will start.
12 - 36 9823/1700-1 12 - 36
03 - HVAC Unit
06 - Pressure Switch
Remove and Install Install

1. Screw the pressure switch into the threaded port
and tighten sufficiently to form a gas-tight seal.
and contains pressurised refrigerant. No part of the 2. Again connect the harness connectors.
has been discharged by a refrigeration engineer 3. Charge the air conditioning system. Refer to (PIL
or a suitably trained person. You can be severely 12-03).
frostbitten or injured by escaping refrigerant. 4. Operate the air conditioning system and check
CAUTION! When working on the HVAC System around the pressure switch for leaks.
gloves, eye protection and protective clothing must
be worn. Refrigerant may be released which can be 4.1. If leaks are found, tighten the pressure
harmful to your skin or eyes. switch further until the leaking stops.
Remove
1. Make the machine safe with the lift arm lowered.
2. Discharge the air conditioning system. Refer to
(PIL 12-03).
3. Remove the harness connectors.
4. Remove the screws and then remove the
pressure switch assembly.
Figure 206.
B
A
A Pressure switch
B Harness connectors
12 - 37 9823/1700-1 12 - 37
03 - HVAC Unit
09 - Expansion Valve
09 - Expansion Valve
Introduction
The purpose of the expansion valve is to remove

pressure from the liquid refrigerant and to allow the
refrigerant to change from liquid to vapour in the
evaporator. The expansion valve is located in the
HVAC unit.
12 - 38 9823/1700-1 12 - 38
03 - HVAC Unit
12 - Blower Motor
12 - Blower Motor
Fault-Finding
Fault
Blower operates on fan speed 3 only Table 63. Page 12-39
Blower does not operate Table 64. Page 12-39
Table 63. Blower operates on fan speed 3 only

Cause Remedy
Blower resistor defective. Install new resistor
Blower motor defective. Remove and install new blower motor unit.
Table 64. Blower does not operate

Cause Remedy
Fuse defective. Install new fuse and test again.
12 - 39 9823/1700-1 12 - 39
03 - HVAC Unit
15 - Thermostat
15 - Thermostat
Remove and Install
Remove 4. Remove the fixing bolts (x2) and then remove the
electrical connectors.
5. Carefully remove the thermostat and the
Refer to: PIL 01-03. thermostat sensor. Note the routing of the sensor
2. Install the safety strut. probe. Do not make sharp bends in the sensor
probe.
3. Remove the screws (x12) and take out the HVAC
(Heating Ventilation Air Conditioning) unit cover.
Figure 207.
H G
A
C E
D D
A Screws (x12) B HVAC unit cover

C Electrical connectors D Fixing bolt (x2)
E Sensor F Thermostat
G Protective sleeve H New sensor
12 - 40 9823/1700-1 12 - 40
03 - HVAC Unit
15 - Thermostat
Install
steps.
1.1. If a new thermostat is to be installed,
carefully remove the protective sleeve from
the new sensor. Do not make sharp bends
in the sensor probe.
1.2. Make sure that the HVAC cover sealing
gasket locates correctly.
12 - 41 9823/1700-1 12 - 41
03 - HVAC Unit
18 - Heater Coil
18 - Heater Coil
Introduction
The heater coil is a tube and fin construction, with the

inlet and outlet on one end of the coil. Hoses connect
the coil to the engine.
The heat energy for heating cab air comes from the
hot engine coolant. The heater systems are designed
to transfer heat energy from the engine coolant to the
air in the cab.
12 - 42 9823/1700-1 12 - 42
04 - Heater Unit
04 - Heater Unit
Contents Page No.
12-04-00 General ........................................................................................................................... 12-45

12-04-18 Heater Coil ..................................................................................................................... 12-49
12 - 43 9823/1700-1 12 - 43
Notes:
12 - 44 9823/1700-1 12 - 44
04 - Heater Unit
00 - General

Operation (Electrical) ..................................... 12-46
Diagram ......................................................... 12-47
Fault-Finding .................................................. 12-48
Figure 208.
C
A HVAC (Heating Ventilation Air Conditioning) unit B Blower fan motor

housing
C Removable cover D Heater control valve
E Electrical harness connector
12 - 45 9823/1700-1 12 - 45
04 - Heater Unit
00 - General
Operation (Electrical)
The blower motor speed is selected by the operator

using the heater fan switch.
The switch outputs direct the supply to the motor

through the resistor.
Each speed is selected by using a different position

on the resistor - the increase in resistance reduces
the supply to the fan motor thus slowing it down.
12 - 46 9823/1700-1 12 - 46
04 - Heater Unit
00 - General
Diagram
Figure 209. Heater Unit
3 B C
L
M 2
H 1
2
3
1 4
5
6
1 Heater fan switch 2 Heater connector

3 Secondary fuse box 4 HVAC (Heating Ventilation Air Conditioning) unit
12 - 47 9823/1700-1 12 - 47
04 - Heater Unit
00 - General
Fault-Finding
Fault
Blower operates on fan speed(3) only Table 65. Page 12-48
Blower does not operate Table 66. Page 12-48
Table 65. Blower operates on fan speed(3) only

Cause Remedy
Blower resistor failed Replace the resistor.
Blower motor failed Replace the complete blower motor unit.
Table 66. Blower does not operate

Cause Remedy
Fuse blown Replace the fuse and re-check.
12 - 48 9823/1700-1 12 - 48
04 - Heater Unit
18 - Heater Coil
18 - Heater Coil
Introduction
The heater coil is a tube and fin construction, with the

inlet and outlet on one end of the coil. Hoses connect
the coil to the engine.
The heat energy for heating cab air comes from the
hot engine coolant. The heater systems are designed
to transfer heat energy from the engine coolant to the
air in the cab.
12 - 49 9823/1700-1 12 - 49
09 - Compressor
09 - Compressor
Contents Page No.
12-09-00 General ........................................................................................................................... 12-51
12 - 50 9823/1700-1 12 - 50
09 - Compressor
00 - General
Introduction .................................................... 12-51 The compressor is located at the front of the engine,
Remove and Install ....................................... 12-52 it is the heart of the air conditioning system since
it produces the refrigerant flow. The compressor is
driven by the engine drive belt.
12 - 51 9823/1700-1 12 - 51
09 - Compressor
00 - General
Remove and Install
Remove 5.1. Put a label on the hoses to help installation.

contamination.
6. Remove the high pressure hose to the
2. Discharge the air conditioning system refrigerant. compressor.
Refer to: PIL 12. 6.1. Put a label on the hoses to help installation.
3. Remove the FEAD (Front End Accessory Drive) 6.2. Plug all the open ports and hoses to prevent
belt. contamination.
7. Support the compressor and remove the
4. Disconnect the electrical harness connector from mount bolts that attach the compressor to the
the compressor and binary pressure switch. crankcase.
5. Remove the low pressure hose to the 8. Lift the compressor and remove from the
compressor. machine.
Figure 210.
E G
A B F
C D
J H
K B
A FEAD belt B Compressor

C Harness connector- binary pressure switch D Bolt
E Harness connector- compressor F High pressure hose
G Mount bolts H Low pressure hose
J Bolt K Cable ties
12 - 52 9823/1700-1 12 - 52
09 - Compressor
00 - General
Install
steps.
2. Replace the FEAD belt.
3. Recharge the air conditioning system refrigerant.
Refer to: PIL 12.
4. Check the air conditioning system for leaks and
correct operation.
12 - 53 9823/1700-1 12 - 53
12 - Receiver Drier
12 - Receiver Drier
Contents Page No.
12-12-00 General ........................................................................................................................... 12-55
12 - 54 9823/1700-1 12 - 54
12 - Receiver Drier
00 - General
Introduction .................................................... 12-55 The receiver drier is a device that removes
Check (Condition) .......................................... 12-56 moisture from the refrigerant as well as filtering any
contaminants or particulates from it. It also acts as a
tank to store excess coolant. Refer to: PIL 12-00-00.
12 - 55 9823/1700-1 12 - 55
12 - Receiver Drier
00 - General
Check (Condition) Figure 212.

2. Clean the sight glass on the top housing of the
receiver drier.
3. Check the sight glass.
3.1. Make sure that the sight glass is clear.
4. Check the pipe connections to the receiver drier
for signs of cracks or wear. 3. Clouded - Dessicant breakdown in the receiver
drier. Refer to Figure 213.
5. Make sure that the pipes are correctly clamped.
Figure 213.
5.1. If necessary, replace the pipes and clamps.
6. Do not remove the pipes from the charged HVAC
(Heating Ventilation Air Conditioning) system.
Sight glass indications

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

supply cool air. The indication then is that the
system is completely discharged of refrigerant.
Refer to Figure 211.
Figure 211.
2. Foam or bubbles - Refrigerant is low and needs

of charging. Some slight bubbling is to be
expected when R134a refrigerant is used. Refer
to Figure 212.
12 - 56 9823/1700-1 12 - 56
15 - Condenser
15 - Condenser
Contents Page No.
12-15-00 General ........................................................................................................................... 12-59
12 - 57 9823/1700-1 12 - 57
Notes:
12 - 58 9823/1700-1 12 - 58
15 - Condenser
00 - General
Introduction .................................................... 12-59 A condenser is a component used to condense
Clean ............................................................. 12-60 a substance from its gaseous to its liquid state,
Check (Condition) .......................................... 12-60 typically by cooling it. In so doing the latent heat is
Remove and Install ....................................... 12-61 given up by the substance, and will transfer to the
condenser coolant.
12 - 59 9823/1700-1 12 - 59
15 - Condenser
00 - General
Clean Check (Condition)
When you are cleaning take extra care not to damage 1. Inspect the condenser coil for a build of dirt. If
the condenser fins or tubes. Damaged fins must necessary, clean the condenser coil.
be straightened out to make sure of a good airflow Refer to: PIL 12-15-00.
through the coil.
2. Inspect the condenser fins or tubes for damage.
1. Make the machine safe. Straighten out the damaged fins and make sure
Refer to: PIL 01-03. of a good airflow through the coil.
2. Raise the grille at the rear of the machine. The working environment of the machine can build
up airborne particles on the condenser coil over a
3. Use compressed air or low pressure water to period of time. This restricts the airflow around the
back flow through the coil fins. Make sure that the condenser coil and reduces the heat dissipation from
fins are not damaged. the refrigerant to the air. This results in poor air
conditioning performance.
4. Start the HVAC (Heating Ventilation Air
Conditioning) system and check the cooling The heavy build up on the condenser coil leads to
performance. over pressurisation of the system. This can cause
the high pressure cut-out switch to operate and
switch off the system. The internal blockage of the
condenser coil can also operate the high pressure
cut-out switch.
12 - 60 9823/1700-1 12 - 60
15 - Condenser
00 - General
Remove and Install
CAUTION When working on the HVAC System 6. Remove the work light securing screws and
gloves, eye protection and protective clothing remove the lights and brackets from the machine.
must be worn. Refrigerant may be released which Make sure the work lights and harness are clear
can be harmful to your skin or eyes. of the condenser.
7. Remove the bolt securing the pipe clamp,
Roof Mounted Condenser remove the clamp.
The condenser matrix is mounted on the cab roof. 8. Disconnect the condenser harness connector.
Use the assistance of a refrigeration engineer or 9. Put a label on the pipes to help installation.
suitably trained person to remove the condenser
10. Disconnect the HVAC pipes at the pipe stubs on
matrix since the refrigerant needs to be drained from
the condenser.
the system.
11. Plug all the open ports and pipes to prevent
Remove contamination.
1. Make the machine safe. 12. To prevent damage to the condenser when you
Refer to: PIL 01-03. remove or install the pipes, hold the hexagon
flats on the pipe stubs with a spanner when you
2. Disconnect the battery. loosen or tighten the pipe nuts.
Refer to: PIL 33-03. 13. When you remove the components or hoses,
retain any lubricant within the component/pipe
3. Make sure that the HVAC (Heating Ventilation Air
and fill the system with the same amount of clean
Conditioning) system is fully discharged.
lubricant (PAG Oil).
Refer to: PIL 12.
14. Using lifting equipment support the weight of the
4. Support the protective cover and remove the condenser unit.
nuts. Lower the cover from the matrix.
15. Remove the nuts and carefully lift the condenser
5. Remove the cable ties to release the work light matrix from the machine.
harness if installed.
12 - 61 9823/1700-1 12 - 61
15 - Condenser
00 - General
Figure 214.
A F
D D
F
B
F
E
C
G J
K
L
L
M
M
L
M
P
L
A Condenser matrix B Protective cover

C Cover fasteners D Air conditioning pipes
E Cable ties F Condenser support bolts
G Work light harness H Pipe clamp bolt
J Pipe clamp K Condenser electrical connector
L Condenser support nuts M Bracket securing screws
N Condenser unit P Support bracket
12 - 62 9823/1700-1 12 - 62
15 - Condenser
00 - General
Install Remove
1. The installation procedure is the opposite of the 1. Make the machine safe.
steps.
1.1. Recharge the HVAC system after
installation. Refer to: PIL 06-06.
Refer to: PIL 12. 3. Disconnect and remove the battery.
1.2. Operate the HVAC system and check for Refer to: PIL 33-00.
leaks.
4. Make sure that the HVAC system is fully
1.3. In the cab, set the HVAC system to discharged.
maximum cooling and check that cooled air
comes through the vents. Refer to: PIL 12.
5. Put a label on the hoses to help installation.
Cooling Pack Mounted Condenser
6. Disconnect the HVAC hoses at the pipe stubs on
The condenser matrix is mounted onto the cooling the side of the condenser.
pack in the engine compartment. If the condenser is
removed only to gain access to the cooling pack, this 7. Plug all the open ports and hoses to prevent
can be done without disconnecting the HVAC hoses contamination.
and with the system fully charged. Put the condenser
carefully on to one side with the hoses still connected 8. To prevent damage to the condenser when you
after you remove the nuts. Take care not to kink the remove or install the hoses, hold the hexagon
hoses. Do not allow the condenser to hang on the flats on the pipe stubs with a spanner when you
hoses unsupported. loosen or tighten the hose nuts.
Use the assistance of a refrigeration engineer or 9. When you remove the components or hoses,
suitably trained person to remove the condenser retain any lubricant within the component/hose
matrix since the refrigerant needs to be drained from and fill the system with the same amount of clean
the system. lubricant (PAG Oil).
10. Remove the nuts and carefully lift the condenser
matrix from the machine.
12 - 63 9823/1700-1 12 - 63
15 - Condenser
00 - General
Figure 215.
A C
B
C
A Condenser matrix B Pipe stub

C Nuts
12 - 64 9823/1700-1 12 - 64
15 - Condenser
00 - General
Install
steps.
1.1. Recharge the HVAC system after
installation.
Refer to: PIL 12.
1.2. Operate the HVAC system and check for
leaks.
1.3. In the cab, set the HVAC system to
maximum cooling and check that cooled air
comes through the vents.
12 - 65 9823/1700-1 12 - 65
18 - Filter
18 - Filter
Contents Page No.
12-18-00 General ........................................................................................................................... 12-67

12-18-06 Fresh Air ........................................................................................................................ 12-68
12 - 66 9823/1700-1 12 - 66
18 - Filter
00 - General
00 - General
Introduction
CAUTION The filter may be filled with dust. Wear
goggles and a face mask when removing the filter.
The air conditioning filter assemblies are designed to

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

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

cleaning/changing more often than detailed in the
maintenance schedule.
12 - 67 9823/1700-1 12 - 67
18 - Filter
06 - Fresh Air
06 - Fresh Air 1.1. Carefully install the new filter into the
housing.
Remove and Install 1.2. Make sure that the tab locates behind the
edge of the panel before you install the
CAUTION The filter may be filled with dust. Wear screw.
goggles and a face mask when removing the filter.
In dusty conditions the filter will require cleaning/

changing more often than detailed in the service
schedule.
Remove
2. Install the safety strut.
3. Remove the screw and the cover to access the
filter.
4. Remove the filter.
Figure 216.
C
E
A Screw
B Cover
C Filter
D Tab
E Panel
Install
Do not try to clean the filter. If the filter gets clogged,
install a new one.

steps.
12 - 68 9823/1700-1 12 - 68
21 - Heater Valve
21 - Heater Valve
Contents Page No.
12-21-00 General ........................................................................................................................... 12-71
12 - 69 9823/1700-1 12 - 69
Notes:
12 - 70 9823/1700-1 12 - 70
21 - Heater Valve
00 - General
00 - General
Remove and Install
The cab heater valve is part of the heater assembly 5. Align the marks on the control cable outer and
installed on the external part of the cab. the valve body.
6. Remove the clip 1.
Remove
7. Be careful, when you remove the hoses from the
valve, some amount of engine coolant will leak.
8. Loosen the clip 2 and remove the hoses from the
2. Remove the ignition key. valve.
3. If the engine is hot let it cool for one hour. 9. Disconnect the control cable from the valve lever.
4. Secure the heater hoses with clamps.
Figure 217.
A
C
D
E
G
H
B
B
F
A Cab heater valve B Heater hoses

C Control cable outer D Valve body
E Clip 1 F Clip 2
G Control cable H Valve lever.
12 - 71 9823/1700-1 12 - 71
21 - Heater Valve
00 - General
Install
steps.
1.1. Align the marks on the control cable outer
and valve body and then install a new clip 1.
1.2. Check the level of the engine coolant.
After installation
1. Start the engine and operate the cab heater at
the maximum temperature.
2. Operate the engine for the specified time.
Duration: 5 min
3. Stop the engine and check for any coolant leaks.
12 - 72 9823/1700-1 12 - 72
96 - Pipe
96 - Pipe
Contents Page No.
12-96-00 General ........................................................................................................................... 12-75
12 - 73 9823/1700-1 12 - 73
Notes:
12 - 74 9823/1700-1 12 - 74
96 - Pipe
00 - General
Introduction .................................................... 12-75 The refrigeration pipes are responsible for carrying
Check (Condition) .......................................... 12-76 the refrigerant ( liquid and gas) around the closed
loop air conditioning system. There are usually 4
pipes that connect the system components:
• Suction Line-Evaporator to Compressor, the

low pressure refrigerant gas line.
• Discharge Line-Compressor to Condensor, the
high pressure, hot gas line coming out of the
compressor.
• Condenser drain line-Condensor to Receiver
drier
• Liquid line-Receiver drier to Evaporator
12 - 75 9823/1700-1 12 - 75
96 - Pipe
00 - General
Check (Condition)
2. Check all the visible pipes and connectors.
3. Look for areas where the hoses flex or are
fastened, clamped, connected, bent or go
through panels. All these areas are potential
wear and damage points.
4. Do not remove the pipes from the charged HVAC
(Heating Ventilation Air Conditioning) system.
5. Tighten the pipes and adaptors to the correct
torque value.
12 - 76 9823/1700-1 12 - 76
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-03 Crankcase
15-03-00 General ........................................................................................................................... 15-37
15-06 Cylinder Head
15-06-00 General ........................................................................................................................... 15-41
15-09 Bedplate
15-09-00 General ........................................................................................................................... 15-49
15-12 Crankshaft
15-12-00 General ........................................................................................................................... 15-57
15-12-03 Main Bearing .................................................................................................................. 15-66
15-12-06 Front Oil Seal ................................................................................................................. 15-68
15-12-09 Rear Oil Seal ................................................................................................................. 15-71
15-12-12 Pulley .............................................................................................................................. 15-75
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-77
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-85
15-18-03 Drive Belt ....................................................................................................................... 15-89
15-18-21 Tensioner ........................................................................................................................ 15-93
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-95
15-24 Air Filter
15-24-00 General ......................................................................................................................... 15-103
15-24-09 Dust Valve .................................................................................................................... 15-106
15-27 Crankcase Ventilation Filter
15-27-00 General ......................................................................................................................... 15-109
15-30 Valve
15-30-00 General ......................................................................................................................... 15-115
15-30-12 Valve Spring ................................................................................................................. 15-124
15-30-24 Stem Seal .................................................................................................................... 15-125
15-33 Connecting Rod
15-33-00 General ......................................................................................................................... 15-127
15-33-06 Big-End Bearing ........................................................................................................... 15-131
15-36 Piston
15-36-00 General ......................................................................................................................... 15-137
15-36-03 Piston Ring ................................................................................................................... 15-149
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-151
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-153
15-42-06 Rocker Cover ............................................................................................................... 15-162
9823/1700-1
2018-06-26
15-42-09 Push Rod ..................................................................................................................... 15-164
15-42-21 Tappet ........................................................................................................................... 15-166
15-42-24 Tappet Cover ................................................................................................................ 15-168
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-171
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-177
15-51-03 Crankshaft Gear ........................................................................................................... 15-182
15-51-06 Camshaft Gear ............................................................................................................. 15-185
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-186
15-51-22 Rear Case .................................................................................................................... 15-189
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-193
15-54-03 Housing ........................................................................................................................ 15-197
15-54-09 Gear Ring ..................................................................................................................... 15-200
15-54-12 Drive Plate .................................................................................................................... 15-201
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-205
15-63 Mount
15-63-00 General ......................................................................................................................... 15-213
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-217
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-225
15-72-03 Pulley ............................................................................................................................ 15-233
15-72-06 Voltage Regulator ......................................................................................................... 15-234
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-237
15-75-03 Solenoid ....................................................................................................................... 15-245
15-75-06 Brush Gear ................................................................................................................... 15-246
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-249
15-84-09 Knock ........................................................................................................................... 15-250
15-84-29 Foot Throttle Control .................................................................................................... 15-251
15-84-33 Coolant Temperature .................................................................................................... 15-255
15-84-43 Engine Oil Level ........................................................................................................... 15-258
15-86 Solenoid
15-86-00 General ......................................................................................................................... 15-263
15-86-03 Engine Shut-off Solenoid (ESOS) ................................................................................ 15-264
15-86-09 Cold Start Advance ...................................................................................................... 15-268
15-87 Switch
15-87-00 General ......................................................................................................................... 15-273
15-87-03 Engine Oil Pressure ..................................................................................................... 15-274
15-87-09 Cold Start ..................................................................................................................... 15-277
15-88 Cold Start Heater
15-88-00 General ......................................................................................................................... 15-283
15-90 Air Intake
15-90-00 General ......................................................................................................................... 15-287
9823/1700-1
2018-06-26
Acronyms Glossary
CAN Controller Area Network

CCV Crankcase Ventilation
DC Direct Current
DTI Dial Test Indicator
ECM Engine Control Module
ESOS Engine Shut-Off Solenoid
LMS Loadall Monitoring System
PTO Power Take-Off
TDC Top Dead Centre
9823/1700-1
2018-06-26
Notes:
9823/1700-1
2018-06-26
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9823/1700-1 15 - 1
Notes:
15 - 2 9823/1700-1 15 - 2
15 - Engine
00 - Engine
00 - General
Introduction ...................................................... 15-3 This section contains information about the complete
Health and Safety ........................................... 15-7 engine assembly. For specific engine technical
Technical Data ................................................. 15-8 information refer to the technical data section.
Component Identification ................................. 15-9 Make sure that the correct engine service tools,
consumables and torque figures are used when you
Operation ....................................................... 15-12 perform service procedures. Renewal of oil seals,
Diagram ......................................................... 15-15 gaskets, etc., and any component showing obvious
Fault-Finding .................................................. 15-16 signs of wear or damage is expected as a matter
Drain and Fill ................................................. 15-25 of course. It is expected that components will be
cleaned and lubricated where appropriate, and that
Clean ............................................................. 15-25
any opened hose or pipe connections will be blanked
Check (Pressure) .......................................... 15-27 to prevent excessive loss of hydraulic fluid, engine oil
Remove and Install ....................................... 15-30 and ingress of dirt.
Store and Recommission .............................. 15-34
Basic Description
The JCB DieselMax engine is a 4 cylinder diesel
engine in which the fuel is ignited by compression
ignition (C.I.). The engine operates on a four stroke
cycle.
The engine is started by an electric starter motor. The

starter motor turns the engine via a pinion and teeth
on the engine flywheel. Refer to: PIL 15-75-00.
When the engine runs the crankshaft drives the

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

injection pump via gears. The pump injects fuel via
injectors, or atomisers into each cylinder in time with
the four stroke cycle.
Air is drawn into the engine via the inlet manifold,

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

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

coolant circulation pump, alternator, radiator cooling
fan and other ancillaries such as an air conditioning
compressor.
15 - 3 9823/1700-1 15 - 3
15 - Engine
00 - Engine
00 - General
Figure 218.
13 9
6
5
11
1
2
15
8
3
10
14
1 Starter motor 2 Flywheel

3 Crankshaft 4 Camshaft
5 Inlet valves (x8) 6 Exhaust valves (x8)
7 Push rods (x8) 8 Fuel injection pump
9 Fuel injectors (x4) 10 Fuel lift pump
11 Inlet manifold 13 Turbocharger
14 Lubrication oil pump 15 Front end drive belt
15 - 4 9823/1700-1 15 - 4
15 - Engine
00 - Engine
00 - General
Internal As viewed on the right hand side. Refer to Figure 219.
The following identifies the main internal components

of a typical engine assembly. Some variants may
differ in detail.
Figure 219.
2 1
3
4 6a
6b
15
6c
6d
16
13
12
14
10
11
9
8
1 Rocker assembly 2 Valve bridge piece (x8)

3 Valve spring (x8) 4 Inlet valve (x8)
5 Exhaust valve (x8) 6 Piston assembly (x4)
6a Piston ring - top compression (x4) 6b Piston ring - 2nd compression (x4)
6c Piston ring - oil control (x4) 6d Gudgeon pin (x4)
7 Connecting rod assembly (x4) 8 Crankshaft
9 Main bearing - crankshaft (x5) 10 Big end bearing - crankshaft/connecting rod
(x4)
11 Front crankshaft oil seal 12 Front end drive belt pulley
13 Flywheel 14 Starter motor pinion
15 - 5 9823/1700-1 15 - 5
15 - Engine
00 - Engine
00 - General
15 High duty PTO (Power Take-Off) idler gear (if 16 High duty PTO device drive gear (if fitted)
fitted)
As viewed on the rear left side. Refer to Figure 220.
Figure 220.
15
14
13
16
10
1a
11
8
12
5 9 4 3
1 Flywheel 1a Flywheel - crankshaft fixing bolts (x8)

2 Fuel injector (atomiser) (x4) 3 Flywheel hub
4 Rear crankshaft oil seal 5 Crankshaft drive gear
6 High duty PTO idler gear (if fitted) 7 High duty PTO device drive gear (if fitted)
8 Low duty PTO device (if fitted) 9 Lubrication oil pump
10 Fuel injection pump drive gear 11 Camshaft compound gear
12 Camshaft drive gear 13 Camshaft
14 Tappet (x8) 15 Push rod (x8)
16 Fuel lift pump actuator pin
15 - 6 9823/1700-1 15 - 6
15 - Engine
00 - Engine
00 - General
Health and Safety accordance with local regulations. Use authorised

waste disposal sites.
Hot Components
Touching hot surfaces can burn skin. The engine and
been running. Allow the engine and components to
cool before servicing the unit.
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
Special precautions must be taken if the machine is
to be washed using a high pressure system. Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment. Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts. When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the maximum level of engine
oil in the sump. If the maximum is exceeded, the
excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
WARNING! The engine has exposed rotating parts.
Switch off the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
WARNING! Hot oil and engine components can burn
you. Make sure the engine is cool before doing
this job. Used engine crankcase lubricants contain
harmful contaminants. In laboratory tests it was
shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel
system with the engine running. Engine operation
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants. Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
15 - 7 9823/1700-1 15 - 7
15 - Engine
00 - Engine
00 - General
Technical Data Table 68. Basic Engine Data - 448 Engine

Engine variants (tier 2/stage 2)
Table 67. Basic Engine Data - 444 Engine - DA Naturally aspirated
Engine variants (Tier 2/stage 2) - DB Turbocharged
- SA Naturally aspirated - DC Turbocharged with in-
- SB Turbocharged ter-cooler
- SC Turbocharged with in- Engine variants (tier 3):
ter-cooler - DG Naturally aspirated
Engine variants (tier 3): - DD Turbocharged
- SG Naturally aspirated - DF Turbocharged with in-
- SD Turbocharged ter-cooler
- SF Turbocharged with in- Rated speed
ter-cooler Vehicle applications 2200 RPM
Rated speed Generator set applica- 1500 RPM
Vehicle applications 2200 RPM (Revolutions tion - 50 Hz
Per Minute) Generator set applica- 1800 RPM
Generator set applica- 1500 RPM tion - 60 Hz
tion - 50 Hz Weight (dry):
Generator set applica- 1800 RPM - DA, DG 472 kg
tion - 60 Hz - DB, DC, DD, DF 477 kg
Weight (dry): Number of cylinders 4
- SA, SG 472 kg Nominal bore size 106 mm
- SB, SC, SD, SF 477 kg Stroke 135 mm
Number of cylinders 4 Cylinder arrangement In line
Nominal bore size 103 mm Combustion cycle 4-stroke
Stroke 132 mm Firing order 1-3-4-2
Cylinder arrangement In line Displacement 4.765 L
Combustion cycle 4-stroke Compression ratio
Firing order 1-3-4-2 - DA 18.6 : 1
Displacement 4.399 L - DC 18.1 : 1
Compression ratio Engine compression see Note
(1)
- SA 18.6 : 1 Direction of rotation Clockwise

- SB 18.3 : 1 (viewed from front
- SC 17.5 : 1 {crankshaft pulley} end)
- SD 17.2 : 1 Valves 4 per cylinder
- SF 17.2 : 1 Valve clearances measured at the valve end of the
Engine compression rocker (measured cold):
see Note
(1)
- Inlet 0.19 –0.27 mm

Direction of rotation Clockwise
(viewed from front - Exhaust 0.56 –0.64 mm
{crankshaft pulley} end) Lubricating oil pressure > 4.6 bar ( 66.7 psi)
(2)
Valves 4 per cylinder Combustion system Direct injection

Valve clearances measured at the valve end of the Fuel injection pump Rotary mechanical
rocker (measured cold): (1) Compression variance between each cylinder
- Inlet 0.19 –0.27 mm should be no greater than 3.5 bar ( 50.7 psi).
- Exhaust 0.56 –0.64 mm (2) Engine at normal operating temperature and
Lubricating oil pressure > 4.6 bar ( 66.7 psi)
(2) maximum revs.
Combustion system Direct injection
Fuel injection pump Rotary mechanical
(1) Compression variance between each cylinder
should be no greater than 3.5 bar ( 50.7 psi).
(2) Engine at normal operating temperature and
maximum revs.
15 - 8 9823/1700-1 15 - 8
15 - Engine
00 - Engine
00 - General
External Remember that the left and right sides are

determined when viewing the flywheel (rear) end of
The following identifies the main components of a the engine.
typical engine assembly visible from the exterior.
Some variants may differ in detail.
Figure 221. Left hand Side

2 1 1 1 1
7 8
9
16
13
14
17
12 4
19
5
15
18 11 6 10
1 Fuel injectors and high pressure fuel pipes 2 Lubrication oil filler cap
3 Timing gear case 4 Flywheel housing
5 Bed plate 6 Lubrication oil sump
7 Engine lifting eye 8 Air inlet manifold
9 Fuel injection pump 10 Fuel lift pump
11 Fuel filter 12 Lubrication oil filler cap
13 Lubrication oil filter 14 Lubrication oil cooler housing
15 Low duty PTO (Power Take-Off) (blanking 16 Water temperature sender (cold start)
cover if no device is installed)
17 Low pressure fuel line (to tank) 18 Oil drain plug (sump)
19 Oil pressure switch
15 - 9 9823/1700-1 15 - 9
15 - Engine
00 - Engine
00 - General
Figure 222. Right Hand Side

1 8
7
10
2
11
12
13
15
18
14
5
4
19 16 6 17
1 Breather chamber inspection cover 2 Crankcase

3 Timing gear case 4 Flywheel housing
5 Bedplate 6 Lubrication oil sump
7 Lifting eye 8 Turbocharger (turbocharged engine only)
9 Turbocharger wastegate actuator assembly 10 Exhaust manifold
11 Alternator and drive pulley assembly (belt not 12 Coolant pump drive pulley (belt not installed)
installed)
13 Coolant pump housing (crankcase) 14 Coolant inlet/radiator hose connector
15 Heavy duty PTO (blanking cover if no device 16 Starter motor
is installed)
17 Turbocharger oil drain line (turbocharged 18 Turbocharger oil feed line (turbocharged
engine only) engine only)
19 Oil drain plug (sump)
15 - 10 9823/1700-1 15 - 10
15 - Engine
00 - Engine
00 - General
Figure 223. Front End

10 11 12
1
5
3
4
1 Cylinder head 2 Lubrication oil filter

3 Crankshaft pulley 4 Lubrication oil sump
5 Bedplate 6 Crankcase
7 Coolant pump and drive pulley assembly 8 Alternator and drive pulley assembly
9 Turbocharger (turbocharged engine only) 10 Coolant thermostat housing/radiator hose
connector
11 Coolant temperature sender 12 Cab heater water hose connector
15 - 11 9823/1700-1 15 - 11
15 - Engine
00 - Engine
00 - General
Operation
The Four Stroke Cycle The stages in the four stroke cycle for each cylinder
are as follows:
This section describes the cycle sequence, for the 6
cylinders of the diesel engine.
Table 69. The Four Stroke Cycle

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

A cylinder is said to be firing, when the fuel/air mixture The piston continues to rise after the start of fuel
ignites and the piston is about to start its power injection causing a further increase in pressure and
stroke. temperature.
Four Stroke Cycle The temperature rises to a point at which the fuel/air
mixture ignites. A cylinder is said to be firing, when
the fuel/air mixture ignites.
Induction
This combustion causes a very rapid rise in
As the piston travels down the cylinder, it draws both temperature and pressure. The high pressure
filtered air at atmospheric pressure and ambient generated propels the piston downward turning the
temperature through an air filter and inlet valves into crankshaft and producing work.
the cylinder.
Exhaust
Compression
Once the piston has reached the bottom of its travel,
When the piston reaches the bottom of its stroke the the exhaust valves open and momentum stored
inlet valves close. The piston then starts to rise up the in the flywheel forces the piston up the cylinder
cylinder compressing the air trapped in the cylinder. expelling the exhaust gases.
This causes the temperature and pressure of the air
to rise. Fuel is injected into the cylinder when the In a running engine these four phases are
piston is near to TDC (Top Dead Centre). continuously repeated. Each stroke is half a
revolution of the crankshaft, thus, in one cycle of a
four stroke engine, the crankshaft revolves twice.
15 - 12 9823/1700-1 15 - 12
15 - Engine
00 - Engine
00 - General
Figure 224.
3
2
C
B
1 4
746030
1 Induction 2 Compression stroke

3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation BDC Bottom dead centre
TDC TDC
15 - 13 9823/1700-1 15 - 13
15 - Engine
00 - Engine
00 - General
Figure 225.
717620
1 2 3 4
B C
A A A A
C B B C B
C
1 Induction stroke 2 Compression stroke

3 Power stroke 4 Exhaust stroke
A Camshaft B Camshaft lobe - Inlet valve operation
C Camshaft lobe - Exhaust valve operation
15 - 14 9823/1700-1 15 - 14
15 - Engine
00 - Engine
00 - General
Diagram
Electrical Operation and Schematics signal will be sent between the Transmission ECU
(Electronic Control Unit) and Engine ECU via the
The schematic diagram shows a typical system. CAN (Controller Area Network)bus to tell the Engine
For machine specific schematics, refer to electrical ECU that the transmission is in Neutral.
system- general, refer to (PIL 33-00).
The engine ECU provides power to the engine
The schematic is shown with the ignition switch compartment fusebox to energise the start relay, the
set to position III and the transmission set to N. A fuel pump relay, the starter motor and the fuel pump.
Figure 226.
Charge
D+
W
A
ECU
F
M
D
+VE -VE
3
4
5 H
1 6
2 7 M
E 8
9 K
10
J
C ECU
+VE G -VE
A Alternator B Battery
C Ignition switch D Starter motor
E Primary fuse F RHC/LMS (Loadall Monitoring System) display
G Engine compartment fusebox H Start signal relay
J Fuel pump relay K Fuel pump
L Engine ECU
15 - 15 9823/1700-1 15 - 15
15 - Engine
00 - Engine
00 - General
Fault-Finding
Fault
Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Table 70. Page 15-16
Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Table 71. Page 15-17
Engine - Will Not Crank or Cranks Slowly Table 72. Page 15-17
Engine - Starts Then Stops Table 73. Page 15-18
Engine - Poor Running Table 74. Page 15-18
Engine - Poor Running at Idle Table 75. Page 15-19
Engine - Noise Excessive Table 76. Page 15-19
Engine - Compression Knocks Table 77. Page 15-20
Engine - Reduced Power Output Table 78. Page 15-20
Engine - Will Not Reach Maximum RPM Table 79. Page 15-21
Engine - RPM Surges Table 80. Page 15-22
Engine - Vibration Excessive Table 81. Page 15-22
Engine - Exhaust Smoke Excessive (Black Smoke) Table 82. Page 15-22
Engine - Exhaust Smoke Excessive (White/Blue Smoke) Table 83. Page 15-23
Engine - Will Not Shut Off Table 84. Page 15-23
Lubricating Oil - Consumption Excessive Table 85. Page 15-23
Lubricating Oil - Contaminated Table 86. Page 15-24
Lubricating Oil - Pressure Low Table 87. Page 15-24
Lubricating Oil - Pressure High Table 88. Page 15-24
Table 70. Engine - Will Not Start or Difficult to Start (No Exhaust Smoke)
Cause Remedy
No fuel in supply tank. Check the level in the fuel tank, use sight gauge or
dipstick. Replenish as required.
Ignition or starter electrical system failure. Check the operation of the starter switch. Check the
correct electrical wires for open or short circuits.
Improper starting procedure. Verify proper starting procedure.
Fuel Filter blocked with water or other contamination. Drain fuel/water separator or replace fuel filter.
Defective fuel lift pump (fuel supply inadequate). Check that the lift pump operates and delivers fuel
to the high pressure fuel pump. Check the correct
electrical wires for open or short circuits. Check
fuses.
Fuel is aerated. Check the fuel system for loose connections and
possible air ingress points. Rectify and bleed the fuel
system.
Fuel inlet restriction. Maximum inlet restriction to fuel lift pump must not
exceed 100mm Hg.
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction. Remove as required. Check
the air filter elements for signs of blocking. Replace
as required.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
properly. connected to the top of the fuel tank.
One or more fuel injectors worn or malfunctioning. Check the electrical connections at the injectors.
Electrical sensor fault. Check the electrical connections at the sensors.
Worn or malfunctioning high pressure fuel pump. Do all the necessary fault finding checks before
removal of the high pressure fuel pump.
Injectors Contaminated. Check the injectors. Use the Servicemaster test
procedure in Servicemaster Tools Actuator Test. Test
and replace as required.
15 - 16 9823/1700-1 15 - 16
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Table 71. Engine - Will Not Start or Difficult to Start (Exhaust Smoke)
Cause Remedy
Starting procedure incorrect. Verify proper starting procedure.
Air intake system blocked or restricted. Visually check the air intake for blockage or
obstruction, remove as required. Check the air filter
elements for signs of blocking, replace as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
Fuel is contaminated or incorrect grade diesel fuel Stop the engine. Replace the fuel filters. Operate
used. the engine with a temporary supply of the correct
grade of clean fuel. Monitor the engine performance.
Dirty fuel will cause damage to the high pressure fuel
pump and injectors.
Fuel filter(s) blocked, fuel supply restricted. Check/replace the fuel filter(s). Check fuel lines for
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
Check fuel inlet restriction. Maximum inlet restriction to fuel transfer pump must
not exceed the stated pressure:
Pressure: 0.133 bar ( 1.9 psi)
Inlet and exhaust valve clearances set incorrectly. Set the valve clearances to the recommended
clearances.
Engine compression low in one or more cylinders. Check the engine compression.
Cranking speed too slow. See Also: Table 72. Engine - Will Not Crank or
Cranks Slowly
Table 72. Engine - Will Not Crank or Cranks Slowly

Cause Remedy
Starting electrical circuit connections loose or Clean and tighten connections.
corroded.
Battery charge low. Check battery voltage, charge the battery or
replace as required. Make sure that the alternator is
functioning correctly and charging the battery.
No electrical connection to starter solenoid. Check voltage to solenoid.
Crankshaft rotation restricted. Use special tool 892/01147 (crankshaft turning tool)
to manually turn the engine and check for any severe
rotational resistance.
Solenoid or starter motor fault. Replace starter motor.
Starter motor operating but not cranking. Remove the starter motor and check for broken teeth
on the ring gear or broken starter motor spring.
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Table 73. Engine - Starts Then Stops

Cause Remedy
Engine starting under load. Check for added loading from malfunctioning
accessories or driven units, brakes dragging and
other changes in vehicle loading. Disengage the
hydraulic controls.
blockage or obstruction - remove as required. Check
the air filter elements for signs of blocking - replace
as required.
system.
Fuel lift pump not operating correctly (fuel supply Check that the lift pump is operating and delivering
inadequate). fuel to the injection pump.
Fuel is waxing due to extremely cold weather. Verify by inspecting the fuel filter. Clean the system
and use acclimatised fuel.
pump and injectors.
restriction.
Fuel drain return line blocked, not connected Verify that the fuel return lines are not obstructed and
Table 74. Engine - Poor Running

Cause Remedy
Condition only occurs at idle. For possible poor running at idle faults.
See Also: Table 75. Engine - Poor Running at Idle
Engine is cold, coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
Check the correct electrical wires for open or short
circuits.
Fuel injection lines leaking. Replace defective fuel lines. Do not repair defective
fuel lines. If there is a fuel leak remove and discard
the necessary components and install new ones.
system
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
restriction.
pump and injectors.
Engine is cold - Thermostat fault. Drain Coolant, Remove and replace Thermostat.
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Cause Remedy
Low Power (particularly at high speed) Exhaust back pressure high, Catalyst problem,
Check Servicemaster Diagnostics.
clearances.
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at theECM and sensors.
Camshaft damaged. Inspect camshaft.
Tappets damaged. Inspect tappets.
Table 75. Engine - Poor Running at Idle

Cause Remedy
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
system.
inadequate). fuel to the injection pump.
restriction.
pump and injectors.
clearances.
Table 76. Engine - Noise Excessive

Cause Remedy
Drive belt squeal, insufficient tension or abnormally Check the tensioner and inspect the drive belt for
high loading. loading. deterioration, Make sure water pump,
tensioner pulley, fan, alternator turn freely. Check
for paint/oil or other material on pulleys. Check the
tension of accessory drive belts.
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Air intake or exhaust leaks. See Also: Table 82. Engine - Exhaust Smoke
Excessive (Black Smoke)
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Cause Remedy
pump and injectors.
clearances.
Turbocharger noise. Check turbocharger impeller and turbine wheel for
housing contact.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Worn crank/connecting rod bearings (knocking under Check/replace rod and main bearings.
load).
Excessive camshaft bearing wear. Check bearings (engine overhaul required).
Worn or damaged pistons and/or piston rings. Check piston assemblies (engine overhaul required).
Gear train noise. Visually inspect and measure gear backlash.
Replace gears as required.
Loss of Pilot injection on one or more cylinders. Use servicemaster to disable pilot injections to
identify audibly if they are still present.
Table 77. Engine - Compression Knocks

Cause Remedy
system.
pump and injectors.
Inlet and exhaust valve springs broken. Check and install new valve springs.
Coolant operating temperature incorrect. Check and if necessary replace engine thermostat.
Table 78. Engine - Reduced Power Output

Cause Remedy
Oil level incorrect. Check oil level.
Engine overload. Check for added loading from malfunctioning
hydraulic controls.
Throttle position sensor (TPS) system defective. Check the throttle assembly.
pump and injectors.
Turbocharger boost control pipe leaking or damaged, Check boost control pressure. Inspect and tighten
or wastegate diaphragm ruptured. fittings, repair pipes, replace wastegate assembly.
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Cause Remedy
restriction.
system.
inadequate). fuel to the injection pump. Check fuses.
as required.
Exhaust leak at the manifold or turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Extra injector sealing washer installed under injector. Remove extra injector sealing washer.
clearances.
removal of the high pressure fuel pump
Excessive exhaust back pressure Inspect Catalyst. Check Exhaust pressure readings
using Servicemaster.
Table 79. Engine - Will Not Reach Maximum RPM

Cause Remedy
Tachometer faulty. Verify engine speed with hand tachometer. Repair as
required.
Engine overloaded. Verify high idle speed without load. Investigate
operation to be sure correct gear is being used.
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly.
defective.
system.
inadequate). fuel to the injection pump. Check fuses.
pump and injectors.
restriction.
Turbocharger wastegate actuator diaphragm Repair or replace turbocharger.
ruptured.
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Table 80. Engine - RPM Surges

Cause Remedy
Fuel level low. Check the level in the fuel tank, use sight gauge or
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly.
defective.
Fuel tank cap vent/breather blocked. Inspect and rectify as required. Replace cap if
necessary.
system.
Table 81. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. See Also: Table 75. Engine - Poor Running at Idle
Fan damaged or accessories faulty. Check/replace the vibrating component. Refer to the
machine's service manual for correct installation and
torque figures.
Fan hub faulty. Inspect/replace the fan hub. Refer to the machine's
service manual for correct installation and torque
figures.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
clearances.
Alternator bearing worn or damaged. Check/replace the alternator.
Flywheel housing misaligned. Check/repair flywheel alignment.
Driveline components worn or unbalanced. Check and inspect driveline components such as
propshafts. Refer to the relevant section of the
service manual for correct installation and torque
figures.
Table 82. Engine - Exhaust Smoke Excessive (Black Smoke)

Cause Remedy
Engine being lugged down. Check for added loading from malfunctioning
hydraulic controls.
as required.
Air leak between the turbocharger and the intake Check/repair leaks in the air crossover tube, hoses,
manifold. or manifold cover.
Intercooler faulty. Check for blocked cooler matrix.
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Cause Remedy
Exhaust leak at the manifold or turbocharger Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Turbocharger wastegate faulty. Repair or replace turbocharger.
Turbocharger malfunction. Replace turbocharger.
Smokes under load at all speeds, but mainly low to
mid speed range.
Table 83. Engine - Exhaust Smoke Excessive (White/Blue Smoke)

Cause Remedy
Improper starting procedure. Verify proper starting procedure.
pump and injectors.
Diesel or hydraulic oil in sump. Check oil consistency. If oil contamination is
suspected check equipment such as PTO (Power
Take-Off) pump for hydraulic oil leaks past the seal
into the engine. Drain, flush and fill with clean oil.
Coolant temperature too low (over-cooling) - light Check the thermostat and replace if necessary.
blue or white high speed/light load.
One or more engine injectors worn or malfunctioning. Check the electrical connections at the injectors.
- white/ blue smoke at operating temperature.
Coolant leaking into combustion chamber. Replace Cylinder head gasket if necessary.
Leaking valve stem seals - evident after long idle Replace valve seals.
period and then acceleration.
Piston rings not sealing - evident with persistent blue Check the engine compression.
smoke at all speeds/load.
Table 84. Engine - Will Not Shut Off

Cause Remedy
Stop switch failure. Check the operation of the stop switch. Check the
correct electrical wires for open or short circuits.
Table 85. Lubricating Oil - Consumption Excessive

Cause Remedy
Oil leaks. Inspect the engine for visible signs of leaks. Pay
particular attentions to seals, gaskets oil cooler and
external connections.
Oil level overfull. Check oil level.
Incorrect lubricating oil (specification of viscosity). Make sure the correct lubricating oil is being used.
Refer to (PIL 75-03). Check for reduced viscosity from dilution with fuel.
Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review/reduce the lubricating oil change intervals.
Lubricating oil cooler leak. Check for lubricating oil in the coolant.
Turbocharger leaking lubricating oil to the air intake Inspect the air crossover tube for evidence of
or exhaust. lubricating oil transfer.
Valve guide seals are leaking. Replace valve guide stem seals as required.
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Cause Remedy
Piston rings not sealing - lubricating oil being Check the engine compression
consumed by the engine (blue smoke from exhaust).
Worn cylinder bores - lubricating oil being consumed Check the engine compression.
by the engine (blue smoke from exhaust).
Glazed cylinder bores. De-glaze bores as required.
Table 86. Lubricating Oil - Contaminated

Cause Remedy
Coolant in the lubricating oil, internal engine Check oil cooler O-rings. If necessary change the oil
component leaks. cooler.
Lubricating oil sludge excessive. Change oil and filter. Review oil and filter change
period. If operating in arduous applications, change
more frequently. Make sure the correct lubricating oil
is being used.
Fuel in the lubricating oil, engine operating too cold. Review the operation for excessive idling resulting in
the engine running below normal temperature.
Table 87. Lubricating Oil - Pressure Low

Cause Remedy
Check for reduced viscosity from dilution with fuel.
Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review oil and filter change period. If operating in
arduous applications, change more frequently.
Pressure switch or gauge fault. Verify the pressure switch is functioning correctly.
Lubricating oil filter blocked. Change lubricating oil filter. Review oil and filter
change period. If operating in arduous applications,
change more frequently.
Lubricating oil filter drain down valve not installed. Change lubricating oil filter.
Suction pump pressure relief valve stuck open. Check/replace seal.
Oil pump pressure relief valve stuck open. Replace oil pump assembly.
Lubricating oil pump worn. Replace oil pump assembly.
Table 88. Lubricating Oil - Pressure High

Cause Remedy
Pressure switch or gauge fault. Verify the pressure switch is functioning correctly.
Engine running too cold. Check and if necessary replace the engine
thermostat.
Oil pump pressure relief valve stuck closed. Replace oil pump assembly.
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Drain and Fill Clean

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

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

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

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

2. Make sure that all electrical connectors are
correctly coupled. If connectors are open fit the
correct caps or seal with water proof tape.
3. Cover the alternator with a plastic bag to prevent
water ingress.
4. Seal the engine air intake, exhaust and breather
system.
5. Make sure that the oil filler caps and dipstick are
correctly installed.
6. Use a low pressure water jet and soft bristle
brush to soak off caked mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical and alternator. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine.
9. When the pressure washing is complete move
the machine away from the wash area, or
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00 - Engine
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alternatively, clean away the material washed

from the machine.
10. Before working on specific areas of the engine
use a compressed air jet to dry off any moisture.
When the area is dry use a soft clean brush to
remove any sand or grit particles that remain.
11. When removing components be aware of any
dirt or debris that may be exposed. Cover any
open ports and clean away the deposits before
proceeding
Additional cleaning must be carried out prior to

working on the high pressure fuel system. Refer to:
PIL 18-00-00.
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Check (Pressure)
Special Tools rotating in the engine compartment. Before starting

Description Part No. Qty. this job make sure that you have no loose clothing
Pressure Gauge (0-40 892/00278 1 (cuffs, ties etc) which could get caught in rotating
Bar) parts. When the engine is turning, keep clear of
rotating parts.
Dummy Injector 892/12347 1
1. Make sure that the engine is safe to work on.
Engine Compression Test Refer to (PIL 01-03).
This test is used to diagnose suspected poor 2. Get access to the engine.
compression in one or more of the engine cylinders. 3. Remove all four fuel injectors.
Use a dummy injector to do the test.
Several factors can influence the compression
pressure, the following conditions are assumed: 3.1. Make sure that the injectors are labelled for
correct fitting at a later stage.
• The valve clearances have been set
correctly.Refer to: PIL 15-30-00. 4. Install the dummy injector in one of the vacant
• The correct engine oil has been used, refer to cylinder injector bores.Refer to Figure 227.
(PIL 75-03). Special Tool: Dummy Injector (Qty.: 1)
• The engine oil level is correct.Refer to: PIL
15-21-00. 5. Install a pressure test gauge into the dummy
• The correct type of diesel fuel has been used injector fitting.
and the system correctly primed, refer to (PIL
75-18). 5.1. Note: The dummy injector is drilled and
• The battery and starting circuit is fully charged tapped 1/8-28 BSP x 8.00mm deep to
and in good condition, e.g. good earth paths, accept a standard pressure gauge fitting.
cable connections tight etc. 6. Remove the ESOS (Engine Shut-Off Solenoid)
to prevent accidental start of the engine. refer to
When comparing the figures recorded in the
(PIL 15-86).
following procedures, there should be a minimum
variation of 3.5 bar ( 50.7 psi) between each 7. Operate the starter motor to crank the engine.
cylinder. If the variation is greater than this figure,
then remove the cylinder head and closely inspect 7.1. Do not crank for longer than 20 seconds.
the cylinder bores, pistons and piston rings for signs
7.2. Record the gauge reading.
of wear or damage. Repair as necessary.Refer to:
PIL 15-06-00. 8. Do the step 3 to 6 again for the remaining three
cylinders.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
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00 - Engine
00 - General
Figure 227.
50
0 0
50 50
A Dummy injector
15 - 28 9823/1700-1 15 - 28
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00 - Engine
00 - General
Engine Oil Pressure 5. Start the engine, increase the engine revs to
the rated speed. Record the pressure gauge
Use the following procedures to measure the engine reading, refer to Technical Data (PIL 15-00), for
oil pressure. Refer to Oil Sump for a full explanation the recommended circuit pressure.
of the lubricating oil circuit. Refer to: PIL 15-45-00.
6. Remove the pressure gauge and install the
Several factors can influence the engine oil pressure, pressure switch.
the following conditions are assumed:
High Lubrication Oil Pressure
• The correct engine oil has been used, refer to
Consumable Products, Oil (PIL 75-03). High oil pressure will be evident when starting in
• The engine oil level is correct.Refer to: PIL cold conditions. Typically the pressure will be 1 –2
15-21-00. bar ( 14.5 –29.0 psi) and higher in cold operation,
the pressure should drop when the engine reaches
1. Make sure that the engine is safe to work on. If normal operating temperature.
the engine has been running, let it cool before
you start the service work. If the pressure remains high when operating
temperature is achieved, check the oil level, if this is
2. Get access to the engine. correct, suspect the oil pump relief valve is at fault.
3. Disconnect the electrical connector to the oil
pressure switch, and remove the switch from the
Low Lubrication Oil Pressure
oil cooler housing. Several factors can be the cause of low lubricating
4. Install a suitable test gauge into the vacant oil pressure:
pressure switch port (M10 x 1.5mm thread).
Make sure that the gauge has a sealing washer • Low oil level - typically evident as a loss of
as shown. pressure when operating on uneven ground or
on a gradient.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) • Blocked oil filter - a blocked filter will show as a
gradual loss of pressure.
Figure 228. • Blocked suction strainer (pick-up pipe) -
typically evident as low pressure on start up,
if the blockage frees itself in the sump, the
pressure will pick up to normal.
• Coolant in the oil - coolant in the lubricating oil
will show as a milky discolouration of the oil and
an increase in oil level. Check for damaged core
plugs, lubricating oil cooler, cylinder head and/
or gasket.
• Fuel in the oil - fuel in the oil will result in thin'
black lubricating oil, the oil will also have a
diesel fuel smell. Check the fuel injection pump
(FIP) shaft seal, piston ring wear, lift pump
diaphragm damage or injector leakage if fuel is
A evident in the oil.
A Oil pressure switch

B Sealing washer
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Remove and Install
Special Tools to manually lift heavy components on your own.

Description Part No. Qty. Always use lifting equipment, or obtain the help of
Lifting Brackets 892/01160 1 an assistant. Inspect the lifting brackets for signs
of damage. The brackets must be correctly torqued
Lifting Equipment to the crankcase. Make sure the lifting equipment
does not damage any of the engine dressing and the
You can be injured if you use incorrect or faulty lifting rocker cover.
be lifted then choose lifting equipment that is strong Component Identification
equipment is in good condition and complies with all The following component identification is for a typical
local regulations. engine installation. There will be some component
differences depending on the machine variant.
The lifting equipment used must be an approved
Before attempting to remove the engine ensure that
type and capable of lifting the engine safely. The
all the necessary components have either been
recommended lifting equipment is shown. Use a
removed, or safely disconnected from the engine.
spreader bar when lifting the engine. Never attempt
Figure 229.
14 25 22 15
6
7
8
10 23
17
16
18
21
24
12 19
11
20
6 Engine mounting bolts 7 Lifting bracket- front

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

16 Electrical sensor- engine oil level 17 Electrical connections- starter motor
18 Lifting bracket- rear 19 Lifting bracket fixing bolts
20 Fixing bolts- gearbox to engine 21 Electrical connector- engine harness
22 Top hose 23 Bottom hose
24 Air inlet hose 25 Exhaust pipe
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15 - Engine
00 - Engine
00 - General
Before Removal 16. Uncouple the electrical harness at the ECM

machine side connector. Important: Do not touch
1. Make sure that the engine is safe to work on. If the connector pins on theECM or harness
the engine has been running, let it cool before connectors. Cover the connectors to prevent
you start the service work. contamination.
2. Position the machine on firm level ground. Make 17. Ensure that all relevant harnesses and hoses are
the machine safe, refer to (PIL 01-03). unclipped from the engine and tied out of the way.
3. Get access to the engine. 18. Disconnect and plug the hoses at the hydraulic
pump.
Remove
19. Disconnect the wiring to the hydraulic pump.
1. Disconnect and remove the battery, refer to (PIL
20. Remove the gearbox to engine retaining bolts,
33-03).
pull the transmission and converter clear of
2. Drain the engine oil. the engine, make sure that the converter stays
mounted on the gearbox shaft.
21. Attach slings to the engine lifting eyes.
3. Drain the engine coolant, remove the cooling
pack refer to (PIL 21-03). Special Tool: Lifting Brackets (Qty.: 1)
4. Discharge the hydraulic pressure, refer to (PIL 22. Take the weight of the engine on the hoist and
30-00). remove the engine mounting bolts.
5. Drain the hydraulic tank. Refer to (PIL 30-03). 23. Withdraw the engine in a level attitude until the
hydraulic pump is clear of the chassis. Raise the
6. Disconnect and plug the hydraulic suction and engine to lift it clear of the machine.
delivery lines at the transmission pump and
gear pump. Label the hoses to ensure correct 24. Lower the engine into a suitable stand that is
reassembly. capable of supporting the weight of the engine.
7. Disconnect and plug the hydraulic cooler hoses.

Label the hoses to ensure correct reassembly
8. Disconnect the exhaust system.
9. Label the cab heater hoses at the engine block
connectors. Release the hose clips and remove
the hoses.
10. Disconnect the wiring connections from the
starter motor.
alternator.
engine sensors and actuators, refer to (PIL
15-84).
13. Disconnect the electrical connector at the oil level
sensor (if installed).
14. Disconnect the fuel supply line at the fuel lift
pump and the spill line at the fuel injection pump.
Cap all hoses and ports to prevent ingress of dirt.
15. Disconnect the electrical harness at the engine
harness.
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Figure 230. Table 89. Torque Values

Item Nm
B A 47
A A
A Lifting bracket mounting bolts

B Lifting equipment
Install
steps.
2. Important: It is vitally important that the torque
converter is installed at the gearbox and engine
flywheel correctly. Failure to locate the converter
correctly will result in damage to the gearbox oil
pump on engine start up.
3. Fill the cooling system with the correct mix of
coolant fluid.
4. Fill and Check the hydraulic fluid level.
5. Fill and Check the engine oil levels.
6. On completion, check the hydraulic and cooling
system for leakage and levels.
7. Check the function of all hydraulic services.
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00 - Engine
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Store and Recommission 2.6. Coat any exposed bare metal with a
suitable product.
Engines should be stored in the original shipping 2.7. Electrical connectors and components
packaging. Damaged or disturbed packaging should should be coated with a protective spray if
be made weatherproof immediately. exposed.
2.8. Cover in weatherproof packaging.
If an engine is shipped with oil, it should be stored in
the correct (upright) position. 2.9. Place in storage, under cover on level
ground or shelving.
If an engine is shipped dry of oil, after 6 months it 2.10. Record details of work as required.
should be filled with oil to the correct level and re-
inhibited, refer to hot test description. 2.11. Do not expose to extremes of temperature
or humidity.
All floor stock engines should be stored under cover Notice: Do not operate the starter motor for more
in dry conditions and not subjected to extreme than 20 s at one time. Let the starter motor cool for
variations in temperature or humidity. at least 2 min.
If an engine is to be placed into storage, all external
signs of surface coating damage or corrosion should Table 90. Oil Pressure Switch Set Points
be cleaned and re-coated. Electrical connectors and
components should be coated with a protective Oil pressure switch > 0.6 bar ( 8.7 psi)
spray. closed
Oil pressure switch open < 0.6 bar ( 8.7 psi)
Capping Engine Openings
OEM Commissioning Check on Engine
All openings on the engine must be suitably capped Installation After More Than 12 Months
to prevent ingress of water and contamination by
foreign particles. 1. Flush the coolant system with proprietary
flushing solution.
12 Month Revalidation Procedure
2. Refill the coolant system with 50/50 mix of long
1. Pre-inspection: term antifreeze mixture.
1.1. Inspect packaging for signs of damage. 3. Hot test engine according to the hot test profile.
Refer to Table 91.
1.2. Inspect the caps for signs of damage.
1.3. Inspect openings for signs of water or dirt 4. Drain engine oil and replace engine oil filter.
ingress. 5. Refill with the correct oil and inhibit the cooling
1.4. Inspect the engine for signs of external system using the correct product.
corrosion.
6. Record details of work as required.
1.5. Inspect the engine for signs of fluid leaks.
Hot Test Description
2. From storage:
WARNING When using cleaning agents, solvents
2.1. Remove the air intake caps. or other chemicals, you must adhere to
2.2. Make sure the engine oil level is correct. the manufacturer's instructions and safety
precautions.
2.3. Using a suitable power supply at the correct
voltage, crank the engine over.
All engines despatched from JCB will have been
2.4. During cranking, check that the oil pressure subjected to a hot test (checking items such as oil
switch opens using a multimeter. The switch pressure, engines speeds, torque values etc.) and
is closed when there is no or low oil therefore the interior surfaces will have been coated
pressure and opens when oil pressure with engine oil.
reaches a set point. After three separate 20
second cranking periods, If the oil pressure All coolant galleries are coated with CRODAFLUID
switch does not open (indicating no, or PA75 corrosion inhibitor.
low oil pressure), contact your JCB engine
dealer. Stored engines will require re-inhibiting every 12
months, this will include hot testing the engine using
2.5. Recap all engine openings. a dynamometer. The hot test profile is:
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Table 91. Hot Test Profile

Stage Mode Speed Torque Time
(rpm) (Nm) (secs)
1 Speed/ 830 0 50
Torque
2 Speed/ 1300 50 60
Torque
3 Speed/ 2500 0 60
Torque
4 Speed/ 1300 0 25
Torque
5 Speed/ 800 0 35
Torque
15 - 35 9823/1700-1 15 - 35
15 - Engine
03 - Crankcase
03 - Crankcase
Contents Page No.
15-03-00 General ........................................................................................................................... 15-37
15 - 36 9823/1700-1 15 - 36
15 - Engine
03 - Crankcase
00 - General
Introduction .................................................... 15-37 The crankcase is the housing for the crankshaft.
Technical Data ............................................... 15-38 The enclosure forms the largest cavity in the engine
and is located below the cylinders. It is integral with
the cylinder bank and forms an engine block. It has
an opening in the bottom to which an oil sump is
attached with a gasket and bolted joint.
The crankcase protects the crankshaft and

connecting rods from foreign objects it also keeps
the engine oil contained and allows the oil to be
pressurised and also provide the rigid structure with
which to join the engine to the transmission.
Figure 231.
A
A Crankcase
B Crankshaft
15 - 37 9823/1700-1 15 - 37
15 - Engine
03 - Crankcase
00 - General
Technical Data
Table 92. Crankcase and Bedplate Data

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

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

Diameter of second oversize bore 104 –104.02 mm
Main bearing bore (without bear-
ings)
Numbers 1 to 4 92 –92.02 mm 92 –92.02 mm
Number 5 105 –105.02 mm 105 –105.02 mm
Main bearing bore (with bearings)
Numbers 1 to 4 88.047 –88.09 mm 88.047 –88.09 mm
Number 5 100.047 –100.09 mm 100.047 –100.09 mm
Camshaft bore
Numbers 1 to 4 60.04 –60.07 mm 60.04 –60.07 mm
Number 5 (bush) 60.29 –60.32 mm 60.29 –60.32 mm
Permissible wave profile wt < 10 m (2.5 distance) wt < 10 m (2.5 distance)
(1) Nominal diameter to be measured 63mm below the cylinder head face.
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures
may result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
(3) The crankcase to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
15 - 38 9823/1700-1 15 - 38
15 - Engine
06 - Cylinder Head
06 - Cylinder Head
Contents Page No.
15-06-00 General ........................................................................................................................... 15-41
15 - 39 9823/1700-1 15 - 39
Notes:
15 - 40 9823/1700-1 15 - 40
15 - Engine
06 - Cylinder Head
00 - General
Introduction .................................................... 15-41 The cylinder head is located above the cylinders
Technical Data ............................................... 15-42 on top of the crankcase. It closes in the top of the
Component Identification ............................... 15-43 cylinder, forming the combustion chamber. This joint
Remove and Install ....................................... 15-44 is sealed by a cylinder head gasket.
The cylinder head also provides the space for the

passages that feed air and fuel to the cylinder and
allow the exhaust to escape. The cylinder head is
also used to mount the valves and fuel injectors.
15 - 41 9823/1700-1 15 - 41
15 - Engine
06 - Cylinder Head
00 - General
Technical Data
Table 93. Cylinder Head Data

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

- Side to side 0.03 mm
Valve recess depth
- Inlet 0.85 mm
- Exhaust 0.85 mm
Valve seat angle
- Inlet 120 (inclusive)
- Exhaust 90 (inclusive)
Cylinder head bolts tourque
(2)
- First stage 40
- Second stage 75
- Third stage Repeat 75
- Fourth stage Torque angle + 90
- Final stage Torque angle + 180
Surface finish for cylinder head joint Rz < 15 Rmax < 20
Permissible wave profile wt < 10 m 2.5 distance
(1) The block to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct remove, install, disassemble and assemble procedure may
result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
15 - 42 9823/1700-1 15 - 42
15 - Engine
06 - Cylinder Head
00 - General
Figure 232.
C
A Cylinder head
B Cylinder head gasket
C Cylinder head bolts
15 - 43 9823/1700-1 15 - 43
15 - Engine
06 - Cylinder Head
00 - General
Remove and Install
Special Tools 2. Make sure that the engine is safe to work on. If
Description Part No. Qty. the engine has been running, let it cool before
Torque Wrench 993/70111 1 you start the service work.
(10-100Nm) 3. Get access to the engine.
Consumables 4. Remove the thermostat, refer to (PIL 21-12).
Cleaner/Degreaser 4104/1557 0.4 L 5. Remove the fuel pipes, refer to (PIL 18-96).
- General purpose 6. Remove the rocker cover, refer to (PIL 15-42).
solvent based parts
cleaner 7. Remove the fuel injectors, refer to (PIL 18-18).
Before Removal 8. Remove the rocker assembly, refer to (PIL

15-42).
1. This procedure requires service parts. Make sure
9. Remove the exhaust manifold, refer to (PIL
you have obtained the correct parts before you
18-24).
start, refer to Parts Catalogue.
10. Remove the inlet manifold, refer to (PIL 18-24).
15 - 44 9823/1700-1 15 - 44
15 - Engine
06 - Cylinder Head
00 - General
Figure 233.
21
22
20
19
18 14 10 6 2 3 7 11
15
16
17 13 9 5 1 4 8 12
0° +90° +180°
1-18 Cylinder head fixing bolts (x18) 19 Cylinder head

20 Crankcase 21 Location dowels (x2)
22 Cylinder head gasket
15 - 45 9823/1700-1 15 - 45
15 - Engine
06 - Cylinder Head
00 - General
Remove Special Tool: Torque Wrench (10-100Nm)

(Qty.: 1)
1. Progressively remove the cylinder head bolts in
4.2. Then, further tighten the bolts, starting with
reverse order, starting at bolt 18. Note that the
the middle pair and working outwards (in
bolts MUST NOT be re-used. Discard the bolts.
sequence 1- 18) to the 2nd stage pre-
2. Carefully lift the cylinder head from the torque.
crankcase. If necessary use a soft face hammer. 4.3. Then, re-tighten the bolts, starting with
DO NOT use a lever to separate the cylinder the middle pair and working outwards (in
head from the crankcase. Discard the head sequence 1-18) to the 3rd stage pre-torque.
gasket.
4.4. Use the angle gauge to angle tighten the
3. Using a suitable cleaning agent, carefully remove bolts, starting with the middle pair and
all traces of the head gasket material from the working outwards (in sequence 1-18) to the
cylinder head and crankcase mating faces. 4th stage pre-torque. As a visual check,
Consumable: Cleaner/Degreaser - General matchmark the bolts to the cylinder head
purpose solvent based parts cleaner before you start. When the bolts have
been angle tightened, the matchmarks will
4. Check the cylinder head and crankcase mating appear as shown at Y.
faces for signs of damage and distortion, refer to 4.5. Finally, angle tighten the bolts, starting with
Technical Data (PIL 15-06). the middle pair and working outwards (in
sequence 1- 18) for the final stage torque.
Before Assembly
Table 94.
1. Obtain the correct new cylinder head bolts. Note
that the original bolts MUST NOT be re-used. Description Torque Value
Cylinder head to
2. Obtain the correct replacement head gasket. crankcase bolts 1-18
Note the number of identification holes as shown - first stage torque 40 N·m
at X.
- second stage torque 75 N·m
3. Make sure that all items are clean and free from - third stage torque 75 N·m
damage and corrosion. - fourth stage torque 90 °
- final stage torque 180 °
Assemble
The cylinder head bolts are tightened using a torque
and angle method, refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
1. Replacement is the reversal of the removal

procedure.
2. Make sure that the location dowels are correctly
installed into the crankcase. Use a dowel punch
to install the dowels as required.
3. Position a new head gasket on to the crankcase
mating face. Make sure that the gasket is
installed the correct way around and correctly
located over the dowels.
4. Lower the cylinder head on to the crankcase.
Make sure that the cylinder head is correctly
located on the dowels. Install new cylinder head
bolts. Tighten the bolts in five stages, use the
torque and angle method, refer to Fasteners and
Fixings, General, Introduction (PIL 72-00).
4.1. Tighten the bolts, starting with the middle
pair and working outwards (in sequence
1-18) to the 1st stage pre-torque.
15 - 46 9823/1700-1 15 - 46
15 - Engine
09 - Bedplate
09 - Bedplate
Contents Page No.
15-09-00 General ........................................................................................................................... 15-49
15 - 47 9823/1700-1 15 - 47
Notes:
15 - 48 9823/1700-1 15 - 48
15 - Engine
09 - Bedplate
00 - General
Introduction .................................................... 15-49 The bedplate acts as the main strength component
Remove and Install ....................................... 15-50 of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 234.
1
1 Bedplate
2 Crankcase
15 - 49 9823/1700-1 15 - 49
15 - Engine
09 - Bedplate
00 - General
Remove and Install
Special Tools 10. Remove the rocker assembly including the push
Description Part No. Qty. rods, refer to (PIL 15-42).
Template for Sealant 892/12356 1 11. It is not necessary to remove the cylinder head
Bedplate to Crankcase assembly to remove the crankshaft. If however
(4 Cyl) the cylinder head needs to be removed for other
Torque Wrench 993/70111 1 reasons (for piston and connecting rod removal
(10-100Nm) for example) remove it now, refer to (PIL 15-06).
Consumables 12. Remove the fuel injection pump, refer to (PIL
Description Part No. Size 18-18).
Cleaner/Degreaser 4104/1557 0.4 L 13. Remove the starter motor, refer to (PIL 15-75).
- General purpose
solvent based parts 14. Remove the high duty PTO (Power Take-Off)
cleaner device (if installed).
CAUTION This component is heavy. It must only 15. Position the engine upside down in a suitable jig
be removed or handled using a suitable lifting or fixture, supported at the front of the cylinder
method and device. block.
16. Remove the flywheel, refer to (PIL 15-54).
Before Removal
17. Remove the flywheel housing, refer to (PIL
1. This procedure requires service parts. Make 15-54).
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue. 18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
2. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before 19. Remove the oil pump, refer to (PIL 15-60).
you start the service work.
20. Remove the high duty PTO idler drive gear (if
3. Remove the engine, refer to (PIL 15-00). installed), refer to (PIL 15-51).
4. Remove the drive belt, refer to (PIL 15-18). 21. Remove the crankshaft drive gear, refer to (PIL
15-51).
5. Remove the crankshaft pulley, refer to (PIL
15-12). 22. Remove the camshaft, refer to (PIL 15-15).
6. Remove the oil sump, refer to (PIL 15-45). 23. Remove the rear timing case, refer to (PIL
15-51).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
8. Remove the rocker cover, refer to (PIL 15-42). caps, refer to (PIL 15-12).
9. Remove the fuel injectors, refer to (PIL 18-18).
15 - 50 9823/1700-1 15 - 50
15 - Engine
09 - Bedplate
00 - General
Figure 235.
4 1 5
11
8 9
7 10
3 P3 2 6
X
12 18
18
18
18
18
13
18
1-10 Main bearing bolts (x10) 11 Bedplate peripheral bolts (x16)

18 Upper bearing shell (x5) P3 O-ring (if installed)
T1 Lifting bolts (obtain locally)
15 - 51 9823/1700-1 15 - 51
15 - Engine
09 - Bedplate
00 - General
Remove suitable lifting equipment (if the bedplate is lifted

manually, two people will be required). DO NOT
1. Remove the bedplate peripheral bolts. use a lever to separate the bedplate.
2. Progressively remove the main bearing bolts in 4. Remove and discard the O-ring.
reverse order starting at bolt 10. The bolts MUST
NOT be re-used. Discard the bolts. 5. Carefully remove the upper bearing shells from
the bedplate, remove the bedplate.
3. Install the four temporary lifting bolts. Carefully
separate the bedplate from the crankcase. Use
Figure 236.
Y P2 Y A (T5) T4
T4
P2
P3
B (T5)
Y Y P2 T6
18
18 18
X
18
T6 18
4 1 5 T6
11
8 9
W
18
12
T6
7 10
3 2 6
13
1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)

18 Lower bearing shells (x5) A Left side template
B Right side template T3 Angle Gauge (obtain locally)
15 - 52 9823/1700-1 15 - 52
15 - Engine
09 - Bedplate
00 - General
T4 Guide pins (x2 obtain locally) T5 Sealant template

T6 Lifting bolts (x4 obtain locally) V Sealant template portion for removal
W Bearing tab X Rear main bearing
Y Bearing location tab P2 Anaerobic sealant
P3 O-ring
15 - 53 9823/1700-1 15 - 53
15 - Engine
09 - Bedplate
00 - General
Before Installation as a guide apply beads of sealant P2 around the

crankcase/bedplate mating face as shown to the
1. Clean off all traces of the old sealant compound dimension specified.
from the crankcase and bedplate mating faces.
2. Use a suitable degreasing agent to carefully
9. Remove the four fixing bolts at positions Y.
clean the main bearing saddles in the bedplate
Remove the templates A and B, make sure
and crankcase. Take care not to block the oil
you do not smudge the sealant. Discard the
ways or the piston cooling jets.
templates.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner 10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
Important: Anaerobic sealant will not start to cure beads as shown at X.
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 11. Make sure that the location guide pins T4 are in
put together) it will immediately start to harden. Make position in the crankcase. Assemble the bedplate
sure that all the necessary tools, bolts etc. are readily to the crankcase use the alignment guide pins.
available prior to assembling the components. The 12. Note: The bedplate is heavy. Two people will
parts must be installed and tightened to the correct be required to lift and rotate the bedplate safely
torque value within 5 minutes (with a maximum on to the crankcase. Install new main bearing
permissible time of 15 minutes). bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
Important: BEFORE installing the bedplate: DO NOT
outwards (in sequence 1-10) to the 1st stage pre-
rotate the crankshaft. Make sure that the upper main
torque.
bearing shells are flush with the bottom face of the
crankcase. Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Install 13. Install the bedplate peripheral bolts. Tighten the
1. The installation procedure is the opposite of the bolts to the correct torque value.
14. After installation and tightening the bedplate
steps.
peripheral bolts, further tighten the main bearing
2. Make sure that all items are clean and free from bolts in pairs, starting in the centre and working
damage and corrosion. outwards (in sequence 1-10) to the 2nd stage
pre-torque.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown. 15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
4. Install the four lifting bolts T6 to the bedplate as (in sequence 1-10) for the final stage torque. Use
shown. the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
5. Install a new O-ring at the bedplate.
Important: If the parts have not been tightened to the
6. Use a suitable degreasing agent to clean both correct torque value within the maximum 15 minute
sides of the lower bearing shells. Assemble the time period, then the parts must be separated,
lower bearing shells into the bedplate. Lubricate thoroughly cleaned and fresh sealant applied.
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
After Installation
Consumable: Cleaner/Degreaser - General 1. Check that the crankshaft can be freely rotated
purpose solvent based parts cleaner by hand. Remove the bedplate lifting bolts T6.
7. Note: The sealant template T5 is used on 2. Carry out the procedures listed, Before removal
the crankcase, NOT the bedplate. The sealant in reverse order.
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Table 95. Torque Table
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1) Item Torque Value
1-10 (1st Stage) 50 N·m
8. Locate the holes in the templates A and B using 1-10 (2nd Stage) 115 N·m
four fixing bolts at positions Y. Use the templates
15 - 54 9823/1700-1 15 - 54
15 - Engine
09 - Bedplate
00 - General
Item Torque Value

1-10 (Final Stage) 180 °
11 24 N·m
15 - 55 9823/1700-1 15 - 55
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-00 General ........................................................................................................................... 15-57

15-12-03 Main Bearing .................................................................................................................. 15-66
15-12-06 Front Oil Seal ................................................................................................................. 15-68
15-12-09 Rear Oil Seal ................................................................................................................. 15-71
15-12-12 Pulley .............................................................................................................................. 15-75
15 - 56 9823/1700-1 15 - 56
15 - Engine
12 - Crankshaft
00 - General
Introduction .................................................... 15-57 The crankshaft is housed inside the crankcase. It is
Technical Data ............................................... 15-58 connected to the piston via a connecting rod, they
Component Identification ............................... 15-59 form a simple mechanism that converts reciprocating
Operation ....................................................... 15-60 motion into rotating motion. Refer to: PIL 15-00-00.
Check (Condition) .......................................... 15-61
15 - 57 9823/1700-1 15 - 57
15 - Engine
12 - Crankshaft
00 - General
Technical Data
Table 96.
Main bearing journal diameter (x4)
- min 87.98 mm
- max 88 mm
Main rear bearing journal diameter (x1)
- min 99.98 mm
- max 100 mm
Connecting rod bearing journal diameter
- min 72.98 mm
- max 73 mm
Maximum wear and ovality on journals
(1)
Crankshaft induction hardness 55 HRc min on surface

Thrust washer width
- min 2.44 mm
- max 2.5 mm
Crankshaft end float
- min 0.05 mm
- max 0.28 mm
(1) No visible damage/wear or marks
15 - 58 9823/1700-1 15 - 58
15 - Engine
12 - Crankshaft
00 - General
Figure 237.
A
A Crankcase
B Crankshaft
15 - 59 9823/1700-1 15 - 59
15 - Engine
12 - Crankshaft
00 - General
Operation
Lubrication transfer to cross drillings in the crankshaft to feed

each of the big end bearings. Crankshaft gear is
Oil is fed from the main gallery via five drillings, one 'splash' lubricated. Front and rear crankshaft oil seals
to each of the main bearings. A groove around the prevent oil leakage from, and dirt ingress to, the
diameter of the upper main bearing shell allows oil engine.
Figure 238.
1 Main gallery 2 Drillings (x5)

3 Main bearings 4 Big end bearings
5 Cross drillings 6 Crankshaft gear
7 Crankshaft oil seal 8 Crankshaft oil seal
15 - 60 9823/1700-1 15 - 60
15 - Engine
12 - Crankshaft
00 - General
Check (Condition) Figure 241.
1. Check the main bearing surfaces for damage and

excessive wear.
Figure 239.
C
D
A
C J-jets
D Fixing screws
A Main bearing shells

2. Measure the crankshaft diameters to confirm
they are within service limits, refer to Technical
Data (PIL 15-12).
Figure 240.
B Crankshaft
3. Check that the oil-way cross drillings in the
crankshaft are clear and free from debris.
Blocked or restricted oil-ways will cause oil
starvation at the big end bearings.
4. Check that the piston cooling J-jets are clear. If
the J-jets cannot be cleared remove the fixing
screws. Remove theJ-jets and discard them.
5. Install new J-jets.
15 - 61 9823/1700-1 15 - 61
15 - Engine
12 - Crankshaft
00 - General
Remove and Install
Consumables reasons (for piston and connecting rod removal

Description Part No. Size for example) remove it now, refer to (PIL 15-06).
Cleaner/Degreaser 4104/1557 0.4 L 12. Remove the fuel injection pump, refer to (PIL
- General purpose 18-18).
solvent based parts
cleaner 13. Remove the starter motor, refer to (PIL 15-75).
CAUTION This component is heavy. It must only 14. Remove the high duty PTO device (if installed).
method and device. 15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
Before Removal
16. Remove the flywheel, refer to (PIL 15-54).
1. This procedure requires service parts. Make
sure you have obtained the correct service parts 17. Remove the flywheel housing, refer to (PIL
before you start, refer to Parts Catalogue. 15-54).
2. Make sure that the engine is safe to work on. If 18. Remove the fuel injection pump drive gear, refer
the engine has been running, let it cool before to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
3. Remove the engine, refer to (PIL 15-00).
20. Remove the high duty PTO idler drive gear (if
4. Remove the drive belt, refer to (PIL 15-18). installed), refer to (PIL 15-51).
5. Remove the crankshaft pulley, refer to (PIL 21. Remove the crankshaft drive gear, refer to (PIL
15-12). 15-51).
6. Remove the oil sump, refer to (PIL 15-45). 22. Remove the camshaft, refer to (PIL 15-15).
7. Disconnect and remove the fuel pipes from the 23. Remove the rear timing case, refer to (PIL
injectors, refer to (PIL 18-96). 15-51).
8. Remove the rocker cover, refer to (PIL 15-42). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
9. Remove the fuel injectors, refer to (PIL 18-18). caps, refer to (PIL 15-12).
10. Remove the rocker assembly including the push 25. Remove the bedplate, refer to (PIL 15-09).
rods, refer to (PIL 15-42).
Remove
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however 1. Remove the thrust washers between the
the cylinder head needs to be removed for other crankshaft and crankcase rear main bearing.
15 - 62 9823/1700-1 15 - 62
15 - Engine
12 - Crankshaft
00 - General
Figure 242.
A
A
A Thrust Washers B Crankshaft

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

that they are installed in the correct positions
during assembly. 1. Clean off all traces of the old sealant compound
from the crankcase and bedplate mating faces.
3. Use suitable lifting equipment to carefully lift the
crankshaft from the crankcase (if the crankshaft 2. Use a suitable degreasing agent to carefully
is lifted manually, two people will be required). clean the main bearing saddles in the bedplate
and crankcase. Take care not to block the oil
4. Carefully lift out the bearing shells. ways or the piston cooling jets.
Figure 243. Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
D
Important: Cleanliness is of the utmost importance.
Blocked oil-ways or oil jets will cause engine failure.
Before you install the crankshaft make sure that ALL
oil-ways and jets are clear and free from debris.
Install
steps.
2. Make sure that all items are clean and free from
3. If removed or a new crankcase is being installed
D Main bearing shells then install cooling J jets as follows:
5. It is recommended that the bearing shells are

replaced. If however they are to be used again,
put label on the shells to make sure that they
are installed in their original positions during
assembly.
6. Inspect the crankshaft and main bearings etc.
for damage and excessive wear. Refer to Check
Condition (PIL 15-12).
15 - 63 9823/1700-1 15 - 63
15 - Engine
12 - Crankshaft
00 - General

G
D
E
F
D Main bearing shells

G Bearing location tab
E J jets (x4)
F Fixing screws 4.1. Use a suitable degreasing agent to make
sure that the surface of the upper bearing
3.1. Insert the cooling jets into the crankcase. shells are clean.
3.2. Note: There are different types of cooling Consumable: Cleaner/Degreaser - General
jets installed depending on the engine purpose solvent based parts cleaner
application. The jets are colour coded. 4.2. Assemble the bearing shells into the
3.3. Be sure to install the correct jets. Refer to crankcase bearing saddles. Make sure that
the relevant parts catalogue for the correct the location tab engages into the slot as
cooling jet identification. shown.
3.4. Tighten the retaining screws to the correct 4.3. Important: Make sure that the oil-way holes
torque value. in the bearing saddles align with the holes
in the bearing shell. If the holes are even
4. Install the upper bearing shells as follows: partially misaligned the piston cooling oil jet
will be restricted, causing the engine to fail.
4.4. Lubricate the upper bearing shells with
clean engine oil.
5. Use suitable lifting equipment (if the crankshaft
is lifted manually, two people will be required), to
carefully lower the crankshaft into the crankcase.
DO NOT rotate the crankshaft, the bearing shells
can become dislodged, refer to step 4.
6. Install the thrust washers as follows:
15 - 64 9823/1700-1 15 - 64
15 - Engine
12 - Crankshaft
00 - General
Figure 246.
B H
A
A
A Thrust washers B Crankshaft

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

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

Item Nm
F 24
15 - 65 9823/1700-1 15 - 65
15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing Introduction

Introduction .................................................... 15-66 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-67 bearings on which the crankshaft rotates.
The bearings hold the crankshaft in place and
prevent the forces created by the piston and
transmitted to the crankshaft by the connecting rods
from dislodging the crankshaft, instead forcing the
crank to convert the reciprocating movement into
rotation.
Figure 247.
A Main bearing
B Crankshaft
15 - 66 9823/1700-1 15 - 66
15 - Engine
12 - Crankshaft
03 - Main Bearing
Check (Condition) Remove and Install

1. Check the bearing shell surfaces for signs of
damage and excessive wear.
2. Measure the crank pin diameters to confirm they
are within service limits.
3. Renew any parts that are worn or not within the
specified tolerances.
15 - 67 9823/1700-1 15 - 67
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Remove and Install
Special Tools Figure 248.

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

5. Remove the crankshaft pulley, refer to (PIL
15-12-12).
A Crankshaft oil seal
Remove B Crankcase
C Crankshaft hub
1. Use a suitable lever behind the lip of the
seal, carefully prise out the oil seal from the
counterbore in the crankcase. Take care not Install
to scratch or damage the counterbore or the 1. Make sure that the counterbore and the
crankshaft hub. Damaged or dirty sealing faces crankshaft hub are clean and free from damage
will cause the oil seal to fail. and corrosion. Use a suitable degreasing agent
to clean all traces of oil and grease from the
counterbore. Important: The oil seal has a special
coating and MUST be installed dry without
lubricant.
2. Dismantle the seal installation tool. Bolt the
centre body to the crankshaft hub, using the
bolts. Refer to Figure 249.
Special Tool: Crankshaft Front Oil Seal
Installation Tool (Qty.: 1)
3. Install the oil seal on to the centre body. Make
sure that the seal is installed the correct way
around. Assemble the outer sleeve on to the
centre body and install the screw. Refer to Figure
249.
15 - 68 9823/1700-1 15 - 68
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 249.
F D A
G G
E
A Crankshaft oil seal B Crankcase

C Crankshaft hub D Seal installation tool
E Fixing bolts (x3) F Centre body
G Outer sleeve H Screw
4. Turn the screw to push the seal squarely into Figure 250.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. B
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore A
within the specified tolerance. Refer to Figure
250. G
Dimension: -0.5 -0/+0.5 mm
C
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
F Centre body
G Outer sleeve
5. Remove the seal installation tool.
15 - 69 9823/1700-1 15 - 69
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
After Installation
1. Install the crankshaft pulley, refer to (PIL
15-12-12).
2. Install the drive belt, refer to (PIL 15-18).
15 - 70 9823/1700-1 15 - 70
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
09 - Rear Oil Seal
Remove and Install
Special Tools Figure 252. 15mm Hub

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

B Flywheel housing
4. Remove the flywheel, refer to (PIL 15-54). C Flywheel hub
E Fixing bolt
Remove
Install (24mm Hub)
1. Use a suitable lever behind the lip of the seal
to carefully prise out the rear oil seal from the 1. Make sure that the counterbore and the flywheel
counterbore in the flywheel housing. Take care hub are clean and free from damage and
not to scratch or damage the counterbore or the corrosion.
flywheel hub. Damaged or dirty sealing faces will
cause the oil seal to fail.
Figure 251. 24mm Hub
C B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
15 - 71 9823/1700-1 15 - 71
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 253.
B
D
A
C
A Crankshaft rear oil seal B Flywheel housing

C Flywheel hub D Oil seal alignment tool
2. To prevent the seal lip rolling over and becoming Special Tool: Crankshaft Rear Oil Seal Alignment
damaged, make sure that you use the oil seal Tool (Qty.: 1)
alignment tool to initially install the oil seal on to
the flywheel hub. Locate the alignment tool over 3. Apply lubricant P80 around the seal outer rubber
the end of the hub, then carefully push the oil seal diameter.
over the alignment tool and on to the crankshaft
diameter. Make sure that the oil seal is installed 4. Dismantle the oil seal installation tool. Bolt the
the correct way around. centre body to the flywheel hub, using the two
flywheel bolts. Assemble the outer sleeve on to
Special Tool: Crankshaft Rear Oil Seal the centre body and install the screw.
Installation Tool (Qty.: 1)
Figure 254.
F
B
E
A C H
H
G
G F

C Outer sleeve E Oil seal installation tool
F Flywheel bolts G Centre body
H Flywheel hub J Screw
5. Turn the screw to push the seal squarely into 6. Remove the oil seal installation tool.
the counterbore until the outer sleeve comes
up against the front edge of the counterbore. Install (15mm Hub)
When correctly installed, the front face of the seal
should be flush with the edge of the counterbore 1. Make sure that the counterbore and the hub are
within the tolerance specified. clean and free from damage.
15 - 72 9823/1700-1 15 - 72
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 255.
B
D
A
C

C Flywheel hub D Oil seal alignment tool
2. Install the new hub on to the crankshaft gear and Special Tool: Crankshaft Rear Oil Seal
install the old hub on the outside of the new hub Installation Tool (Qty.: 1)
to create a double thickness flywheel hub, install Special Tool: Crankshaft Rear Oil Seal Alignment
the fixing bolt as shown at A. Do not touch the Tool (Qty.: 1)
PTFE seal lips of the crankshaft oil seal.
4. Apply the lubricant P80 around the seal outer
3. Make sure that you use the oil seal alignment tool rubber diameter.
to initially install the oil seal on to the flywheel
hub to prevent damage to the seal lip. Locate the 5. Dismantle the oil seal installation tool. Use the
alignment tool over the end of the hub, carefully two flywheel bolts to attach the centre body on to
push the oil seal over the alignment tool as far the flywheel hub. Assemble the outer sleeve on
on to the crankshaft hub as possible. Make sure to the centre body include the extension ring and
that the seal is installed the correct way around. install the screw.
Figure 256.
B F
G
A C1 K C2
H
L
K
J

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

the counterbore so that the screw will not turn.
15 - 73 9823/1700-1 15 - 73
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
7. Remove the oil seal installation tool, remove the

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

Item Nm
E 47
15 - 74 9823/1700-1 15 - 74
15 - Engine
12 - Crankshaft
12 - Pulley
12 - Pulley Install
Remove and Install removal procedure. Additionally do the following
steps.
Special Tools
Description Part No. Qty. 2. Make sure that all items are clean and free from
Torque Wrench 993/70111 1 damage and corrosion.
(10-100Nm)
3. Renew the fixing bolts. Tighten the new bolts in
three stages to the correct torque value.
Before Removal
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1. This procedure requires service parts. Make 1)
before you start, refer to Parts Catalogue. 4. The bolts are tightened using a torque and
angle method. Refer to Fasteners and Fixings,
2. Make sure that the engine is safe to work on. If General, Introduction (PIL 72-00).
you start the service work. Figure 258.
3. Get access to the engine.

4. Remove the drive belt. Refer to (PIL 15-18).
Remove
1. Remove the fixing bolts and withdraw the pulley C
from the crankshaft.
Figure 257.
C Angle gauge (obtain locally)
After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
A
Table 99.
Item Torque Value Torque Angle
(Nm) (Degrees)
2 (1st stage) 30 N·m
2 (2nd stage) 75 N·m
2 (Final stage) 180 °
A
B
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.
15 - 75 9823/1700-1 15 - 75
15 - Engine
15 - Camshaft
15 - Camshaft
Contents Page No.
15-15-00 General ........................................................................................................................... 15-77
15 - 76 9823/1700-1 15 - 76
15 - Engine
15 - Camshaft
00 - General
Introduction .................................................... 15-77 When the engine runs the crankshaft drives the
Technical Data ............................................... 15-78 camshaft via gears. The camshaft opens and closes
Component Identification ............................... 15-79 the inlet and exhaust valves via push rods in time with
Operation ....................................................... 15-80 the four stroke cycle. Refer to: PIL 15-00-00.
Check (Condition) .......................................... 15-81 The relationship between the rotation of the camshaft
Remove and Install ....................................... 15-81 and the rotation of the crankshaft is of critical
importance. Since the valves control the flow of the
air/fuel mixture intake and exhaust gases, they must
be opened and closed at the appropriate time during
the stroke of the piston. For this reason, the camshaft
is connected to the crankshaft directly, via a gear
mechanism.
15 - 77 9823/1700-1 15 - 77
15 - Engine
15 - Camshaft
00 - General
Technical Data
Table 100. Camshaft Data

Camshaft journal diame-
ter
- 4 off 59.99 –59.97 mm
- 1 off 60.25 –60.22 mm
Camshaft lobe wear lim-
its
SA, SB, SC Inlet: 7.23 ± 0.025 mm
Exhaust: 7.269 ± 0.025
mm
SD, SF Inlet: 7.385 –7.435 mm
Inlet: 7.545 –7.595 mm
Camshaft bore diame- 60.32 –60.29 mm
ter
(1)
Camshaft gear
(2)
104 teeth
(1) Bush no longer fitted from January 2008.
(2) The camshaft gear is not available as a separate
item. The gear must be heated on to the camshaft
in the correct timed position. Specialist fixtures are
used during the production process to achieve the
correct timing.
15 - 78 9823/1700-1 15 - 78
15 - Engine
15 - Camshaft
00 - General
Figure 259.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700
1 Camshaft drive gear 2 Crankshaft gear

3 Camshaft 3a Camshaft lobes
4 Tappets 5 Push rods
15 Inlet valves 16 Exhaust valves
15 - 79 9823/1700-1 15 - 79
15 - Engine
15 - Camshaft
00 - General
Operation
As the crankshaft rotates the camshaft also rotates, during the cycle it follows that the camshaft is driven
driven by a gear on the crankshaft. The inlet and at half crankshaft (engine) speed.
exhaust valves are opened by lobes on the camshaft
in time with the cycle. Lubrication
The diagrams show the position of the camshaft at Oil is fed from the main gallery via a drilling to the
each part of the four stroke cycle, refer to Engine- camshaft bearing. A groove around the diameter of
General, Operation. Refer to: PIL 15-00-00. the bearing and connecting the cross drilling ensures
that oil is always fed to the centre drilling. Oil is then
It can be seen that for a complete cycle the camshaft transferred to the remaining camshaft bearings by
revolves once. Since the crankshaft revolves twice further cross drillings in the shaft. The cam lobes and
tappets are 'splash' lubricated.
Figure 260.
1 Main gallery 2 Camshaft bearing

3 Groove 4 Centre drilling
15 - 80 9823/1700-1 15 - 80
15 - Engine
15 - Camshaft
00 - General

1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
Before Removal
1. Drain the oil from the engine.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting. 2. Disconnect and remove the fuel pipes from the
injectors. Refer to (PIL 18-96).
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the 3. Remove the rocker cover. Refer to (PIL 15-42).
dimensions are within service limits.
4. Remove the fuel injection pump. Refer to (PIL
4. Inspect the cam bearing surfaces inside the 18-18).
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within 5. Remove the rocker assembly and push rods.
service limits. Refer to (PIL 15-42).
5. Inspect the bearing surfaces of the tappets for 6. Remove the starter motor. Refer to (PIL 15-75).
signs of excessive wear or damage. Check that
the dimensions are within service limits. 7. Remove the oil sump. Refer to (PIL 15-45).
6. Inspect the tappet bores inside the crankcase for 8. Remove the flywheel. Refer to (PIL 15-54).
the dimensions are within service limits. 9. Remove the flywheel housing. Refer to (PIL
15-54).
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries 10. Rotate the crankshaft until the camshaft timing
in the crankcase and camshaft may be blocked. pin can be inserted through the gear and into the
Make sure all oil ways are clear and free from aligning hole in the rear gear case.
debris. Figure 261.
A Timing pin- camshaft

11. Remove the taper blanking plug and insert
crankshaft locking pin. The camshaft and
crankshaft locking pins must be in position to lock
the crankshaft and camshaft before removing the
camshaft assembly.
15 - 81 9823/1700-1 15 - 81
15 - Engine
15 - Camshaft
00 - General
Figure 262. 3. Access the tappets through the apertures in

the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a
suitable magnetic probe. Label the tappets to
ensure replacement in their original positions.
B
Figure 264.
C
B Timing pin- crankshaft E
C Blanking plug
E
12. Remove the fuel injection pump drive gear. Refer
to (PIL 15-51).
Remove
The engine must be inverted. Do not attempt to
remove the camshaft and its drive gears with the
engine upright. The tappets and push rods will
fall into the engine and further dismantling will be
required to retrieve them.
1. Remove the camshaft timing pin.

2. Carefully withdraw the camshaft and gear
assembly from the crankcase. Make sure that
you fully support the camshaft to prevent the
lobes contacting the bearing surfaces in the
crankcase. The bearing surfaces can easily be
damaged by the sharp hard edges on the cam
lobes.
Figure 263. E Tappet
F Magnetic probe
Inspection
1. Refer to Camshaft- Check Condition (PIL 15-15).
Install
1. Lubricate the tappets and tappet bores inside the
A crankcase with clean engine oil.
2. Insert the tappets in their original positions in the
crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
preventing the lobes contacting the bearing
D surfaces in the crankcase. Before meshing the
camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
A Timing pin - camshaft aligns with the dowel hole in the gear casing.
D Camshaft and drive gear Insert the timing pin T1 to lock the camshaft in
this position.
15 - 82 9823/1700-1 15 - 82
15 - Engine
15 - Camshaft
00 - General
After Installation
1. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
injection pump replacement procedure. Refer to
(PIL 18-18).
2. Do the procedures in Before Removal in reverse
order.
15 - 83 9823/1700-1 15 - 83
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-85

15-18-03 Drive Belt ....................................................................................................................... 15-89
15-18-21 Tensioner ........................................................................................................................ 15-93
15 - 84 9823/1700-1 15 - 84
15 - Engine
18 - Engine Belt
00 - General
Introduction .................................................... 15-85 A crankshaft pulley is used to drive a FEAD
Health and Safety .......................................... 15-86 (Front End Accessory Drive) belt. The belt drives
Component Identification ............................... 15-86 the coolant pump. Depending on the machine
application, the belt is configured to drive engine
mounted accessories, such as the alternator, cooling
fan and air conditioning compressor.
Some applications have a second pulley on the

crankshaft which drives a dedicated fan belt. The belt
drives an engine mounted cooling fan.
15 - 85 9823/1700-1 15 - 85
15 - Engine
18 - Engine Belt
00 - General
Health and Safety Component Identification

Turning the Engine Figure 265. A - With air condition-
Do not try to turn the engine by pulling the fan or fan ing compressor, no cooling fan
belt. This could cause injury or premature component
failure. A 4
engine cover open.
Notice: A drive belt that is loose can cause damage 4
to itself and/or other engine parts.
5
15 - 86 9823/1700-1 15 - 86
15 - Engine
18 - Engine Belt
00 - General
Figure 266. B - Without air condi- Figure 267. C - With air conditioning com-
tioning compressor, no cooling fan pressor, cooling fan pulley installed
B
4 C 6
4
5 5
3 4 3
7
2
2
1
1
1 Crankshaft drive pulley
2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
7 Air conditioning compressor drive pulley
15 - 87 9823/1700-1 15 - 87
15 - Engine
18 - Engine Belt
00 - General
Figure 268. D - Without air conditioning

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

2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
6 Cooling fan drive pulley
7 Air conditioning compressor drive pulley
Note: Idler pulley positions differ slightly depending

on the size of the fan pulley installed.
Note: Different fan pulley size options are available.

This enables a choice of fan/engine speed ratios.
15 - 88 9823/1700-1 15 - 88
15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Introduction

Introduction .................................................... 15-89 The crankshaft pulley is used to drive the coolant
Health and Safety .......................................... 15-90 pump via a FEAD (Front End Accessory Drive) belt.
Check (Condition) .......................................... 15-90 In addition to the coolant pump the drive belt can
Adjust ............................................................ 15-91 also be configured to drive the engine mounted
accessories.
The belt is maintained at a constant tension by a
spring loaded tensioner. To achieve the necessary
belt/pulley contact area the belt is routed around
idler wheels as required. The configuration varies
depending on the accessories installed.
15 - 89 9823/1700-1 15 - 89
15 - Engine
18 - Engine Belt
03 - Drive Belt
Health and Safety Check (Condition)

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

2. Stop the engine and let it cool down.
3. Renew the drive belt if it has cracks or if it is
frayed or has pieces of material missing.
Figure 269.
B
A
C
A Crack in belt
B Missing piece of belt
C Frayed belt
15 - 90 9823/1700-1 15 - 90
15 - Engine
18 - Engine Belt
03 - Drive Belt
Adjust Remove and Install
Adjustment is not possible with this drive belt. A Remove

spring loaded tensioning unit ensures that the FEAD
(Front End Accessory Drive) belt is kept at the correct 1. Make the machine safe. Refer to (PIL 01-03).
tension.
3. Use a socket of the specified size to locate
on to the hexagon spigot nut, carefully rotate
the tensioner against the spring force in the
direction shown. Do not use excessive force or
the tensioner will be damaged.
Dimension: 16 mm
4. Keep holding the tensioner against the spring
force and lift the belt off the drive tensioner pulley.
5. Slowly release the spring force by rotating the
tensioner unit in the opposite direction.
15 - 91 9823/1700-1 15 - 91
15 - Engine
18 - Engine Belt
03 - Drive Belt
Figure 270.
A Spring loaded tensioner

B Drive belt
C Example of frayed drive belt (refer to Check
Condition)
D Spigot nut
Install
step.
2. Before you install the new belt, check that the
tensioner roller and the fan pulley rotate smoothly
and that there is no play in the bearings.
15 - 92 9823/1700-1 15 - 92
15 - Engine
18 - Engine Belt
21 - Tensioner
21 - Tensioner Install
steps.
Before Removal 2. Tighten the bolts to the correct torque value.
1. Make the machine safe. Refer to (PIL 01-03). 3. Install the drive belt, refer to (PIL 15-18).
2. Make sure that the engine is safe to work on. If 4. Make sure that the drive belt is under tension
the engine has been running, let it cool before and the locking pin is removed before starting the
you start the service work. engine. Refer to Drive Belt - Adjust (PIL 15-18).
3. Get access to the engine. Table 101. Torque Values

4. Remove the drive belt, refer to (PIL 15-18). Item Nm
2 24
Figure 271.
3 2 1
2
X
T3
1 Drive belt tensioner pulley
2 Fixing bolts (x3)
3 Drive belt
T3 Locking pin
X Spigot nut
Remove
The drive belt tensioner is a non-serviceable item.
If the drive belt tensioner or the idler wheel is faulty
or damaged it must be renewed as a complete
assembly.
1. To remove the tensioner assembly, remove the

bolts and lift the tensioner pulley from the cylinder
block.
15 - 93 9823/1700-1 15 - 93
15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ........................................................................................................................... 15-95
15 - 94 9823/1700-1 15 - 94
15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................... 15-95 The oil filter is a spin on type which screws on and
Health and Safety .......................................... 15-96 off the oil filter head.
Operation ....................................................... 15-99
Check (Level) ................................................ 15-99
15 - 95 9823/1700-1 15 - 95
15 - Engine
21 - Oil Filter
00 - General
Health and Safety

Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
accordance with local regulations. Use authorised
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove
the plug.
CAUTION! The oil filter canister will contain some oil
which could spill out when you remove the canister.
15 - 96 9823/1700-1 15 - 96
15 - Engine
21 - Oil Filter
00 - General
Figure 272.
6 5
7
13
A
8 10
9
16
11
12
14
1
19
2
15
18
10
3 9
13
B
16
14
12
4
3
18
15
17
3
1 Oil cooler and filter housing 2 Oil filler cap

3 Oil filter head 4 Oil filter drain down plug
5 Oil cooler matrix 6 Sealing gasket - housing to crankcase
7 Coolant gallery 8 Oil gallery - from pump to cooler
15 - 97 9823/1700-1 15 - 97
15 - Engine
21 - Oil Filter
00 - General
9 Oil gallery - from cooler to filter head 10 Oil gallery - from filter head to main oil gallery
11 Oil filler port 12 Oil pressure switch
13 Oil filter 14 Filter element
15 Anti-drain seal 16 Spring
17 O-ring 18 Anti-drain pipe
A Oil filter state - engine running B Oil filter state - engine stopped
15 - 98 9823/1700-1 15 - 98
15 - Engine
21 - Oil Filter
00 - General
Operation Check (Level)
At Engine Running Engine oil and oil filter replacement must be

completed in accordance with the service schedules.
The oil pump delivers oil at pressure to the oil filter Failure to replace the oil and filter at the
via a port. The anti-drain seal is forced off its seat and recommended interval could cause serious engine
oil flows through a large area paper element. Filtered failure.
oil enters the inner part filter before leaving the filter
head via a port. We recommend that you check the oil level before
starting a cold engine. Park the machine on level
ground at the end of the working day, then check the
At Engine Stopped oil level the next day.
With the engine stopped oil pressure in the galleries 1. Make the machine safe. If the engine has been
and filter decays. The anti-drain seal falls on running, let it cool before you check the oil level
its seat and oil is prevented from draining from refer to (PIL 01-03).
the filter assembly. The anti-drain pipe prevents
approximately half the filters oil capacity from 2. Get access to the engine.
draining. These features help protect the engine from
oil starvation on start up. 3. Check that the oil level is between the two marks
on the dipstick.
3.1. Note: A false level will be shown on the
dipstick if the oil is hot.
4. If necessary, add recommended oil through one
of the filler points.
Figure 273.
B
A Dipstick
B Oil filler point
15 - 99 9823/1700-1 15 - 99
15 - Engine
21 - Oil Filter
00 - General
Remove and Install Figure 275.

A
Special Tools
Oil Filter Removal Tool 892/00292 1
CAUTION Oil will gush from the hole when the

drain plug is removed. Keep to one side when you
remove the plug.
1. Drain the oil. Follow the procedure at step 2 or

step 3 as applicable.
1.1. Drain the oil when the engine is warm as
contaminants held in suspension will then B B
be drained with the oil. A Drain tube
B Dust cap
2. For engines with a normal sump drain plug, drain
the oil as follows. 3.1. Remove the dust cap from the sump drain
port.
Figure 274.
3.2. Attach the drain tube and put the free end
into a suitable container.
3.3. Screw in the drain tube assembly to open
the drain valve.
3.4. When all the oil has drained, unscrew the
drain tube assembly. Install the dust cap.
4. Loosen and remove the filter head drain plug. Let
the oil fully drain.
5. Install the filter head drain plug and tighten to the
correct torque value.
Torque: 40 N·m
A B
6. Unscrew the filter canister, use special tool if
A Sump drain plug necessary.
B O-ring Special Tool: Oil Filter Removal Tool (Qty.: 1)
2.1. Place a container of suitable size beneath 7. Clean the seal face of the filter head.
the sump drain plug.
2.2. Remove the sump drain plug and the O- 8. Smear the seal on the new filter canister with
ring. clean engine oil.
2.3. Let the oil drain out, then clean and install 9. Screw in the new filter canister (hand tight only).
the sump drain plug with a new O-ring.
10. Through one of the oil filler points, fill the engine
2.4. Tighten the sump drain plug to the correct with the recommended oil to the MAX mark on
torque value. the dipstick. Wipe off any spilt oil, install the filler
Torque: 40 N·m cap and make sure it is secure.
3. For engines with a drain valve, drain the oil as 11. Operate the engine, until the oil pressure low
follows. warning light has extinguished. Check for oil
leakage. When the oil has cooled, check the oil
level again, and if necessary top up with clean
engine oil.
15 - 100 9823/1700-1 15 - 100

15 - Engine
21 - Oil Filter
00 - General
Figure 276.
C B
A Oil filler points
B Dipstick
C Filter head drain plug
D Filter head
E Seal
F Filter canister
15 - 101 9823/1700-1 15 - 101

15 - Engine
24 - Air Filter
24 - Air Filter
Contents Page No.
15-24-00 General ......................................................................................................................... 15-103

15-24-09 Dust Valve .................................................................................................................... 15-106
15 - 102 9823/1700-1 15 - 102

15 - Engine
24 - Air Filter
00 - General
Introduction .................................................. 15-103 Engine performance and durability will be severely
Health and Safety ........................................ 15-104 affected if the quality of the air intake is poor.
Check (Condition) ........................................ 15-104
Remove and Install ..................................... 15-105 A dirty and blocked air cleaner element will reduce
the amount of air entering the combustion chamber
which can cause engine mis-firing, black smoke and
low output power.
A dirty and blocked air filter can also lead to abrasion

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

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

installed.
15 - 103 9823/1700-1 15 - 103

15 - Engine
24 - Air Filter
00 - General

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

with a vacuum switch. The switch will detect if there
is a restriction on the air intake, and activate warning
indicators such as an audible alarm and/or a visual
indicator.
15 - 104 9823/1700-1 15 - 104

15 - Engine
24 - Air Filter
00 - General
Remove and Install
Note: Do not attempt to wash or clean the elements,

they must only be renewed.
Note: A new inner element must be installed at least

every other time the outer element is changed. As a
reminder, mark the inner element with a felt tipped
pen each time the outer element is changed.
A typical air filter is shown below.
Remove
(PIL 06-06).
3. Depress the clips and lift off the cover.
4. Remove the outer element. Take care not to tap
or knock the element.
5. If the inner element is to be changed, lift up and
pull to remove the inner element.
Figure 277.
A Outer element
B Inner element
Install
steps.
2. Clean inside the housing, and cover, make sure
that the air holes are clear.
3. Install the cover and fasten the latch. Make sure
that the dust valve is at the bottom.
15 - 105 9823/1700-1 15 - 105

15 - Engine
24 - Air Filter
09 - Dust Valve
09 - Dust Valve
Remove and Install
Do not run the engine with the dust valve removed.

3. Make sure that the dust valve is not blocked.
4. Inspect the rubber flaps for cuts and nicks.
4.1. Make sure that the rubber has not perished.
5. If necessary, replace the dust valve.
Figure 278.
A Dust valve
15 - 106 9823/1700-1 15 - 106

15 - Engine
27 - Crankcase Ventilation Filter
Contents Page No.
15-27-00 General ......................................................................................................................... 15-109
15 - 107 9823/1700-1 15 - 107

Notes:
15 - 108 9823/1700-1 15 - 108

15 - Engine
00 - General
Introduction .................................................. 15-109 Depending on the specification, the engine may be
Component Identification ............................. 15-110 installed with open loop, filtered open loop or a closed
Operation ..................................................... 15-112 loop CCV (Crankcase Ventilation) system.
15 - 109 9823/1700-1 15 - 109

15 - Engine
00 - General
For: SD Engine, SF Engine ..... Page 15-110

For: SA Engine, SB Engine, SC Engine
................................................. Page 15-111
(For: SD Engine, SF Engine)
Figure 279. Open loop crankcase ventilation (CCV) system

H A
E
G
H
F
C
B
D
A Engine breather assembly B Ventilation chamber

C Oil separator D Oil droplets
E Diaphragm F Breather port
G Spring H Vent to atmosphere port
15 - 110 9823/1700-1 15 - 110

15 - Engine
00 - General
(For: SA Engine, SB Engine, SC Engine)
Figure 280. Closed loop crankcase ventilation (CCV) system
E
A
D J
B A C
D H
E
F G
A Cover plate B Diaphragm

C Spring D Breather hose
E Gauze filter F Breather port
G Crankcase breather port H Cylinder head breather port
J Rocker cover breather port
15 - 111 9823/1700-1 15 - 111

15 - Engine
00 - General
Operation process. The breather also separates the oil trapped

in the vapour from the crankcase.
For: SD Engine, SF Engine ..... Page 15-112
A series of ports in the crankcase and cylinder head
For: SA Engine, SB Engine, SC Engine
................................................. Page 15-112 allow hot vapour to vent from the crankcase and pass
into the rocker cover. The vapour flows through a
ventilation chamber inside the rocker cover to the oil
(For: SD Engine, SF Engine) separator.
Closed loop crankcase ventilation (CCV) Galleries inside the separator create a 'cyclone'
system effect, this effect separates out the oil droplets
suspended in the vapour. The trapped oil droplets
The engine breather assembly is housed in the drain from the bottom of the separator back into the
rocker cover under a plate. The breather prevents the engine sump. The oil drains via a port in the cylinder
build up of pressure in the crankcase, caused by the head and crankcase.
reciprocating motion of the pistons, and hot gases
that may 'blow by' the pistons during the combustion A possible cause of negative crankcase pressure is
process. a blocked air filter. This can result in oil being sucked
from the sump into the cylinders. The engine can
A series of ports in the crankcase, cylinder head 'run-away' by burning its own oil.
and rocker cover allow hot vapour to vent from the
crankcase. The diaphragm acts as a non-return valve. When
there is positive pressure in the crankcase, the
Gauze located inside the rocker cover acts as a filter filtered vapour opens the breather port assisted by
trapping the oil mist. The gauze prevents oil droplets the force of the spring allowing the crankcase gas
suspended in the vapour escaping from the engine. to vent to atmosphere via a port. Should a negative
The trapped oil droplets drain from the gauze back pressure develop however, the diaphragm will move
into the engine. against the force of the spring and close off the
breather port to prevent unfiltered air being drawn
A diaphragm acts as a non-return valve. When there into the engine.
is positive pressure in the crankcase, the filtered
vapour opens the breather port assisted by the force
of the spring, allowing the crankcase gas to vent
along the breather hose. Should a negative pressure
develop however, the diaphragm will move against
the force of the spring and close off the breather port
to prevent air being drawn into the engine.
A possible cause of negative crankcase pressure is

a blocked air filter. This can result in oil being sucked
from the sump into the cylinders. The engine can
'run-away' by burning its own oil.
On naturally aspirated engines, the breather

hose connects directly to the inlet manifold. On
turbocharged engines, the breather hose connects
to the air filter housing, and then enters the inlet
manifold via the turbocharger. The crankcase gas is
then drawn back into the engine.
(For: SA Engine, SB Engine, SC Engine)
Open loop crankcase ventilation (CCV)

system
The engine breather assembly is mounted on
the rocker cover. The breather prevents the build
up of pressure in the crankcase, caused by the
reciprocating motion of the pistons, and hot gases
that may 'blow by' the pistons during the combustion
15 - 112 9823/1700-1 15 - 112

15 - Engine
30 - Valve
30 - Valve
Contents Page No.
15-30-00 General ......................................................................................................................... 15-115

15-30-12 Valve Spring ................................................................................................................. 15-124
15-30-24 Stem Seal .................................................................................................................... 15-125
15 - 113 9823/1700-1 15 - 113

Notes:
15 - 114 9823/1700-1 15 - 114

15 - Engine
30 - Valve
00 - General
Introduction .................................................. 15-115 The valve train system opens and closes the
Technical Data ............................................. 15-116 valves with correct timing in relation to the piston
Component Identification ............................. 15-117 movements.
Operation ..................................................... 15-119
Each push rod has one end in a valve tappet and the
Adjust .......................................................... 15-119 other end under a rocker arm, or as applicable. The
Remove and Install ..................................... 15-121 adjusting screw has a ball shaped end that locates in
the push rod. The adjusting screw is used for setting
the valve clearance.
The valves extend through the cylinder head. There

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

head. The seat inserts are also made from a special
metal to provide for a long service life. Damaged or
worn seat inserts can be removed and replaced with
new ones.
15 - 115 9823/1700-1 15 - 115

15 - Engine
30 - Valve
00 - General
Technical Data
Table 102. Inlet and Exhaust Valve Data

Max lift Inlet
- SA, SB, SC 9.37 mm @ 101 ° AT-
DC
- SD, SF 9.64 mm @ 101 ° AT-
DC
Max lift exhaust
-SA 9.42 mm @ 110 ° BTDC
- SB, SC 9.42 mm @ 115 ° BTDC
- SD, SF 9.84 mm @ 115 ° BTDC
Inlet opens (top of ramp)
- SA, SB, SC 10 ° BTDC
- SD, SF 6 ° BTDC
Inlet closes
- SA, SB, SC 32 ° ABDC
- SD, SF 28 ° ABDC
Exhaust opens
- SA 50 ° BBDC
- SB, SC 60 ° BBDC
- SD, SF 41 ° BBDC
Exhaust closes
- SA, SB, SC 10 ° ATDC
- SD, SF 9 ° ATDC
Valve stem diameter
- SA, SB, SC Inlet: 6.935 ± 0.0075
mm
Exhaust: 6.975
± 0.0075 mm
- SD, SF Inlet: 6.928 –6.943 mm
Exhaust: 6.975 –6.933
mm
Valve spring free length 40.18 mm
Valve guide bore diameter
- min 6.958 mm
- max 6.968 mm
Valve face angle
- Inlet 60.5 °
- Exhaust 45.17 °
Valve length 131.9 –132.4 mm
Valve sealing Stem seal with sealing
washer
Valve head depth (below cylinder head surface)
- Inlet 0.89 –1.39 mm
- Exhaust 0.95 –1.45 mm
Valve rim thickness 2.98 –3.38 mm
Valve Clearances (measured cold)
- Inlet 0.19 –0.27 mm
- Exhaust 0.56 –0.64 mm
15 - 116 9823/1700-1 15 - 116

15 - Engine
30 - Valve
00 - General
Figure 281.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700
1 Camshaft drive gear 2 Crankshaft gear

3 Camshaft 3a Lobes
4 Tappets (x8) 5 Push rods (x8)
6a Rockers - inlet (x4) 6b Rockers - exhaust (x4)
6c Adjusting screws (x8) 6d Swivel tip - rockers
7 Rocker shaft 8 Wave washers (x8)
9 Bridge pieces (x8) 10 Valve springs (x16)
11 Retainer (x16) 12 Collets (x32)
13 Oil seal - valve stems (x16) 14 Valve seat inserts (x16)
15 - 117 9823/1700-1 15 - 117

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

17 Valve stem
Cross Sectional View
Figure 282.
17
6c 11 12
8 10
6a 6b 13
6d
745930
14
6a Rockers - inlet (x4) 6b Rockers - exhaust (x4)

6c Adjusting screws (x8) 6d Swivel tip - rockers
8 Wave washers (x8) 9 Bridge pieces (x8)
10 Valve springs (x16) 11 Retainer (x16)
12 Collets (x32) 13 Oil seal - valve stems (x16)
14 Valve seat inserts (x16) 17 Valve stem
15 - 118 9823/1700-1 15 - 118

15 - Engine
30 - Valve
00 - General
Operation Adjust
Special Tools
The camshaft drive gear is driven by the crankshaft Description Part No. Qty.
gear at half the speed of the crankshaft. Camshaft Crankshaft Turning Tool 892/01147 1
lobes, two for each cylinder, (operating exhaust and (95.25mm PCD)- JCB
inlet valves) actuate the valve tappets. 4 Cylinder Ecomax and
Dieselmax
When the camshaft rotates the cam lobes act on the
tappets. The push rods act on the rockers which pivot
on the camshaft, depressing two valves at the same Before Adjustment
time via the bridge piece.
The screw is self locking in the rocker by means of the engine has been running, let it cool before
a tapered thread. Wave washers act like springs to you start the service work.
keep the rockers in their correct positions along the
camshaft and prevent them contacting one another. 2. Remove the high pressure fuel pipes.
The rockers incorporate a swivel tip to ensure Refer to: PIL 18-96-03.
alignment with the bridge piece. This prevents
excessive wear. 3. Remove the rocker cover.
Each valve has a compression spring. The function
of the spring is to close the valve and at the same
time return the rocker arm and push rod to ensure Adjust
that the tappets follow the camshaft lobes. The spring
The preferred method to measure the clearance
is located on the valve stem by a retainer and split
is to use a DTI (Dial Test Indicator) mounted on
collets.
a magnetic base. The DTI must be positioned to
contact the machined surface of the rocker on the
centre line. If a DTI is not available, feeler gauges
can be used to measure the clearance between the
bridge piece and the rocker insert.
15 - 119 9823/1700-1 15 - 119

15 - Engine
30 - Valve
00 - General
Figure 283. open the valves against the force of the

T1 springs.
T2
3.2. Slowly relax the force on the rocker until you
X feel the exact position at which the valves
shut. Measure the valve clearance from this
point. Take care to keep the rocker at right
angles to the rocker shaft when making
measurements, otherwise incorrect values
will be obtained. Always use a socket or ring
spanner to turn the tappet adjusters, DO
B NOT use an open ended spanner.
4. Repeat steps 2 and 3 for the remaining cylinders.
A
Figure 284.
C
E
I
Y
E
CYL. 1 I
E
CYL. 2
I
A Rocker
B Bridge piece
CYL. 3 E
C Tappet adjusters
X Rocker centre line
Y Bridge piece to rocker insert clearance I
T1 DTI
T2 Socket or wrench CYL. 4
Table 103. Valve Adjustment Sequence

'Set-up' Cylinder Check/adjust Cylinder
4 1
2 3
1 4
3 2
1. The valve clearances should be checked/

adjusted in a set sequence. Refer to Table 103.
2. Rotate the crankshaft in the normal direction of 1 2 3 4
rotation (clockwise when viewed from the front of
the engine) to 'set-up' the valves of cylinder 4 so
that the point is reached where the exhaust valve
is closing while the inlet valve is just starting to
open. This is the point where the two rockers are
moving past one another in opposite directions.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax
(Qty.: 1) I Inlet valves
E Exhaust valves
3. With cylinder 4 in this position, measure the CYL.1 Cylinder 1
clearance of cylinder 1 inlet and exhaust valves. CYL.2 Cylinder 2
Adjust the valve clearance if necessary: CYL.3 Cylinder 3
Refer to: PIL 15-30-00. CYL.4 Cylinder 4
3.1. Using a socket and wrench (or a short

extension) as shown, move the rocker to
15 - 120 9823/1700-1 15 - 120

15 - Engine
30 - Valve
00 - General
After Adjustment Remove and Install

1. Install the rocker cover. Special Tools
Refer to: PIL 15-42-00. Description Part No. Qty.
Valve Stem Seal 892/01152 1
2. Install the high pressure fuel pipes. Installation Tool
Refer to: PIL 18-96-03. (444/448/672 Engine)
Before Removal
4. Remove the thermostat, refer to (PIL 21-12).
5. Remove all of the fuel injector pipes, refer to (PIL
18-96).
6. Remove the rocker cover, refer to (PIL 15-42).
7. Remove the fuel injectors, refer to (PIL 18-18).
8. Remove the rocker assembly, refer to (PIL
15-42).
9. Remove the exhaust manifold, refer to (PIL
18-24).
10. Remove the inlet manifold, refer to (PIL 18-24).
11. Remove the cylinder head assembly from the
cylinder block, refer to (PIL 15-06).
12. Measure the valve recession with a suitable DTI
(Dial Test Indicator). Clean the carbon deposits
from a small area of the valve heads for location
of the DTI probe. If the valve recession is outside
the serviceable limits, it is advisable to obtain
a new or reconditioned cylinder head assembly,
refer to Technical Data (PIL 15-06).
13. To aid removal and replacement, use a wooden
valve stand to retain the valves after removal.
Add labels to make sure that the valves are
correctly replaced.
15 - 121 9823/1700-1 15 - 121

15 - Engine
30 - Valve
00 - General
Figure 285. Valve Stand Figure 288.
G
EXHAUST
EXHAUST
EXHAUST
E
INLET
INLET
INLET
F
CYL. 1 CYL. 2 CYL. 3
Remove
1. Use a spring compressor tool to compress each
valve spring and remove the collets. Make sure E Cylinder head
that the springs are compressed squarely. F Inlet valves
G Exhaust valves
Figure 286.
4. When removing, note the respective position of
B each valve. Use a suitable valve stand to keep
the valves together and identify them with their
respective cylinder. Note: The exhaust valves
have smaller diameter heads.
5. Remove the valve stem seals. Discard the seals.
Figure 289.
A
J H
A Spring compressor tool

B Collets
2. Remove the spring compressor tool and lift off
the retainer and valve spring.
Figure 287.
C
H Valve stem seals

D J Punch tool
Inspection
1. Carefully clean the carbon deposits from the
valves, take care not to damage the valve seats.
2. Check that the valves and valve seats are not
cracked, burnt or damaged.
C Retainer 3. Check the valve stems and valve guides for wear,
D Valve spring refer to Technical Data (PIL 15-30).
3. Turn the cylinder head on its side and withdraw

the inlet valves and exhaust valves as shown.
15 - 122 9823/1700-1 15 - 122

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

guides or seats, it is advisable to obtain a new or
reconditioned cylinder head assembly.
Before Installation
1. Position the cylinder head upside down in a
suitable jig or fixture.
3. Install the injectors into the cylinder head to
do a trial check of the nozzle protrusion. Note
the relative positions for the injectors, and then
remove the injectors for installation at a later
stage.
Installation
steps.
2. Install the new valve stem seals as shown. Use
the installation tool to avoid damaging the seals.
Pre-assemble the seal into the tool. Locate the
tool over the valve guide and gently press the
seal into place. Lubricate the seal with P80 fluid.
Special Tool: Valve Stem Seal Installation Tool
(444/448/672 Engine) (Qty.: 1)
3. With the cylinder head on its side, insert the
inlet valves and exhaust valves as shown. Make
sure that the valves are installed in the correct
positions. Lubricate the valve stems with clean
engine oil before assembly. Carefully push the
end of the valve stem through the stem seals.
4. Install the valve springs on to the valve
stems, together with a retainer. Use the spring
compressor tool to compress each valve spring
and insert the collets. Make sure that the collets
are correctly seated in the valve stem grooves,
before you remove the spring compressor tool.
After Installation
1. Tap the valve stems in turn using a rubber mallet
top fully seat the valves.
15 - 123 9823/1700-1 15 - 123

15 - Engine
30 - Valve
12 - Valve Spring
12 - Valve Spring
Remove and Install

15 - 124 9823/1700-1 15 - 124

15 - Engine
30 - Valve
24 - Stem Seal
24 - Stem Seal
Remove and Install

15 - 125 9823/1700-1 15 - 125

15 - Engine
33 - Connecting Rod
33 - Connecting Rod
Contents Page No.
15-33-00 General ......................................................................................................................... 15-127

15-33-06 Big-End Bearing ........................................................................................................... 15-131
15 - 126 9823/1700-1 15 - 126

15 - Engine
33 - Connecting Rod
00 - General
Introduction .................................................. 15-127 The connecting rod connects the piston to the
Technical Data ............................................. 15-128 crankshaft. They form a simple mechanism that
Component Identification ............................. 15-128 converts reciprocating motion into rotating motion.
Check (Condition) ........................................ 15-129
Connecting rods are usually made of high strength
Remove and Install ..................................... 15-129 steel. They are not rigidly fixed at either end, so that
Disassemble and Assemble ........................ 15-130 the angle between the connecting rod and the piston
can change as the rod moves up and down and
rotates around the crankshaft.
The small end of the connecting rod attaches to the

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

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

the big end of the connecting rod so that pressurised
lubricating engine oil squirts out on to the thrust
side of the cylinder wall to lubricate the travel of the
pistons and piston rings.
15 - 127 9823/1700-1 15 - 127

15 - Engine
33 - Connecting Rod
00 - General
Technical Data Component Identification
Table 104. Connecting Rods Data Refer to Piston- Component Identification.Refer to:
PIL 15-36-00.
Connecting rod type
(1)
Split fracture
Connecting rod bore di- 77 –77.01 mm
ameter
Connecting rod side
clearance
min 0.05 mm
max 0.4 mm
Big end bearings
Width 32.5 –33 mm
Thickness (at centre) 1.99 –1.981 mm
Small end bearings
Inside diameter 40.034 –40.02 mm
(1) Split fracture type connecting rods MUST NOT be
dot punched or etched in anyway during disassembly
- refer to relevant service procedures.
15 - 128 9823/1700-1 15 - 128

15 - Engine
33 - Connecting Rod
00 - General

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

renewable. If the small end bearing bush is damaged
or worn the connecting rod must be renewed as a
complete assembly.
15 - 129 9823/1700-1 15 - 129

15 - Engine
33 - Connecting Rod
00 - General

15 - 130 9823/1700-1 15 - 130

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

Introduction .................................................. 15-131 In a piston engine, the big-end bearings are the
Check (Condition) ........................................ 15-132 bearings at the big-end of the connecting rod.
15 - 131 9823/1700-1 15 - 131

15 - Engine
33 - Connecting Rod

Special Tools
1. Check the bearing shell surfaces for signs of Description Part No. Qty.
Torque Wrench 993/70111 1
Refer to: PIL 15-33-00. (10-100Nm)
2. Measure the crank pin diameters to confirm they
are within service limits. Before Removal
Refer to: PIL 15-12-00. This procedure requires service parts. Make sure
you have obtained the correct service parts before
3. Renew any parts that are worn or not within the you start. Refer to Parts Catalogue.
specified tolerances.
3. Remove the engine from the machine.
injectors.
5. Remove the rocker cover.
6. Remove the fuel injectors.
8. Remove the oil sump.
9. Position the engine upside down in a suitable jig
or fixture, supported at the front of the crankcase.
The connecting rod and the big-end bearing cap

have been fracture split and must be kept together
as a set. Care must be taken to avoid contamination
and or damage to the fracture split surfaces.
Remove
1. It is recommended that the big-end bearing caps
are removed in pairs, cylinders 1 and 4 and
cylinders 2 and 3. Rotate the crankshaft so that
the big-end bearing caps on cylinders 2 and 3 are
positioned as shown.
2. Remove the bolts and lift off the big-end bearing
caps from the connecting rods. The bolts must
not be re-used, discard the bolts.
15 - 132 9823/1700-1 15 - 132

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

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

with the bolt to avoid damaging the screw 1 Big-end bearing cap
thread. 2 Bolts
3 Connecting rod
3. Lift out the bearing shells from the bearing caps. 4 Piston
Carefully rotate the crank to disengage from the 5 Piston rings
connecting rods and get access to the upper 6 Big end bearing shells
bearing shells. Lift out the upper bearing shells. Z Fracture split surfaces
It is recommended that the bearing shells are
renewed. If they are to be reused, label the 4. Carefully rotate the crankshaft to position the big-
bearing shells to make sure that they are installed end bearing caps of cylinders 1 and 4. Make
in their original positions on assembly. sure that the crank does not foul the connecting
rods of cylinders 2 and 3. Remove the bearing
caps and bearing shells as described in previous
steps.
5. Inspect the big-end bearings for signs of damage
and excessive wear.
Install
steps.
3. Install the upper bearing shell to the connecting
rod. Lubricate the bearing shell with clean engine
oil.
4. Install the lower bearing shell to the big-end
bearing cap. Lubricate the bearing shell with
15 - 133 9823/1700-1 15 - 133

15 - Engine
33 - Connecting Rod
clean engine oil. Install the big-end bearing cap

to the connecting rod. Make sure that the cast
notch on the bearing cap faces to the front of the
engine. Use compressed air to clean the fracture
surfaces before assembly.
5. Install new big end bearing cap bolts. Tighten the
new bolts in three stages to the correct torque
value.
1)
5.1. Make sure that the tool is kept in inline
with the bolt to avoid damaging the screw
thread.
5.2. The bolts are tightened using a torque and
angle method.
Figure 292.
0° +90°
Figure 293.
T3
T3 Angle gauge (obtain locally)
After Installation
1. The after installation procedure is the opposite of
the before removal procedure.

Item Torque Value Angle (de-
(Nm) grees)
2 (1st Stage) 35
2 (2nd Stage) 65
2 (Final Stage) 90
15 - 134 9823/1700-1 15 - 134

15 - Engine
36 - Piston
36 - Piston
Contents Page No.
15-36-00 General ......................................................................................................................... 15-137

15-36-03 Piston Ring ................................................................................................................... 15-149
15 - 135 9823/1700-1 15 - 135

Notes:
15 - 136 9823/1700-1 15 - 136

15 - Engine
36 - Piston
00 - General
Introduction .................................................. 15-137 The piston is acted upon by the pressure of the
Technical Data ............................................. 15-138 expanding combustion gases in the combustion
Component Identification ............................. 15-139 chamber space at the top of the cylinder. This force
Operation ..................................................... 15-140 then acts downwards through the connecting rod and
on to the crankshaft.
Check (Condition) ........................................ 15-141
Calibrate ...................................................... 15-141 The pistons are cast from aluminium alloys for
Remove and Install ..................................... 15-143 increased strength and improved fatigue life.
Disassemble and Assemble ........................ 15-146
The connecting rod is attached to the piston by a
swivelling piston pin. This pin is mounted within the
piston, The pin itself is of hardened steel and is fixed
in the piston, but free to move in the connecting rod.
The pins are prevented from moving sideways and
the ends of the pin digging into the cylinder wall by
circlips.
15 - 137 9823/1700-1 15 - 137

15 - Engine
36 - Piston
00 - General
Technical Data
Table 106.
Engine 444 448
Gudgeon pin bore diameter
- min. 40.01 mm 42.008 mm
- max. 40.015 mm 42.013 mm
Piston ring clearance
- Top ring Full keystone ring Full keystone ring
- Middle ring 0.125 –0.08 mm 0.125 –0.08 mm
- Bottom (oil) ring 0.09 –0.05 mm 0.09 –0.05 mm
Piston ring gap
- Top ring 0.3 –0.4 mm 0.3 –0.4 mm
- Middle ring 0.55 –0.8 mm 0.55 –0.8 mm
Piston height above crankcase 0.00025 –0.36825 mm
(1)
0.00025 –0.36825 mm
(1)
(cold)
Piston groove width
- Top ring 3.114 –3.134 mm 3.114 –3.134 mm
- Middle ring 2.575 –2.595 mm 2.575 –2.595 mm
Piston skirt 102.853 –102.871 mm 105.851 –105.869 mm
Piston pin 39.994 –40 mm 41.994 –42 mm
(1) Nominal measurement is 0.03325 mm
15 - 138 9823/1700-1 15 - 138

15 - Engine
36 - Piston
00 - General
Figure 294.
C
D
E
A F
F
A Piston
B Connecting rod
C Oil control ring
D Piston ring - compression No.1
E Piston ring - compression No.2
F Retaining circlips
G Piston pin
15 - 139 9823/1700-1 15 - 139

15 - Engine
36 - Piston
00 - General
Operation
The groove around the diameter of the upper main top of the pistons. Oil spray also enters the small end
bearing shells allows oil transfer to an oil jet located bearing bushes via a feed hole on the top of each
in the crankcase bearing saddle. Jets are installed at connecting rod.
the main bearing positions.
Note: On turbocharged engines additional J-jets are
The jets spray oil directly to the under side of the installed. Oilways connect the J-shaped jets fixed to
pistons effectively transferring heat away from the the crankcase at the underside of each cylinder bore.
Figure 295.
1 1
6
2
5
1 Groove 2 Oil jet

3 Pistons 4 Bearing bushes
5 Crankshaft 6 J shaped jets
15 - 140 9823/1700-1 15 - 140

15 - Engine
36 - Piston
00 - General
Check (Condition) Calibrate

1. Check the piston for signs of damage and
excessive wear. Measure the piston skirt
Piston Height Measurement Above
diameter, piston pin bore and the clearance in Cylinder Block- DTI Method
the piston ring grooves to confirm they are within
service limits. In the event of sufficient liquid entering the engine, a
hydraulic lock can occur. This may result in bending
Refer to: PIL 15-36-00. of one or more of the connecting rods. Bending of the
connecting rod(s) can occur even when the engine is
2. Check the piston pin for signs of damage and cranked by the starter motor.
excessive wear. Measure the pin diameter to
confirm it is within service limits. Refer to Piston. Bending of the connecting rod may be very slight and
Refer to: PIL 15-36-00. can be checked by carrying out this procedure prior
to a full strip down:
The connecting rod small end bearing bush is not
renewable. If the small end bearing bush is damaged 1. With the cylinder head removed, make sure the
or worn the connecting rod must be renewed as a surface of the engine block and piston are clean.
complete assembly.
2. Zero a DTI (Dial Test Indicator) on the top face
of the cylinder block adjacent to the area on the
piston to be measured. The aim of the procedure
is to use the DTI to take a measurement across 2
locations on the piston that are on the axis of the
gudgeon pin. This will be towards the front and
rear of the engine.
3. Rotate the engine and bring the piston up until
it is 3mm below the engine block face. Carefully
reposition the zeroed DTI above the area of the
piston to be measured.
4. Rotate the engine to bring the piston up to
exactly TDC (Top Dead Centre) and record the
measurement at position 1.
5. Repeat steps 2 to 4 for position 2.
6. Calculate the average of the 2 readings to give
a figure of the piston height above the cylinder
block.
7. Compare the reading obtained to the technical
data.
7.1. If the reading obtained is lower than zero,
the connecting rod may be bent.
7.2. If the reading obtained is equal to the range
stated in technical data, the connecting rod
is not bent.
8. Repeat steps 2 to 7 to check all connecting rods/
pistons.
9. If any connecting rods are bent, strip the engine
and check for further damage.
10. If the engine is serviceable, any connecting rod
that is bent must be replaced.
15 - 141 9823/1700-1 15 - 141

15 - Engine
36 - Piston
00 - General
Figure 296. DTI Measurement 5. Calculate the average of the 2 readings to give
D a figure of the piston height above the cylinder
block.
C
5.1. If the reading obtained is lower than zero,
the connecting rod may be bent.
5.2. If the reading obtained is equal to the range
stated in technical data, the connecting rod
is not bent.
B Refer to: PIL 15-36-00.
6. Repeat steps 1 to 5.2 to check all connecting
rods/pistons.
Figure 297. Straight Edge Measurement
G
F
E
A Gudgeon pin axis

B Line of measurement above gudgeon pin axis K
C Piston measurement point 1
D Piston measurement point 2
L
Piston Height Measurement Above
Cylinder Block- Straight Edge Method
If a DTI is not available, a calibrated straight E Straight edge
edge may be used to take a measurement. The F Measurement position 1
measurement will be less accurate. G Measurement position 2
H Cylinder block- top face
1. With the cylinder head removed, make sure the J Gudgeon pin axis
surface of the engine block and piston are clean. K Piston
L Connecting rod
2. Rotate the engine until the piston to be measured
is at TDC.
3. Position the straight edge on top of the piston
along the axis of the gudgeon pin.
4. Use feeler gauges to measure the gap between
the cylinder block face and underside of the
straight edge on both sides, position 1 and
position 2.
15 - 142 9823/1700-1 15 - 142

15 - Engine
36 - Piston
00 - General
Remove and Install
Before Removal 3. Get access to the engine.
The following procedure is for one piston and 4. Disconnect and remove the fuel pipes from the
connecting rod assembly. Note that each assembly injectors. Refer to (PIL 18-96).
must be replaced in the same cylinder bore. Label 5. Remove the rocker cover. Refer to (PIL 15-42).
each piston and connecting rod assembly to make
sure it is installed in the correct position on assembly. 6. Remove the fuel injectors. Refer to (PIL 18-18).
1. This procedure requires service parts. Make sure 7. Remove the cylinder head assembly. Refer to
that you have obtained the correct service parts (PIL 15-06).
before you start. Refer to Parts Catalogue.
8. Remove the oil sump. Refer to (PIL 15-45).
the engine has been running, let it cool before 9. Remove the big end bearing caps. Refer to (PIL
you start the service work. 15-33-06).
15 - 143 9823/1700-1 15 - 143

15 - Engine
36 - Piston
00 - General
Figure 298.
X
1
1 Piston 2 Piston ring

3 Connecting rod X Longest side of connecting rod
15 - 144 9823/1700-1 15 - 144

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

the carbon deposits from around the top of the
cylinder bore. Take care not to scratch or damage
the cylinder bore.
2. Use a hammer and a short length of wood to
tap the piston from the connecting rod side. Take
care not to scratch or damage the cylinder bore
or the connecting rod bearing surface.
Install
steps.
3. If the upper big end bearing shell has been
removed replace it. Refer to (PIL 15-33-06).
4. Lubricate the cylinder bore with clean engine oil.
5. Use a suitable compressor tool to compress the
piston rings.
6. Insert the piston and connecting rod assembly
into the cylinder bore, make sure that the longest
side of the connecting rod is on the exhaust side
of the crankcase. Take care not to damage the
cooling jets when you guide the connecting rod
down the cylinder bore and over the crank pin
diameter.
After Installation
1. Install the big end bearing caps. Refer to (PIL
15-33-06).
2. Carry out the procedures listed under Before
removal in reverse order.
15 - 145 9823/1700-1 15 - 145

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

To avoid damage or distortion to the rings, use a
1. Clamp the connecting rod in a vice. Take care not suitable piston ring expander tool. Note that the
to damage the connecting rod. oil control ring is installed with a spiral wire. Pull
the wire apart and remove it.
2. It is recommended that the piston rings are
renewed. If they are to be reused, label the 3. Remove the circlips and push out the piston pin.
rings to ensure they are installed in the correct
positions and the correct way up on assembly. 4. Use a suitable cleaning agent, clean the carbon
deposits from the piston.
15 - 146 9823/1700-1 15 - 146

15 - Engine
36 - Piston
00 - General
Figure 299.
A TOP
2 X
B 3
TOP
C
4a
TOP
1
4
6
7
0°
12
12
0°
120°
1 Piston 2 Piston ring - compression No.1

3 Piston ring - compression No.2 4 Piston ring - oil control ring
4a Spiral wire - oil control ring 5 Connecting rod
6 Piston pin 7 Retaining circlip (x2)
X Connecting rod - longest side Y Cast boss - piston
Inspect
1. Inspect the pistons for signs of wear or damage.
Refer to Check (Condition) (PIL 15-36-00).
15 - 147 9823/1700-1 15 - 147

15 - Engine
36 - Piston
00 - General
Assemble
the disassemble procedure. Additionally do the
following steps.
3. Lubricate the piston pin with clean engine oil.
Assemble the connecting rod to the piston and
insert the piston pin. Make sure that the long side
of the connecting rod is on the same side as the
internal cast boss in the piston.
4. Install new circlips. Make sure that they are
installed correctly in the groove in the piston.
5. Lubricate the piston with clean engine oil. Install
the piston rings to the piston in sequence as
follows:
5.1. Install the spiral wire for the oil control ring
in the bottom groove and locate the locking
wire inside both ends of the spiral as shown.
Using a piston ring expander tool to install
the oil control ring in the bottom groove and
locate the locking wire inside both ends of
the spiral as shown. Ensure that the ring
gap is positioned 180° to the locking wire.
Note: The correct ring orientation can also
be determined from the profile shape of the
ring as shown at C.
5.2. Install the No.2 compression ring into
the middle groove. Note that new rings
have a reference number etched on one
face. Make sure that this face is installed
uppermost in the piston groove. Note:
The correct ring orientation can also be
determined from the profile shape of the
ring as shown at B.
5.3. Install the No.1 compression ring into the
top groove. Note that new rings have a
reference number etched on one face.
Make sure that this face is installed
uppermost in the piston groove. Note:
The correct ring orientation can also be
determined from the profile shape of the
ring as shown at A.
6. Rotate the piston rings so that the ring gaps are
120° apart as shown.
15 - 148 9823/1700-1 15 - 148

15 - Engine
36 - Piston
03 - Piston Ring
03 - Piston Ring
Introduction
Gas sealing inside the piston is achieved by the use

of piston rings. The rings are loosely installed into
grooves in the piston. The rings are split at a point in
the rim, to allow them to press against the cylinder
with a light spring pressure.
Two types of ring are used:
- Upper rings have solid faces and provide gas

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

shaped profile, to act as oil scrapers.
15 - 149 9823/1700-1 15 - 149

15 - Engine
39 - Manifold
39 - Manifold
Contents Page No.
15-39-00 General ......................................................................................................................... 15-151
15 - 150 9823/1700-1 15 - 150

15 - Engine
39 - Manifold
00 - General
00 - General
Introduction
15 - 151 9823/1700-1 15 - 151

15 - Engine
42 - Rocker and Fittings
Contents Page No.
15-42-00 General ......................................................................................................................... 15-153

15-42-06 Rocker Cover ............................................................................................................... 15-162
15-42-09 Push Rod ..................................................................................................................... 15-164
15-42-21 Tappet ........................................................................................................................... 15-166
15-42-24 Tappet Cover ................................................................................................................ 15-168
15 - 152 9823/1700-1 15 - 152

15 - Engine
00 - General
Introduction .................................................. 15-153 The rocker assembly is an indirect valve actuating
Technical Data ............................................. 15-154 system consisting of rocker arms and a shaft.
Component Identification ............................. 15-155
Operation ..................................................... 15-156 The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
Check (Condition) ........................................ 15-157 movement at the poppet valve to open it. One end is
Remove and Install ..................................... 15-158 raised and lowered by a rotating lobe of the camshaft
Disassemble and Assemble ........................ 15-160 via a tappet and push rod while the other end acts
on the bridge piece which is connected to the valve
stem.
15 - 153 9823/1700-1 15 - 153

15 - Engine
00 - General
Technical Data
Table 107. Rocker Levers, Rocker Shafts and Tappets Data

Valve tip clearances (measured cold):
- SA, SB, SC Inlet: 0.19 –0.27 mm
Exhaust: 0.56 –0.64 mm
- SD, SF Inlet: 0.35 mm
Exhaust: 0.56 –0.64 mm
Rocker lever bore diameter
- min 26.046 mm
- max 26.129 mm
Rocker shaft diameter
- min 26 mm
- max 26.021 mm
Tappets stem diameter
- min 19.987 mm
- max 19.975 mm
Tappet bore diameter
- min 20 mm
- max 20.021 mm
Tappet height (maximum) 55.25 mm
15 - 154 9823/1700-1 15 - 154

15 - Engine
00 - General
Figure 300.
2
4
6
2 1
4
3
5
7
2
4
2
4
2
4
2
4
2
4
743830
1 Rocker shaft assembly 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Bridge pieces (x8)
7 Push rods (x8)
15 - 155 9823/1700-1 15 - 155

15 - Engine
00 - General
Operation
When the camshaft lobe raises the outside of the rocker arm is permitted to return due to the camshafts
rocker arm, the inside presses down on the valve rotation, the inside rises to allow the valve spring to
stem to open the valve. When the outside of the close the valve.
Figure 301.
1 Oil feed from main gallery 2 Small transfer gallery

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

where it flows by gravity along a groove to the rocker
Oil is fed from the main gallery via a drilling which tip.
passes up through the crankcase and the cylinder
head to a small transfer gallery under the rocker
shaft pedestal. The oversize rocker shaft fixing bolt
hole allows oil to pass into a drilling in the centre of
the rocker shaft. Further cross drillings transfer oil
to each of the rocker pivot bushes. A cross drilling
15 - 156 9823/1700-1 15 - 156

15 - Engine
00 - General
Check (Condition)
1. Check the rocker shaft and rocker bushings for
signs of damage and excessive wear. Measure
the rocker shaft diameter and rocker bearing
bushes to confirm they are within service limits.
Refer to Technical Data. Note: The rocker
bearing bushes are not renewable. If a rocker
bearing bush is damaged or worn the rocker
must be renewed as a complete assembly.
2. Make sure that all oil-ways and cross drillings in
the rocker shaft, rocker arms and pedestals are
clear and free from debris. Use an air line to blow
through cross drillings.
15 - 157 9823/1700-1 15 - 157

15 - Engine
00 - General
Remove and Install
1. Make sure that the engine is safe to work on. If 3. Disconnect and remove the fuel pipes from the
the engine has been running, let it cool before fuel injectors, refer to Fuel pipes (PIL 18-96).
4. Remove the rocker cover, refer to (PIL 15-42).
Figure 302.
2
4
6
2 1
4
3
5
7
2
4
2
4
2
4
2
4
2
4
743830
1 Rocker shaft assembly 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Bridge pieces (x8)
7 Push rods (x8)
15 - 158 9823/1700-1 15 - 158

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

Item Nm
2 24
3 24
15 - 159 9823/1700-1 15 - 159

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

15-42).
1. Remove the rocker cover. Refer to (PIL 15-42).
Figure 303.
2
2
3
1
2
2
4
4
4
5
4
5
6
7
4
1 Rocker shaft 2 Rocker shaft fixing bolts (x7)

3 Rocker shaft - Oil feed pedestal fixing bolt (x1) 4 Pedestals (x7)
5 Oil feed pedestal (x1) 6 Rockers - inlet (x4)
7 Rockers - exhaust (x4) 8 Wave washers (x8)
15 - 160 9823/1700-1 15 - 160

15 - Engine
00 - General
Disassemble
1. Lift out the rocker shaft fixing bolts, then slide
the pedestals, rockers and wave washers off the
rocker shaft as shown. Label the pedestals and
rockers to make sure that they are installed in the
correct positions on assembly.
2. Check the rocker shaft and rocker bushings for
signs of damage and excessive wear. Refer to
Check (Condition) (PIL 15-42).
Assemble
the disassemble procedure. Additionally do the
following steps.
2. Lubricate the rocker shaft and rocker bearing
bushes with clean engine oil.
3. Make sure that the rockers and pedestals are
installed in their original positions along the
rocker shaft. Note the position of the oil feed
pedestal.
4. Insert the rocker shaft fixing bolts to hold the
rockers and pedestals loosely in position before
fitting the assembly into the cylinder head. Note
the position of the longer bolt.
After Assembly
1. Install the rocker assembly. Refer to (PIL 15-42).
2. Install the rocker cover. Refer to (PIL 15-42).
15 - 161 9823/1700-1 15 - 161

15 - Engine
06 - Rocker Cover
06 - Rocker Cover
Remove and Install
Before Removal 3. Disconnect and remove the fuel pipes from the
injectors.
you start the service work. 3.1. Caps for blanking the open ends of the fuel
pipes are supplied with the rocker cover
2. Clean the top of the rocker cover and around
gasket kit.
the fuel injectors. Refer to Engine - Clean (PIL
15-00).
Figure 304.
7
4
1
2
5
3 8
1 Rocker cover 2 Bolts (x6)

3 Pipe stub (breather hose) 4 Turbocharger outlet (Turbocharged engines
only) Injector seals
5 Inlet manifold 6 Gasket
7 Injector sleeves/covers 8 Rocker cover injector seals
15 - 162 9823/1700-1 15 - 162

15 - Engine
06 - Rocker Cover
Remove
2. Disconnect the breather hose from the pipe stub.
3. Disconnect the air hose from the turbocharger
outlet and inlet manifold. Remove the hose. (For
Turbocharged Engine Only)
4. Remove the bolts and lift the rocker cover from
the cylinder head.
5. Discard the gasket.
6. Put the sleeves/covers over the injectors.
7. The rocker cover injector seals must be replaced.
Refer to Injector seals (PIL 18-18).
Install
steps.
2. Remove all oil and sludge contamination from
inside the rocker chamber.
3. Install new the injector seals. Refer to Injector
seals (PIL 18-18).
4. Install new the rocker cover gasket.
5. Prevent damage to the seals. Put sleeves/covers
on the four injectors. Apply a rubber lubricant to
the seals and then install the rocker cover.
7. Remove the sleeves/covers.
After Installation
1. Connect the fuel pipes to the injectors.
2. Start the engine and check for oil and fuel leaks.

Item Nm
B 24
15 - 163 9823/1700-1 15 - 163

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

Introduction .................................................. 15-164 Push rods are used in a reciprocating engine to open
Remove and Install ..................................... 15-165 and close the valves. They are moved by the cams
on the camshaft. One end is pushed up by the cam
and the other end makes contact with the rocker
arms which rotates and pushes the valve open.
15 - 164 9823/1700-1 15 - 164

15 - Engine
09 - Push Rod
Remove and Install

15 - 165 9823/1700-1 15 - 165

15 - Engine
21 - Tappet
21 - Tappet Figure 305.
Remove and Install

Special Tools
Description Part No. Qty. A
Crankshaft / 892/01148 1
Camshaft Timing Pin
(444/448/672 Engine)
Before Removal
A Timing pin - camshaft
injectors.
Refer to: PIL 18-96. 11. Remove the taper blanking plug and insert
crankshaft locking pin. The camshaft and
3. Remove the rocker cover. crankshaft locking pins must be in position to lock
Refer to: PIL 15-42-06. the crankshaft and camshaft before removing the
camshaft assembly.
4. Remove the fuel injection pump. Special Tool: Crankshaft / Camshaft Timing Pin
Refer to: PIL 18-18-15. (444/448/672 Engine) (Qty.: 1)
5. Remove the rocker assembly and push rods. Figure 306.

6. Remove the starter motor.
Refer to: PIL 15-75-00. B
8. Remove the flywheel.
C
Refer to: PIL 15-54-00. B Timing pin- crankshaft
C Blanking plug
9. Remove the flywheel housing.
Refer to: PIL 15-54-03. 12. Remove the fuel injection pump drive gear.
10. Rotate the crankshaft until the camshaft timing
pin can be inserted through the gear and into the
aligning hole in the rear gear case. Removal
Special Tool: Crankshaft / Camshaft Timing Pin The engine must be inverted. DO NOT attempt
(444/448/672 Engine) (Qty.: 1) to remove the camshaft and its drive gears with
the engine upright. The tappets and push rods will
fall into the engine and further dismantling will be
required to retrieve them.
1. Remove the camshaft timing pin.

Special Tool: Crankshaft / Camshaft Timing Pin
(444/448/672 Engine) (Qty.: 1)
2. Carefully withdraw the camshaft and gear
assembly from the crankcase. Make sure you
fully support the camshaft to prevent the lobes
contacting the bearing surfaces in the crankcase.
The bearing surfaces can easily be damaged by
the sharp hard edges on the cam lobes.
15 - 166 9823/1700-1 15 - 166

15 - Engine
21 - Tappet
Figure 307. Inspection

1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting.
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the
dimensions are within service limits.
A
4. Inspect the cam bearing surfaces inside the
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within
service limits.
5. Inspect the bearing surfaces of the tappets for
the dimensions are within service limits.
D 6. Inspect the tappet bores inside the crankcase for
the dimensions are within service limits.
A Timing pin - camshaft 7. If any of the camshaft bearings or lobes are worn
D Camshaft and drive gear or damaged then the relative oil feed galleries in
the cylinder block and camshaft may be blocked.
3. Access the tappets through the apertures in
Make sure all oil ways are clear and free from
the crankcase bedplate next to the crankshaft.
debris.
Lift out the tappets from the crankcase using a
suitable magnetic probe. Label the tappets to
ensure replacement in their original positions. Installation
Figure 308. 1. Lubricate the tappets and tappet bores inside the
crankcase with clean engine oil.
F 2. Insert the tappets in their original positions in the
crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
E the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
E crankcase as shown. Support the camshaft
preventing the lobes contacting the bearing
surfaces in the crankcase. Before meshing the
camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
aligns with the dowel hole in the gear casing.
Insert the camshaft timing pin to lock the
camshaft in this position.
After Installation
1. Note that the fuel injection pump drive gear fixing
nut is torque tightened as part of the fuel injection
pump replacement procedure.
E Tappet (8 off)
F Magnetic probe
2. In reverse order, carry out the procedures in
Before Removal.
15 - 167 9823/1700-1 15 - 167

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

steps.
It is not necessary to remove the tappet covers 2. Inspect the tappet cover seals for signs of
unless a new rocker cover is to be installed. It is damage. Replace any damaged seals.
necessary to remove the tappet covers to measure
and adjust the valve clearances. Refer to Valve- 3. Install the tappet covers. Tighten the screws to
Adjust, Valve Clearances (PIL 15-30). the correct torque value.
Remove Table 110. Torque Values

Item Nm
the engine has been running, let it cool before A 9
3. Clean the tappet covers and the adjacent areas
of the rocker cover. Refer to Engine - Clean.
Important: Make sure that the screws do not fall
into the engine.
4. Remove the tappet cover screws.
5. Keep the screws away from the engine.
6. Use a screwdriver in the slot to remove the tappet
covers. Make sure that dirt or debris does not fall
into the engine.
Figure 309.
B B D B B
B A
E C
A Screws
B Tappet covers
C Slot
D Rocker cover
E Tappet cover seals
15 - 168 9823/1700-1 15 - 168

15 - Engine
45 - Oil Sump
45 - Oil Sump
Contents Page No.
15-45-00 General ......................................................................................................................... 15-171
15 - 169 9823/1700-1 15 - 169

Notes:
15 - 170 9823/1700-1 15 - 170

15 - Engine
45 - Oil Sump
00 - General
Introduction .................................................. 15-171 The lubrication system distributes oil around the
Component Identification ............................. 15-172 engine by a system of galleries and drillings in the
Remove and Install ..................................... 15-173 crankcase and cylinder head. The oil lubricates and
seals the moving parts of the engine, reducing friction
and wear. In addition the oil plays an important role in
cooling the engine by carrying heat from the engine
to the cooler. A piston cooling jet sprays oil onto the
underside of the pistons to keep them cool, refer to
(PIL 15-36).
Oil is drawn from the oil sump by the integral oil pump
via the suction strainer. The strainer prevents any
large particles of debris passing through, which may
damage the pump.
The oil passes from the outlet side of the pump

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

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

bearings it reverts to sump pressure and splash
lubricates the internal components such as rocker
tips, cam lobes and timing gear teeth. Gravity
drains the oil via drains into the cylinder head and
crankcase, back into the oil sump. A drain slot allows
the oil to drain from the timing case back to the oil
sump.
15 - 171 9823/1700-1 15 - 171

15 - Engine
45 - Oil Sump
00 - General
Figure 310.
1 Oil sump 2 Suction strainer

3 Oil pump 4 Oil cooler
5 Filter 6 Camshaft - high pressure oil feed
7 Crankshaft main bearings - high pressure oil 8 Rocker assembly - high pressure oil feed
feed
9 PTO (Power Take-Off) idler gear bearing/ 10 External high pressure oil feed connection
timing case - high pressure oil feed (crankcase) - Turbocharger (if installed)
11 Main high pressure oil feed gallery 12 Oil pressure switch
(crankcase)
Green- Oil at sump pressure Red- Oil at high pressure
Pink- Oil at lower pressure but higher than
sump pressure
15 - 172 9823/1700-1 15 - 172

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

Template for Sealant 892/01149 1 Removal
Oil Sump - Pressed
1. Remove the fixing bolts and remove the oil sump
Oil Sump Location 892/01150 2
from the engine. The oil sump may be difficult to
Dowel
remove due to adhesion of sealing compound.
Template for Sealant 892/12354 1 If necessary, carefully lever the mating flanges
Oil Sump (Cast) apart. Do not use excessive force, the oil sump
could be damaged. Be sure to retrieve the oil pick
Consumables up seal.
Clear Silicone Sealant 4102/0901 0.31 L 2. Use a gasket removal compound, carefully
remove all traces of sealing compound from the
oil sump and engine mating faces. Do not allow
Before Removal the sealing compound to enter the engine.
1. Make sure that the engine is safe to work on. 3. Use a suitable degreasing agent to thoroughly
If the engine has been running, make sure the clean the oil sump.
engine has cooled sufficiently before you start.
Figure 311.
1 Oil sump 1a Integral suction tube

1b Integral baffle plates 2 Oil sump fixing bolts (x20)
3 Oil pick up seal
15 - 173 9823/1700-1 15 - 173

15 - Engine
45 - Oil Sump
00 - General
Installation Figure 313.
1. Lightly smear the new oil pick up seal with oil and X
install into the bedplate as shown.
Figure 312.
3 Oil pick up seal

2. Install the two guide pins at the oil sump screw
holes in the engine.
Special Tool: Oil Sump Location Dowel (Qty.: 2)
S Hole
3. Use the fixing bolts to locate the template to T Hole
the oil sump mating face. Make sure that the T2 Guide pins
template is the correct way round (note that holes X 4mm Bead of sealant
are on different centres).
8. Position the oil sump with the suction tube outlet
Special Tool: Template for Sealant Oil Sump aligned with the oil pump inlet port on the engine.
(Cast) (Qty.: 1) Take care not to damage the oil pick up seal when
Special Tool: Template for Sealant Oil Sump - you install the oil sump. Damage to the seal could
Pressed (Qty.: 1) cause a drop in oil pressure and subsequently
damage to the engine.
4. Apply a bead of sealing compound around the
oil sump flange using the inside edge of the 9. Locate the oil sump on the guide pins on the
template as a guide as shown. Note the beads engine. Avoid smudging the sealant beads. DO
around holes. NOT remove the guide pins until sufficient bolts
Length/Dimension/Distance: 4 mm have been installed to secure the oil sump.
Consumable: Clear Silicone Sealant 10. Install the bolts and tighten the bolts to the correct
5. Carefully remove the template without smudging torque value. Note that the bolts are not installed
the sealant beads. at 6 positions.
6. Apply a bead of sealant so as to join the sealant Figure 314.

beads around holes with the bead around the oil
sump flange.
7. After applying the sealing compound, the oil
sump must be installed and the bolts torque
tightened within
Duration: 5 min
2 Bolts
Y No bolts to be installed at this position (x6)
15 - 174 9823/1700-1 15 - 174

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

Item Nm
2 24
15 - 175 9823/1700-1 15 - 175

15 - Engine
51 - Timing Gear
51 - Timing Gear
Contents Page No.
15-51-00 General ......................................................................................................................... 15-177

15-51-03 Crankshaft Gear ........................................................................................................... 15-182
15-51-06 Camshaft Gear ............................................................................................................. 15-185
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-186
15-51-22 Rear Case .................................................................................................................... 15-189
15 - 176 9823/1700-1 15 - 176

15 - Engine
51 - Timing Gear
00 - General
Introduction .................................................. 15-177 The timing gears are located inside a case at the
Component Identification ............................. 15-178 flywheel end of the engine.
Operation ..................................................... 15-179
Check (Condition) ........................................ 15-181 The engine must be timed so that the camshaft
operates the valves at the correct times relative to
the crankshaft position.
Valve timing is achieved by ensuring that the

camshaft drive gear is meshed to the crankshaft gear
at their correct angular positions, refer to Engine-
General, Operation, The Four Stroke Cycle (PIL
15-00) for more information about valve timing.
15 - 177 9823/1700-1 15 - 177

15 - Engine
51 - Timing Gear
00 - General
Figure 315.
8
1
2 9
3
7
4
5
1
2
3
1 High duty PTO (Power Take-Off) idler gear 2 Idler gear hub
3 Idler gear hub retaining screws (x3) 4 Flywheel hub
5 Flywheel hub fixing bolt 6 Idler gear bearing bush
7 Crankshaft gear 8 Oil feed drilling
9 Idler gear hub location dowel
15 - 178 9823/1700-1 15 - 178

15 - Engine
51 - Timing Gear
00 - General
Operation
All the gears are driven via the crankshaft gear as • Oil pump gear-The lubrication oil pump is driven
follows: directly by the crankshaft gear.
• Power Take-Off (PTO)-driven by the crankshaft
• Camshaft gear-The camshaft is driven at half gear via idler gear.
crankshaft speed. • Low Duty Power Take-Off (PTO) Gear (if
• High pressure fuel pump gear-The high installed)-driven by the camshaft gear.
pressure fuel pump is driven via the camshaft
gear installed to the camshaft.
Figure 316.
F
B
D
G
H
A
A Crankshaft gear B Camshaft gear

C Fuel injection pump gear D Compound camshaft gear
E Oil pump gear F Heavy duty PTO device gear (if installed)
15 - 179 9823/1700-1 15 - 179

15 - Engine
51 - Timing Gear
00 - General
G Heavy duty PTO device gear (if installed) H Low duty PTO device gear (if installed)
15 - 180 9823/1700-1 15 - 180

15 - Engine
51 - Timing Gear
00 - General
Check (Condition)
1. Inspect the gears for wear or damage. If one or
more of the gears are worn or damaged, replace
them.
15 - 181 9823/1700-1 15 - 181

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

3. Remove the flywheel housing. Refer to (PIL
Crankshaft / 892/01148 2 15-54).
Camshaft Timing Pin
(444/448/672 Engine) 4. Rotate the crankshaft until the camshaft locking
pin can be inserted through the gear and into the
Note: The illustrations show the engine inverted. If aligning hole in the rear gear case. Note: The
the drive gear components are being removed prior camshaft and crankshaft locking pins must be
to crankshaft or camshaft removal the engine must in position to lock the crankshaft and camshaft
be inverted. If the gear components only are being before removing the crankshaft gear.
removed (for inspection/renewal) then the engine
need not be inverted. Special Tool: Crankshaft / Camshaft Timing Pin
(444/448/672 Engine) (Qty.: 2)
Before Removal 5. Remove the taper blanking plug and insert the
crankshaft locking pin.
1. Remove the starter motor. Refer to (PIL 15-75).
15 - 182 9823/1700-1 15 - 182

15 - Engine
51 - Timing Gear
Figure 317.
7 T1
T2
6
1 Drive gear and flywheel hub fixing bolt 2 Flywheel hub

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

Make sure you retrieve the location dowel.
1. Remove the flywheel hub fixing bolt and remove
the flywheel hub.
15 - 183 9823/1700-1 15 - 183

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

Item Nm
1 47
6 11
15 - 184 9823/1700-1 15 - 184

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

the end of the camshaft and cannot be removed
individually. If the gear is damaged or worn the
complete camshaft and gear assembly must be
replaced. Refer to Camshaft- Remove and Install
(PIL 15-15).
15 - 185 9823/1700-1 15 - 185

15 - Engine
51 - Timing Gear
09 - Fuel Injection Pump Gear
Remove and Install
Note: The illustrations show the engine inverted. If 2. Loosely install the high pressure fuel pump and
the drive gear components are being removed prior fixing nut, retain the gear.
to crankshaft or camshaft removal the engine must
be inverted. If the gear components only are being 3. Remove the starter motor. Refer to (PIL 15-75).
removed (for inspection/renewal) then the engine
need not be inverted. 4. Remove the flywheel. Refer to (PIL 15-54).
Before Removal 15-54).
1. Remove the high pressure fuel injection pump.
15 - 186 9823/1700-1 15 - 186

15 - Engine
51 - Timing Gear
Figure 318.
1 Drive gear - high pressure fuel pump 2 Fixing nut - drive gear - high pressure fuel pump
Remove Install
1. Remove the fixing nut and lift out the gear. 1. Use the fixing nut to loosely install the high
pressure fuel pump and the drive gear. DO NOT
2. If the rear timing case is to be removed, remove lock the gear to the taper on the fuel pump drive
the high pressure fuel pump. shaft.
2. Follow the procedures listed under Before
Removal in reverse order. Note that the gear
fixing nut is torque tightened as part of the
15 - 187 9823/1700-1 15 - 187

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

15 - 188 9823/1700-1 15 - 188

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

Description Part No. Qty. device (if installed).
Template for Sealant 892/01176 1 7. Remove the low duty PTO device (if installed).
Flywheel Housing to
Gear Case (4 Cyl and 6 8. Remove the flywheel. Refer to (PIL 15-54).
Cyl Elec)
Before Removal 15-54).
1. Drain the oil from the engine. Refer to (PIL 10. Remove the fuel injection pump drive gear. Refer
15-21). to (PIL 15-51).
2. Disconnect and remove the fuel pipes from the 11. Remove the oil pump. Refer to (PIL 15-60).
injectors. Refer to (PIL 18-96). 12. Remove the high duty PTO idler drive gear (if
3. Remove the fuel injection pump. Refer to (PIL installed). Refer to (PIL 15-51).
18-18). 13. Remove the crankshaft drive gear. Refer to (PIL
4. Remove the fuel lift pump. Refer to (PIL 18-21). 15-51).
5. Remove the starter motor. Refer to (PIL 15-75). 14. Remove the camshaft. Refer to (PIL 15-15).
15 - 189 9823/1700-1 15 - 189

15 - Engine
51 - Timing Gear
22 - Rear Case
Figure 319.
2
T1
3
T1
1
Y B (T2) C (T2) X X
P1 5 A (T2)
X
P1 1
Y
Y
P1 Y
X X
Z V
1 Timing gear case - rear 2 Timing case fixing bolts (x19)

3 Crankcase/bedplate assembly 4 Dowel
5 Dowel - with flats P1 Anaerobic sealant
T1 Alignment pins (Locally manufacture) T2 Sealant template (comprises: Main template
- A, Long gallery template - B, Short gallery
template - C
15 - 190 9823/1700-1 15 - 190

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

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

whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 1. Replace all the components listed under Before
put together) it will immediately start to harden. Make removal in reverse order.
sure that all the necessary tools, bolts etc. are readily
available prior to assembling the components. The Table 113. Torque Values
parts must be installed and torque tightened within
Item Nm
5 minutes (with a maximum permissible time of 15
minutes). 2 37
Install
1. Carefully remove all traces of the old sealing
compound from the timing case and crankcase/
bedplate assembly mating faces. Make sure
that the mating faces are clean and free from
damage. Clean the inside of the timing case
using a suitable degreaser.
2. Install two alignment pins T1 to the crankcase/
bedplate assembly.
3. Make sure that dowels are correctly located in the
crankcase. Note: Dowel 5 has flats which must
be positioned relative to dowel 4, as shown at
W. This ensures correct alignment of the timing
cover.
4. The sealant template T2 comprises three pieces.
Locate parts B and C using the holes in the
templates and fixing bolts at positions Y as
shown.
Special Tool: Template for Sealant Flywheel
Housing to Gear Case (4 Cyl and 6 Cyl Elec)
(Qty.: 1)
5. Use the templates B and C as a guide apply a
continuous 1.5 mm (0.060 in.) bead of sealant
P1 to the case. Remove the bolts from positions
Y. Remove the templates make sure you do not
smudge the sealant. Discard the templates.
6. Locate part A of the template T2 using the holes
in the template and bolts at positions X as shown.
7. Use the template A as a guide apply a continuous
1.5 mm (0.060 in.) bead of sealant P1 to the case.
Do not follow the template at V, instead apply a
continuous bead Z (inboard of the fixing hole).
Remove the bolts from positions X. Remove the
template make sure you do not smudge the
sealant. Discard the template.
8. Locate the timing case on the alignment pins T1
and install the timing case fixing bolts (remove
15 - 191 9823/1700-1 15 - 191

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

15-54-03 Housing ........................................................................................................................ 15-197
15-54-09 Gear Ring ..................................................................................................................... 15-200
15-54-12 Drive Plate .................................................................................................................... 15-201
15 - 192 9823/1700-1 15 - 192

15 - Engine
54 - Flywheel
00 - General
Introduction .................................................. 15-193 Flywheels are used to provide continuous energy in
Component Identification ............................. 15-194 systems, where the energy source is not continuous.
Remove and Install ..................................... 15-195 In such cases, the flywheel stores energy when
torque is applied by the energy source, and it
releases stored energy when the energy source is
not applying torque to it.
In a reciprocating engine, a flywheel is used to

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

stores energy when torque is exerted on it by a firing
piston, and it releases energy to its mechanical loads
when no piston is exerting torque on it.
15 - 193 9823/1700-1 15 - 193

15 - Engine
54 - Flywheel
00 - General
Figure 320.
1 Flywheel
2 Flywheel gear ring
15 - 194 9823/1700-1 15 - 194

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

before you start. The flywheel is installed with a 1. Remove the bolts and withdraw the flywheel from
crankshaft position sensor target disc. DO NOT the crankshaft hub. The bolts MUST NOT be
remove the target disc. If the disc is defective the reused. Discard the bolts.
flywheel must be replaced.
Figure 321.
3 1 2
1
T3
1 Flywheel 2 Flywheel fixing bolts (x8)

3 Flywheel location dowel Y Angle tightening mark
15 - 195 9823/1700-1 15 - 195

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

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

Item Torque Value Angle (de-
(Nm) grees)
2 (Ist Stage) 40
2 (2nd Stage) 120
2 (Final Stage) +120
15 - 196 9823/1700-1 15 - 196

15 - Engine
54 - Flywheel
03 - Housing
03 - Housing
Remove and Install
Special Tools 2. Remove the flywheel.

Description Part No. Qty. Refer to: PIL 15-54-00.
Template for Sealant 892/01176 1
Flywheel Housing to 3. Remove the starter motor.
Gear Case (4 Cyl and 6 Refer to: PIL 15-75-00.
Cyl Elec)
Remove
Before Removal
1. Remove the flywheel housing fixing bolts and
The flywheel housing is integral with the drive gears then separate the flywheel housing from the gear
front case. When the housing is removed the drive case.
gears will be exposed. Do not attempt to remove
the camshaft and the drive gears. Removing the 2. If required, undo the bolts and remove the access
camshaft with the engine in the upright position cover.
will cause the tappets to dislodge, requiring the
crankcase to be dismantled. 3. Remove and discard the crankshaft rear oil seal.
Take care not to damage the seal bore in the
1. This procedure requires service parts. Make housing.
before you start.
15 - 197 9823/1700-1 15 - 197

15 - Engine
54 - Flywheel
03 - Housing
Figure 322.
4 Z
3
Y Y
2
6
2 X
T4 Y
1 Flywheel housing 2 Dowel - 12 mm

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

inside of the flywheel housing.
1. Carefully remove all traces of the old sealant
compound from the flywheel housing mating 3. Carefully inspect all gears, bearings and shafts
faces. for signs of excessive wear or damage. If wear
or damage is evident, the components must be
renewed.
15 - 198 9823/1700-1 15 - 198

15 - Engine
54 - Flywheel
03 - Housing
Refer to: PIL 15-51. After Installation

Install 1. Install a new crankshaft rear oil seal. Refer to
(PIL 15-12-09).
Anaerobic sealant will not start to cure whilst it
is open to the atmosphere, however when air is 2. Install the flywheel.
excluded (for instance when the two parts are put Refer to: PIL 15-54-00.
together) it will immediately start to harden. Make
sure that all the necessary tools, bolts etc. are readily 3. Install the starter motor.
available prior to assembling the components. The Refer to: PIL 15-75-00.
parts must be installed and torque tightened within 5
min with a maximum permissible time of 15 min Table 115. Torque Values
1. The installation procedure is the opposite of the Item Nm
removal procedure. Additionally do the following 4 47
steps. 5 24
2. Make sure that all items are clean and free from 7 24
3. Make sure that the dowels are installed to the
mating face of the flywheel housing.
4. Install the sealant template T4 on the housing.
Locate the holes in the template, use the dowel
and three fixing bolts in the fixing points.
Special Tool: Template for Sealant Flywheel
Housing to Gear Case (4 Cyl and 6 Cyl Elec)
(Qty.: 1)
5. Use the template T4 as a guide, apply a
continuous bead of sealant around the flywheel
housing mating face
5.1. Some engines feature a flywheel housing
with a different fixing hole pattern. Use the
template to apply the sealant but apply
sealant manually in the position shown at Z.
6. Remove the three fixing bolts at positions.
Remove the template T4, make sure not to
smudge the sealant. Discard the template.
7. Locate the flywheel housing on the alignment
pins T3 on the crankcase and install the fixing
bolts. Progressively tighten the bolts to the
7.1. Remove the alignment pins to install the last
two M10 fixing bolts.
7.2. The parts must be separated, thoroughly
cleaned and fresh sealant applied if the
parts have not been torque tightened within
the maximum time period.
Duration: 15 min
8. Install the access cover and use the bolts to
secure. Tighten the bolts to the correct torque
value. Refer to Table 115.
15 - 199 9823/1700-1 15 - 199

15 - Engine
54 - Flywheel
09 - Gear Ring
09 - Gear Ring of the gear teeth as shown. Drive a chisel into the
adjacent tooth to spread the gear ring apart. Take
care not to damage the flywheel or the position
Remove and Install sensor target disc.
CAUTION Wear eye protection when you drive
the gear ring off the flywheel. Installation
If the flywheel gear teeth are damaged or excessively damage and corrosion.
worn, the gear ring can be replaced with a new one.
2. Heat up the new gear ring, preferably in an
Before Removal oven to make sure that the heat is applied
evenly around the circumference, to the specified
This procedure requires service parts. Make sure temperature.
you have obtained the correct service parts before Temperature: 280 °C ( 535.6 °F)
you start. Refer to the Parts Catalogue.
3. When the gear ring is sufficiently heated, install
1. Remove the flywheel from the crankshaft hub. the gear ring into position over the flywheel. Make
sure that the gear ring is installed the correct way
Figure 323. around.
X
4. Allow the gear ring to cool and shrink into
position.
After Installation
1. Install the flywheel to the crankshaft hub.
2
1
1 Flywheel
2 Gear ring
x Position of hole
Removal
1. Note that the gear teeth have a lead-in chamfer
on one side to assist the starter motor pinion to
engage. Note which way around the gear ring is
installed to make sure that the new gear ring is
installed the same way on assembly.
2. Place the flywheel flat on a firm surface. Drill a
hole through the gear ring below the root of one
15 - 200 9823/1700-1 15 - 200

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

Introduction .................................................. 15-201 This is a gear type coupling comprising a drive plate
Remove and Install ..................................... 15-202 bolted to the engine flywheel and a coupling clamped
to the input shaft of the wheel drive pump. Both are
contained within the engine bell housing and rear
support frame to which the wheel drive pump is fixed.
Figure 324.
B
A Drive plate
B Coupling (PIL 2731)
15 - 201 9823/1700-1 15 - 201

15 - Engine
54 - Flywheel
12 - Drive Plate
Remove and Install Table 116. Torque Values

Item Nm
Consumables
Description Part No. Size C 23
Strength)
Remove
1. Make the machine safe with the lift arm and cab
raised. Refer to (PIL 01-03).
2. Remove the Wheel drive pump and coupling,
3. Remove the bolts, remove the drive plate from
the flywheel.
Install
removal procedure. additionally do the following
steps.
2. Make sure that the drive plate is installed with
the flat face against the flywheel and the boss is
facing outwards.
3. Coat the threads of the bolts with JCB
Threadlocker and Sealer and tighten to the
(Medium Strength)
Figure 325.
A Drive plate
C Bolts
E Boss
15 - 202 9823/1700-1 15 - 202

15 - Engine
60 - Oil Pump
60 - Oil Pump
Contents Page No.
15-60-00 General ......................................................................................................................... 15-205
15 - 203 9823/1700-1 15 - 203

Notes:
15 - 204 9823/1700-1 15 - 204

15 - Engine
60 - Oil Pump
00 - General
Introduction .................................................. 15-205 The oil pump is a rotor type pump located inside the
Component Identification ............................. 15-206 timing gear case. The pump is driven by gears via
Check (Condition) ........................................ 15-208 the crankshaft.
The pump consists of two rotors, one running inside
the other. The outer rotor has one more lobe than the
inner rotor and turns on a different axis.
When rotated the gap between the inner and outer

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

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

pump body. As oil pressure increases it acts on a
spool to overcome the pressure of the spring. As the
spool moves it uncovers a port allowing pressurised
oil directly back to the inlet port. In practice the
spool is continually opening and closing to maintain
the correct oil pressure value. The valve is not
adjustable.
15 - 205 9823/1700-1 15 - 205

15 - Engine
60 - Oil Pump
00 - General
Figure 326.
5
1
1 3 2 4
1 5
8 8a
7 7a
9 4
6
1 Oil pump 2 Outer rotor

3 Inner rotor 4 Inlet port
5 Outlet port 6 Relief valve assembly
7 Relief valve spring 7a Relief valve port (return to inlet port 4)
8 Relief valve spool 8a Relief valve pressure port (connected to port 5)
9 Oil pump connecting ports (engine bed plate)
15 - 206 9823/1700-1 15 - 206

15 - Engine
60 - Oil Pump
00 - General
Figure 327.
10
10 CCV Anti drain back valve
15 - 207 9823/1700-1 15 - 207

15 - Engine
60 - Oil Pump
00 - General
Check (Condition)
1. Check the oil pump internal parts for signs of
2. Check that the engine oil pressure is within the
specified tolerance.
15 - 208 9823/1700-1 15 - 208

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

Torque Wrench 993/70111 1 1. Make sure that the engine is safe to work on. If
(10-100Nm) the engine has been running, let it cool before
The illustrations show the engine inverted. If the 2. Drain the oil from the engine, refer to (PIL 15-21).
oil pump is being removed prior to crankshaft or
camshaft removal, the engine must be inverted. If 3. Remove the starter motor, refer to (PIL 15-75).
the oil pump only is being removed (for inspection or
renewal) then the engine need not be inverted. 4. Remove the flywheel, refer to (PIL 15-54).
This procedure requires service parts. Make sure 5. Remove the flywheel housing, refer to (PIL
you have obtained the correct service parts before 15-54).
you start, refer to Parts Catalogue.
Figure 328.
4 3 X
1 Oil pump 2 Oil pump fixing bolts (x4)

3 Flywheel hub 4 Flywheel hub fixing bolt
X Crankshaft gear Y Oil pump location dowel
15 - 209 9823/1700-1 15 - 209

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

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

Item Nm
2 24
4 47
15 - 210 9823/1700-1 15 - 210

15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ......................................................................................................................... 15-213
15 - 211 9823/1700-1 15 - 211

Notes:
15 - 212 9823/1700-1 15 - 212

15 - Engine
63 - Mount
00 - General
Introduction .................................................. 15-213 Engine mounts support the engine and in some
Remove and Install ..................................... 15-214 cases the transmission, they dampen noise and
vibration. The mounts isolate the engine and
transmission from the chassis so that vibrations and
noise are not transmitted to the rest of the machine.
Most engine mounts consist of metal attachment

plates and large rubber insulator blocks. The rubber
portions of the mount are flexible and provide the
cushioning that dampens the engine vibrations.
The metal bracket part of the mount provides the
mechanical support and attachment points for the
engine mounts.
15 - 213 9823/1700-1 15 - 213

15 - Engine
63 - Mount
00 - General
Remove and Install
Remove
3. Remove the engine compartment cover.
4. Remove the engine.
5. Remove the engine mounts.
Install
removal procedure.
15 - 214 9823/1700-1 15 - 214

15 - Engine
69 - Oil Cooler
69 - Oil Cooler
Contents Page No.
15-69-00 General ......................................................................................................................... 15-217
15 - 215 9823/1700-1 15 - 215

Notes:
15 - 216 9823/1700-1 15 - 216

15 - Engine
69 - Oil Cooler
00 - General
Introduction .................................................. 15-217
Oil Cooler Assembly
Operation ..................................................... 15-219 The oil cooler and filter are incorporated in a housing
Check (Condition) ........................................ 15-219 that is bolted to the side of the crankcase. The
Remove and Install ..................................... 15-220 housing allows transfer of lubricating oil from the
crankcase to the oil cooler and filter head.
Some installations have a remote oil filter head. The
oil cooler housing incorporates feed and return ports
for hose connections to the filter head. A remote
oil filter head is used when access to the engine is
restricted.
Oil Cooler Matrix

The oil cooler matrix is a non-serviceable part and
must not be removed from the housing. The housing/
cooler assembly is leak tested during manufacture to
minimise the risk of cross contamination of coolant
and lubricating oil.
15 - 217 9823/1700-1 15 - 217

15 - Engine
69 - Oil Cooler
00 - General
Figure 329.
B
A
A H G
E J
D
A Oil cooler housing B Bolts - cooler housing

C Oil filter head D Oil cooler matrix
E Bolts - oil cooler matrix F Port - oil pressure switch
G Bolt - fuel filter / dipstick tube clamp H Drain plug - oil filter
J Sealing gasket
15 - 218 9823/1700-1 15 - 218

15 - Engine
69 - Oil Cooler
00 - General
Operation Check (Condition)
The oil cooler housing allows transfer of lubricating 1. Inspect the sealing faces on the oil cooler matrix,
oil from the crankcase to the oil cooler and filter head. oil cooler housing and the crankcase. Make sure
The coolant also transfers to the housing and passes that the faces are clean and free from scale or
over the oil cooler matrix causing heat to exchange damage.
from the oil to the coolant.
2. Inspect the sealing gasket and o-rings for signs
The cooled and filtered oil then passes back into the of damage. If in doubt, renew the gasket or O-
main oil gallery into the crankcase. rings.
An engine oil filler point is also included via cap and

port which aligns with a port in the crankcase.
15 - 219 9823/1700-1 15 - 219

15 - Engine
69 - Oil Cooler
00 - General
Remove and Install
Before Removal 3. Remove the oil filter.

the engine has been running, let it cool before 4. Remove the fuel filter, refer to (PIL 18-09).
2. Drain the coolant, refer to (PIL 21-00).
Figure 330.
2 1
3 8 6 7
5 4 9
1 Oil cooler housing 2 Oil cooler housing fixing bolts (x11)

3 Oil filter head 4 Oil cooler matrix
5 Oil cooler matrix fixing bolts (x4) 6 Oil pressure switch port
7 Fuel filter/dipstick tube retaining bolt 8 Oil filter drain plug
9 Sealing gasket
15 - 220 9823/1700-1 15 - 220

15 - Engine
69 - Oil Cooler
00 - General
Remove
2. Remove the fuel filter/dipstick tube retaining bolt
and release the filter and dipstick tube clips from
the cooler housing.
3. Disconnect the electrical connectors at the oil
pressure switch installed at the oil pressure
switch port.
4. Remove the bolts that attach the oil cooler
housing and lift the oil cooler housing away from
the crankcase. Do not attempt to remove the oil
cooler matrix from the oil cooler housing.
If there is cross contamination of coolant and

lubricating oil, the oil cooler matrix may be faulty. If
a faulty matrix is suspected use a new matrix and
seals.
Install
steps.
2. Make sure not to damage the sealing gasket and
correctly locate in its groove. A faulty gasket will
cause cross contamination of the lubricating oil
and coolant. If in doubt install a new gasket.
After Installation
1. Install the oil filter and fuel filter.
2. Refill the cooling system with the recommended
coolant mixture, refer to (PIL 21-00).
3. Start the engine and check for oil and coolant
leaks.

Item Nm
2 24
15 - 221 9823/1700-1 15 - 221

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

1. Refer to Oil Cooler - Check Condition.
Disassembly of the oil cooler and oil filter head
assembly is not necessary unless the oil cooler Assemble
matrix or the seals are faulty.
1. Locate the new O-rings. Install the oil cooler
Disassemble matrix. Tighten the bolts to the correct torque
value.
1. Remove the fixing bolts (x4) and lift off the oil
cooler matrix. 2. Install the sealing gasket to the oil cooler
housing.
2. Remove and discard the sealing O-rings (x2).
3. Remove the sealing gasket.
Item Nm
Figure 331. A 21–25
D
C
A
B
C
E
A
A A
A Fixing bolts (x4)

B Oil cooler matrix
C O-rings (x2)
D Sealing gasket
E Oil cooler housing
15 - 222 9823/1700-1 15 - 222

15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ......................................................................................................................... 15-225

15-72-03 Pulley ............................................................................................................................ 15-233
15-72-06 Voltage Regulator ......................................................................................................... 15-234
15 - 223 9823/1700-1 15 - 223

Notes:
15 - 224 9823/1700-1 15 - 224

15 - Engine
72 - Alternator
00 - General
Introduction .................................................. 15-225 The alternator is a three phase generator having a
Health and Safety ........................................ 15-226 rotating field winding and static power windings.
Technical Data ............................................. 15-226
Component Identification ............................. 15-227 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Operation ..................................................... 15-228 warning light to the field winding. This creates
Check (Condition) ........................................ 15-229 a magnetic field which supplements the residual
Remove and Install ..................................... 15-231 magnetism in the rotor poles. As the engine is
Disassemble and Assemble ........................ 15-232 started, the FEAD (Front End Accessory Drive)
belt drives the rotor and the alternating current is
generated in the power windings as they are cut by
the rotating magnetic field. Output is controlled by a
solid state regulator which varies the field current in
accordance with electrical demand.
15 - 225 9823/1700-1 15 - 225

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

• Ensure that the battery negative terminal is Technical data may differ between machine variants
connected to the earthing cable. and installations. For full data relating to the
• Never make or break connections to the battery alternator refer to the applicable parts information.
or alternator, or any part of the charging circuit
whilst the engine is running. Disregarding this
instruction will result in damage to the regulator
or rectifying diodes.
• Main output cables are 'live' even when the
engine is not running. Take care not to earth
connectors in the moulded plug if it is removed
from the alternator.
• During arc welding on the machine, protect the
alternator by removing the moulded plug (or if
separate output cables installed, remove the
cables).
• If slave starting is necessary, connect the
second battery in parallel without disconnecting
the vehicle battery from the charging circuit.
The slave battery may then be safely removed
after a start has been obtained. Take care to
connect batteries positive to positive, negative
to negative.
15 - 226 9823/1700-1 15 - 226

15 - Engine
72 - Alternator
00 - General
Figure 332.
A Alternator
B Regulator and brush assembly
C Drive pulley
D Tie bolts
15 - 227 9823/1700-1 15 - 227

15 - Engine
72 - Alternator
00 - General
Operation
The alternator is a three phase generator with a The solid state regulator and rectifier controls the
rotating field winding and static power windings. output. The regulator varies the field current in
accordance with electrical demand. The rectifier
When the start switch is turned on, current from the converts the AC output from the alternator to a DC
battery flows by way of the 'No Charge' warning supply for the machine battery.
light to the field winding. This creates a magnetic
field which supplements the residual magnetism in The alternator brushes and regulator/rectifier can be
the rotor poles. When the engine is started, the replaced. If the alternator bearings or windings are
engine driven accessory drive belt drives the rotor. defective the alternator must be replaced with a new
An alternating current is generated in the power one.
windings as they are cut by the rotating magnetic
field.
Figure 333.
D-
D+ B+ W
A
D+
B+
C E
A Voltage regulator B W alternator terminal

C Rectifier D D+ Alternator terminal
E D- Alternator terminal F Alternator windings
G W Alternator terminal
15 - 228 9823/1700-1 15 - 228

15 - Engine
72 - Alternator
00 - General
Check (Condition) 1. Stop the engine and turn the ignition switch to
OFF.
2. Withdraw the alternator plug and connect the
Charging Circuit Test Multimeter between the large terminals and
1. Make sure that all the battery and alternator earth. With the Multimeter set to measure,
connections are in place, secure and making Voltage: 12 V
good metal - to - metal contact, especially the
earth connections to chassis and engine. Figure 335.
2. Adjust the alternator drive belt tension if

necessary and make sure that the battery is well
charged.
3. Turn the ignition switch to the ON position. Oil
pressure and ''No Charge'' warning lights should
glow. If any light fails, re-check the connections.
4. Start the engine; all warning lights should
extinguish rapidly. If the ''No Charge'' warning
light remains ON, re-check the alternator drive
belt tension and that the battery is charged. If 2.1. The Multimeter should show battery
the oil pressure warning remains on stop the voltage.
engine Immediately and investigate the engine
lubrication system. 2.2. If the reading is zero, check the cables
for continuity, particularly at the starter
Check 1 terminals.
3. If the voltage is correct, check the alternator.
With the ignition switch ON, check that the heater
motor and screen wiper will operate.
Alternator Charging Test
If they operate normally, check the warning light bulb Figure 336.
for a blown filament.
Simultaneous failure of all items indicates a fault at

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

withdraw the triple plug from the back of the
alternator. Make a temporary connection between
the small terminal in the plug and earth as shown
below. If the 'No Charge' warning bulb still fails to
light, check the cable for continuity. If the bulb now
lights, check the alternator for a defective regulator.
Figure 334.
1. Make sure that all battery and alternator

connections are in place, secure and making
good metal to metal contact, especially the earth
connections to chassis and engine.
2. Make sure that the alternator drive belt tension is
correctly adjusted.
3. If the battery is in a fully charged condition, before
Check 2
commencing the test switch on the working lights
The following checks should be made using an for
analogue (moving pointer) type Multimeter. Duration: 3 min
15 - 229 9823/1700-1 15 - 229

15 - Engine
72 - Alternator
00 - General
4. Alternatively, operate the starter for a few 12.6. Open or short circuited power (stator)
moments with the ESOS (Engine Shut-Off windings.
Solenoid) fuse removed.
13. To check for a fault, disconnect the capacitor and
5. Install an open type shunt between the battery repeat the charging test. Renew the capacitor if
positive lead and the battery positive terminal. necessary.
Current: 100 A 14. To check for faults with the slip rings, bushes or
regulator, remove the regulator and brush box
6. Connect a Multimeter positive lead to machine
assembly. Check the condition of the brushes
side of the shunt and negative lead to battery side
and, if necessary, clean the slip rings using extra-
of the shunt.
fine glass paper. The regulator may only be
7. Connect the leads to the Multimeter and set the renewed.
Multimeter to the relevant range as follows.
15. Faults with the rectifier, rotor and stator may be
8. AVO 2002 checked only by removing and dismantling the
alternator for further testing.
8.1. Red lead to volts (middle) socket on
Multimeter.
8.2. Black lead to negative on Multimeter.
8.3. Right side slider to DC (Direct Current)
voltage.
8.4. Left side slider,Refer to Figure 336.
9. AVO 2003
9.1. Red lead to amps socket (A) on the
Multimeter.
9.2. Black lead to negative on Multimeter.
9.3. Right side slider to DC voltage
9.4. Left side slider to 200 Shunt
10. FLUKE 85
10.1. Red lead to volts socket (V ) on Multimeter.
10.2. Black lead to COM socket on Multimeter.
10.3. Set dial to mV.
11. Start the engine and run at maximum speed
(see Technical Data). Multimeter should show
maximum alternator output in Amps (see
Technical Data). The Multimeter reading should
be taken as soon as possible after starting the
engine, as the charging current will fall rapidly.
12. A zero reading indicates failure of the alternator
and may be caused by one of the following
conditions. These are listed in the order of
probability.
12.1. Defective suppression capacitor.
12.2. Dirty slip rings or worn brushes.
12.3. Defective regulator.
12.4. Defective rectifier.
12.5. Open or short circuited field (rotor)
windings.
15 - 230 9823/1700-1 15 - 230

15 - Engine
72 - Alternator
00 - General

Figure 337. Alternator location removal procedure. Additionally do the following
steps.
2. It is not necessary to adjust the position of the
alternator in order to tension the drive belt, as
the accessory drive belt arrangement is self-
tensioning.
3. Tighten the alternator securing bolts to the
4. Make sure you reconnect the electrical leads to
the alternator in the correct positions and tighten
Remove to the correct torque.
1. Disconnect the negative (-) lead followed by the Table 120. Alternator securing bolt torque
positive (+) lead from the battery terminals. Item Torque Value
2. Remove the alternator (accessory) drive belt. A 47 N·m
B 47 N·m
3. Disconnect the electrical leads from the
alternator terminals. Label the leads to make Figure 339.
sure that they are installed in the correct positions
on assembly.
L
4. Undo the alternator securing bolts and lift the
alternator away from the cylinder block mounting.
Figure 338.
A
Table 121. Alternator

electrical connection torque
B Item Torque Value
B+ 9 –13 N·m
A Alternator L 2.7 –3.8 N·m
B Securing bolts
W 2.7 –3.8 N·m
Inspect
1. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 231 9823/1700-1 15 - 231

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

1. The voltage regulator and brush set is a
combined assembly. Refer to (PIL 15-72-06).
Drive Pulley
1. Refer to (PIL 15-72-03).
15 - 232 9823/1700-1 15 - 232

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

complete alternator. Refer to: PIL 15-72-00.
15 - 233 9823/1700-1 15 - 233

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

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

complete alternator. Refer to: PIL 15-72-00.
15 - 234 9823/1700-1 15 - 234

15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ......................................................................................................................... 15-237

15-75-03 Solenoid ....................................................................................................................... 15-245
15-75-06 Brush Gear ................................................................................................................... 15-246
15 - 235 9823/1700-1 15 - 235

Notes:
15 - 236 9823/1700-1 15 - 236

15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................. 15-237 The electric starter motor is either a permanent-
Health and Safety ........................................ 15-238 magnet or a series-parallel wound direct current
Technical Data ............................................. 15-238 electric motor with a starter solenoid mounted on to
Component Identification ............................. 15-239 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Check (Condition) ........................................ 15-239 the solenoid engages a lever that pushes out the
Remove and Install ..................................... 15-241 drive pinion on the starter driveshaft and meshes the
Disassemble and Assemble ........................ 15-243 pinion with the starter ring gear on the flywheel of the
engine.
The solenoid also closes high current contacts for the

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

use, the electrical components are designed only to
operate for a time period of 20 s before overheating.
15 - 237 9823/1700-1 15 - 237

15 - Engine
75 - Starter Motor
00 - General

working on it. Park the machine on level ground Refer to Electrical System- General, Technical Data
and lower the loader arm. Stop the engine and (PIL 33-00).
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to
protect the circuits and components. The battery
must still be disconnected even if a battery
isolator is installed.
Notice: Do not isolate the machine electrics when
the engine is running, this may cause damage to
the machine electrics.
15 - 238 9823/1700-1 15 - 238

15 - Engine
75 - Starter Motor
00 - General
Component Identification Check (Condition)

Figure 340. Before carrying out the multimeter tests, check
the battery condition and make sure that all the
1 applicable electrical connections are clean and tight.
Make sure that the starter motor fixing bolts are
tightened to the correct torque.
To prevent the engine starting during the tests make

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

a multimeter. Unless otherwise stated, the readings
must be taken with the ignition switch held in the
start position (HS) and the controls set to enable the
starter motor. The readings are shown for both 12
V and 24 V systems. The highest values are for
machines with 24 V systems. Identify the applicable
3 system before carrying out the tests.
1 Solenoid Do not operate the starter motor for more than 20 s

2 Brush gear at one time. Let the starter motor cool for at least 2
3 Tie bolts min between starts.
1. Connect the multimeter across the battery

terminals.
Figure 341.
1.1. Reading in start position approximately

Voltage: 10 V
Voltage: 20 V
1.2. Minimum permissible reading in start
position
Voltage: 9.5 V
Voltage: 18 V
1.3. A low reading probably indicates a fault in
the starter motor.
2. Connect the multimeter between the starter main
terminal and the commutator end bracket. In the
start position, the reading should not be below
the reading obtained in 1 by any more than
Voltage: 0.5 V
Voltage: 1 V
15 - 239 9823/1700-1 15 - 239

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

B Commutator end bracket (Starter earth B Starter earth connection
connection) C Solenoid terminal
2.1. Minimum permissible reading in start D Start relay feed
position E Start relay switched output
H Battery positive and solenoid connection
Voltage: 9 V
Voltage: 17 V 4.1. If the reading is less than specified, connect
the multimeter between the start relay feed
2.2. If the reading is within this limit, continue to
and earth.
3. If the reading is outside the limit, proceed
to 4. 4.2. A faulty start relay or a fault in the feed to
the relay solenoid is indicated if the voltage
3. Connect the multimeter between the solenoid increases to
terminal and a good earth. Minimum permissible
reading in start position Voltage: 8 V
Voltage: 16 V
Voltage: 8 V
Voltage: 16 V 4.3. Check also the solenoid earth connection.
The fault must be in either the starter switch
Figure 343. or in the wiring between the solenoid, starter
switch, and the start relay, if the reading
between terminal and earth is less than
Voltage: 8 V
Voltage: 16 V
5. Connect the multimeter between battery
negative and starter earth connection. The
reading in the start position should be practically
zero, maximum permissible reading
Voltage: 0.25 V
Figure 345.
C Solenoid terminal
4. If the reading is less than specified, connect
the multimeter between the start relay switched
output and earth. A fault is indicated with the
wiring from the start relay to the solenoid if the
reading increases to
Voltage: 8 V
Voltage: 16 V
B Starter earth connection
15 - 240 9823/1700-1 15 - 240

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

permissible voltage, a high resistance in the
earth lead or connections is indicated.
Figure 348.
6. Connect the voltmeter between battery positive
and the starter main terminal. With the starter A
switch off, the voltmeter should indicate battery E
voltage, but it should fall to practically zero when
the switch is turned to the on position, maximum
permissible reading B
Voltage: 0.25 V
Figure 346.
D
C
A Electrical lead (Terminal 30)
B Security cover
C Starter motor
D Bolt (x3)
E Electrical lead (Terminal 50)
A Starter main terminal Remove

7. If the reading is above the maximum permissible 1. Make the machine safe.
voltage, a high resistance is present in the
insulated lead or in the solenoid. Connect the Refer to: PIL 01-03.
multimeter between the battery positive and 2. Make sure the engine is safe to work on. If the
solenoid connection. If the multimeter now reads engine has been running, make sure that the
zero with the switch closed, the fault is in the engine has cooled sufficiently before you start
solenoid. work.
Figure 347. 3. Disconnect the battery negative lead followed by
the positive lead from the battery terminals.
4. Remove the security nut and bolt, remove the
security cover (if installed).
5. Disconnect the electrical leads from the starter
motor terminals. Label the leads to make sure
they are installed in the correct positions on
assembly.
6. Undo the bolts (x3) and withdraw the starter
motor from the flywheel housing.
H Battery positive and solenoid connection Inspection

8. Finally install the engine stop fuse. 1. Check the drive pinion splines for damage and
excessive wear.
2. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 241 9823/1700-1 15 - 241

15 - Engine
75 - Starter Motor
00 - General
Install
steps.
2. Make sure that the flywheel housing and starter
motor mating faces are clean.
4. Make sure you reconnect the electrical leads to
the starter motor in the correct positions.
5. Install the security cover (if installed).

Item Nm
A 15 ± 3
D 47 ± 4
E 3.6 ± .6
15 - 242 9823/1700-1 15 - 242

15 - Engine
75 - Starter Motor
00 - General
These parts are non-serviceable if any part fails, sure the wave washer is installed inside the
replace the complete starter motor. For cleaning cover.
and checking purposes only, dismantle the motor as
1.6. Carefully install the commutator end cover,
follows:
then tighten the tie bolts.
Brush Gear Starter Solenoid
1. Check the brush gear as follows:
1. Check the starter solenoid as follows:
1.1. Remove the tie bolts and carefully separate
1.1. Disconnect the starter motor cable from the
the commutator end cover.
solenoid connector post.
1.2. Remove the screws. Remove the brush
1.2. Remove the screws and carefully withdraw
holder and brushes.
the solenoid assembly.
1.3. Check the brushes for wear. Install or
1.3. Make sure that the sealing ring is
renew the brush set as required. Renew the
undamaged and correctly installed.
brushes if they are less than
Length/Dimension/Distance: 8 mm 1.4. Before you install the solenoid make sure
you engage the pinion lever arm through
1.4. Clean the commutator. the hole in the solenoid actuator rod, then
tighten the screws.
1.5. Before installing the commutator end
cover, make sure that the sealing ring is 1.5. Reconnect the starter motor cable to the
undamaged and correctly installed. Make solenoid connector post.
15 - 243 9823/1700-1 15 - 243

15 - Engine
75 - Starter Motor
00 - General
Figure 349.
A
F C A
B
D P
E N
P G
H
K
M
743740-C1 J
L
A Starter solenoid B Screws - starter solenoid (3 off)

C Sealing ring - solenoid D Solenoid actuator rod
E Pinion lever arm F Tie bolts (2 off)
G Commutator end cover H Screws - commutator end cover (2 off)
J Brush set K Commutator
L Sealing ring - commutator end cover M Wave washer
N Cable connector post P Pinion gear
15 - 244 9823/1700-1 15 - 244

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

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

the complete starter motor.
15 - 245 9823/1700-1 15 - 245

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

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

the complete starter motor.
15 - 246 9823/1700-1 15 - 246

15 - Engine
84 - Sensor
84 - Sensor
Contents Page No.
15-84-00 General ......................................................................................................................... 15-249

15-84-09 Knock ........................................................................................................................... 15-250
15-84-29 Foot Throttle Control .................................................................................................... 15-251
15-84-33 Coolant Temperature .................................................................................................... 15-255
15-84-43 Engine Oil Level ........................................................................................................... 15-258
15 - 247 9823/1700-1 15 - 247

Notes:
15 - 248 9823/1700-1 15 - 248

15 - Engine
84 - Sensor
00 - General
00 - General
Check (Operation)
1. Check the applicable fuse.
2. Check the display for related fault codes.
3. Using Servicemaster perform the required
diagnostic tests.
4. Check the sensor condition, make sure the
sensor or housing is not damaged, broken,
contaminated or subjected to excess heat. If
necessary replace sensor and make sure the
damage can not reoccur.
5. Check the condition of sensor to harness
connection, make sure the seals are in place,
check for signs of corrosion or contamination.
Repair/replace as necessary.
6. Check the sensor location and make sure it is
mounted correctly. Where applicable check the
sensor is tightened to the correct torque. Refer to
the applicable sensor procedure for details.
7. Check the sensor is of the correct type and
specification. If incorrect replace with correct
sensor. Refer to the applicable sensor procedure
for details.
8. Disconnect the sensor, check sensor voltage
supply at the harness connector (Refer
to the applicable sensor Technical Data
and Component Identification procedures.
Alternatively refer to engine electrical
schematic). If the voltage supply is faulty,
disconnect all other sensors in turn until voltage
supply returns. Trace the supply fault and rectify.
9. Check the sensor characteristics. Refer to the
applicable sensor Technical Data. If sensor is out
of specification replace.
10. Disconnect the harness from the engine ECM
(Engine Control Module) and inspect. Check
seals are in place, check for signs of corrosion or
contamination.
11. Check the harness continuity. Check the
machine and engine earth contacts. Repair /
replace as necessary.
15 - 249 9823/1700-1 15 - 249

15 - Engine
84 - Sensor
09 - Knock
09 - Knock
Operation
The knock sensors detect pre-ignition (knock) by

means of sensing engine vibration. The vibration
signal is sent to the engine ECM (Engine Control
Module)where the ECM will adjust the fuel timing to
give optimum performance, economy and driveability
and prevent engine damage. The voltage signal is
proportional to engine vibration/acceleration.
15 - 250 9823/1700-1 15 - 250

15 - Engine
84 - Sensor
29 - Foot Throttle Control
29 - Foot Throttle Control Technical Data

Technical Data ............................................. 15-251
Operation ..................................................... 15-252
Throttle Position Sensor
Remove and Install ..................................... 15-253 Figure 350. Throttle Pedal Movement
A
B
Table 123.
Pedal Position Voltage Output
A Signal 1 = 0 Signal 2 = 5
B Signal 1 = 2 Signal 2 = 3
C Signal 1 = 5 Signal 2 = 0
15 - 251 9823/1700-1 15 - 251

15 - Engine
84 - Sensor
Operation
The throttle pedal sensor (TPS) converts the

movement from the pedal into an electrical signal
for interpretation by the Engine ECU (Electronic
Control Unit), variflow pump ECU hi(if installed) or
the hydraulic control ECU.
The the movement of the throttle pedal is transmitted

from the footplate to the roller and the swing arm
on the throttle position sensor (TPS) unit. A variable
resistor within the TPS unit changes the voltage
output in relation to the position of the pedal.
Two signals are output from the unit, a track 1 signal

and a track 2 signal. One signal varies the voltage by
the angle below the foot pedal pad. The other signal
varies the voltage by the angle above the foot pedal
pad. Both signals will always add up to 5 V. Refer to
engine- sensor, refer to (PIL 15-84).
Figure 351.
B
A
C
D
A Throttle position sensor unit

B Throttle pedal
C Swing arm
D Roller
15 - 252 9823/1700-1 15 - 252

15 - Engine
84 - Sensor
Remove and Install
Consumables 4. Remove the floor mat from the cab.

JCB Threadlocker 4101/0250 0.01 L chassis harness, from below the cab.
Strength) 6. Remove the socket head bolts.
Remove 7. Make sure you keep the spacer plate (if

installed).
1. Park the machine and make it safe. Refer to (PIL
01-03). 8. Remove the nut to release the clip and the
connector from the floor.
2. Follow the general safety precautions. Refer to
(PIL 01-03). 9. Slowly remove the pedal assembly from inside
the cab.
3. Make sure that the engine cannot be started.
10. Pull the connector through the hole in the floor.
Figure 352.
D
B B
E
A
F
A Pedal assembly B Socket head bolts

C Spacer plate D Nut
E Connector F Hole in the floor
15 - 253 9823/1700-1 15 - 253

15 - Engine
84 - Sensor
Install
1. The installation is the opposite of the removal
procedure.
2. When you install do the following steps also:
2.1. Apply sealant to the thread of the bolts.
(Medium Strength)
15 - 254 9823/1700-1 15 - 254

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

Introduction .................................................. 15-255 The coolant temperature sensor is located on the
Remove and Install ..................................... 15-256 cylinder head at the drive belt end.
Figure 353.
1
1
1 Coolant temperature sensor 2 Cylinder head

3 Sealing washer
15 - 255 9823/1700-1 15 - 255

15 - Engine
84 - Sensor
Remove and Install
Before Removal 2. Drain the coolant, refer to (PIL 21-00).

Figure 354.
1
1
1 Coolant temperature sensor 2 Cylinder head

P1 Sealing washer
15 - 256 9823/1700-1 15 - 256

15 - Engine
84 - Sensor
Remove
2. Disconnect the electrical connector at the sensor.
3. Remove the sensor from the cylinder head.
4. Discard the sealing washer. Cap the open port
with a blanking cap to prevent loss of fluid and
ingress of dirt.
The coolant temperature sensor is a non-serviceable

item. If the sensor is faulty or damaged it must be
renewed.
Install
steps.
2. Renew the sealing washer.
3. Tighten the coolant temperature sensor to the
After Installation
1. Refill the cooling system with the recommended
coolant mixture. Refer to Technical Data (PIL
21-00-00).
2. Start the engine and check for coolant leaks.

Item Nm
1 16
15 - 257 9823/1700-1 15 - 257

15 - Engine
84 - Sensor
43 - Engine Oil Level
43 - Engine Oil Level Introduction

Introduction .................................................. 15-258 The engine oil level sensor is used to warn the
Operation ..................................................... 15-259 operator that the engine oil level is low and damage
Check (Operation) ....................................... 15-259 may be caused if it is not topped up immediately. It is
Remove and Install ..................................... 15-260 mounted on the engine oil sump.
15 - 258 9823/1700-1 15 - 258

15 - Engine
84 - Sensor
Operation Check (Operation)
The engine oil level sensor is a normally closed 1. For the full inspection and testing procedure refer
switch. When the oil level drops below a certain point to the help files in ServiceMaster.
the switch will open and the low oil warning light will
be illuminated.
15 - 259 9823/1700-1 15 - 259

15 - Engine
84 - Sensor
Remove and Install
Before Removal 2. Make sure that the engine is safe to work on.
If the engine has been running, make sure the
1. Make the machine safe. engine has cooled sufficiently before you start.
Figure 355.
A
C
B
D
E
A Engine oil level sensor B Oil level sensor float

C Bolts (x2) D Clip
E Oil Sump
Remove
2. Drain the engine oil.
3. Disconnect the electrical connector.
5. Remove the bolts (x2) securing the oil level
sensor float to the oil sump.
6. Remove the clip.
7. Remove the oil level sensor.
The engine oil level sensor is a non-serviceable item.

If the sensor is faulty or damaged it must be replaced.
Install
steps.

Item Nm
C 10 ± 1
15 - 260 9823/1700-1 15 - 260

15 - Engine
86 - Solenoid
86 - Solenoid
Contents Page No.
15-86-00 General ......................................................................................................................... 15-263

15-86-03 Engine Shut-off Solenoid (ESOS) ................................................................................ 15-264
15-86-09 Cold Start Advance ...................................................................................................... 15-268
15 - 261 9823/1700-1 15 - 261

Notes:
15 - 262 9823/1700-1 15 - 262

15 - Engine
86 - Solenoid
00 - General
00 - General
Introduction
A solenoid refers to a variety of transducer devices

that convert energy into linear motion. The term also
refers to a solenoid valve, which is an integrated
device containing an electromechanical solenoid
which actuates a hydraulic valve, or a solenoid
switch.
15 - 263 9823/1700-1 15 - 263

15 - Engine
86 - Solenoid
03 - Engine Shut-off Solenoid (ESOS)
03 - Engine Shut-off Solenoid Introduction

(ESOS)
The ESOS (Engine Shut-Off Solenoid) is attached to
Introduction .................................................. 15-264 the engine fuel injection pump.
Check (Condition) ........................................ 15-265
The ESOS is a solenoid operated fuel valve.
When the solenoid energises, by means of an engine
run / stop switch for example, the fuel supply is
connected to the fuel injection pump and the engine
can run.
When the solenoid de-energises the fuel supply to

the engine fuel injection pump is isolated. If the
engine is running it will stop, it cannot re-start until
the solenoid energises again.
15 - 264 9823/1700-1 15 - 264

15 - Engine
86 - Solenoid
Check (Condition)
If a faulty solenoid is suspected, perform tests to

confirm its serviceability.
15 - 265 9823/1700-1 15 - 265

15 - Engine
86 - Solenoid
Remove and Install
Before Removal
Figure 356.
2
1 ESOS (Engine Shut-Off Solenoid) cartridge 2 Fuel injection pump

3 O-ring
15 - 266 9823/1700-1 15 - 266

15 - Engine
86 - Solenoid
Remove
2. Disconnect the electrical connector at the ESOS.
3. Loosen the ESOS cartridge from the fuel
injection pump body.
4. Discard the O-ring. Cap the open ports to prevent
ingress of dirt.
The ESOS is a non-serviceable component. If the

ESOS is faulty or damaged it must be replaced.
It is essential that the correct solenoid is installed,
as there are types available which operate in
the reverse sense or require additional wiring and
resistors.
Install
1. Installation is the opposite of the removal
procedure.
2. Install a new O-ring.
3. Tighten the ESOS cartridge to the correct torque
value.
4. Start the engine and check for fuel leaks.

Item Nm
1 15
15 - 267 9823/1700-1 15 - 267

15 - Engine
86 - Solenoid
09 - Cold Start Advance
09 - Cold Start Advance Introduction

Introduction .................................................. 15-268 The cold start advance solenoid consists of an
Check (Condition) ........................................ 15-269 electrical solenoid and a valve which allows extra
Remove and Install ..................................... 15-270 fuel to spray into the inlet manifold at specific
temperatures for starting purposes. The fuel is
supplied to this valve by the electric fuel pump.
Under cold starting conditions, the solenoid is

energised that opens the fuel valve allowing jets of
fuel to spray into the inlet manifold and mix with the
incoming air, thus richening the air/fuel mixture to
help in cold starting conditions.
15 - 268 9823/1700-1 15 - 268

15 - Engine
86 - Solenoid
Check (Condition)
1. If a faulty solenoid is suspected, perform tests to
confirm its serviceability.
15 - 269 9823/1700-1 15 - 269

15 - Engine
86 - Solenoid
Remove and Install

Figure 357.
2
1 Cold start advance solenoid 2 Fuel injection pump

3 O-ring - cold start advance solenoid
Removal Install
1. Disconnect the electrical connector at the cold 1. Replacement is the reversal of the removal
start advance solenoid. procedure.
2. Remove the solenoid cartridge from the fuel 2. Install a new O-ring seal.
injection pump body.
3. Discard the O-ring seal. Cap all open ports to
prevent ingress of dirt and debris. 4. Start the engine and check for fuel leaks.
The cold start advance solenoid is a non-serviceable Table 127. Torque Values
item. If the solenoid is faulty or damaged it must be Item Nm
renewed. It is essential that the correct solenoid is
1 15
installed.
15 - 270 9823/1700-1 15 - 270

15 - Engine
87 - Switch
87 - Switch
Contents Page No.
15-87-00 General ......................................................................................................................... 15-273

15-87-03 Engine Oil Pressure ..................................................................................................... 15-274
15-87-09 Cold Start ..................................................................................................................... 15-277
15 - 271 9823/1700-1 15 - 271

Notes:
15 - 272 9823/1700-1 15 - 272

15 - Engine
87 - Switch
00 - General
00 - General
Introduction
The engine electrical switches send signals to the

ECM (Engine Control Module) to help the ECM
to control the smooth running of the engine and
related components. The ECM processes signals
from the switches and its response will be based
on an evaluation of the combination of the switches
signals.
After removal from the engine, protect the switches

from knocks, dampness and any high temperature
sources. The switches are not serviceable, therefore
they must be replaced in the event of damage.
15 - 273 9823/1700-1 15 - 273

15 - Engine
87 - Switch
03 - Engine Oil Pressure
03 - Engine Oil Pressure Introduction

Introduction .................................................. 15-274 The oil pressure switch is mounted in a port on the
Operation ..................................................... 15-275 oil cooler housing.
Check (Operation) ....................................... 15-275
Figure 358.
A Engine oil pressure switch B Sealing washer
15 - 274 9823/1700-1 15 - 274

15 - Engine
87 - Switch
The oil pressure switch contacts open when the 1. For the full inspection and testing procedure,
engine oil pressure is below 0.6bar. refer to the help files in ServiceMaster.
15 - 275 9823/1700-1 15 - 275

15 - Engine
87 - Switch
Remove and Install The engine oil pressure switch is a non-serviceable

item. If the switch is faulty or damaged it must be
Special Tools renewed.
Deep Socket 892/12351 1 Install
Before Removal removal procedure. Additionally do the following
steps.
the engine has been running, let it cool before 2. Renew the sealing washer.
3. Use the special tool to tighten the engine oil
Figure 359. pressure switch to the correct torque value.

A
Item Nm
1 16
B
C
A Engine oil pressure switch

B Electrical connector
C Sealing washer
Remove
2. Disconnect the electrical connector at the engine
oil pressure switch.
3. Use the special tool to remove the switch from
the oil cooler housing.
Special Tool: Deep Socket (Qty.: 1)
4. Discard the sealing washer. Cap the open port
with a blanking cap to prevent loss of fluid and
ingress of dirt.
15 - 276 9823/1700-1 15 - 276

15 - Engine
87 - Switch
09 - Cold Start
09 - Cold Start Introduction

Introduction .................................................. 15-277 The cold start switch will send a signal to turn on the
Check (Condition) ........................................ 15-278 cold start advance solenoid at specific temperatures
Remove and Install ..................................... 15-279 to help in cold starting conditions.
15 - 277 9823/1700-1 15 - 277

15 - Engine
87 - Switch
09 - Cold Start
Check (Condition)
1. If a faulty switch is suspected, use a suitable
multimeter to check that the correct supply
voltage is present at the switch electrical
connector.
2. Carry out tests on the machine electrical circuits
to check for possible wiring faults. The fault may
be caused by failure of other components within
the electrical system.
15 - 278 9823/1700-1 15 - 278

15 - Engine
87 - Switch
09 - Cold Start
Remove and Install
The engine cold start switch is a non-serviceable Before Removal

item. If the engine cold start switch is faulty or
damaged it must be renewed. 1. Make sure that the engine is safe to work on. If
2. Drain the coolant. Refer to (PIL 21-00).
Figure 360.
2
1 Engine cold start switch 2 Crankcase

3 Sealing washer - switch
15 - 279 9823/1700-1 15 - 279

15 - Engine
87 - Switch
09 - Cold Start
Removal
1. Disconnect the electrical connector at the engine
cold start switch.
2. Remove the engine cold start switch from the
crankcase.
3. Discard the O-ring. Cap the open ports to prevent
ingress of dirt.
Install
steps.
2. Install a new sealing washer.
3. Tighten the engine cold start switch to the correct
torque value.
After Installation
1. Fill the cooling system with the recommended
coolant mixture. Refer to (PIL 21-00).

Item Nm
1 16
15 - 280 9823/1700-1 15 - 280

15 - Engine
88 - Cold Start Heater
Contents Page No.
15-88-00 General ......................................................................................................................... 15-283
15 - 281 9823/1700-1 15 - 281

Notes:
15 - 282 9823/1700-1 15 - 282

15 - Engine
00 - General
00 - General Operation
Operation ..................................................... 15-283 The system aids engine starting by heating the air
Diagram ....................................................... 15-285 in the induction manifold through an electrical grid
heater. Operation of the system is fully automatic and
is controlled by the engine ECU (Electronic Control
Unit).
The power to the grid heater is supplied by a primary

fuse through the link harness to relay. The relay when
energised supplies power to the heater through the
power lead.
The relay is located at the side of the coolant

expansion tank.
The relay is energised by a feed from the engine

compartment fusebox, with the engine ECU proving
an earth for the relay.
The heating sequence is as follows:
1. Ignition key set to the on position.

2. Warning light illuminated (grid heater on)- engine
not ready to start.
Figure 361.
B
A
G
C D
E
F
A Coolant expansion tank B Warning light- grid heater on
15 - 283 9823/1700-1 15 - 283

15 - Engine
00 - General
C Relay D Primary fuse

E Induction manifold F Grid heater
G Heater H Harness
3. After a preset pre-heat time the warning light will

off- engine ready to start.
3.1. The pre-heat stage can not be repeated
unless the ignition key is first set to the off
position.
4. Turn the ignition key to engage the starter motor
and start the engine- grid heater on.
5. Engine started and starter motor disengaged-
grid heater off.
5.1. If the engine stalls and is restarted without
turning the ignition key to off, the grid heater
will come on while the starter motor is
engaged.
The 'pre-heat' stage can not be repeated unless the

ignition key is first set to the off position.
If the engine stalls and is restarted without turning the

ignition key to off position, the grid heater will come
on while the starter motor is engaged.
15 - 284 9823/1700-1 15 - 284

15 - Engine
00 - General
Diagram
Figure 362.
FUSE
A C
D
FUSE
F
G
A Primary fuse link B Engine compartment fuse

C Cold start relay D Grid heater element
E Engine ECU (Electronic Control Unit) F +VE
G -VE
15 - 285 9823/1700-1 15 - 285

15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ......................................................................................................................... 15-287
15 - 286 9823/1700-1 15 - 286

15 - Engine
90 - Air Intake
00 - General
00 - General
Check (Condition)
15 - 287 9823/1700-1 15 - 287

Notes:
15 - 288 9823/1700-1 15 - 288

Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-00-30 Throttle Control System ................................................................................................. 18-13
18-03 Tank
18-03-00 General ........................................................................................................................... 18-15
18-06 Level Sender
18-06-00 General ........................................................................................................................... 18-21
18-09 Filter
18-09-00 General ........................................................................................................................... 18-25
18-09-09 Pre-Filter Element .......................................................................................................... 18-30
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-33
18-12-04 Water in Fuel Sensor ..................................................................................................... 18-36
18-18 Injection
18-18-00 General ........................................................................................................................... 18-39
18-18-03 Injector ............................................................................................................................ 18-47
18-18-07 Injector Seal ................................................................................................................... 18-51
18-18-15 Pump .............................................................................................................................. 18-53
18-21 Fuel Pump
18-21-00 General ........................................................................................................................... 18-67
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-75
18-24-03 Inlet Manifold .................................................................................................................. 18-77
18-24-04 Outlet Manifold ............................................................................................................... 18-81
18-24-06 Silencer .......................................................................................................................... 18-85
18-35 Turbocharger
18-35-00 General ........................................................................................................................... 18-89
18-39 Fuel Cooler
18-39-00 General ........................................................................................................................... 18-95
18-96 Fuel Pipe
18-96-00 General ........................................................................................................................... 18-99
18-96-03 High Pressure Pipe ...................................................................................................... 18-103
18-96-06 Low Pressure Pipe ....................................................................................................... 18-105
9823/1700-1
2018-06-27
Acronyms Glossary
DEF Diesel Exhaust Fluid

IMV Inlet Metering Valve
SCR Selective Catalytic Reduction
TDC Top Dead Centre
WIF Water in Fuel
9823/1700-1
2018-06-27
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3

18-00-30 Throttle Control System ................................................................................................. 18-13
18 - 1 9823/1700-1 18 - 1
Notes:
18 - 2 9823/1700-1 18 - 2
00 - General
Introduction ...................................................... 18-3
Health and Safety ........................................... 18-4
(For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3
Mech Turbo and Aftercooled)
Technical Data ................................................. 18-4
Component Identification ................................. 18-5 The engines use a direct fuel injection system
Operation ......................................................... 18-6 controlled with a mechanically actuated fuel injection
Fault-Finding .................................................... 18-8 pump.
Discharge and Pressurise ............................... 18-9 The fuel injection pump is mounted in the crankcase.
Clean ............................................................... 18-9 The fuel injection pump is operated by lobes on the
Bleed ............................................................. 18-12 camshaft. The fuel transfer pump is located on the
right hand side of the crankcase. The fuel transfer
pump is also operated by lobes on the camshaft.
The fuel injection pump conforms to requirements for
emissions. No adjustments to the fuel injection pump
timing and high idle are permitted.
Some fuel injection pumps have mechanical

governors that control the engine rpm. Some fuel
injection pumps have a governor that is electronically
controlled.
18 - 3 9823/1700-1 18 - 3
00 - General

Fuel
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel
leak is suspected. Do not smoke while refuelling or
Table 130. Fuel System Data
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel High pressure pump Delphi DFP 210/310
which could cause a fire. There could be a fire and type
injury if you do not follow these precautions. Direction of rotation from Anti-clockwise
Fluid Under Pressure drive end
Fuel lift pump type Mechanical diaphragm
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under Fuel filter restriction - maximum pressure drop:
pressure and wear personal protective equipment. For pressure filter 0.65 bar ( 9.4 psi)
Hold a piece of cardboard close to suspected For suction filter 0.27 bar ( 3.9 psi)
leaks and then examine the cardboard for signs of Fuel return restriction - 0.1 bar ( 1.4 psi)
fluid. If fluid penetrates your skin, get medical help maximum
immediately.
Injector information VCO type nozzle me-
WARNING! Do not open the high pressure fuel chanical injectors
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow these
instructions will lead to dirt entering the fuel system.
Dirt in the fuel system will seriously damage the fuel
injection equipment and could be expensive to repair.
Notice: The high pressure fuel system is extremely
susceptible to damage if it is contaminated. Always
clean the engine using the correct procedures before
carrying out maintenance. Contamination of the fuel
system can cause catastrophic failure of the engine.
Notice: Running the engine with air in the system
could damage the fuel injection pump. After
maintenance, the system must be bled to remove
any air.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
accordance with local regulations. Use authorised
18 - 4 9823/1700-1 18 - 4
00 - General
(For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3 Mech Turbo and Aftercooled)
Figure 363.
4
1
3
1 Fuel tank (refer to PIL 18-03) 2 Water separator (refer to PIL 18-12)
3 Lift pump (refer to PIL 18-21) 4 Fuel filter (refer to PIL 18-09)
5 Fuel injection pump (refer to PIL 18-18) 6 Fuel injectors (refer to PIL 18-18)
Suction (Green) Low pressure (Yellow)
High pressure (Red) Bleed-off- return to tank (Orange)
18 - 5 9823/1700-1 18 - 5
00 - General
Operation
(For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3 and engine can be damaged beyond repair by
Mech Turbo and Aftercooled) contaminated fuel or use of incorrect fuel.
The fuel system is central to the performance and The fuel injection pump is a rotary type and is gear
efficiency of the engine, distributing an accurate driven by the engine. The pump delivers fuel at high
amount of fuel to each cylinder at exactly the right pressure to the fuel injectors. The high pressure fuel
time. is delivered in pulses, timed at the correct point in the
combustion cycle for each cylinder.
Fuel is drawn from the fuel tank by the engine driven
lift pump via the pre-filter/water separator. The pre- When the fuel injectors receive a pulse of fuel at
filter/water separator, separates any water in the fuel high pressure, they inject atomised fuel into the
before if passes through the lift pump. combustion chamber.
Fuel is pressurised at low pressure by the lift pump When the pressure of the fuel at the injectors falls,
and passes through a fuel filter on its way to the inlet the injector snaps shut and any trapped fuel bleeds
on the high pressure pump (DP210 pump shown). back to the fuel tanks via the bleed off fuel lines.
Important: Use of the correct fuel grade, together Some fuel flows through the pump at all times to
with effective filtration and decontamination of the provide internal lubrication and cooling. This fuel
fuel is essential. The high pressure pump, injectors bleeds back to tank via the bleed-off fuel lines.
18 - 6 9823/1700-1 18 - 6
00 - General
Figure 364.
4
1
3
High pressure (Red) Bleed-off - return to tank (Orange)
18 - 7 9823/1700-1 18 - 7
00 - General
Fault-Finding
Fault
Fuel Consumption Excessive Table 131. Page 18-8
Fuel/Oil- Leaking from Exhaust Manifold Table 132. Page 18-8
General Fuel System Faults Table 133. Page 18-8
Table 131. Fuel Consumption Excessive

Cause Remedy
Additional load on engine. Check/repair accessories and vehicle components.
Refer to the equipment manufacturer's procedures
Operator technique. Review operation for correct gear shifts, deceleration
and idling
Fuel leaks. Check for external leaks at the fuel tank, fuel lines,
filters and lift pump WARNING: Do not repair
defective fuel lines. If there is a fuel leak remove and
discard the necessary components and install new
ones.
Air intake or exhaust leaks.
One or more engine injectors worn or malfunctioning. Check the electrical connections at the injectors.
clearances.
Table 132. Fuel/Oil- Leaking from Exhaust Manifold

Cause Remedy
Operating for extended periods under light or no load Review operation for correct gear shifts, deceleration
conditions. and idling.
Air intake or exhaust leaks.
Exhaust leak at the Manifold or Turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Check for a cracked manifold.
Valve guide seals are leaking. Replace valve guide stem seals as required.
One or more engine injector worn or malfunctioning. Check the electrical connections at the injectors.
Table 133. General Fuel System Faults

Cause Remedy
Fuel supply fault Check the low pressure circuit connections are
secure.
Check the fuel pressure in low circuit/tank level.
Check the fuel type.
Check for the external diesel fuel leaks.
Check the filter is not blocked.
Check the fuel lift pump operation.
Replace/repair as necessary.
18 - 8 9823/1700-1 18 - 8
00 - General
Discharge and Pressurise Clean

Notice: Running the engine with air in the system
could damage the fuel injection pump. After (For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3
maintenance, the system must be bled to remove Mech Turbo and Aftercooled)
any air.
Cleanliness Requirements
Obey all fuel system health and safety information.
Refer to (PIL 18-00). Important: Additional cleaning must be carried out
prior to working on the high pressure fuel system.
The entry of air into the fuel system can cause It is extremely important the high pressure fuel
problems such as difficult engine starting and components and the adjacent parts of the engine
unstable engine running. Air can enter the system if are meticulously cleaned before any components are
the following occurs: removed. Refer to:-Effects of Contamination.
• A fuel system component has been Before starting work on the high pressure fuel
disconnected. For example, a fuel filter renewal. system, make sure that the working environment is
• A leak in the low pressure side of the fuel suitable.
system during engine operation, or the low
pressure pipes have been disconnected. Refer 1. Refer to: Fuel - Health and Safety (PIL 18-00).
to Fuel System - General (PIL 18-00) for a more
detailed description of the fuel circuit. 2. Clean the machine, prior to completing any
• The fuel tank is allowed to drain fully during maintenance work.
normal operation.
3. Clean the engine, refer to: Engine - Clean (PIL
The engine installation features an electrically 15-00).
operated fuel lift pump. The system is designed to
bleed automatically when the lift pump is operated. 4. Remove the hoses, electrical harnesses and
Make sure that as much air is removed from the fuel ancillaries to improve access and expose any
as possible before you start the engine. Bleed the remaining trapped dirt close to the relevant high
system as follows: pressure components.
Important: DO NOT attempt to bleed the high 5. Wash away any remaining dirt or debris and then
pressure fuel system by loosening the high pressure dry the area using a compressed air jet. When
pipe connections even when the engine is not the area is dry use a soft clean brush to remove
running. To bleed the fuel system follow the correct sand or grit particles that remain.
procedure.
Effects of Contamination
1. Turn on the machine ignition switch to start the
fuel lift pump. DO NOT start the engine. Allow the A good level of cleanliness is required in high
pump to run for 30 seconds. pressure fuel injection system.
2. Turn off the machine ignition switch to stop the Once inside the system, fuel circuit contaminants
fuel lift pump. Wait 10 seconds and then turn the greatly affect the performance and life of the fuel
ignition switch to start the pump. DO NOT start injection equipment. For example, contaminants in
the engine. Allow the pump to run for 30 seconds. the fuel pump will develop internal wear to cause
internal leakage and hence lower discharges. Use
3. Repeat step 2 twice more before you start the of poor quality fuels and poor maintenance could
engine. also lead to contaminants entering the fuel injectors.
There is a possibility of catastrophic equipment
4. Start the engine and make sure it runs smoothly.
failure if debris should prevent the injectors from fully
closing. The main contaminants can be classified as
follows:
• Solid Particles - sand, fibres, metallic particles,

welding scale, sealing materials and wear
particles etc.
• Liquid - usually water and incompatible oils and
greases.
• Gases - Air, sulphur dioxide etc. which can
create corrosive compounds if dissolved in the
fluid.
18 - 9 9823/1700-1 18 - 9
00 - General
These contaminants can appear during Worksite - Open to weather

manufacture, assembly, operation and maintenance.
This repair site is not an acceptable location. Only
The main filter is rated at 5 micron = 0.005 mm in extreme circumstances should a machine be
(0.0001968 in). The pre-filter is rated at 10 micron. repaired on an open site. Use the guidelines below:
Listed are a few typical comparisons of micron size:
• Clean the engine, refer to (PIL 15-00). If the
Figure 365. machine is on hard standing, clean away the
material washed from the engine.
• Place suitable clean boards on the ground
around the machine.
• Erect clean plastic sheeting to shelter the
engine from wind and rain.
• Wear a new disposable environmental type suit
when working on the fuel system. If the suit
C becomes contaminated with mud, move away
B
from the engine and change into a new suit.
• Use clean latex gloves (non-powdered).
• Before you start work make sure that all the
A required replacement parts and tools are on
site. Make sure that the replacement parts are
still sealed inside their packaging.
A 8 Microns • Cap all exposed ports and orifices immediately.
B 70 Microns Do not leave them open.
C 100 Microns • High pressure fuel pipes MUST BE RENEWED
if any pipe joint is loosened or disconnected. DO
• Red Blood Cell = 8 microns (0.008 mm, NOT re-use the original pipe.
0.000315 in).
• Human Hair = 70 microns (0.07 mm, 0.00275
in).
Worksite - Closed to weather from above
• Grain of Salt = 100 microns (0.1 mm, 0.00394 This repair site is the least acceptable condition,
in). if possible move the machine to a more suitable
• The smallest particle visible to the naked eye is environment. Use the guidelines below:
40 microns (0.00157in) approximately.
• Clean the engine, refer to (PIL 15-00). Clean the
The main filter and pre-filter must be changed in floor of all material washed from the engine.
accordance with the applicable service schedule • Place suitable clean boards on the ground
and procedures. The water in fuel sensor must be around the machine.
maintained to ensure correct operation at all times. • Erect clean plastic sheeting to shelter the
engine from the wind and the possibility of
Maintenance Environment debris such as dirt and dust falling from above.
• Wear a new disposable environmental type suit
Depending on circumstances engine maintenance when working on the fuel system. If it becomes
may be required in various working environments. contaminated with mud, move away from the
Obviously procedures are best carried out in a engine and change into a new suit.
dedicated workshop equipped with a suitable clean • Use clean latex gloves (non-powdered).
room, but in practice this is not always possible. • Before you start work make sure that all the
required replacement parts and tools are on
Maintenance procedures requiring removal or site. Make sure that the replacement parts are
replacement of fuel system components, particularly still sealed inside their packaging.
high pressure components, require special • Cap all exposed ports and orifices immediately.
precautions to make the working environment Do not leave them open.
suitable, reducing the risk of contamination to an • High pressure fuel pipes MUST BE RENEWED
absolute minimum. if any pipe joint is loosened or disconnected. DO
NOT re-use the original pipe.
Use the following guidelines to make sure you reduce
the chances of fuel system contamination when
working in different environments:
Vehicle Maintenance Workshop
Unless the workshop has a dedicated `sealable
clean room' work bay, precautions must still be taken.
18 - 10 9823/1700-1 18 - 10
00 - General
• Clean the engine, refer to (PIL 15-00). Clean the

engine in the dedicated area and then move it
to the workshop.
• Clean the floor area around the machine.
• Erect clean plastic sheeting to shelter the
engine from any wind and the possibility of
debris such as dirt and dust falling from above.
• Ensure that workshop doors to the outside are
kept closed. A gust of wind through an open
door will easily blow sand particles into the air.
• Make sure your work wear is clean, non-flocking
and lint free. If in doubt wear a new disposable
environmental type suit.
• Use clean latex gloves (non-powdered).
• Before you start work make sure that all the
required replacement parts and tools are on
site. Make sure that the replacement parts are
still sealed inside their packaging
• Cap all exposed ports and orifices immediately.
Do not leave them open.
• High pressure fuel pipes MUST BE RENEWED
if any pipe joint is loosened or disconnected. DO
NOT re-use the original pipe.
18 - 11 9823/1700-1 18 - 11
00 - General
Bleed
WARNING Do not open the high pressure fuel bleed automatically when the lift pump is operated.
system with the engine running. Engine operation Make sure that as much air is removed from the fuel
causes high fuel pressure. High pressure fuel as possible before the engine is started.
spray can cause serious injury or death.
Do not try to bleed the high pressure fuel system by
WARNING Bleeding of the high pressure fuel loosening high pressure pipe connections even when
system by opening the high pressure lines is not the engine is stopped. To bleed the fuel system follow
required. High fuel pressure can persist for a the steps below.
period of time when the engine has stopped. High
pressure fuel spray can cause serious injury or 1. Turn on the ignition key to start the fuel lift pump.
death.
2. Do not start the engine. Allow the pump to run for
The engine installation contains an electrically the specified time.
operated fuel lift pump. The system is designed to Duration: 30 s
Figure 366.
A Fuel lift pump (The installation position and pump

may differ on your machine)
3. Turn off the ignition key to stop the fuel lift pump. 5. Start the engine and make sure it runs smoothly.
3.1. Wait for the specified time and turn the
ignition key to start the pump.
3.2. Do not start the engine. Allow the pump to
run for the specified time.
Duration: 30 s
4. Do the step 3 for two more times before you start
the engine.
18 - 12 9823/1700-1 18 - 12
30 - Throttle Control System
30 - Throttle Control System
Introduction
(For: JCB 4.4 T2 Mech Nat Asp, JCB 4.4

T2 Mech Turbo, JCB 4.4 T3 Mech Turbo,
JCB 4.4 T3 Mech Turbo and Aftercooled)
For details of the throttle pedal assembly refer to (PIL
09-27-36).
For details of the throttle control cable refer to (PIL

09-28-06).
18 - 13 9823/1700-1 18 - 13
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-15
18 - 14 9823/1700-1 18 - 14
03 - Tank
00 - General
Introduction .................................................... 18-15 The fuel tank is a safe container for storing flammable
Clean ............................................................. 18-16 fluids, from here the fuel is pumped into the engine.
There can be condensation in a partially filled fuel
tank. Therefore, you must fill the fuel tank after you
operate the engine.
Drain the water and sediment from any fuel storage

tank at the recommended service intervals.
18 - 15 9823/1700-1 18 - 15
03 - Tank
00 - General
Clean
The diesel tank must be drained if there is a chance

the fuel is contaminated or it has been filled with the
incorrect fuel.

2. Drain the diesel tank.
3. Drain the fuel from the low pressure fuel pipes.
4. Replace the fuel filters.
5. Refill the tank to the specified level with clean
diesel.
Percentage: 25 %
6. Start the engine and leave it to run for the
specified time period.
Duration: 10 min
7. Stop the engine.
8. Drain the water separator and the main fuel filter.
9. If there was any water or other liquid in the water
separator, repeat 6 to 8.
18 - 16 9823/1700-1 18 - 16
03 - Tank
00 - General
Remove and Install
Remove 6. Put a label on the hoses to help installation.
Some machines have a DEF (Diesel Exhaust Fluid) 7. Disconnect the fuel feed and return hoses.
tank installed, if the machine has an SCR (Selective 8. Disconnect the fuel hoses.
Catalytic Reduction) system installed. The DEF tank
is a separate component but is installed within the Figure 368.
area of the fuel tank. When the fuel tank is removed,
the DEF tank remains in place. The fuel tank must be
removed before removing the DEF tank. D
D
The removal and installation procedure of all fuel
tanks is similar. Some illustrations may differ from
your machine.

2. Place a suitable container under the fuel tank.
3. Remove the drain plug and then drain the fuel
tank.
4. Install the fuel tank drain plug and tighten to the
correct torque value. E
5. Remove the screws 1 and screws 2 then remove

the fuel tank upper mounting bracket.
Figure 367. D Fuel hoses
E Fuel sender electrical connector
A 9. Plug all the open ports and hoses to prevent

contamination.
B 10. Disconnect the fuel sender electrical connector.

11. If a fuel tank guard is installed, remove the
securing bolts (x2).
A Screws 1
B Fuel tank upper mounting bracket
C Screws 2
18 - 17 9823/1700-1 18 - 17
03 - Tank
00 - General
Figure 369.
F G
H J J
F Bolt 3 G Bolt 4
H Fuel tank guard J Securing bolts
11.1. The guard is removed with the tank. that any fuel tank or DEF tank connections do not
get pulled or damaged during the tank removal.
12. From beneath the machine, support the tank
mounting bracket tray and then remove the bolts 14. If installed, remove bolt 3 and bolt 4 then remove
1 and bolts 2. the tank guard from the tank.
13. Lift the tank slightly to clear the chassis rail and 15. To remove the DEF tank. Refer to (PIL18-30-03).
pull the tank out from under the cab. Make sure
Figure 370.
K
L
M
N K R P K L
K
K Bolts 1 L Bolts 2
M Fuel tank N Drain plug
P Tank mounting tray Q Bracket
18 - 18 9823/1700-1 18 - 18
03 - Tank
00 - General
R DEF tank cover plate
Install
steps.
1.1. Use the bracket as a guide when you slide
the tank under the cab.
1.2. Make sure that the DEF tank and
connections are not damaged during this
procedure.
1.3. It may be necessary to slightly lift the tank
to locate the front lip on the chassis rail.
1.4. Make sure that the hoses are installed
correctly.
1.5. If the tank sender unit has been removed,
it should be installed with the float arm
orientated towards the front of the machine.
1.6. Fill the fuel tank with clean fuel.
1.7. Make sure all connections are tight and
check for leaks.
1.8. Bleed the fuel system. Refer to (PIL 18-00).
1.9. Check for leaks. Refer to (PIL 18-00).
Table 134. Torque table

Item Value
A
(1)
22 N·m
C 83 N·m
F 22 N·m
G 83 N·m
J 47 N·m
L
(1)
22 N·m
K 83 N·m
(1) To avoid damage to the threads in the tank make
sure that this torque figure is not exceeded.
18 - 19 9823/1700-1 18 - 19
06 - Level Sender
06 - Level Sender
Contents Page No.
18-06-00 General ........................................................................................................................... 18-21
18 - 20 9823/1700-1 18 - 20
06 - Level Sender
00 - General
Operation ....................................................... 18-21 The fuel level sender generates an analogue signal.
Remove and Install ....................................... 18-22 The float moves up or down as the fuel quantity in
the tank changes. As the float moves it opens the
switch at the position of the float. Each position has
a different resistance value which informs the ECU
(Electronic Control Unit) of the float position.
Position 0 = Empty and position 8 = Full.
Figure 371.
1 2
A 6
A Float
18 - 21 9823/1700-1 18 - 21
06 - Level Sender
00 - General
Remove and Install
The design of the tank may differ but the location of 2. Follow the general health and safety procedures
the tank sender unit is similar. Refer to Figure 372. (Refer to (PIL 01-03).
3. Remove the screws 1 and screws 2 and remove
Remove the fuel tank upper mounting bracket.
Figure 372.
A E
B
A Screws 1 B Upper mounting bracket

C Screws 2 D Fuel tank (Tier 4i)
E Fuel tank (Tier 4f)
4. Put a label on the hoses to help installation. Figure 373.

5. Disconnect the fuel feed and return hoses.
6. Plug all the open ports and hoses to prevent D
contamination.
7. Disconnect the fuel sender electrical connector.
8. Remove the sender unit from the fuel tank.
E F
D Hoses
E Fuel sender electrical connector
F Sender unit
G Fuel tank
Install
steps.
18 - 22 9823/1700-1 18 - 22
06 - Level Sender
00 - General
1.1. Check the gasket to make sure it is clean

and in good condition. If not then replace
the gasket.
1.2. Bleed the fuel system. Refer to (PIL 18-00).
1.3. Tighten the screws 1 and screws 2 to the

Item Value
A
(1)
22 N·m
C 83 N·m
(1) To avoid damage to the threads in the tank make
sure that this torque figure is not exceeded.
18 - 23 9823/1700-1 18 - 23
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-25

18-09-09 Pre-Filter Element .......................................................................................................... 18-30
18 - 24 9823/1700-1 18 - 24
09 - Filter
00 - General
Introduction .................................................... 18-25 The fuel filter consists of a paper element folded in
Component Identification ............................... 18-26 such a way as to give a very large surface area. It is
Operation ....................................................... 18-27 most important that the fuel filter is changed regularly
Drain and Fill ................................................. 18-27 in accordance with the machine maintenance
schedule. Use only the correct specification filters.
18 - 25 9823/1700-1 18 - 25
09 - Filter
00 - General
Figure 374.
1e 1
1f
1d
2a
2b 1a
2c 1b 1c
1 Fuel pre-filter/ water separator 1a Water bowl

1b Drain screw 1c Water level probe
1d Fuel filter element 1e Electric lift pump
1f Air bleed to tank 2 Fuel filter
2a Paper element 2b Sediment bowl
2c Drain screw
18 - 26 9823/1700-1 18 - 26
09 - Filter
00 - General
Operation Drain and Fill
Fuel is pumped into the filter and passes through 1. Make the machine safe. Refer to (PIL 01-03).
the paper element where any dirt particles or water
droplets are retained. An integral sediment bowl at 2. Drain off any water in the filter element by turning
the bottom of the filter enables water to be drained the drain tap. Any fuel and water mix drained
off by means of a drain screw. must be disposed of in accordance with local
regulations. Do not reuse the drained fuel.
Refer to fuel and exhaust system, filter, component
3. Drain off any water in the water separator bowl.
identification, (PIL 18-09).
Any fuel and water mix drained must be disposed
of in accordance with local regulations. Do not
reuse the drained fuel.
18 - 27 9823/1700-1 18 - 27
09 - Filter
00 - General
Remove and Install Remove - Disposable Type

Description Part No. Qty. E
Spanner - HP Fuel 334/G5933 1 C
Filter
Fuel Filter Removal 892/01383 1
Tool (4 cyl)
D
Before Removal
2. Get access to the filter.
A
2.1. On some machines the filter is located on
the engine. Other machines have remotely
located filters. There may be more than
one filter. Refer to the relevant service point
information for details.
2.2. There are different types of filters. Refer to B
the correct procedure. A Filter
B Drain tap
3. Thoroughly clean the outside of the filter housing C Low pressure fuel line
and around the filter head. D Screw
E Low pressure fuel line
4. Loosen the drain tap and allow the water / fuel to
drain into a suitable container. 1. Remove the low pressure fuel lines.
5. On machines with a fuel shut-off valve, set the 1.1. Put a label on the hoses to help installation.
valve to isolate the fuel supply.
Figure 375. contamination.
A
2. Release the filter strap retaining screw and lift the
filter upward.
Install - Disposable Type

1. Make sure that the filter is in the correct position
B to enable connection of the fuel lines.
2. Install the filter strap.
2.1. Tighten the filter strap to the correct torque
value.
A Fuel filter element
B Drain tap Torque: 24 N·m
3. Install the low pressure fuel lines.
3.1. Make sure they are installed at the correct
ports.
4. Open the fuel shut-off valve (if applicable).
5. Bleed the fuel system. Refer to Fuel System-
General, Discharge and Pressurise.
18 - 28 9823/1700-1 18 - 28
09 - Filter
00 - General
Remove - Element Type

Figure 377.
C
A Filter head
B Filter element
C Drain tap
1. Use the applicable service tool to unscrew the
filter element from the filter head (anticlockwise).
Special Tool: Fuel Filter Removal Tool (4 cyl)
(Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.: 1)
Install - Element Type

1. Lubricate the element seals with clean fuel and
install a new filter element.
1.1. Make sure that the filter flange touches the
filter head.
1.2. Use the applicable service tool to tighten to
the correct torque value.
Torque: 35 N·m
Special Tool: Fuel Filter Removal Tool (4
cyl) (Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.:
1)
2. Open the fuel shut-off valve (if applicable).
3. Bleed the fuel system. Refer to Fuel System-
General, Discharge and Pressurise.
18 - 29 9823/1700-1 18 - 29
09 - Filter
09 - Pre-Filter Element
09 - Pre-Filter Element Introduction

Introduction .................................................... 18-30 The fuel pre-filter with water separator is installed on
Remove and Install ....................................... 18-31 to the fuel lift pump. The fuel lift pump is a sealed
integral electrical unit.
18 - 30 9823/1700-1 18 - 30
09 - Filter
09 - Pre-Filter Element

Remove removal procedure. Additionally do the following
steps.
2. Install a new filter element and secure in position
2. Get access to the filter. with the locking ring.
3. On machines with a fuel shut off valve, set the 3. Make sure that the water in fuel electrical
valve to isolate the fuel supply. connector is correctly installed.
4. Drain the water separator bowl. 4. On machines with a fuel shut-off valve, set the
valve to connect the fuel supply.
5. Disconnect the water in fuel sensor.
6. Release the locking ring and remove water
separator bowl. Any fuel and water mix drained
must be disposed of in accordance with local
regulations. Do not reuse the drained fuel.
7. Release the locking ring and remove the filter
element, discard the element.
Figure 378.
E
A Filter Element
B Filter element locking ring
C Water separator bowl locking ring
D Water separator bowl
E Water in fuel electrical connector
18 - 31 9823/1700-1 18 - 31
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-33

18-12-04 Water in Fuel Sensor ..................................................................................................... 18-36
18 - 32 9823/1700-1 18 - 32
00 - General
Introduction .................................................... 18-33 The water separator with fuel pre-filter and the fuel
Drain and Fill ................................................. 18-34 lift pump is a sealed integral electrical unit. The
Clean ............................................................. 18-34 assembly is a non-serviceable component. If any
Remove and Install ....................................... 18-35 part is defective, replace the complete pump, filter
and separator assembly.
Figure 379.
A Fuel lift pump

B Fuel pre- filter
C Water separator
The pre-filter/water separator is designed to separate

water and dirt from the fuel using a special chemically
treated paper filter element. A bowl installed in the
bottom of the trap collects the water removed from
the fuel.
The bowl is installed with an electric probe which

senses when the water is above a preset level.
The probe enables a suitable alarm/indicator device.
Water can be drained off by means of the drain screw
installed in the base of the bowl. It is essential that
the water trap is drained regularly. Water must be
drained immediately if the probe signals an alarm.
Refer to fuel and exhaust system, filter, component

identification, (PIL 18-09).
18 - 33 9823/1700-1 18 - 33
00 - General
Drain and Fill Clean

1. Obey all fuel system health and safety
information.
Draining the Water Separator
Refer to: PIL 18-00-00. 1. Make the machine safe.
2. Make the machine safe. 2. Get access to the filter.

Refer to: PIL 01-03. 3. If there is water but no sediment, open the tap
to drain the water. If there is any sediment in
3. Drain off any water in the filter element by turning the bowl replace the fuel filter element. Do not
the tap. disconnect the electrical connector (if installed).
4. Drain off any water in the water separator bowl 4. Tighten the drain tap when all the water is
by turning the tap. Do not disconnect the water drained.
in fuel electrical connector (if installed).
Figure 381.
5. If there is sediment in the bowl after draining,
support the bowl and release the locking ring.
6. Wash the bowl in clean fuel.
7. Install the bowl, secure in position with the
locking ring.
8. Make sure that the water in fuel electrical
connector is correctly installed.
Figure 380. Typical Engine
A
B
B
A Tap
B Bowl
A Fuel filter
B Drain tap
18 - 34 9823/1700-1 18 - 34
00 - General
Remove and Install
Refer to Fuel and Exhaust system - Filter - Pre-Filter

Element. Refer to: PIL 18-09.
18 - 35 9823/1700-1 18 - 35
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor Introduction

Introduction .................................................... 18-36 The water in fuel sensor is installed in the fuel
Remove and Install ....................................... 18-37 filter water bowl. A warning light will illuminate in
the instrument panel to indicate that water has
accumulated in the fuel filter water bowl and must be
drained.
18 - 36 9823/1700-1 18 - 36
04 - Water in Fuel Sensor
Remove and Install
Remove
2. Remove the ignition key.
3. Get access to the fuel filter.
4. Disconnect the electrical connections.
5. Remove the sensor fixing screw.
6. Remove the sensor.
Figure 382.
A 1
1 Fixing screw
2 Electrical connections
A Water in fuel sensor
Install
removal procedure.
18 - 37 9823/1700-1 18 - 37
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-39

18-18-03 Injector ............................................................................................................................ 18-47
18-18-07 Injector Seal ................................................................................................................... 18-51
18-18-15 Pump .............................................................................................................................. 18-53
18 - 38 9823/1700-1 18 - 38
18 - Injection
00 - General
Introduction .................................................... 18-39
Operation ....................................................... 18-41
Fault-Finding .................................................. 18-44 Fuel is continuously supplied to the injectors through
Check (Operation) ......................................... 18-45 the high pressure fuel pipes from the fuel injection
Calibrate ........................................................ 18-46 pump.
The high pressure fuel injector pipes consist of thick

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

removed for any reason they must be replaced.
Installing the existing fuel pipes will cause fuel leaks
at the pipe connections.
Fuel injection takes place when the fuel injection

pump is driven by the engine. The fuel injection pump
is an engine driven positive displacement fuel pump.
Combustion
The engine uses a direct injection system. Fuel is
injected directly into the cylinder, the mixing taking
place in the combustion chamber which is recessed
into the crown of the piston.
The process of mixing starts during the induction

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

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

timing control and pump-to-engine timing of the fuel
injection pump are improved.
18 - 39 9823/1700-1 18 - 39
18 - Injection
00 - General
Figure 383.
4
1
3
High pressure (Red) Bleed-off- return to tank (Orange)
18 - 40 9823/1700-1 18 - 40
18 - Injection
00 - General
Operation
Fuel Injection Cycle
Figure 384.
5 4
11
1 Low pressure fuel inlet port 2 Integral fuel transfer pump

3 Integral transfer pump relief valve 4 IMV (Inlet Metering Valve)
5 Throttle linkage 11 High pressure fuel outlet ports
18 - 41 9823/1700-1 18 - 41
18 - Injection
00 - General
Injection Cycle Fuel from the lift pump enters the injection pump at
low pressure port. Fuel then passes to the integral
The job of the fuel injection pump is to deliver a vane type transfer pump. The transfer pump raises
precise quantity of fuel to the cylinder at exactly the the fuel pressure to a pre-set value. The fuel pressure
right time in accordance with the required power. is controlled via integral relief valve.
The fuel is injected into the cylinder at very high Fuel flows through internal ports to the IMV
pressure (up to 600 bar ( 8,695.6 psi)). The pump which controls the amount of fuel that enters the
is manufactured to fine tolerances and it is essential high pressure system via the throttle linkage and
that no dirt or water is allowed to enter the pump. governor.
Equally vital to the performance of the pump is the
use of the correct quality diesel fuel. State 1 - Charging
The fuel pump is driven by the engine at half engine As the pump shaft rotates internal ports align and
speed. The fuel injection pump is of a rotary type and metered fuel charges a chamber between two
its basic principle of operation is as follows (DP210 plungers.
pump shown):
Figure 385.
1 4 5
1 10 9
8
9
3 8
7
1 Low pressure fuel inlet port 3 Integral transfer pump relief valve
4 IMV 5 Throttle linkage
6 Integral governor 7 Injection pump shaft (engine driven)
8 Charging chamber 9 Plungers
10 Cam ring
18 - 42 9823/1700-1 18 - 42
18 - Injection
00 - General
State 2 - Injecting pressurising the fuel in the chamber. As the fuel

is pressurised, internal ports align to allow high
As the pump shaft continues to rotate, the plungers pressure fuel to leave the pump via one of the four
are forced together by lobes on the cam ring, high pressure fuel outlet ports to an injector.
Figure 386.
2
4 5
11
10
1
9
9
3
1 Low pressure fuel inlet port 3 Integral transfer pump relief valve
4 IMV 5 Throttle linkage
9 Plungers 10 Cam ring
This cycle is repeated once for every cylinder per

revolution of the pump.
18 - 43 9823/1700-1 18 - 43
18 - Injection
00 - General
Fault-Finding

Fault
Fuel Faults Table 136. Page 18-44
Table 136. Fuel Faults

Cause Remedy
No fuel in supply tank Check the level in the fuel tank, use sight gauge or
Fuel Filter blocked with water or other contamination Drain fuel/water separator or replace fuel filter.
Fuel lift pump not operating correctly (fuel supply g Check that the lift pump is operating and delivering
inadequate) fuel to the injection pump.
Fuel is aerated Check the fuel system for loose connections and
system.
Fuel drain return line blocked, not connected properly Verify that the fuel return line is not obstructed and
connected to the top of the fuel tank.
Injection pump timing incorrect If the pump has recently been removed and
replaced, the timing could be incorrect if the correct
removal procedures were not followed.
The timing can only be checked by a local Fuel
Injection specialist using the appropriate equipment.
Fuel is contaminated or incorrect grade diesel fuel Only recommended diesel fuels are accepted. If the
used fuel is suspect, verify by operating the engine with
the recommended clean fuel from a temporary tank.
Fuel filter blocked, fuel supply restricted Check/replace the fuel filters.
Fuel drain return line blocked, not connected properly Verify that the fuel return line is not obstructed and
connected to the top of the fuel tank.
Check fuel inlet restriction Maximum inlet restriction to fuel transfer pump must
not exceed 100 mm Hg.
Fuel level low Check/top up with recommended fuel.
18 - 44 9823/1700-1 18 - 44
18 - Injection
00 - General
Check (Operation)
(For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3 2. Make the machine safe. Refer to (PIL 01-03).
Mech Turbo and Aftercooled) 3. Do not check the fuel injection on a hot engine,
WARNING Fuel is flammable, keep naked flames fuel spilled onto a hot engine may create a risk
away from the fuel system. Stop the engine of fire.
immediately if a fuel leak is suspected. Do not
smoke while refuelling or working on the fuel 4. Turn the ignition switch to the OFF position.
system. Do not refuel with the engine running. 5. Let the engine cool.
Completely wipe off any spilt fuel which could
cause a fire. There could be a fire and injury if you 6. Loosen all the union connectors of the high
do not follow these precautions. pressure fuel pipes that connect to the injectors.
WARNING Fine jets of fluid at high pressure can Refer to Figure 387.
penetrate the skin. Keep face and hands well
6.1. It is not necessary to remove the union
clear of pressurised fluid and wear protective
connectors from the injectors completely.
glasses. If fluid penetrates your skin, get medical
help immediately. 6.2. Simply release the holding torque and
keep the union connectors loose but not
completely removed.
Check (Operation)
1. Do steps 2 to 8 to check the fuel injection for the
high pressure fuel discharge.
Figure 387.
A A
A
A Union connectors - high pressure fuel pipes
7. Crank the engine and do the fuel discharge

check from the connectors is free from air.
8. Tighten the connectors to the specified torque
value.
Torque: 25 –26 N·m
18 - 45 9823/1700-1 18 - 45
18 - Injection
00 - General
Calibrate

There is no calibration required for this fuel injection
system.
18 - 46 9823/1700-1 18 - 46
18 - Injection
03 - Injector
03 - Injector Introduction
Introduction .................................................... 18-47
The injectors are supplied with pressurised fuel by
the high pressure fuel injection pump and when
energised, the injector atomizes the fuel into a fine
mist so that it can burn easily by the vehicle’s engine.
The fuel injectors are mounted in the cylinder head

so that fuel is sprayed directly into the combustion
chamber.
The injector tips are located inside the combustion

chambers, so effective cooling is essential. A special
thin walled sleeve is screwed into the cylinder head
which allows a coolant jacket close to the injector.
The coolant jacket is sealed at the bottom by sealant
on the sleeve thread and at the top by O-ring.
Figure 388.
52 5 1 4
1 Injector
2 Sleeve
3 Cylinder head
4 Coolant jacket
5 Sleeve thread
6 O-ring
18 - 47 9823/1700-1 18 - 47
18 - Injection
03 - Injector
Figure 389. Typical Mechanical Engine
4
5 1 6
8
2
1 Injector 2 Injector clamp

3 Injector clamp bolt 4 Injector sleeve
5 Injector bleed-off port 6 Fuel Injector caps
7 Sealing Washer 8 Injector sealing O-ring
18 - 48 9823/1700-1 18 - 48
18 - Injection
03 - Injector
Remove and Install Figure 390. Typical Engine
4 X 1
The following procedure is for one injector, the
procedures are identical for all injectors.
Before Removal
3. Remove the high pressure fuel pipes.
4. Remove the fuel bleed off fuel pipes.
5. Remove the rocker cover. 3
6. Record which injector is for which cylinder. The 2
injectors must be installed in the same positions. 1 Injector
2 Injector clamp
Note: If a fuel injector is defective, it must be 3 Retaining bolt
replaced. 4 Injector sleeve
X Injector bleed-off port
Remove
2. Remove and discard the sealing washer. Label
1. Remove the injector clamp retaining bolt and lift the injector to make sure it is installed in its
the clamp away. original cylinder. Put a clean protective cap over
the nozzle of the injector.
3. Remove and discard the O-ring.
18 - 49 9823/1700-1 18 - 49
18 - Injection
03 - Injector
Figure 391. 5. Make sure that the injector is installed in the

correct orientation, with the bleed-off port facing
5 the right hand side (exhaust manifold) of the
engine. Make sure the injector is pushed fully into
the cylinder head.
6. Tighten the injector clamp bolt to the correct
torque value.
After Installation
1. Replace the rocker cover.
2. Renew the high pressure fuel pipes.
3. Replace the low pressure fuel pipes.

Item Nm
3 28
4 39
5 Protective cap
6 Protective cap
7 Sealing washer
Install
steps.
2. Clean off any sludge or oil from the inner bore
of the injector sleeve. Make sure you do not
damage the surface of the bore. Any damage
or surface contamination will cause the injector
sealing O-ring to fail.
4. Install a new sealing washer.
18 - 50 9823/1700-1 18 - 50
18 - Injection
07 - Injector Seal
07 - Injector Seal
Remove and Install
Special Tools Before Removal

Injector Seal 892/01159 1 1. Make sure that the engine is safe to work on. If
Installation Tool the engine has been running, let it cool before
(Mechanical Engine) you start the service work.
Injector Sleeve 892/12348 1 2. Clean the engine. Refer to Engine - Clean (PIL
Installation/Removal 15-00).
Tool
Figure 392.
D
A Rocker cover B Bolts

C Gasket D Injector seals
18 - 51 9823/1700-1 18 - 51
18 - Injection
07 - Injector Seal
Remove 4. Renew the rocker cover gasket.
1. Get access to the engine. 5. Prevent damage to the seals. Put sleeves/covers
on the injectors. Apply a rubber lubricant to the
2. Remove the high pressure fuel pipes. Refer to seals.
Fuel Pipes (PIL 18-96).
Special Tool: Injector Sleeve Installation/
3. Remove the rocker cover from the cylinder head. Removal Tool (Qty.: 1)
6. Install the rocker cover. Refer to (PIL 15-42).
4. Put wooden supports under the rocker cover and
tap out the injector seals using the special tool. After Installation
Discard the seals.
1. The high pressure fuel pipes must be replaced
Special Tool: Injector Seal Installation Tool with new parts. Refer to Fuel Pipes (PIL 18-96).
(Mechanical Engine) (Qty.: 1)
2. Start the engine and check for oil and fuel leaks.
Figure 393.
F E
G
E Injector seal installation tool
F Injector seals
G Wooden supports
Install
1. Replacement is the reversal of the removal
procedure.
2. Remove all oil and sludge contamination from
inside the valve chamber.
3. Renew the injector seals. Put supports under the
rocker cover and tap in the new seals using the
special tool.
Special Tool: Injector Seal Installation Tool
(Mechanical Engine) (Qty.: 1)
Figure 394.
G
E Injector seal installation tool
F Injector seals
G Wooden supports
18 - 52 9823/1700-1 18 - 52
18 - Injection
15 - Pump
15 - Pump Introduction
Introduction .................................................... 18-53 The high pressure fuel injection pump is a rotary
Component Identification ............................... 18-54 type device that pumps fuel into the cylinders of
Operation ....................................................... 18-55 the engine. The pump is driven indirectly from the
Remove and Install ....................................... 18-61 crankshaft by gears.
18 - 53 9823/1700-1 18 - 53
18 - Injection
15 - Pump
Figure 398. DP 210/310

9 5 4
10
15
7
8
12
18 F GH
3
16
6 2
1 Fuel injection pump 2 Pump fixing nuts (x3)

3 Injection pump gear cover 4 Injection pump lock bolt
5 Keyhole washer 6 Cold start advance solenoid
7 ESOS (Engine Shut-Off Solenoid) 8 Fuel line connector (inlet)
9 Fuel bleed-off connector 10 Turbo boost vacuum pipe (if installed)
11 Drive shaft nut 12 Drive gear
14 Injection pump oil seal 15 Throttle lever
16 Fuel lift pump
18 - 54 9823/1700-1 18 - 54
18 - Injection
15 - Pump
Operation
(For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3 The fuel pump is driven by the engine at half engine
Mech Turbo and Aftercooled) speed.
The fuel injection pump is of a rotary type and its

Fuel Injection Pump - Injection Cycle basic principle of operation is as follows:
The function of the fuel injection pump is to deliver Fuel from the lift pump enters the injection pump at
a precise quantity of fuel to the cylinder at exactly port, at low pressure. Fuel then passes to the integral
the right time in accordance with the required power. vane type transfer pump. The transfer pump raises
The fuel is injected into the cylinder at very high the fuel pressure to a pre-set value. The fuel pressure
pressure (up to 600 bar (8702 lb/in2)). The pump is is controlled via an integral relief valve. Refer to
manufactured to fine tolerances and it is essential Figure 399.
that no dirt or water is allowed to enter the pump.
Equally vital to the performance of the pump is the
use of the correct quality diesel fuel.
Figure 399.
5
4
1
1 Injection pump low pressure fuel inlet port 2 Integral fuel transfer pump
3 Integral transfer pump relief valve 4 IMV (Inlet Metering Valve)
5 Throttle linkage
Fuel flows through the internal ports to the IMV which system via the throttle linkage and governor. Refer to
controls the amount of fuel entering the high pressure Figure 400.
18 - 55 9823/1700-1 18 - 55
18 - Injection
15 - Pump
Figure 400.
A 5
6
4
2 1
10 9
8
3 9
8
7
B 4 5
6
11
2 1
10
9

8 Charging chamber 9 Plungers
10 Cam ring 1 High pressure fuel outlet ports
A Fuel pump state - charging B Fuel pump state - Injecting
State - A pressure fuel to leave the pump via one of the high
pressure fuel outlet ports to an injector.
As the pump shaft rotates internal ports align and
metered fuel charges a chamber between two Fuel Injector Pump - Governor
plungers.
Refer to Figure 401. and Refer to Figure 402.
State - B
The pump incorporates a mechanical governor. This
As the pump shaft continues to rotate, the plungers works in conjunction with the throttle mechanism to
are forced together by lobes on the cam ring, control engine speed. The governor also acts to limit
pressurising the fuel in the chamber. As the fuel the maximum engine speed.
is pressurised, internal ports align to allow high
18 - 56 9823/1700-1 18 - 56
18 - Injection
15 - Pump
The governor consists of a series of weights The linkage turns the IMV to increase the fuel supply
arranged around the rotating pump drive shaft. and thus increase the engine speed.
State A - Increasing Engine Speed The governor control over the IMV is precise,
enabling fine control over the engine speed. Such is
As the pump rotation speed increases, weights the degree of control that the engine is maintained at
are forced outwards by centrifugal force, moving a virtually constant speed.
a mechanical linkage connected to the IMV. The
linkage turns theIMV, reducing the fuel supply and The point at which the governor acts on the IMV is
thus reducing the engine speed. determined by throttle position. So when the operator
sets the throttle for the required engine speed, the
State B - Decreasing Engine Speed governor maintains the chosen speed.
As the engine speed slows a reduction in centrifugal The connection between the IMV, throttle and
force causes the governor weights to fall inwards. governor linkages is via rods and springs housed in
the case.
Figure 401.
4 5
18 - 57 9823/1700-1 18 - 57
18 - Injection
15 - Pump
Figure 402.
A 3 5
4
B 3
4 5
1 Injection pump shaft (engine driven) 2 Governor weights

3 Governor linkage 4 IMV
5 Throttle linkage, governor linkage housing case A Governor state - Increasing engine speed
B Governor state - Decreasing engine speed
Features of the DP210/DP310 Fuel is useful as an aid to cold starting and is achieved
Injection Pump hydraulically using the fuel pressure.
Refer to Figure 403. When the engine coolant is cold, the electrical switch
closes, energising the cold advance solenoid. The
The fuel pump incorporates several advanced design solenoid plunger lifts from its seat allowing fuel
features to help improve engine performance and pressure to act on the advance piston, moving the
at the same time comply with the current emissions cam ring to the advance position. The cold advance
regulations. solenoid is de-energised to return the cam ring to the
hot running position.
Cold Start Advance
By changing the angular position of the cam ring,
the timing of the fuel injection can be altered. This
18 - 58 9823/1700-1 18 - 58
18 - Injection
15 - Pump
Hydraulic Light Load Advance Latch valve

It is advantageous to alter the injection timing when The latch valve isolates the torque trimmer and
the engine is running at light load. The light load timing advance systems until the engine has started,
advance valve uses fuel pressure to detect light load ensuring the pump remains in the optimum state for
conditions which acts on the advance piston to alter engine starting.
the injection timing in a similar way to the cold start
advance. ESOS - Engine Shut-Off Solenoid
Variable Fuelling The ESOS (Engine Shut-Off Solenoid) solenoid
valve is de-energised to isolate the fuel supply to
To further enhance engine power and emissions the injection pump and thus stop the engine. For
control, the fuel injection curve is variable, depending the engine to start and run the solenoid must be
on engine speed and load. permanently energised.
The injection curve is controlled by the shape of Turbo Boost Control (Turbocharged Engines
the lobes on the cam ring. The lobes determine the only)
exact duration and pressure characteristics of each
injection of fuel. Since one cam shape or profile will Injection pumps on turbocharged engines are
never be ideal for all engine operating conditions, installed with a boost diaphragm. The diaphragm has
the profile is changed by using scroll plates. These a vacuum connection from the engine inlet manifold.
plates are moved radially to change the cam profile As the turbocharger boost pressure rises the boost
and thus the movement of the injection pump rollers diaphragm acts on the fuel IMV to increase the fuel
and plungers. The scroll plates are activated by the supply to the engine. There is also a link to the scroll
position of the governor, the torque trimmer unit and plates to alter the fuel curve for maximum engine
the turbo boost control (if installed). performance.
The torque trimmer moves the scroll plates according
to fuel pressure.
18 - 59 9823/1700-1 18 - 59
18 - Injection
15 - Pump
Figure 403.
6A
5A
1E
2A 1B 1C
6A 6B
3B
4A
A B 1A 3A
1A
1D
1A Cam ring 1B Cold start advance solenoid

1C Advance unit 1D Advance piston
1E Cold start switch 2A Light load advance valve
3A Scroll plates 3B Torque trimmer
4A Latch valve 5A ESOS
6A Turbo boost diaphragm 6B Turbo boost diaphragm vacuum connection
18 - 60 9823/1700-1 18 - 60
18 - Injection
15 - Pump
Remove and Install
(For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3 Figure 404. Install Crankshaft Turning Tool
Special Tools C
Crankshaft Turning Tool 892/01147 1
(95.25mm PCD)- JCB
4 Cylinder Ecomax and
Dieselmax
Crankshaft / 892/01148 1
Camshaft Timing Pin
(444/448/672 Engine)
Tamper proof Cover 892/01154 1
Removal Tool
Pump Gear Removal 892/01155 1
Tool
TDC Setting tool, 892/01169 1
Dieselmax 4 Cyl
A
Remove
13
1. Make the machine safe, refer to (PIL 01-03).
2. Make sure the battery is isolated. Refer to (PIL A Timing pin
33-03-03). C Crankshaft turning tool
13 Taper blanking plug
3. Label, disconnect and cap all fuel lines. Make
sure that no debris enter the fuel system. 6.1. Remove the taper blanking plug.
6.2. Bolt the turning tool to the crankshaft pulley.
4. Disconnect the electrical connectors at the shut-
off solenoid. 6.3. Locate a suitable socket and ratchet drive
on the tool.
5. Disconnect the throttle cable.
7. Set number 1 piston to top dead centre
6. Install the crankshaft turning tool: (compression stroke):
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax
(Qty.: 1)
18 - 61 9823/1700-1 18 - 61
18 - Injection
15 - Pump
Figure 405. Install TDC Setting tool 8. Remove the fuel injection pump gear cover using
the correct service tool and a suitable ratchet
drive.
Special Tool: Tamper proof Cover Removal Tool
(Qty.: 1)
9. Undo and remove the drive shaft nut.
Figure 406. Fuel Injection Pump Gear Cover
11
19
3
B
D
D
17
D TDC Setting tool
17 Lift pump retaining bolts
19 Lift pump actuating pin
7.1. Remove the fuel lift pump, refer to remove
and install (PIL 18-21-00).
7.2. Install the TDC (Top Dead Centre) setting
tool, use one of the lift pump retaining bolts
to hold the tool in position. Make sure that F G
the top hole locates centrally over the lift
pump actuating pin.
Special Tool: TDC Setting tool, Dieselmax 4 H
Cyl (Qty.: 1)
7.3. Using the crankshaft turning tool, turn the
crankshaft until the timing pin engages in E
the crankshaft timing hole. Check that the
lift pump actuating pin is protruding from the
face of the setting tool.
7.4. Make sure the timing pin is engaged in B Service tool
the crankshaft timing hole. (It is possible E Service tools
that the pin may appear to ‘engage’ but it F Service tool- reaction cap
is in fact between the crankshaft webbing. G Service tool- threaded adapter
Always check the pin has engaged correctly H Service tool- bolt
by trying to move the crankshaft clockwise 3 Fuel injection pump gear cover
and counter-clockwise, if you cannot do 11 Drive shaft nut
this, the pin should be engaged correctly). If
10. Loosen the lock bolt on the fuel injection pump
you can not complete these steps, do these
so that the special keyhole washer can be slid
steps next. 7.5 and 7.6.
across to its locking position. Screw the lock bolt
Special Tool: Crankshaft / Camshaft Timing in and tighten to the specified torque. The washer
Pin (444/448/672 Engine) (Qty.: 1) should be loose.
7.5. Remove the timing pin. Torque: 12 N·m
7.6. Rotate the crank pulley the specified
amount and install the timing pin.
Angle: 360 °
7.7. Repeat.
18 - 62 9823/1700-1 18 - 62
18 - Injection
15 - Pump
Figure 407. DP210/310 Pump (If Installed) pump). Use the correct spanner to undo the nut
10 nearest to the engine block.
5 4 12
7 12. Install the reaction cap over the pump shaft.
F Screw the service tool to the housing. Using a
suitable ratchet drive and socket screw in the bolt
G (service tool) until resistance is felt.
Special Tool: Pump Gear Removal Tool (Qty.: 1)
13. The injection pump drive gear is located on
a taper on the pump drive shaft. There is no
mechanical locking key. To remove the pump
the taper lock must be ‘broken’. Support the fuel
injection pump. Tap the end of bolt with a soft
2 H faced hammer. When the taper ‘breaks’ there will
6
be an audible sound.
X 2
14. Remove the service tools 12 and withdraw the
pump from the flywheel housing.
Y Figure 409.
2 Retaining nuts
4 Lock bolt
5 Keyhole washer
12 Pump drive gear
F Service tool- reaction cap
G Service tool- threaded adapter 11
H Service tool- bolt
X Keyhole washer position
Y Keyhole washer position 3
B
Figure 408. DB4 Pump (If Installed)
F G
E
X
Y 3 Fuel injection pump gear cover

11 Drive shaft nut
4 Lock bolt B Service tool
5 Keyhole washer F Reaction cap (service tool)
X Keyhole washer position G Service tool
Y Keyhole washer position H Bolt (service tool)
11. Undo and remove the pump retaining nuts (X3). 14.1. Do not remove the engine locking pin at
Be sure to remove all 3 nuts (not shown on DB4 this stage.
18 - 63 9823/1700-1 18 - 63
18 - Injection
15 - Pump
14.2. Do not loosen the fuel injection pump lock Tighten the gear cover to the correct torque.
bolt. Refer to Table 138.
Special Tool: Tamper proof Cover Removal Tool
Install (Qty.: 1)
Service procedures on the fuel injection pump can Figure 411.
only be carried out by specialist personnel with the
relevant training and equipment. Before replacing
an injection pump with a new one, or one that
has been serviced, make sure that the drive shaft
is locked, with the service bolt tightened with the
special keyhole washer free to rotate. Make sure that
the engine is still locked in the correct position.
3
Some parts of the DB4 injection pump are not B
illustrated but are similar to those on the DP210/310.
1. Make sure that taper surfaces on the injection

pump drive shaft and gear are clean and free
from oil.
2. Make sure that the oil seal is correctly located on
the injection pump mounting face. 3 Fuel injection pump gear cover
8 Service tool
Figure 410. DP210/310 Injection Pump
9. Remove the engine locking pin and install the
blanking plug.
16
16
Figure 412.
16 Oil seal
3. Locate the pump onto the mounting studs.
Locate the drive gear over the pump drive shaft.
4. Install and torque tighten the nuts to the specified A
torque.
4.1. Use the correct spanner to tighten the nut 13
close to the cylinder block. 13 Blanking plug
A Locking pin
5. Install and torque tighten the pump gear nut to
the 1st stage pre torque. Refer to Table 138. 10. Couple the electrical connectors at the ESOS
(Engine Shut-Off Solenoid)and cold advance
5.1. If the washer is supplied with the solenoid.
replacement pump, do not install the
washer. Secure the gear with nut 11 only. 11. Turbocharged Engines (If installed): Reconnect
the boost control vacuum pipe at the diaphragm
6. Loosen the lock bolt until the keyhole washer can on the injection pump.
be slid under the bolt. Then torque tighten the bolt
to the specified torque. Make sure the washer is 12. Install the rocker cover.
locked. Refer to Table 138.
7. Torque tighten pump gear nut to the final stage
13. Reconnect the fuel line couplings at the inlet
torque. Refer to Table 138.
connection and bleed-off connection on the
8. Install the gear cover using the service tool. Make pump. Install the high pressure fuel lines, refer to
sure the sealing ‘O’ ring is correctly located. (PIL 96).
18 - 64 9823/1700-1 18 - 64
18 - Injection
15 - Pump
Figure 413. DP210/310 Pump (If Installed) Figure 414. DB4 Pump (If Installed)
9
9
8
8 Inlet connection
9 Bleed-off connection
14. Remove the TDC setting tool and install the fuel
lift pump.
15. Install the throttle cable.
16. Bleed the fuel system.
17. Reconnect the battery. Refer to (PIL 33-03-03).
18. Make sure there are no leaks.
Table 138. Torque Settings

Item Pump Type Stage 1 (Nm) Stage 2 (Nm) Stage 3 (Nm)
3 (Fuel injection Both 70
pump gear cover)
4 (Lock bolt) Both 12
11 (Drive shaft nut) DP210/310 25 90
11 (Drive shaft nut) DB4 25 90 180
18 - 65 9823/1700-1 18 - 65
21 - Fuel Pump
21 - Fuel Pump
Contents Page No.
18-21-00 General ........................................................................................................................... 18-67
18 - 66 9823/1700-1 18 - 66
21 - Fuel Pump
00 - General
Introduction .................................................... 18-67 The fuel lift pump is a sealed electrical unit integral
Technical Data ............................................... 18-69 with the fuel pre-filter and water separator.
Operation ....................................................... 18-70
Check (Operation) ......................................... 18-71 The fuel lift pump is a non-serviceable component.
If any part is defective, replace the complete pump,
Remove and Install ....................................... 18-73 filter and separator assembly.
Figure 415.
A Fuel lift pump

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

from a 24 V supply by means of an in-line voltage
reducer.
18 - 67 9823/1700-1 18 - 67
21 - Fuel Pump
00 - General
Figure 416.
A
A Lift pump motor

B Voltage reducer
C In-line electrical connector
D Harness electrical connector
18 - 68 9823/1700-1 18 - 68
21 - Fuel Pump
00 - General
Technical Data
Table 139.
Component Value
Operating pressure 0.8 bar ( 11.6 psi)
Expected minimum free 2.5 L/min
flow delivery
Table 140. Expected electrical values

Machine Minimum Maximum Minimum Maximum Minimum Maximum
Voltage V Voltage V Voltage V Resistance Resistance Current Draw Current Draw
Ohms Ohms A A
12 8 16 0.8 1.5 4 8
24 20 30 4.9 5.7 4 5.5
18 - 69 9823/1700-1 18 - 69
21 - Fuel Pump
00 - General
Operation
The pump draws fuel from the tank, through the water
separator, pumping it through the fuel filter and into
the fuel injection pump. The pump has a built in
protection against running dry and will shut down
after 2 min if no fuel is present.
18 - 70 9823/1700-1 18 - 70
21 - Fuel Pump
00 - General
Check (Operation)
Flow Test out during this period of time. Minimum expected fuel
flow. 1 L in 24 s.
If the fuel lift pump is suspect, measure the delivery
flow rate. Alternatively use Servicemaster to energise the fuel
pump as follows.
2. Disconnect the fuel hose from the outlet of the
pump/ filter assembly. 2. Turn the ignition switch ON. Do not start the
engine.
3. Connect a length of fuel hose from the pump
outlet to a suitable fuel container. 3. Allow the fuel pump priming to occur at key on
before starting the test.
Volume: 5 L
4. Put a container of suitable capacity to collect the
4. Activate the fuel pump. Do not attempt to start fuel at the outlet port of the lift pump.
the engine.
5. Select the fuel lift pump test using Servicemaster.
5. Run the pump. The fuel flow must be equal to or
greater than the value shown. 6. There is a delay of the specified duration before
Duration: 1 min the test starts.
Flowrate: 2.5 L/min Duration: 5 s
Fuel Lift Pump Test - Machines with 7. The test will operate the lift pump for specified
duration.
Electronic Control Fuel Injection
Duration: 24 s
When the ignition is set to ON the ECM (Engine
Control Module) energises the fuel lift pump. If the 8. Make sure that the fuel collected in the container
engine is not started the pump is de-energised after is not more or less than the specified value.
a period of 24 s. A fuel pump flow test can be carried Volume: 1 ± 0.2 L
18 - 71 9823/1700-1 18 - 71
21 - Fuel Pump
00 - General
Figure 417. Servicemaster fuel lift pump test screen
18 - 72 9823/1700-1 18 - 72
21 - Fuel Pump
00 - General
Remove and Install
Remove 4. Disconnect the WIF (Water in Fuel) sensor

harness connector.
5. Make sure to mark label on the fuel pipes to aid
The fuel lift pump is installed on the loader tower. in the installation.
This procedure is also similar for the machines with
6. Disconnect the fuel pipes at the fuel lift pump by
lift pumps installed on the side of the fuel tank.
means of the quick release connectors.
1. Make the machine safe. 7. Disconnect the drain hose at drain tube.
2. Disconnect the battery. 8. Support the fuel lift pump and remove the bolts.
3. Disconnect the fuel lift pump harness connector. 9. Remove the fuel lift pump together with its pre-
filter/separator from the machine.
Figure 418.
D
C
A B E
H
F
A WIF sensor harness connector B Fuel pipe

C Fuel lift pump harness connector D Fuel lift pump
E Fuel pipe F Bolt
G Drain tube H Pre-filter/Separator
J Fuel pipe
Install
removal procedure.
Table 141. Colour code

Fuel pipe Colour
E Blue
J Red
18 - 73 9823/1700-1 18 - 73
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-75

18-24-03 Inlet Manifold .................................................................................................................. 18-77
18-24-04 Outlet Manifold ............................................................................................................... 18-81
18-24-06 Silencer .......................................................................................................................... 18-85
18 - 74 9823/1700-1 18 - 74
24 - Exhaust
00 - General
Introduction .................................................... 18-75 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-76 away from the controlled combustion inside the
Check (Condition) .......................................... 18-76 engine by means of an exhaust pipe.
The exhaust pipe carries the toxic and noxious gases

away from the users of the machine. Note machines
or generators that work indoors can quickly fill an
enclosed space with carbon monoxide or other
poisonous exhaust gases if they are not properly
vented to the outdoors.
18 - 75 9823/1700-1 18 - 75
24 - Exhaust
00 - General

Exhaust Gases Excessive smoke from the exhaust stack combined
Machine exhaust gases can harm and possibly kill with a complaint of low power could be as a result of:
you or bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure • Dirt or dust (unfiltered air) ingested directly into
there is good ventilation. If possible, install an the engine, resulting in damage to the cylinder
exhaust extractor. If you begin to feel drowsy, stop bores, there will also be a possible increase in
the machine at once and get into fresh air. oil consumption.
• Air leaks from the air hose connections.
Sparks • Exhaust manifold leaks.
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
Hot Components
Touching hot surfaces can burn skin. The engine and
been running. Allow the engine and components to
cool before servicing the unit.
engine cover open.
18 - 76 9823/1700-1 18 - 76
24 - Exhaust
03 - Inlet Manifold
03 - Inlet Manifold Introduction

Introduction .................................................... 18-77 The inlet manifold (or intake manifold) supplies
Component Identification ............................... 18-78 combustion air to the cylinders in compression
Check (Condition) .......................................... 18-78 ignition engines or the air/fuel mixture for spark
Remove and Install ....................................... 18-79 ignition engines (except most direct injection spark
ignition engines). Even distribution of the air or
air/fuel is important to optimize the efficiency and
performance of the engine.
The manifold is required to be air tight under pressure

and vacuum conditions and can be required to
provide mounting points for sensors, grid heaters,
throttle bodies and other components depending on
the engine type and specification.
18 - 77 9823/1700-1 18 - 77
24 - Exhaust
03 - Inlet Manifold

Figure 419. 1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
1
1 Inlet Manifold
18 - 78 9823/1700-1 18 - 78
24 - Exhaust
03 - Inlet Manifold
Remove and Install
Before Removal 2. Make sure that the engine is safe to work on. If
1. This procedure requires service parts. Make you start the service work.
before you start, refer to Parts Catalogue. 3. Get access to the engine.
Figure 420.
4
5
2 1
6 9
8 7
1 Inlet manifold 2 Bolts (x8)

3 Boost control pipe (turbocharged engines only) 4 Grid heater blanking plate (if installed)
5 Bolts (x2) 6 Breather pipe connector (naturally aspirated
engines only)
7 Grid heater (if installed) 8 Electrical connection, grid heater (if installed)
9 Manifold gasket
Remove 3. Disconnect the grid heater electrical cable at the

heater connector (if installed).
1. Disconnect the boost control pipe from the
adaptor (For Turbocharged Engines). 4. Disconnect the air inlet hose.
2. Disconnect the breather hose at the manifold 5. Remove the eight bolts that attach the inlet
connection (For Naturally Aspirated Engines). manifold to the cylinder head.
18 - 79 9823/1700-1 18 - 79
24 - Exhaust
03 - Inlet Manifold
6. Lift the inlet manifold from the cylinder head.

Discard the gasket.
7. Cap the inlet ports with blanking caps to prevent
ingress of dirt.
8. If required, remove the two bolts that attach the
grid heater blanking plate.
9. Remove the grid heater blanking plate or the grid
heater (if installed).
10. Discard the gasket.
Install
steps.
2. Renew the manifold gasket.
3. Loosely assemble the manifold, together with the
new inlet gasket to the cylinder head, use the two
bolts (one at each end).
4. With the manifold and gasket in position, install
the remaining six bolts.
6. If the grid heater or blanking plate have been
removed, renew the gasket.
7. Make sure to install the grid heater the correct
way up. Orientate with the arrow pointing down
(aligned with the air flow direction through the
manifold).

Item Nm
2 24
5 (If required) 24
18 - 80 9823/1700-1 18 - 80
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction

Introduction .................................................... 18-81 The exhaust outlet manifold collects the exhaust
Component Identification ............................... 18-82 gases from the multiple cylinders and delivers it to
Check (Condition) .......................................... 18-82 the turbocharger or the exhaust pipe.
18 - 81 9823/1700-1 18 - 81
24 - Exhaust

Figure 421. 1. Check the manifold mating faces for signs of
A B damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
4. Visually inspect for leaks at the exhaust manifold.
Make sure all gaskets are in good condition,
replace as required.
A Exhaust manifold
B Manifold gasket and heat shield
18 - 82 9823/1700-1 18 - 82
24 - Exhaust
Remove and Install
Note that the illustration shows an engine installed 2. Make sure that the engine is safe to work on. If
with a turbocharger. the engine has been running, let it cool before
4. Disconnect the oil pipes to the turbocharger.
Figure 422.
C A
A Exhaust manifold B Fixing bolts (x8)

C Oil pipes (turbocharged engines only)
Remove 3. Install the lower four bolts, together with the new
exhaust gasket to the cylinder head (screw in the
1. Remove the upper four bolts. bolts approximately to a length of 8 mm).
2. Loosen the lower four bolts and lift the exhaust 4. Rest the manifold in position on the row of
manifold from the cylinder head. Remove the lower bolts by locating the slots, then install the
bolts and discard the gasket. remaining four upper bolts.
3. Cap the exhaust ports to prevent ingress of dirt. 5. Tighten the bolts to the correct torque value.
4. Inspect the manifold.
After Installation
1. Reconnect the oil pipes to the turbocharger (if
Install installed).
1. The installation procedure is the opposite of the 2. Install the exhaust pipe and the silencer box.
removal procedure. Additionally do the following 3. Start the engine and check for exhaust leaks.
steps.
2. Renew the manifold gasket.
18 - 83 9823/1700-1 18 - 83
24 - Exhaust

Item Nm
2 25
18 - 84 9823/1700-1 18 - 84
24 - Exhaust
06 - Silencer
06 - Silencer Figure 424. Turbo machines

E
Remove and Install B
CAUTION The exhaust pipe becomes extremely
hot when the engine is running and will remain so F
for some time after the engine is stopped. If you C
touch the hot pipe you could be severely burned.
Figure 423. Non Turbo machines
D E H
C D H
J
A
G
H
A Flange nuts
F B U bolt 1 nuts
C U bolt 1
D U bolt 2 nuts
H E U bolt 2
F Silencer
A G Gasket
H Rubber mounts
J Studs
J
G
Remove
2. Allow the engine and exhaust system to cool
before working on the machine.
3. Make sure that the engine cannot be started.
4. Open the engine cover. Refer to (PIL 06-06).
5. Install the assembly clamp to the flexible section
of the exhaust pipe. The clamp is designed to
protect the flexible section of the exhaust pipe so
that it can be installed correctly. New silencers
are supplied with a clamp installed.
18 - 85 9823/1700-1 18 - 85
24 - Exhaust
06 - Silencer
Figure 425.
K Exhaust assembly clamp

6. Remove the flange nuts.
7. Remove the two U bolt 1 nuts and U bolt 1
assembly
8. Support the silencer.
9. Remove the two U bolt 2 nuts and U bolt 2
assembly.
10. Lift off the silencer.
11. Remove and discard the gasket.
12. Examine the rubber mounts. If they are defective
replace them with new ones.
13. Examine the studs. If they are defective replace
them with new ones.
Install
steps.
2. Use a new gasket.
3. Tighten the flange nuts to the correct torque
value.
4. Remove clamp before starting the engine.

Item Nm
A 22–26
18 - 86 9823/1700-1 18 - 86
35 - Turbocharger
35 - Turbocharger
Contents Page No.
18-35-00 General ........................................................................................................................... 18-89
18 - 87 9823/1700-1 18 - 87
Notes:
18 - 88 9823/1700-1 18 - 88
35 - Turbocharger
00 - General
Introduction .................................................... 18-89 The turbocharger (turbo) is a turbine driven forced
Component Identification ............................... 18-90 induction device that makes an engine more efficient
Check (Condition) .......................................... 18-90 and helps to produce more power for its size.
Check (Operation) ......................................... 18-91
Engine exhaust gasses drive a turbine, which in turn
Remove and Install ....................................... 18-92 drives a compressor via a common shaft. The shaft
bearings are lubricated by a feed from the engine
lubrication system.
A turbocharged engine is more powerful and efficient

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

flap type valve is housed in the turbocharger body.
The valve is actuated by a diaphragm type actuator
via an actuator rod. When the pressure generated
by the turbocharger compressor reaches a pre-set
value the actuator opens the valve, some exhaust
gas is diverted back to the exhaust manifold and
the turbocharger turbine speed reduces. In this way
the pre-set maximum boost pressure from the turbo
charger is not exceeded, regardless of engine speed.
18 - 89 9823/1700-1 18 - 89
35 - Turbocharger
00 - General

1. Visually inspect for leaks at the turbocharger.
(For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3 Make sure that all gaskets are in good condition,
Mech Turbo and Aftercooled) replace as required.
Figure 426. 2. Check the turbine and compressor blades inside
A B the turbocharger rotate freely and smoothly by
J hand. If the blades are stiff to turn, or damaged
the turbocharger must be replaced.
H
3. Make sure that the oil feed pipe and oil drain pipe
are clear and free from debris and sludge.
4. Check the turbine shaft running clearance.
C
4.1. Place the stylus of a DTI (Dial Test Indicator)
against the shaft.
G 4.2. Move the shaft sideways.
F
Figure 427.
E
D
A Turbocharger
B Air outlet
C Air inlet
D Oil drain pipe
E Oil feed pipe
F Exhaust manifold
G Wastegate (if applicable)
H Actuator rod - wastegate (if applicable)
J Actuator - wastegate (if applicable) 4.3. Make sure that the turbine shaft running
clearance is within the specified limits.
5. Check the shaft end float.
5.1. Place the stylus of the DTI against the end
of the shaft.
18 - 90 9823/1700-1 18 - 90
35 - Turbocharger
00 - General
Figure 428. Check (Operation)
To maximise the duration of the turbocharger follow

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

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

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 91 9823/1700-1 18 - 91
35 - Turbocharger
00 - General
Remove and Install
Figure 429.
9
17, 4
10 7
16
13
12
1
18
3
8
17, 4 3
11
6 15 5
1 Turbocharger 2 Exhaust manifold

3 Oil feed pipe (turbo bearing) 4 Banjo bolts (x2)
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
9 Boost air hose - wastegate 10 Actuator - wastegate
11 Pipe clip 12 Operating rod - wastegate
13 Mounting bracket - wastegate 14 Gasket - exhaust manifold
15 Gasket - oil drain pipe 16 O-ring - oil drain pipe connector
17 Sealing washers (x4) - oil feed pipe banjo 18 Gasket - turbocharger
18 - 92 9823/1700-1 18 - 92
35 - Turbocharger
00 - General
Before Removal 3. Note that the exhaust manifold gasket also

functions as a heat-shield. Be sure to position the
1. This procedure requires service parts. Make sure gasket the correct way around.
you have obtained the correct parts before you
start, refer to Parts Catalogue. 4. Tighten the nuts, bolts and banjo bolts to the
2. Make sure that the engine is safe to work on.
If the engine has been running, make sure the After Installation
engine has cooled sufficiently before you start.
1. Start the engine and check for exhaust leaks.
2. Test the turbocharger boost pressure.
Remove
1. Disconnect the air cross over hose at the inlet Item Nm
manifold and turbocharger. Remove the hose.
4 21
2. Remove the pipe clip. Remove the two bolts that 6 24
attach the oil drain pipe. 8 24
3. Remove the oil drain pipe.
3.1. Note that the pipe pulls off the pipe adaptor,
leaving the adaptor in place.
4. Cap the open ports to prevent ingress of dirt.
Discard the O-ring and the gasket.
5. Loosen the banjo bolts at each end of the oil feed
pipe, remove the pipe.
6. Cap the open ports to prevent ingress of dirt.
Discard the sealing washers.
7. Remove the exhaust manifold from the cylinder
head complete with the turbocharger still
installed, refer to (PIL 18-24). Discard the
exhaust manifold gasket.
8. With the exhaust manifold removed from the
engine, loosen the nuts and separate the
turbocharger from the manifold. Discard the
gasket.
If the rotor and bearing housing only are to be

renewed there is no need to remove the turbocharger
from the exhaust manifold.
Important: It is important that the waste gate actuator

setting is not altered. The waste gate operating rod is
factory set and sealed. Do not remove the actuator,
mounting bracket or make any adjustment to the
wastegate actuator operating mechanism.
Install
steps.
2. Replace all the O-rings, sealing washers and
gaskets with a new one.
18 - 93 9823/1700-1 18 - 93
39 - Fuel Cooler
39 - Fuel Cooler
Contents Page No.
18-39-00 General ........................................................................................................................... 18-95
18 - 94 9823/1700-1 18 - 94
39 - Fuel Cooler
00 - General
00 - General
Remove and Install
Remove 5. Open the engine compartment cover. Refer to

(PIL 06-06).
6. Disconnect the fuel hoses from the matrix at the
2. Follow the general health and safety procedures. quick release couplings.
7. Support the matrix.
3. Switch off the engine before working in the
engine compartment. Remove ignition key or 8. Remove the nuts.
isolate battery to prevent the engine from being
started. Refer to (PIL 33-03). 9. Remove the fuel cooler matrix from the machine.
4. If the engine is hot let it cool for one hour.
Figure 430.
B
B C
A Quick release couplings B Nuts

C Matrix
18 - 95 9823/1700-1 18 - 95
39 - Fuel Cooler
00 - General
Install
steps also.
1.1. Bleed the fuel system. Refer to fuel system-
general, refer to (PIL 18-00).
1.2. After installation, start the engine and check
for fuel leaks.
18 - 96 9823/1700-1 18 - 96
96 - Fuel Pipe
96 - Fuel Pipe
Contents Page No.
18-96-00 General ........................................................................................................................... 18-99

18-96-03 High Pressure Pipe ...................................................................................................... 18-103
18-96-06 Low Pressure Pipe ....................................................................................................... 18-105
18 - 97 9823/1700-1 18 - 97
Notes:
18 - 98 9823/1700-1 18 - 98
96 - Fuel Pipe
00 - General
Introduction .................................................... 18-99
Preparation .................................................. 18-102 Fuel is continuously supplied to the injectors through
the high pressure fuel pipes. The high pressure fuel
injector pipes consist of thick walled, seamless steel
tubing. The ends of the tubes are formed with conical
nipples for sealing in the sealing cones on the injector
at port.
It is necessary that the pipes are maintained and

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

The fuel injection pump injects fuel in response to the
engine load. During fuel injection some fuel bleeds
off the injectors and back to tank through the low
pressure bleed off pipes.
Important: If the high pressure fuel pipes are

removed for any reason they must be replaced.
Installing the existing fuel pipes will cause fuel leaks
at the pipe connections.
18 - 99 9823/1700-1 18 - 99
96 - Fuel Pipe
00 - General
Health and Safety

WARNING Do not open the high pressure fuel
causes high fuel pressure. High pressure fuel
spray can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously
damage the fuel injection equipment and could be
expensive to repair.
18 - 100 9823/1700-1 18 - 100

96 - Fuel Pipe
00 - General
Figure 431.
D E F G
C J
A B
A Low pressure fuel supply pipe - fuel tank to lift B Low pressure fuel supply pipe - lift pump to filter
pump
C Low pressure fuel supply pipe - filter to fuel D High pressure fuel pipe - cylinder 1
injection pump
E High pressure fuel pipe - cylinder 2 F High pressure fuel pipe - cylinder 3
G High pressure fuel pipe - cylinder 4 H Fuel bleed off pipe - fuel injectors to tank
J Fuel bleed off pipe - fuel injection pump to tank
18 - 101 9823/1700-1 18 - 101

96 - Fuel Pipe
00 - General
Preparation
(For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3 1. Make sure that the engine is safe to work on. The
Mech Turbo and Aftercooled) engine must cool and pressure in the fuel system
must decay before you start work. If the engine
Important: Before you disconnect or remove fuel has been running, wait at least one hour before
pipes make sure that you have the correct new parts. you start work.
The high pressure fuel pipes MUST BE REPLACED
2. Clean the engine. Refer to Engine-Clean (PIL
with new ones. The new fuel pipes must remain
15-00).
sealed inside their bags before use. If a bag is open
DO NOT USE the fuel pipe, get a new one. 3. Remove the screws and lift off the protective
cover.
Refer to (PIL 18-00). 4. Remove any dirt or debris that is exposed. Refer
to Engine-Clean (PIL 15-00).
Figure 432.
4
5 3
4
5 2
1 Union nuts - high pressure fuel lines 2 Bleed-off fuel line

3 Protective cover 4 Screws - protective cover
5 Removable inserts - protective cover
18 - 102 9823/1700-1 18 - 102

96 - Fuel Pipe
03 - High Pressure Pipe
03 - High Pressure Pipe Figure 434.

E
Remove and Install
(For: JCB 4.4 T3 Mech Turbo, JCB 4.4 T3 E

Injector Fuel Pipes E
Before Removal
C
the engine has been running, let it cool before E
you start the service work.. A
2. Clean off all dirt and debris from around the fuel
pipe connectors. D
E B
Do not attempt to repair fuel pipes or connectors. If
a fuel pipe or connector is damaged the fuel pipe
assembly must be renewed.
Figure 433.
A High pressure fuel pipes

B Bleed-off fuel line
C Protective cover
D Screws - protective cover
E Removable inserts protective cover
3. Use the 17mm deep socket special tool at the top
of nut. This will prevent damage to the nut.
Figure 435.
A
A High pressure fuel pipes
Remove
1. Remove the protective cover. Push out the four
plastic segments. Remove the screws and lift off
the cover.
2. Remove the fuel pipe in pairs, starting with the 4. Remove the nuts at the fuel injection pump and
pipes for cylinder C and D. injectors and lift the fuel pipes away.
5. Repeat step 4 to remove the other fuel pipes A
and B.
6. Seal all the open ports, use the correct parts from
the service kit.
7. Discard the old fuel pipes.
18 - 103 9823/1700-1 18 - 103

96 - Fuel Pipe
03 - High Pressure Pipe
Install
Important: The high pressure fuel pipes must be
replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a bag
is open do not use the fuel pipe, get a new one. Do
not open the bag until you are ready to assemble the
fuel pipe.
1. Make sure that the bleed-off adaptors are

assembled on the injectors before you install the
high pressure pipes.
2. Make sure the fuel pipes are properly sealed.
3. Tighten the nut to the correct torque value, refer
to torque table.
4. Do not over tighten. If the nuts are over tightened
the pipe sealing seats may be damaged or
causing fuel leaks.
After Installation
1. Ensure that all pipes are correctly installed
and located in retaining clips as applicable. If
retaining clips are missing or damaged they must
be replaced or renewed.

Item Nm
A 27
18 - 104 9823/1700-1 18 - 104

96 - Fuel Pipe
06 - Low Pressure Pipe
06 - Low Pressure Pipe Figure 436.
Remove and Install

2
1 1
Before Removal
3
2. Clean off all dirt and debris from around the fuel
pipe connectors.

a fuel pipe or connector is damaged the fuel pipe

Refer to Fuel System - Preparation and Health and
Safety (PIL 18-00).
Low Pressure Fuel Pipes

Remove
The low pressure fuel pipes have a nylon fitting
attached to the pipe that replaces the nut and olive.
The fittings are part of the pipe and not a separate 1 Release Buttons
item. 2 Coupler
3 Spigot
A damaged fitting will result in the pipe having to be
replaced as a completed assembly. After Installation
WARNING Fine jets of fluid at high pressure can
1. To release the fuel pipe, first press and hold the
release buttons (one each side of the coupler).
clear of fluid under pressure and wear personal
Push the coupler towards the connector spigot
protective equipment. Hold a piece of cardboard
and then withdraw.
close to suspected leaks and then examine the
2. Cap all open ports to prevent ingress of dirt and cardboard for signs of fluid. If fluid penetrates your
debris. skin, get medical help immediately.
WARNING Fuel is flammable, keep naked flames
Install away from the fuel system. Stop the engine
1. To install the fuel pipe, press and hold the release smoke while refuelling or working on the fuel
buttons. Push the coupler over the connector system. Do not refuel with the engine running.
spigot and release the button. The connector will Completely wipe off any spilt fuel which could
be heard to click when it is fully home and locked cause a fire. There could be a fire and injury if you
in place. do not follow these precautions.
2. To check that the connection has been fully
made, attempt to pull the connector from the 1. Make sure that all the fuel pipes are correctly
connector spigot without releasing the lock installed and located in the retaining clips as
mechanism. (A gentle pull is all that is required, applicable. If retaining clips are missing or
if the connection is not good the connector will damaged they must be replaced or renewed.
release very easily.)
18 - 105 9823/1700-1 18 - 105

96 - Fuel Pipe
06 - Low Pressure Pipe
Fuel Bleed-off Pipes Figure 437.
Before Removal

1 4 2
2. Clean off all dirt and debris from around the
fuel pipe connectors. Refer to Engine-Clean (PIL
15-00).
3. Remove the high pressure fuel pipes.

a fuel pipe or connector is damaged the fuel pipe 3
1
1 Location tabs - bleed line clip
Remove 2 Connector - bleed line
3 Bleed pipe clip
The following details the removal and replacement 4 O-ring - bleed line connector (x4)
of one bleed-off connector. The procedure for the
remaining connectors is identical. After Assembly
1. Gently spring the location tabs apart and pull out penetrate the skin. Keep face and hands well
the bleed pipe connector. Do not use excessive clear of fluid under pressure and wear personal
force on the tabs. protective equipment. Hold a piece of cardboard
2. Remove and discard the O-ring. close to suspected leaks and then examine the
cardboard for signs of fluid. If fluid penetrates your
3. Remove and discard the bleed pipe clip. skin, get medical help immediately.
4. Cap all open ports to prevent ingress of dirt and WARNING Fuel is flammable, keep naked flames
debris. away from the fuel system. Stop the engine
smoke while refuelling or working on the fuel
Install system. Do not refuel with the engine running.
1. Install a new bleed line clip correctly over the Completely wipe off any spilt fuel which could
injector, aligned with the bleed port in the injector. cause a fire. There could be a fire and injury if you
do not follow these precautions.
1. Make sure that all pipes are correctly installed
3. Push in the bleed pipe connector until the and located in retaining clips as applicable.
location tabs snap over the connector.
2. Replace the high pressure fuel lines.
18 - 106 9823/1700-1 18 - 106

21 - Cooling System
Contents Page No.
21-00 Cooling System

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ........................................................................................................................... 21-13
21-03-09 Transmission Oil Cooler ................................................................................................. 21-21
21-03-15 Fan ................................................................................................................................. 21-25
21-05 Fan Motor
21-05-00 General ........................................................................................................................... 21-27
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-39
21-09 Pump
21-09-00 General ........................................................................................................................... 21-45
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-51
21-21 Inlet
21-21-00 General ........................................................................................................................... 21-59
21-93 Hose
21-93-00 General ........................................................................................................................... 21-63
9823/1700-1
2018-06-23
Acronyms Glossary
CAC Charge Air Cooler

EGR Exhaust Gas Recirculation
PWM Pulse Width Modulation
9823/1700-1
2018-06-23
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9823/1700-1 21 - 1
Notes:
21 - 2 9823/1700-1 21 - 2
21 - Cooling System
00 - Cooling System
00 - General
Introduction ...................................................... 21-3 During the working cycle of the engine a great deal
Health and Safety ........................................... 21-4 of heat is generated. It is important that the engine is
Technical Data ................................................. 21-4 kept at its normal operating temperature to achieve
Component Identification ................................. 21-5 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Operation ......................................................... 21-7 quickly and then maintain it.
Fault-Finding .................................................... 21-8
Drain and Fill ................................................. 21-10
Check (Condition) .......................................... 21-10
Check (Leaks) ............................................... 21-11
Check (Level) ................................................ 21-11
21 - 3 9823/1700-1 21 - 3
21 - Cooling System
00 - Cooling System
00 - General

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the Table 147.
cap, hot coolant can spray out and burn you. Radiator cap pressure 1 bar ( 14.5 psi)
Make sure that the engine is cool before you work setting
on the cooling system.
Thermostat Wax element with by-
CAUTION Antifreeze can be harmful. Obey the pass blanking
manufacturer's instructions when handling full Thermostat operating temperatures:
strength or diluted antifreeze.
- Nominal temperature 88 °C ( 190.3 °F)
- Start to open tempera- 86 –90 °C ( 186.7 –
ture 193.9 °F)
- Full open temperature 102 °C ( 215.5 °F)
- Travel (fully open) 9 mm
Fan belt type FEAD (Front End Acces-
sory Drive)
Fan belt (FEAD) adjust- Automatic belt tensioner
ment
Fan belt (FEAD) type Multi-groove belt
Coolant temperature Refer to PIL 15-84
switch / sender range
Coolant pump
(1)
Bolt on, belt driven unit
(1) The coolant pump is a non-serviceable part.
21 - 4 9823/1700-1 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Figure 438.
15
14 8
11
10
9
7
13 12
7
6
4 5
16
1 Coolant pump 2 Drive belt
21 - 5 9823/1700-1 21 - 5
21 - Cooling System
00 - Cooling System
00 - General
3 Pump cavity (crankcase) 4 Pump outlet gallery (crankcase)

5 Oil cooler cavity (crankcase) 6 Coolant gallery (crankcase)
7 Cylinder cooling jackets (crankcase) 8 Link galleries (crankcase to cylinder head)
9 Thermostat housing (cylinder head) 10 Thermostat (cylinder head)
11 Top hose connection port (cylinder head) 12 By-pass gallery (cylinder head and crankcase)
13 Bottom hose connection port (crankcase) 14 Port for coolant temperature sensor and
switch unit
15 Port for cab heater hose connection
21 - 6 9823/1700-1 21 - 6
21 - Cooling System
00 - Cooling System
00 - General
Operation
The coolant pump is driven via a pulley and front end

accessory drive belt, the pump draws coolant from
the pump cavity.
The coolant is pumped through the outlet gallery

to the oil cooler cavity in the left-hand side of the
crankcase. As the coolant flows past the oil cooler
matrix, heat is exchanged from the oil to the coolant.
This enables the oil to function as a coolant as well
as a lubricant. Refer to Oil Cooler (PIL 15-69) and Oil
Filter (PIL 15-21).
The coolant leaves the oil cooler cavity and passes

into the main crankcase gallery. The gallery is
connected to the cylinder water jackets. Coolant
flows around and up the jackets and then passes into
the cylinder head via the link galleries. The coolant
circulates around the cylinder head where it conducts
heat away from the combustion chambers and also
the fuel injector tips, refer to (PIL 18-18). The coolant
then passes to the thermostat housing.
When the engine is below normal operating

temperature the thermostat is closed, preventing
coolant flowing to the machine radiator via the top
hose connection port. Instead coolant is directed
through the by-pass gallery back to the pump
cavity and is again drawn into the pump. Refer to
Thermostat (PIL 21-12).
When the engine is at operating temperature the

thermostat opens, closing the by-pass gallery to the
pump and opening the top hose connection port to
the machine radiator. The coolant passes through
the radiator matrix and is cooled. The coolant flows
back to the engine via the bottom hose connection
port and is again drawn into the pump. Refer to
Thermostat (PIL 21-12).
A coolant temperature gauge and warning light

sender unit is installed at port 14. Refer to Engine
Sensors (PIL 15-84).
A cab heater hose can be installed at port 15. This

enables coolant to circulate through a heater matrix
when the thermostat is open or closed, ensuring fast
heater warm up.
21 - 7 9823/1700-1 21 - 7
21 - Cooling System
00 - Cooling System
00 - General
Fault-Finding
Fault
Coolant - Loss. Table 148. Page 21-8
Coolant - Over Temperature. Table 149. Page 21-8
Coolant - Under Temperature. Table 150. Page 21-9
Coolant - Contaminated. Table 151. Page 21-9
Table 148. Coolant - Loss.

Cause Remedy
Incorrect coolant level. Check the level.
Coolant leaking from engine radiator or cab heater. Visually inspect the radiator heater, hoses and
connection to locate the leak. If oil is present in the
coolant, check for a transmission or engine oil cooler
leak.
External engine coolant leak. Visually inspect the engine and components for
seal, gasket hose connection leaks. Make sure all
hose clips are in good condition and torqued to the
recommended figure. Make sure all spring band
clamps are in good condition and apply sufficient
pressure to the hoses.
Overheating or compression gases leaking, resulting See Also: Table 149. Coolant - Over Temperature.
in loss through the radiator overflow.
If installed, transmission cooler leak. Check/replace the transmission cooler. Check for
coolant in the inlet manifold and in the oil.
Lubricating oil cooler leak. Check/replace the oil cooler. Check for coolant in the
oil.
EGR (Exhaust Gas Recirculation) cooler leak (if Check/replace the EGR cooler. Check for signs of
applicable). coolant leaking into combustion chamber.
Cylinder head gasket leak. Check/replace the head gasket.
Cylinder head cracked or porous. Check/replace the cylinder head.
Crankcase coolant passages leaking. Check/replace the crankcase.
Table 149. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 148. Coolant - Loss.
External radiator matrix blocked with dirt or chaff. Clean exterior or radiator matrix.
Air flow to the radiator inadequate or restricted. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Coolant pump or fan drive belts loose. Check/correct belt tension.
Radiator hose collapsed, restricted or leaking. Check/replace hose.
Oil level overfilled. Check oil level.
Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system.
Over concentration of anti-freeze. Remove part of the coolant from cooling system and
replace with water.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, incorrect or missing. Check/replace the thermostat.
Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the
correct vented thermostat is installed. If aeration
continued, check for a compression leak through the
head gasket.
21 - 8 9823/1700-1 21 - 8
21 - Cooling System
00 - Cooling System
00 - General
Cause Remedy
Coolant pump faulty. Check/replace the coolant pump.
Vent line from engine and/or radiator blocked or Check routing and operation or vent line.
incorrectly routed (sudden overheating).
Leak between the top tank and the auxiliary tank Check for coolant leakage between radiator auxiliary
(sudden overheating). tank and radiator top tank.
Cooling passages in radiator, cylinder head, head Flush the system and fill with clean coolant.
gasket or crankcase blocked.
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault (if applicable). connections at the ECM and sensors.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
connections at the injectors.
Table 150. Coolant - Under Temperature.

Cause Remedy
Air flow across the radiator excessive. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, (open - not sealing). Check/replace the thermostat.
Coolant not flowing by temperature sensor. Check/clean coolant passages. A total coolant loss
may result in the gauge showing low temperature
initially. In which case, check the level.
Table 151. Coolant - Contaminated.

Cause Remedy
Coolant rusty, operation without correct mixture of Drain and flush the cooling system. Fill with correct
antifreeze and water. mixture of antifreeze and water. Review the coolant
change interval.
Engine oil cooler, or cooler housing allowing cross Remove the oil cooler assembly and check relevant
contamination of coolant with engine oil. sealing elements for damage.
Transmission lubricating oil cooler leaking (if Check/replace lubricating oil cooler. Refer to
applicable). equipment manufacturer's procedures.
Lubricating oil leaks from lubricating oil cooler, head See Also: Table 148. Coolant - Loss.
gasket, head and crankcase.
21 - 9 9823/1700-1 21 - 9
21 - Cooling System
00 - Cooling System
00 - General
Drain and Fill Check (Condition)

Consumables
Description Part No. Size 1. Visually inspect the engine and related cooling
components for:
Antifreeze HP/ 4006/1101 5L
Coolant ASTM D6210 4006/1120 20 L 1.1. Leaks.
Concentrate 4006/1103 200 L 1.2. Cracked, burnt or perished hoses.
The graphic shows a typical engine cooling system, 1.3. Hose clips are in good condition and
the system you are working on may look slightly torqued to the correct value.
different.

4. Carefully loosen the cap just enough to let any
pressure escape. Remove the cap when all
pressure is released.
5. Disconnect the bottom radiator hose and allow
the coolant to drain into a suitable container.
6. Flush the system by pouring clean water into the
filler port.
7. Connect the bottom radiator hose.
8. Fill the expansion tank, using the necessary anti-
freeze solution, to the level indicated.
Consumable: Antifreeze HP/Coolant ASTM
D6210 Concentrate
9. Run the engine for a while to raise the coolant
to working temperature and pressure. Stop the
engine and check for leaks. Check the level in
the expansion tank and top up if necessary.
Figure 439.
A
B
A Cap
B Bottom radiator hose
C Expansion tank
21 - 10 9823/1700-1 21 - 10
21 - Cooling System
00 - Cooling System
00 - General
Check (Leaks) Check (Level)
Before you start the machine, inspect the system for 1. Make the machine safe.
leaks. Refer to: PIL 01-03.
1. Make the machine safe. Refer to (PIL 01-03). 2. Get access to the coolant expansion tank.
2. Get access to the cooling pack. 3. Check the level of coolant in the coolant
expansion tank. If necessary remove the filler
3. Check the cooling system for leaks. cap and top up to the level indicated.
4. If necessary, contact your JCB dealer. 4. Install the filler cap and make sure it is tight.
5. Run the engine for a while to raise the coolant to
working temperature and pressure.
6. Stop the engine and check for leaks.
21 - 11 9823/1700-1 21 - 11
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ........................................................................................................................... 21-13

21-03-09 Transmission Oil Cooler ................................................................................................. 21-21
21-03-15 Fan ................................................................................................................................. 21-25
21 - 12 9823/1700-1 21 - 12
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction .................................................... 21-13 The cooling pack contains the following major
Component Identification ............................... 21-14 components:
Clean ............................................................. 21-16
Check (Condition) .......................................... 21-16 • Radiator.
• Cooling fan.
Remove and Install ....................................... 21-17 • CAC (Charge Air Cooler).
Disassemble and Assemble .......................... 21-20 • Condenser for air-conditioning (if installed).
• Oil cooler (if installed).
21 - 13 9823/1700-1 21 - 13
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 440.
A
A
E
A
E
D
F
B
E
L F
C
G H K
Q
P J
21 - 14 9823/1700-1 21 - 14
21 - Cooling System
03 - Cooling Pack
00 - General
Table 152.
Item Description
A Air cleaner / fuse box
support bolts
B Fuel sedimentor and
pump
C Air to air inter cooler ma-
trix
D Hydraulic oil cooler ma-
trix (if installed)
E Fixing points
F Hydraulic hoses- Fan
Motor/Oil Cooler
G Solenoid valve- re-
versible fan (if installed)
H Fan speed sensor
J Proportional fan speed
control solenoid
K Engine coolant radiator
matrix
L Radiator top hose con-
nection
M Inter cooler inlet hose
connection
N Fixed Speed Cooling fan
and hydraulic motor as-
sembly (55KW engines)
P Variable Speed Cooling
fan and hydraulic motor
assembly (81, 93 and
108 KW engines)
Q Inter cooler outlet hose
connection
R Radiator bottom hose
connection
21 - 15 9823/1700-1 21 - 15
21 - Cooling System
03 - Cooling Pack
00 - General
If the radiator tubes/fins get clogged the radiator will 1. Make the machine safe. Refer to (PIL 01-03).
be less efficient.
2. Let the engine cool.
3. Get access to the cooling pack. Refer to (PIL
2. Open the engine cover. Refer to (PIL 06-06-06). 21-03)
3. Remove the undershield. Refer to (PIL 4. Check the hoses, radiator and fan for:
06-06-30).
4.1. Condition.
4. Use a soft bristle brush to remove all unwanted 4.2. Damage.
material from the rear of the radiator.
4.3. Security.
5. Release the fastener and pull the condenser
away from the radiator. 5. If necessary, Replace the system hoses/radiator.
6. Use the soft bristle brush to remove all unwanted

material from both sides of condenser and
the front of the radiator. Then push back the
condenser and lock in position with the fastener.
7. Make sure that the loosened material is removed
out of the engine compartment.
21 - 16 9823/1700-1 21 - 16
21 - Cooling System
03 - Cooling Pack
00 - General
Remove and Install
Although it is possible to remove individual 11. Plug all the open ports and hoses to prevent
components it is quicker and easier to remove contamination.
the complete sub assembly, particularly if access
is necessary for engine overhaul or removal and 12. Disconnect the hydraulic hoses from the chassis.
replacement for example.
contamination.
Disassembly
14. On 527-56 machines, the fan motor hydraulic
1. Make the machine safe. Refer to (PIL 01-03). hoses are connected to the bulkhead plate.
2. Make sure that the engine and hydraulic system Figure 441.
are cool before you start the removal procedure.
3. Remove the engine cover and side console
assembly. Refer to (PIL 06-06).
4. Put a label on the fuel lines, hoses and electrical
connectors to help installation.
5. Disconnect the fuel lines and electrical connector
from the fuel separator or remove the fuel
separator bolts, the fuel line clips and tie the
assembly safely out of the way.
6. Disconnect the radiator bottom hose and drain S T
the coolant.
7. Disconnect the radiator top hose. S Bulkhead plate
T Fan motor hydraulic hoses
8. Disconnect the fan motor electrical connections
(if installed). 15. Disconnect the intercooler inlet and outlet hoses.
9. For 81 kW, 93 kW and 108 kW Machines. 16. Support the cooling pack assembly, remove the
fusebox bolts and the fixing bolts.
9.1. Disconnect the electrical connectors from
the fan motor direction control valve (if 17. Carefully lift and move the assembly away from
installed), control solenoid and the speed the machine.
sensor.
10. Disconnect the transmission cooler hoses from
the chassis.
21 - 17 9823/1700-1 21 - 17
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 442.
A
A
E
A
E
D
F
B
E
L F
C
G H K
Q
P J
Table 153.
Item Description
A Fusebox support bolts
B Fuel separator and pump
C Air to air intercooler matrix
(1)
D Hydraulic oil cooler matrix (if installed)

(1)
E Fixing points
21 - 18 9823/1700-1 21 - 18
21 - Cooling System
03 - Cooling Pack
00 - General
Item Description
F Hydraulic hoses- Fan Motor/Oil Cooler
G Solenoid valve- reversible fan (if installed)
H Fan speed sensor
J Proportional fan speed control solenoid
K Engine coolant radiator matrix
(1)
L Radiator top hose connection

M Intercooler inlet hose connection
N Fixed Speed Cooling fan and hydraulic motor assem-
bly (55KW engines)
P Variable Speed Cooling fan and hydraulic motor as-
sembly (81, 93 and 108 KW engines)
Q Intercooler outlet hose connection
R Radiator bottom hose connection
(1) The engine coolant radiator, transmission oil cooler and air to air inter cooler matrix are all integral part. If
any part of the assembly has failed the complete unit must be replaced.
Install 1.1. Tighten the clamps to the correct torque

value.
steps.
Figure 443.
U
U
U Clamp
1.2. Fill the engine cooling system with the Table 154. Torque Values
correct type of coolant. Refer to (PIL 21-00).
Item Description Nm
1.3. Operate the engine and check the fan motor U Clamp 5.5
speed.
30-00-00).
1.5. Check the transmission oil level and top up
as necessary.
21 - 19 9823/1700-1 21 - 19
21 - Cooling System
03 - Cooling Pack
00 - General
With the cooling pack removed from the machine

disassemble the components as necessary.
• Remove the transmission oil cooler. Refer to

(PIL 21-03-09).
• Remove the cooling fan motor. Refer to (PIL
21-05).
• Remove the hydraulic oil cooler. Refer to (PIL
21-03-12).
• Remove the fuel cooler. Refer to (PIL 18-39-00).
• Remove the air conditioning condenser. Refer
to (PIL 12-15-00).
21 - 20 9823/1700-1 21 - 20
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
09 - Transmission Oil Cooler Check (Condition)

Check (Condition) .......................................... 21-21
T2 Mech Turbo, JCB 4.4 T3 Mech Turbo)
The liquid to liquid cooler is a possible source of
water contamination. It should be tested for possible
failure as follows:
1. Drain any remaining oil/water from the cooler.

2. Install a blanking plug to the outlet of the cooler.
3. Connect an air supply to the transmission oil inlet.
4. The air test pressure must not exceed the
specified value.
Pressure: 6 bar ( 87.0 psi)
5. Submerge the cooler in a tank of water and apply
air pressure to test for leakage. If bubbles are
visible there is a breakdown between the water
and hydraulic circuits.
6. Replace the cooler. Refer to cooling system-
cooling pack.
7. If the cooler is not damaged, clean and make it
dry before you assemble it to the machine.
21 - 21 9823/1700-1 21 - 21
21 - Cooling System
03 - Cooling Pack
Remove and Install
For: JCB 4.4 T2 Mech Nat Asp, JCB 4.4 2. Follow the general health and safety procedures.
T2 Mech Turbo, JCB 4.4 T3 Mech Turbo Refer to (PIL 01-03).
................................................... Page 21-22
For: JCB 4.4 T2 Mech Turbo and 3. Remove the engine cover base for easy access
Aftercooled, JCB 4.4 T3 Mech Turbo and to the transmission oil cooler. Refer to (PIL
Aftercooled ................................ Page 21-23 06-06).
4. Drain the engine coolant. Refer to (PIL 21-00).
T2 Mech Turbo, JCB 4.4 T3 Mech Turbo) 5. Disconnect the electrical oil temperature sensor.
6. Carefully disconnect the oil feed and return
Remove hoses. The oil may be hot.
1. Make the machine safe. Refer to (PIL 01-03). 7. Remove the water hose clips and the retaining
clips. Take out the cooler.
Figure 444.
A
C D C C C
A Electrical oil temperature sensor B Oil feed and return hoses

C Retaining clips D Cooler
21 - 22 9823/1700-1 21 - 22
21 - Cooling System
03 - Cooling Pack
Install should be no contamination. Refill the transmission

with fresh oil.
removal procedure. Additionally do the following (For: JCB 4.4 T2 Mech Turbo and
steps.
Aftercooled, JCB 4.4 T3 Mech Turbo and
1.1. Check the transmission oil level. Refer to Aftercooled)
(PIL 27-00).
The transmission oil cooler matrix is an integral part
1.2. Fill the cooling system. Refer to (PIL 21-00). of the engine coolant matrix and aftercooler matrix.
1.3. Operate the machine, stop the engine and
check for water/oil leaks at the cooler hose If the transmission oil cooler has failed the complete
connections. unit must be renewed.
1.4. Check the transmission oil level. Refer to The combined cooler matrix is part of the engine
(PIL 27-00). cooling pack.
1.5. Check the coolant level.
Although it is possible to remove individual
If a faulty oil cooler has been replaced with a new components with the cooling pack installed on the
one, the transmission may be contaminated with machine it will often be quicker and easier to
water. Carry out the flushing procedure. Refer to (PIL remove the complete sub assembly and then remove
27-06). components as required. Refer to Remove and
Install (PIL 210-03-00).
After 50- 100 operating hours, drain the transmission
oil and check for signs of water contamination. There
21 - 23 9823/1700-1 21 - 23
21 - Cooling System
03 - Cooling Pack
Figure 445.
A Transmission oil cooler matrix B Engine coolant matrix

C Aftercooler matrix
21 - 24 9823/1700-1 21 - 24
21 - Cooling System
03 - Cooling Pack
15 - Fan
15 - Fan
Introduction
Refer to (PIL 12-05-00).
21 - 25 9823/1700-1 21 - 25
21 - Cooling System
05 - Fan Motor
05 - Fan Motor
Contents Page No.
21-05-00 General ........................................................................................................................... 21-27
21 - 26 9823/1700-1 21 - 26
21 - Cooling System
05 - Fan Motor
00 - General
Introduction .................................................... 21-27 The product is equipped with a hydraulically driven
Operation ....................................................... 21-28 fan motor to provide air flow though the cooling pack.
Disassemble and Assemble .......................... 21-36 Some products may have either a fixed speed fan or
a variable speed hydraulic fan.
On some products, the fan may be reversible to

assist with the removal of debris from the cooling
pack.
21 - 27 9823/1700-1 21 - 27
21 - Cooling System
05 - Fan Motor
00 - General
Operation
Fixed speed Schematic diagram
The schematic diagram shows an general overview Figure 446.

of the system. Your machine may have a triple pump D F
installed but the system will be similar.
C
The cooling fan motor is hydraulically driven. The
motor turns the cooling fan and air is drawn through
E
the radiators in the machine cooling pack.
Hydraulic oil from the pump supplies the fan motor

and pilot pressure supply valve.
The pressure relief valve prevents component

damage.
A Main pump
B Hydraulic tank
C Pump pressure supply
D Fan motor case drain line
E Fan motor pressure relief valve
F Fan motor
21 - 28 9823/1700-1 21 - 28
21 - Cooling System
05 - Fan Motor
00 - General
Table 155. Colour key-Oil flow and pressure to inform the right hand instrument ECU of the
ambient air temperature.
Full pressure
The ECU varies the speed of the fan motor according
Exhaust to the temperature signals, the fan will be at a higher
speed in high temperatures and a lower speed in low
temperatures.
Neutral
The ECU generates the correct PWM (Pulse Width
Modulation) signal for operation of the fan speed
proportional solenoid.
Variable speed
The proportional solenoid operates as a pressure
The engine cooling pack is cooled by a hydraulically reducing valve. The supply to the fan motor is at a
powered cooling fan motor. pressure in relation to the ambient temperature.
The fan speed is controlled by the right hand The fan speed sensor sends a signal to the ECU to
instrument ECU (Electronic Control Unit). record current fan speed.
The engine air temperature sensor sends a signal A reversible fan option is provided where an operator
over the machine CAN (Controller Area Network)bus switch energises the fan direction solenoid to reverse
the direction of the fan.
21 - 29 9823/1700-1 21 - 29
21 - Cooling System
05 - Fan Motor
00 - General
Schematic diagram
Figure 447.
G H
B
C
A Hydraulic tank B Hydraulic variflow pump assembly

C Hydraulic gear pump (Fan supply) D Oil cooler
E Fan speed proportional solenoid F Fan direction solenoid (if installed)
G Fan motor housing H Fan motor
21 - 30 9823/1700-1 21 - 30
21 - Cooling System
05 - Fan Motor
00 - General
Table 156. Colour key-Oil flow and pressure

Full pressure
Exhaust
Neutral
21 - 31 9823/1700-1 21 - 31
21 - Cooling System
05 - Fan Motor
00 - General
Remove and Install
Fixed Speed Fan (If Installed) If the performance is below that specified, the
motor should be renewed. Renewal of individual
Your machine may be installed with a fixed or components such as gears, bearings and housings
variable speed fan. Removal and installation of both will not result in a permanent cure. If the motor
types of fan are shown. performance is satisfactory, but there is external
leakage, it should be dismantled for re-sealing
Before you remove the fan motor, check its purposes only.
performance.
Figure 448.
21 - 32 9823/1700-1 21 - 32
21 - Cooling System
05 - Fan Motor
00 - General
A Fan retaining nut B Motor retaining bolts

C Fan bracket securing bolts D Feed and return hoses
E Case drain hose
Remove If the performance is below that specified, the motor

should be renewed.
1. Make the machine safe. Refer to (PIL 01-06)
Remove
2. Install the safety strut. Refer to (PIL 06-69).
30-00). 2. Follow the general health and safety procedures.
4. Mark the hydraulic feed and return hoses to help
identification when you install. 3. Install the safety strut. Refer to (PIL 06-69).
5. Disconnect and plug the feed and return hoses. 4. Discharge the hydraulic pressure. Refer to (PIL
30-00).
6. Disconnect and plug the case drain hose.
5. Mark the electrical connectors to help in
7. Remove the fan guard. identification when you install.
8. Undo the fan bracket securing bolts (x4) and lift 6. Disconnect the harness from the solenoid
the fan and motor assembly from the machine. electrical connector.
9. Prevent the fan from turning, release the tab 7. Disconnect the harness from the speed sensor
washer and then undo the fan retaining nut. electrical connector.
10. Withdraw the fan from the motor shaft. Retain the 8. If installed, disconnect the harness from the
drive key (not shown). direction solenoid.
11. Undo the motor retaining bolts and remove the 9. Mark the hydraulic hoses to help in identification
motor. when you install.
Install 10. Disconnect and plug the feed hose and return
hose.
removal procedure. Additionally do the following 11. If installed, disconnect and plug the case drain
steps. hose.
1.1. Tighten all the fastening nuts and bolts to 12. Support the motor and the fan.
1.2. Make sure all hoses are attached to the
correct ports. The case drain hose (if 14. Remove the fan bracket, the fan and then the
installed) must be fed in to a tank line motor from the machine.
otherwise damage to the motor will occur.
15. Stop the fan from turning.
1.3. Check and adjust the hydraulic fluid level.
16. Remove the tab washer and then remove the nut.
Table 157. Torque Settings 17. Remove the fan from the motor shaft. Keep the
Item Value drive key.
A 36 N·m 18. Remove the motor/ control pack retaining nuts.
B 28 N·m
19. Remove the motor from the bracket.
C 47 N·m
Variable Speed Fan (If Installed)

Before you remove the fan motor, check its
performance.
21 - 33 9823/1700-1 21 - 33
21 - Cooling System
05 - Fan Motor
00 - General
Figure 449.
A
A
J H
E
B G
K
A D F
A
A Bolts B Case drain hose

C Feed hose D Return hose
E Motor retaining nuts F Solenoid electrical connector
G Speed sensor electrical connector H Bracket
J Direction solenoid K Fan nut
21 - 34 9823/1700-1 21 - 34
21 - Cooling System
05 - Fan Motor
00 - General
Install 1.2. The case drain hose (if installed) must be

fed into a tank line otherwise the motor can
1. The installation procedure is the opposite of the be damaged.
steps. 1.3. Replace the tab washer located on the fan
nut.
1.1. Make sure all hoses are attached to the 1.4. Check the hydraulic fluid level. Refer to (PIL
correct ports. 30-00).
Table 158. Torque settings

Item Value
B 27 N·m
C 48 N·m
D 48 N·m
K 36 N·m
21 - 35 9823/1700-1 21 - 35
21 - Cooling System
05 - Fan Motor
00 - General
Do not attempt to dismantle the motor. If it is

defective, it must be renewed.
21 - 36 9823/1700-1 21 - 36
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-39
21 - 37 9823/1700-1 21 - 37
Notes:
21 - 38 9823/1700-1 21 - 38
21 - Cooling System
06 - Expansion Tank
00 - General
Introduction .................................................... 21-39 The expansion tank retains coolant that has been
Remove and Install ....................................... 21-40 forced out of the machines radiator under pressure.
As the machine runs, the temperature of the coolant

circulating around the system increases, this causes
an increase of pressure in the cooling system. When
the pressure builds to a high enough point, the
radiator cap allows that pressure to escape into the
coolant tank through a rubber overflow tube that
is connected from the neck of the radiator to the
expansion tank.
Most of the coolant that is forced into the expansion

tank returns to the radiator naturally when the engine
is cold.
21 - 39 9823/1700-1 21 - 39
21 - Cooling System
06 - Expansion Tank
00 - General
Remove and Install
Consumables 5. Open the engine compartment cover. Refer to

Description Part No. Size (PIL 06-06).
JCB Threadlocker 4101/0250 0.01 L 6. Drain the engine coolant. Refer to (PIL 21-00).
Strength) 7. Remove the bolts.
Remove 8. Remove the expansion tank cover.
1. Make the machine safe. Refer to (PIL 01-03). 9. Disconnect the coolant level sensor electrical
connector (if installed).
2. Follow the general health and safety procedures.
Refer to (PIL 01-03). 10. Loosen the hose clips and disconnect the hoses
from the expansion tank.
3. Switch off the engine before working in the
engine compartment. Remove the ignition key or 11. Support the expansion tank.
isolate battery to prevent the engine from being 12. Remove the expansion tank from the bracket.
started. Refer to (PIL 33-03).
4. If the engine is hot, let it cool for one hour.
21 - 40 9823/1700-1 21 - 40
21 - Cooling System
06 - Expansion Tank
00 - General
Figure 450.
D A
E F E E
A Hose clips B Hoses

C Tank cover D Expansion tank
E Bolts F Bracket
21 - 41 9823/1700-1 21 - 41
21 - Cooling System
06 - Expansion Tank
00 - General
Install
steps.
1.1. Apply sealant to the bolts.
(Medium Strength)
1.2. Tighten the bolts to the specified torque
value.
1.3. Fill the engine cooling system with the
correct type of coolant. Refer to (PIL 21-00).
1.4. When the installation procedure is
complete, start the engine and check for
coolant leaks.

Item Description Nm
E Bolts 5
21 - 42 9823/1700-1 21 - 42
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-45
21 - 43 9823/1700-1 21 - 43
Notes:
21 - 44 9823/1700-1 21 - 44
21 - Cooling System
09 - Pump
00 - General
Introduction .................................................... 21-45 The coolant pump is a centrifugal type located in the
Component Identification ............................... 21-46 front of the crankcase, driven by the engine drive belt.
Operation ....................................................... 21-46
Remove and Install ....................................... 21-47 The impeller rotates to circulate the coolant through
the cooling system. The pump shaft bearing and seal
are not renewable.
21 - 45 9823/1700-1 21 - 45
21 - Cooling System
09 - Pump
00 - General
Component Identification Operation

Figure 451. The coolant pump is driven via a pulley and front end
1 accessory drive belt, the pump draws coolant from
2 the pump cavity. The coolant is pumped through the
outlet gallery to the oil cooler cavity in the left side
of the crankcase. As the coolant flows past the oil
cooler matrix, heat is exchanged from the oil to the
coolant. This enables the oil to function as a coolant
as well as a lubricant.
For cooling system operation.
1 Coolant pump
2 Drive pulley
3 Impeller
21 - 46 9823/1700-1 21 - 46
21 - Cooling System
09 - Pump
00 - General
Before Removal
1. Make sure that the machine is safe. If the engine
has been running, let it cool before you start the
service work. Refer to (PIL 01-03).
3. Drain the coolant.
4. Remove the coolant pump drive belt.
Remove
2
1. Remove the fixing screws. 1
2. Remove the coolant pump assembly.
3. Remove and discard the sealing O-ring.
1 Coolant pump assembly

2 Fixing screws
The pump is a non-serviceable item. If the pump is

faulty or damaged it must be renewed.
Install
steps.
2. Make sure that the mating face on the crankcase
is clean and free from damage.
3. Install a new sealing O-ring.
4. Tighten the screws to the correct torque value.
21 - 47 9823/1700-1 21 - 47
21 - Cooling System
09 - Pump
00 - General
Figure 453.
P1
P1 Sealing O-ring
After Installation
1. Install the coolant pump drive belt.
2. Refill the engine with the recommended coolant
mixture.

Item Nm
2 24
21 - 48 9823/1700-1 21 - 48
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-51
21 - 49 9823/1700-1 21 - 49
Notes:
21 - 50 9823/1700-1 21 - 50
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-51 The thermostat is located between the engine and
Component Identification ............................... 21-52 the radiator. The function of the thermostat is to block
Operation ....................................................... 21-52 the flow of coolant to the radiator until the engine has
Check (Condition) .......................................... 21-53 warmed up to a sufficient temperature.
Check (Operation) ......................................... 21-54 When the engine is cold, no coolant flows through
Remove and Install ....................................... 21-55 the engine. Once the engine reaches its operating
temperature, generally about 95 °C ( 203 °F), the
thermostat opens. By letting the engine warm up as
quickly as possible, the thermostat reduces engine
wear, deposits and emissions.
21 - 51 9823/1700-1 21 - 51
21 - Cooling System
12 - Thermostat
00 - General
Component Identification Operation

Figure 454. The thermostat is a wax element type and is
configured for by-pass blanking. The thermostat
functions as follows:
State A - Closed (Engine Cold)

When the engine is cold the wax pellet has
contracted into its housing. This allows the spring to
act against the thermostat body and move the valve
A plate up against its seat, closing the outlet port to the
radiator. Since the bottom valve plate is connected
to the top valve plate it also moves up, opening the
bypass port. The coolant flows from the thermostat
housing inlet port into the bypass gallery.
Figure 455.
7 3
8 11
6
10
5
A Thermostat
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1 mm diameter orifice
State B - Open (Engine Hot)

When the engine is hot, the wax pellet melts,
as it does so it expands and pushes against
the diaphragm. The diaphragm reacts against
the actuating rod and both the top and bottom
valve plates move down into the thermostat body,
compressing spring. The outlet port to the radiator
is now open and the bypass port is closed. A 1
21 - 52 9823/1700-1 21 - 52
21 - Cooling System
12 - Thermostat
00 - General
mm diameter orifice allows trapped air to be expelled Check (Condition)

from the system.
Figure 456. 1. If the thermostat is suspected of being faulty,

7 3 perform a thermostat test, refer to Thermostat
- Check Operation to confirm its serviceability.
Note that the thermostat is a non-serviceable
8 11 item. If the thermostat is faulty or damaged it
must be renewed.
2. Inspect the seal for damage or splits. If necessary
renew the seal. Make sure that the seal is
correctly located.
9
6
10
5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1 mm diameter orifice
21 - 53 9823/1700-1 21 - 53
21 - Cooling System
12 - Thermostat
00 - General
Check (Operation)
A period of 3 –5 min before the thermostat valve

starts to operate is normal because of the time
required to heat soak the thermostat.

2. Remove the thermostat housing and the
thermostat. Refer to (PIL 21-12).
3. Suspend the thermostat in a suitable container
of coolant. Use an external heat source to
gradually increase the temperature of the
coolant. Note: When working with boiling water,
all the necessary safety precautions must be
taken. Refer to Figure 457.
Figure 457.
4. Use a thermometer to measure the temperature

of the coolant.
5. When the coolant reaches the operating range of
the thermostat the valve should start to open, the
movement of the valve plate should be evident.
6. Record the start to open temperature, the fully
open temperature and the amount of valve lift
travel when fully open. Compare this with the
data in Technical Data (PIL 21-00).
21 - 54 9823/1700-1 21 - 54
21 - Cooling System
12 - Thermostat
00 - General
Remove and Install
1. Make sure that the engine is safe to work on. If 3. Drain the coolant.
Figure 458.
1
1
1
2
1 Thermostat housing 2 Bolts (x3)
Remove Figure 459.
1. Disconnect the radiator hose at the thermostat

housing.
2. Remove the three bolts that attaches the
thermostat housing and lift off the thermostat
housing.
3
3. Lift out the thermostat.
3 4
3 Thermostat
4 Seal
4. If the thermostat is suspected of being faulty,
perform tests to confirm its serviceability.
21 - 55 9823/1700-1 21 - 55
21 - Cooling System
12 - Thermostat
00 - General
Note The thermostat is a non-serviceable item. If the

thermostat is faulty or damaged it must be renewed.
Install
steps.
2. Inspect the seal for damage or splits. If necessary
use a new seal. Locate the seal correctly as
shown.
3. Make sure you install the thermostat the right way
up.
5. Connect the radiator hose at the housing.
After Installation
1. Fill the cooling system with the recommended
coolant mixture. Refer to (PIL 21-03-03).

Item Nm
2 24
21 - 56 9823/1700-1 21 - 56
21 - Cooling System
21 - Inlet
21 - Inlet
Contents Page No.
21-21-00 General ........................................................................................................................... 21-59
21 - 57 9823/1700-1 21 - 57
Notes:
21 - 58 9823/1700-1 21 - 58
21 - Cooling System
21 - Inlet
00 - General
00 - General Figure 460.
Remove and Install

1
Before Removal
the engine has been running, let it cool before 1
1
3. Drain the cooling system. 2
The housing may be orientated differently to that

shown in the illustration, depending on the engine
installation.
Remove
1. Disconnect the radiator hose at the inlet housing.
2. Undo the bolts and lift off the housing.
X 6.8
1 Inlet housing
2 Fixing bolts
6 Sealing Ring
X Locating tab - sealing ring
Install
steps.
2. Make sure that the sealing ring is undamaged.
If necessary install a new seal. Make sure that
the seal is correctly located in its groove on the
housing. Note the locating tab.
4. Reconnect the radiator hose at the housing.
After Installation
1. Refill the engine with the recommended coolant
mixture.
21 - 59 9823/1700-1 21 - 59
21 - Cooling System
21 - Inlet
00 - General

Item Nm
2 24
21 - 60 9823/1700-1 21 - 60
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-63
21 - 61 9823/1700-1 21 - 61
Notes:
21 - 62 9823/1700-1 21 - 62
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-63 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-64 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-64 between the engine and the radiator/cooling pack.
21 - 63 9823/1700-1 21 - 63
21 - Cooling System
93 - Hose
00 - General

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the 1. Visually inspect the engine and related cooling
cap, hot coolant can spray out and burn you. components for:
Make sure that the engine is cool before you work
on the cooling system. 1.1. Leaks.
1.2. Cracked, burnt or perished hoses.
1.3. Hose clips are in good condition and
tightened to the correct torque value.
21 - 64 9823/1700-1 21 - 64
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-03 Service Brake
24-03-00 General ........................................................................................................................... 24-15
24-03-01 Master Cylinder .............................................................................................................. 24-22
24-03-39 Piston ............................................................................................................................. 24-23
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-27
24-03-46 Vacuum Pump ................................................................................................................ 24-30
24-03-50 Light Switch .................................................................................................................... 24-34
24-03-57 Pressure Sensor ............................................................................................................ 24-38
24-18 Park Brake
24-18-00 General ........................................................................................................................... 24-41
24-18-03 Switch ............................................................................................................................. 24-46
24-18-06 Cable .............................................................................................................................. 24-48
24-18-15 Pad ................................................................................................................................. 24-54
24-18-18 Caliper ............................................................................................................................ 24-55
24-18-21 Disc ................................................................................................................................ 24-62
9823/1700-1
2018-07-03
Acronyms Glossary
9823/1700-1
2018-07-03
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9823/1700-1 24 - 1
Notes:
24 - 2 9823/1700-1 24 - 2
24 - Brake System
00 - Brake System
00 - General

Health and Safety ........................................... 24-3 Brake Fluid
Technical Data ................................................. 24-5 Use of incorrect brake fluid will cause serious
Component Identification ................................. 24-7 damage to the seals of the braking system. This will
Operation .................................................. 24- result in brake failure.
Fault-Finding .................................................... 24-9 Accumulators
Check (Level) ................................................ 24-12 The accumulators contain hydraulic fluid and gas at
Check (Pressure) ..................................... 24- high pressure. Prior to any work being carried out
on systems incorporating accumulators, the system
pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
cause serious injury or death.
Service Brake Bleeding
Before bleeding the service brake system, park on
level ground and set the park brake to on. Put blocks
on both sides of the wheels on one axle to prevent
the machine rolling. Stop the engine and disconnect
the battery so that the engine cannot be started. If
you do not take these precautions the machine could
run over you.
Park Brake Maintenance
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels
to prevent the machine rolling. Stop the engine and
disconnect the battery so that the engine cannot be
started. If you do not take these precautions the
machine could run over you.
movement.
Brake Dust
Brake pads generate dust, which if inhaled may
endanger health. Wash off the caliper assemblies
before commencing work. Clean hands thoroughly
after completing the work.
Brake Dust
Brake shoes generate dust, which if inhaled
may endanger health. Make sure that dust is
removed correctly, particularly before installing
new components. Clean hands thoroughly after
completing the work.
Springs
Always wear personal protective equipment when
dismantling assemblies containing components
under pressure from springs. This will protect against
eye injury from components accidentally flying out.
Notice: Using incorrect fluid could damage the
system. See Fluids, Capacities and Lubricants for
24 - 3 9823/1700-1 24 - 3
24 - Brake System
00 - Brake System
00 - General
the correct fluid. The fluid can harm your skin. Wear
rubber gloves. Cover cuts or grazes.
WARNING! Before working on the brake system,
make sure that the machine is on solid level ground.
Put blocks on all wheels to prevent the machine
rolling.
WARNING! Do not use the machine with any part of
its brake system disconnected or inoperative. When
the test has been completed, make sure all brake
system components are installed and the system is
operating correctly.
WARNING! Before testing the park brake make sure
the area around the machine is clear of people.
WARNING! If the machine starts to move during the
park brake test, immediately apply the foot brake and
reduce the engine speed.
WARNING! If the machine starts to move during the
service brake test, immediately reduce the engine
speed and apply the park brake.
WARNING! Do not use a machine with a faulty park
brake.
WARNING! Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
WARNING! Oil on the brake disc will reduce brake
effectiveness. Keep oil away from the brake disc.
Remove any oil from the disc with a suitable solvent.
Read and understand the solvent manufacturer's
safety instructions. If the pads are oily, install with the
new pads.
WARNING! Faulty brakes can kill. If you have to top
up the brake oil reservoir frequently, get the brake
system checked by your JCB Dealer. Do not use the
machine until the fault has been put right.
WARNING! The park brake must not be used to
slow the machine from travelling speed, except in an
emergency, otherwise the efficiency of the brake will
be reduced. Whenever the park brake has been used
in an emergency the brake friction components must
be renewed and the other components inspected.
Notice: Over adjustment or failure to disengage the
park brake properly will cause excessive wear of the
park brake mechanism.
24 - 4 9823/1700-1 24 - 4
24 - Brake System
00 - Brake System
00 - General
Technical Data
For: 506-36 [T2/T3] ..................... Page 24-5

For: 507-42 [T2/T3], 509-42 [T2/T3], 510-56
[T2/T3], 512-56 [T2/T3] ............... Page 24-5
(For: 506-36 [T2/T3])
Single axle service brakes system

Table 163. Service brake
Type Single circuit, oil immersed multi-plate disc.
Actuation Hydraulic.
Hydraulic, servo assisted.
(1)
Location Front axle, centre mounted (2 brake packs).

(1) Machines with turbo inter-cooled engines.
Table 164. Master cylinder

Type Master cylinder.
Master cylinder with remote servo unit.
(1)
No. of Cylinders 1
Diameter 31.75 mm
Stroke 39 mm
Displacement Minimum- 2835 cc.
(1) Machines with turbo inter-cooled engines.
Table 165. Servo unit

Type Vacuum assisted hydraulic valve.
Vacuum cylinder diameter 175 mm
Hydraulic cylinder diameter 22.2 mm
Brake vacuum pressure 0.8 –1 bar ( 11.6 –14.5 psi)
Minimum oil displacement 23.6 cc
Stroke 61 mm
Table 166. Park brake

Type Independent disc (with manually adjusted calliper)
park brake in the drive to the front axle.
Actuation Cable operated.
Location Mounted on the gearbox.
Disc diameter 279.4 mm
(For: 507-42 [T2/T3], 509-42 [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3])
Twin axle service brake system (S1)

Table 167. Service brakes
Type Single circuit, oil-immersed multi-plate disc.
Actuation Hydraulic, servo assisted.
(1)
Location Front axle, centre mounted (2 brake packs).

Rear axle, centre mounted (2 brake packs).
(1) Machines installed with turbo inter-cooled engines.
24 - 5 9823/1700-1 24 - 5
24 - Brake System
00 - Brake System
00 - General
Table 168. Master Cylinder

Type Master cylinder with remote servo unit.
(1)
No. of Cylinders 1
Diameter 38.1 mm
Stroke 35 mm
Displacement 39.5 cc/min
(1) Machines installed with turbo inter-cooled engines.
Table 169. Servo unit

Type Vacuum assisted hydraulic valve.
Vacuum cylinder diameter 201 mm
Hydraulic cylinder diameter 22.2 mm
Brake vacuum pressure 0.8 –1 bar ( 11.6 –14.5 psi)
Oil displacement 32 cc
Stroke TBA
Table 170. Park brake

Type Independent disc (with manually adjusted caliper)
park brake in the drive to the front axle.
Actuation Cable operated.
Location Mounted on the gearbox.
24 - 6 9823/1700-1 24 - 6
24 - Brake System
00 - Brake System
00 - General
For: 506-36 [T2/T3] ..................... Page 24-7

For: 507-42 [T2/T3], 509-42 [T2/T3], 510-56
[T2/T3], 512-56 [T2/T3] ............... Page 24-8
(For: 506-36 [T2/T3])
Figure 461.
G
E
B C
C
D
E
A
A Brake packs B Service brake pedal

C Cylinder D Vacuum pump
E Servo unit F Brake fluid tank
G Electrical switch
24 - 7 9823/1700-1 24 - 7
24 - Brake System
00 - Brake System
00 - General
(For: 507-42 [T2/T3], 509-42 [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3])
Figure 462.
F
D
E
C
G
A
A Brake pack 1 B Brake pack 2

C Service brake pedals D Cylinder
E Vacuum pump F Servo unit
G Brake fluid tank H Electrical switch
24 - 8 9823/1700-1 24 - 8
24 - Brake System
00 - Brake System
00 - General
Fault-Finding
Fault
One or more brakes do not apply. (Brake travel not excessive, brakes not Table 171. Page 24-9
pulling to one side)
Pedal travel excessive (but not touching floor) Table 172. Page 24-9
Pedal hard to operate Table 173. Page 24-9
Pedal touches floor under constant pressure- no fluid loss Table 174. Page 24-10
Pedal touches floor under constant pressure and fluid loss Table 175. Page 24-10
Poor braking (not pulling to one side) Table 176. Page 24-10
Brakes not releasing Table 177. Page 24-10
Poor braking when hot Table 178. Page 24-11
Excessive brake noise in operation (Due to the metal to metal contact of oil Table 179. Page 24-11
immersed brakes, limited noise can be heard which is consistent and normal
with this type of design).
Fluid loss when machine standing (for example- overnight). (Conform that Table 180. Page 24-11
the fault is as indicated by checking that the brake pedal does not touch the
floor when it is operated under constant pressure).
Table 171. One or more brakes do not apply. (Brake travel not excessive, brakes not pulling to one side)
Cause Remedy
Master cylinder fault. Check master cylinder to identify fault area, service
as necessary. Refer to (PIL 24-03-01).
Friction/counter plate distortion. Replace friction/counter plates- both sides of relevant
axle.
Table 172. Pedal travel excessive (but not touching floor)

Cause Remedy
Air in hydraulic system. Check fluid reservoir level. Check for fluid/air leaks,
correct as necessary. Refer to (PIL 24-03).
Bleed the brake system. Refer to (PIL 24-00-00).
Leak in hydraulic system. Check for fluid loss at master cylinder and brake
piston, all pipes and fittings for loose connections.
correct as necessary. Refer to (PIL 24-03-39).
Check fluid reservoir level. Check for fluid/air leaks,
axle.
Table 173. Pedal hard to operate

Cause Remedy
Tightness at pedal pivot. Check the pedal pivot. Free-off/lubricate.
Fluid contamination/seal damage. Flush system and renew all hydraulic seals. Bleed
the brake system. Refer to (PIL 24-00-00).
Misaligned push rod/pedal. Check and correct as necessary.
Kinked or crushed brake pipes. Check/replace brake pipework.
Vacuum failure due to low vacuum at source. Check/service engine mounted exhauster unit as
(Machines fitted with servo assisted brakes only). necessary.
Blocked/leaking vacuum pipe. (Machines fitted with Check/renew vacuum pipe. Refer to (PIL 24-03-96).
servo assisted brakes only).
Servo defect. (Machines fitted with servo assisted Replace the servo unit.
brakes only).
24 - 9 9823/1700-1 24 - 9
24 - Brake System
00 - Brake System
00 - General
Table 174. Pedal touches floor under constant pressure- no fluid loss
Cause Remedy
axle.
Air in hydraulic system. Check fluid reservoir level. Check for fluid/air leaks,
Table 175. Pedal touches floor under constant pressure and fluid loss
Cause Remedy
External fluid leaks. Check fluid reservoir level. Check for fluid/air leaks,
correct as necessary. Refer to (PIL 24-03)
Internal fluid leaks. Bleed the brake system. Refer to (PIL 24-00-00).
Table 176. Poor braking (not pulling to one side)

Cause Remedy
Friction plates worn beyond limits or distorted. Replace friction/counter plates- both sides of relevant
axle.
Annular piston fault. See table 'Brakes not releasing', item 'Annular brake
piston(s) binding in axle'.
Incorrect/low axle oil. Fill the axle with correct type of oil.
Vacuum failure Check vacuum source/pipes, service as necessary.
Table 177. Brakes not releasing

Cause Remedy
Brake pedal spring fault. Install a new spring.
Master cylinder fault (plunger stuck in bore). Check master cylinder to identify fault area, service
Blocked hole in master cylinder reservoir cap Install a new reservoir cap.
Brake pedal free travel incorrect. Adjust pedal free travel.
Fluid contamination/seal damage. Flush system and replace hydraulic seals. Refill with
clean fluid.
Annular brake piston(s) binding in axle. Check that correct brake fluid has been used
(incorrect fluid could swell the annular brake piston
seals).
Check if annular brake piston seals are in good
condition.
Check that annular brake piston rotates freely in its
housing with no seals installed.
Check that the annular brake piston seal retracts the
piston approximately to the specified value.
Length: 0.5 mm
Kinked or crushed brake pipes. Check and replace pipes as necessary.
Friction/counter plates not free on splines and/or Check friction/counter plates for free movement,
dowels. replace if necessary- both sides of relevant axle.
24 - 10 9823/1700-1 24 - 10
24 - Brake System
00 - Brake System
00 - General
Table 178. Poor braking when hot

Cause Remedy
Moisture in system vaporising when axle is hot. Strip axle and clean annular piston to remove
moisture.
Remove master cylinder and check for corrosion,
service as necessary.
Flush system and replace hydraulic seals. Refill with
clean fluid.
Table 179. Excessive brake noise in operation (Due to the metal to metal contact of oil immersed brakes,
limited noise can be heard which is consistent and normal with this type of design).
Cause Remedy
Deterioration of axle oil or wrong type of axle oil Change axle oil. Refer to check level (PIL 20-00)
Axle oil loss. Refill axle with correct oil and check for leaks. Refer
to (PIL 20-00).
Friction plates worn beyond limits. Renew friction/counter plates on both sides of
relevant axle.
Friction/counter plates in poor condition. Check for distortion or surface pitting and/or
roughness of the plates. (Annular grooving of counter
plates is acceptable).
Table 180. Fluid loss when machine standing (for example- overnight). (Conform that the fault is as
indicated by checking that the brake pedal does not touch the floor when it is operated under constant
pressure).
Cause Remedy
Severe damage or slight cut/nick in the brake piston Test the brake piston seals for leakage. If necessary,
seal. strip axle and renew seal(s).
External leakage through brake pipe connections etc. Check for and repair leaking connections.
24 - 11 9823/1700-1 24 - 11
24 - Brake System
00 - Brake System
00 - General
Check (Level)
1. Make the machine safe. Refer to (PIL 01-03). 4.1. Remove the tank cap. Do not use ordinary
brake fluid. Carefully pour in the fluid until it
2. Remove the clip from the plate. reaches the fluid level mark. Avoid spillage.
Wipe up any spillage.
3. Open the cover to get access to the brake fluid
tank. 4.2. Install the tank cap.
4. The correct fluid level is marked on the tank. If 5. Close then lock the cover with the clip.
necessary, add fluid.
Figure 463.
A B C
A Plate B Clip
C Cap D Tank
E Cover
24 - 12 9823/1700-1 24 - 12
24 - Brake System
03 - Service Brake
03 - Service Brake
Contents Page No.
24-03-00 General ........................................................................................................................... 24-15

24-03-01 Master Cylinder .............................................................................................................. 24-22
24-03-39 Piston ............................................................................................................................. 24-23
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-27
24-03-46 Vacuum Pump ................................................................................................................ 24-30
24-03-50 Light Switch .................................................................................................................... 24-34
24-03-57 Pressure Sensor ............................................................................................................ 24-38
24 - 13 9823/1700-1 24 - 13
Notes:
24 - 14 9823/1700-1 24 - 14
24 - Brake System
03 - Service Brake
00 - General
00 - General Diagram
Diagram ......................................................... 24-15 For: 506-36 [T2/T3] ................... Page 24-15
Check (Leaks) ............................................... 24-18 For: 507-42 [T2/T3], 509-42 [T2/T3], 510-56
[T2/T3], 512-56 [T2/T3] ............. Page 24-17
Bleed ............................................................. 24-19
(For: 506-36 [T2/T3])
Single axle service brakes system

Hose and pipework- Machines with trailer brakes
Figure 464.
B
D
E
C
A Servo exhauster unit B Master cylinder

C Servo unit D Front axle
E T-piece F Check valve
G Trailer brake valve
24 - 15 9823/1700-1 24 - 15
24 - Brake System
03 - Service Brake
00 - General
Hose and pipework- Machines without trailer brakes
Figure 465.
D
C
A Servo exhauster unit B Master cylinder

C Servo unit D Front axle
24 - 16 9823/1700-1 24 - 16
24 - Brake System
03 - Service Brake
00 - General
(For: 507-42 [T2/T3], 509-42 [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3])
Twin axle service brakes system

Hydraulic operation and schematics
Figure 466.
A Fluid tank B Master cylinder

C Master cylinder (servo unit) D Servo unit
E Front brake packs F Rear brake packs
24 - 17 9823/1700-1 24 - 17
24 - Brake System
03 - Service Brake
00 - General
Check (Leaks) Figure 467.
Special Tools
D
Pressure Gauge (0-70 892/00346 1 A
Bar)
Consumables B C
JCB Hydraulic Fluid HP 4002/0501 1L
15 4002/0503 5L
WARNING Before working on the brake system, A Port 1

make sure that the machine is on solid level B Pipe
ground. Put blocks on all wheels to prevent the C Port 2
machine rolling. D Port 3
WARNING Do not use the machine with any part
of its brake system disconnected or inoperative. 6. Test for a low pressure leak as follows:
When the test has been completed, make sure all 6.1. Install an adaptor with a piece of clear tube
brake system components are installed and the to the brake piston port.
system is operating correctly.
6.2. Make sure you keep the tube vertical during
the test. Use tape to attach the tube to the
The most common reason for internal piston seal
side of the machine.
leakage is a build-up of axle contamination as a result
of excessive brake wear caused by extended service 6.3. Fill the tube until approximately three
periods. quarters full with the correct Hydraulic Fluid.
Two types of internal leakage can occur within the 6.4. Use a suitable pen to mark the level line of
axle or hub: the brake fluid on the tube.
6.5. After approximately 30 minutes, check if
1. Low Pressure Leaks- Seal damage, or scoring to the level has dropped below the original
seal component surfaces, caused by a build-up marked line. If it has, check the brake piston
of metal particles. seal for slight nicks, cuts or generally for
wear.
2. High Pressure Leaks- Mechanical leakage past
a badly damaged or perished seal. 6.6. Repeat the step 6.1 to step 6.5 at port 4.
The low pressure leak test should be performed Figure 468.

first. Low pressure leaks are difficult to find using a
high pressure test- seals and other components can
distort and form a seal under pressure.
X
The following procedures explain how to check for
low or high pressure leaks without the need to
dismantle the axle first. The test must only be done
when the axle is COLD.

2. Disconnect the brake piston feed pipe (or hose,
as applicable) at port 1. E

contamination. F
4. Completely remove the pipe and install a plug at
port 2.
E Port 4
5. Fill both brake piston housings with JCB Light F Brake piston port
Hydraulic Fluid through the port 1 and port 3. X Brake fluid level line
Consumable: JCB Hydraulic Fluid HP 15
24 - 18 9823/1700-1 24 - 18
24 - Brake System
03 - Service Brake
00 - General
7. Test for a high pressure leak as follows: Bleed

7.1. Install a hand pump installed with a For: 507-42 [T2/T3], 509-42 [T2/T3], 510-56
pressure gauge of the specified value to the [T2/T3], 512-56 [T2/T3] ............. Page 24-19
brake piston port.
For: 506-36 [T2/T3] ................... Page 24-20
Special Tool: Pressure Gauge (0-70 Bar)
(Qty.: 1) (For: 507-42 [T2/T3], 509-42 [T2/T3],
7.2. Fill the hand pump with the correct 510-56 [T2/T3], 512-56 [T2/T3])
Hydraulic Fluid.
7.3. Use the hand pump to generate a pressure Twin axle service brake system
in the brake piston housing. Do not exceed
WARNING Use of incorrect fluid will cause
the specified value.
serious damage to the seals which could in turn
Pressure: 69 bar ( 1,000.0 psi) cause brake failure.
7.4. If the pressure falls off rapidly, or if no
pressure reading can be obtained, the 1. Make the machine safe. Refer to (PIL 01-03).
piston seal is severely damaged. Install a
2. Follow all the health and safety precautions.
new seal.
7.5. Repeat the 7.1 to step 7.4 at port 4.
3. Fill the tank with correct fluid. Refer to (PIL
Figure 469. 75-00).
4. Make sure that the fluid level does not fall under
the "minimum" mark when you do the bleeding
procedure.
X
5. Bleed the brake system as follows:
5.1. Bleed at the point on the servo unit, the
point on the front axle and the point on the
rear axle (first left side, then right side).
Figure 470. Servo unit
E
E Port 4 B
F Brake piston port
X Brake fluid level line
8. Put the brake system back to the original
condition as follows:
8.1. Connect all the brake pipes and bleed
the brake system. Refer to brakes- service
brake. Refer to (PIL 24-03).
B Bleed point on servo unit
For twin axle brake systems, do this procedure on
the other axle, if applicable.
24 - 19 9823/1700-1 24 - 19
24 - Brake System
03 - Service Brake
00 - General
Figure 471. Axle bleed screw Figure 472. Front axle
A A
A Bleed point on front axle A Bleed point on front axle

6. Attach a tube to the applicable bleed screw. 5.2. Machines with servo brakes- Bleed at the
point on the servo unit and the point on the
7. Make sure that the free end of the tube is put fully front axle.
into the fluid in a suitable container.
Figure 473. Servo unit
8. Open the bleed screw and apply one rapid full
stroke of the brake pedal followed by three rapid
short strokes from the halfway pedal position.
After the third short stroke, allow the pedal to
return quickly to its stop.
9. Continue to bleed the air normally until all the air
is removed. Push the pedal fully and close the
bleed screw.
10. Top up the tank to the full mark.
(For: 506-36 [T2/T3])
Single axle service brake system

WARNING Use of incorrect fluid will cause
serious damage to the seals which could in turn B
cause brake failure.

2. Follow all the care and safety procedures. Refer
to (PIL 01-03).
3. Fill the tank with correct fluid. Refer to operators
manual.
4. Make sure that the fluid level does not fall under
the Minimum mark when you do the bleeding
procedure.
B Bleed point on servo unit
5. Bleed the brake system in the applicable
sequence as follows: 6. Attach a tube to the applicable bleed screw.
5.1. Machines without servo brakes- Bleed at 7. Make sure that the free end of the tube is put fully
the point on the front axle. into the fluid in a suitable container.
8. Open the bleed screw and apply one rapid full
stroke of the brake pedal followed by three rapid
short strokes from the halfway pedal position.
24 - 20 9823/1700-1 24 - 20
24 - Brake System
03 - Service Brake
00 - General
After the third short stroke, allow the pedal to

return quickly to its stop.
9. Continue to bleed the air normally until all the air
is removed. Push the pedal fully and close the
bleed screw.
10. Top up the tank to the full mark.
24 - 21 9823/1700-1 24 - 21
24 - Brake System
03 - Service Brake
01 - Master Cylinder
01 - Master Cylinder
The master cylinder is not serviceable and must be

renewed if faulty.
24 - 22 9823/1700-1 24 - 22
24 - Brake System
03 - Service Brake
39 - Piston
39 - Piston Introduction
Introduction .................................................... 24-23
Check (Leaks) ............................................... 24-24
Brake Piston Seal Leakage
Disassemble and Assemble .......................... 24-26 The most common reason for internal piston seal
leakage is a build-up of axle contamination. It is
caused as a result of excessive brake wear caused
by extended service periods.
Two types of internal leakage can occur within the

axle or hub:
• Low Pressure Leaks- Seal damage, or scoring

to seal component surfaces, caused by a build-
up of metal particles.
• High Pressure Leaks- Mechanical leakage past
a badly damaged or perished seal.
Do the low pressure leak test first. Low pressure

leaks are difficult to find using a high pressure test.
The seals and other components can distort and form
a seal under pressure.
Do the low pressure or high pressure leak test

without disassembling the axle. Refer to brakes-
service brake, refer to (PIL 24-03).
Make sure that you do the leak test only when the
axle is cold.
24 - 23 9823/1700-1 24 - 23
24 - Brake System
03 - Service Brake
39 - Piston
Check (Leaks) 5. Fill both brake piston housings with JCB Light
Hydraulic Fluid through the port 1 and port 3.
Consumable: JCB Hydraulic Fluid HP 15
(For: 506-36 [T2/T3], 509-42 [T2/T3],
510-56 [T2/T3], 512-56 [T2/T3]) Figure 474.
Special Tools
D
Pressure Gauge (0-70 892/00346 1 A
Bar)
Consumables B C
JCB Hydraulic Fluid HP 4002/0501 1L
15 4002/0503 5L
WARNING Before working on the brake system,

A Port 1
make sure that the machine is on solid level
B Pipe
ground. Put blocks on all wheels to prevent the
C Port 2
machine rolling.
D Port 3
WARNING Do not use the machine with any part
of its brake system disconnected or inoperative. 6. Test for a low pressure leak as follows:
When the test has been completed, make sure all
brake system components are installed and the 6.1. Install an adaptor with a piece of clear tube
system is operating correctly. to the brake piston port.
6.2. Make sure you keep the tube vertical during
The most common reason for internal piston seal the test. Use tape to attach the tube to the
leakage is a build-up of axle contamination as a result side of the machine.
of excessive brake wear caused by extended service 6.3. Fill the tube until approximately three
periods. quarters full with the correct Hydraulic Fluid.
Two types of internal leakage can occur within the 6.4. Use a suitable pen to mark the level line of
axle or hub: the brake fluid on the tube.
6.5. After approximately 30 minutes, check if
1. Low Pressure Leaks- Seal damage, or scoring to the level has dropped below the original
seal component surfaces, caused by a build-up marked line. If it has, check the brake piston
of metal particles. seal for slight nicks, cuts or generally for
2. High Pressure Leaks- Mechanical leakage past wear.
a badly damaged or perished seal. 6.6. Repeat the step 6.1 to step 6.5 at port 4.
The low pressure leak test should be performed
first. Low pressure leaks are difficult to find using a
high pressure test- seals and other components can
distort and form a seal under pressure.
The following procedures explain how to check for

low or high pressure leaks without the need to
dismantle the axle first. The test must only be done
when the axle is COLD.

2. Disconnect the brake piston feed pipe (or hose,
as applicable) at port 1.
contamination.
4. Completely remove the pipe and install a plug at
port 2.
24 - 24 9823/1700-1 24 - 24
24 - Brake System
03 - Service Brake
39 - Piston
X X
E E
F F
E Port 4 E Port 4
F Brake piston port F Brake piston port
X Brake fluid level line X Brake fluid level line
7. Test for a high pressure leak as follows: 8. Put the brake system back to the original
condition as follows:
7.1. Install a hand pump installed with a
pressure gauge of the specified value to the 8.1. Connect all the brake pipes and bleed
brake piston port. the brake system. Refer to brakes- service
brake. Refer to (PIL 24-03).
Special Tool: Pressure Gauge (0-70 Bar)
(Qty.: 1) For twin axle brake systems, do this procedure on
7.2. Fill the hand pump with the correct the other axle, if applicable.
Hydraulic Fluid.
7.3. Use the hand pump to generate a pressure
in the brake piston housing. Do not exceed
the specified value.
Pressure: 69 bar ( 1,000.0 psi)
7.4. If the pressure falls off rapidly, or if no
pressure reading can be obtained, the
piston seal is severely damaged. Install a
new seal.
7.5. Repeat the 7.1 to step 7.4 at port 4.
24 - 25 9823/1700-1 24 - 25
24 - Brake System
03 - Service Brake
39 - Piston
Refer to driveline- front axle, refer to (PIL 27-20).
24 - 26 9823/1700-1 24 - 26
24 - Brake System
03 - Service Brake
45 - Vacuum Servo Unit
45 - Vacuum Servo Unit Check (Leaks)

Check (Leaks) ............................................... 24-27 Refer to (PIL 24-03-46).
24 - 27 9823/1700-1 24 - 27
24 - Brake System
03 - Service Brake
Remove and Install
For: 506-36 [T2/T3] ................... Page 24-28 3. Disconnect the servo vacuum hose.
For: 507-42 [T2/T3], 509-42 [T2/T3], 510-56
[T2/T3], 512-56 [T2/T3] ............. Page 24-29 4. Disconnect and install a plug on the master
cylinder output pipe. Install a plug on the cylinder
port.
(For: 506-36 [T2/T3])
5. Disconnect and install a plug on the cylinder
Servo unit- Single axle brakes output hose. Install a plug on the cylinder port.
6. Loosen the securing bolts (x3) and slide the
Remove servo unit out of its mounting bracket.
1. Make the machine safe. Refer to (PIL 01-03). 7. Make sure you carefully keep the washers (if
2. Follow the general health and safety procedures. installed).
Figure 477.
D A B
D D
D
E
G F
A Servo vacuum hose B Master cylinder output pipe

C Cylinder output hose D Bolts (x3)
E Bracket F Washers
G Servo unit
24 - 28 9823/1700-1 24 - 28
24 - Brake System
03 - Service Brake
Install Figure 478.
1. The installation procedure is the opposite of the E B

steps.
1.1. Check the brake fluid level. Refer to (PIL
24-00).
1.2. Make sure to install the washers, if installed.
1.3. Bleed the brake system. Refer to (PIL
24-03). D
(For: 507-42 [T2/T3], 509-42 [T2/T3],

510-56 [T2/T3], 512-56 [T2/T3])
Servo Unit- Twin axle brakes

C
Remove
1. Make the machine safe. Refer to (PIL 01-03). E A
2. Follow the general health and safety procedures. F E
A Servo vacuum hose
3. Disconnect the servo vacuum hose. B Master cylinder hose
C Cylinder output hose
4. Disconnect and install a plug on the master D Servo breather hose
cylinder hose. Install a plug on the cylinder port. E Securing nuts (x3)
F Mounting bracket
5. Disconnect and install a plug on the cylinder
output hose. Install a plug on the cylinder port.
Install
6. Disconnect the servo breather hose.
7. Remove the securing nuts (x3) and lift the servo removal procedure. Additionally do the following
unit complete with the rear mounting bracket steps.
from the front mounting bracket.
1.1. Check the brake fluid level. Refer to (PIL
24-00).
1.2. Bleed the brake system. Refer to (PIL
24-03).
24 - 29 9823/1700-1 24 - 29
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
46 - Vacuum Pump Check (Leaks)

Check (Leaks) ............................................... 24-30 The procedure explains how to determine if the brake
Remove and Install ....................................... 24-32 servo vacuum system is functioning correctly.
The following test equipment is used to carry out this

test:
• Vacuum gauge (range up to 1 bar).

• T-adaptor.
• Vacuum hose- 2 lengths x 75 mm (3 inch) long.
• Clips- worm drive.
Brake Vacuum Test (if applicable)

(PIL 06-06).
3. Disconnect the brake vacuum line at the brake
vacuum pump and connect a vacuum gauge
directly to the pump.
3.1. The location of the vacuum pump may
differ depending on the specification of your
machine.
4. Run the engine at 1500 RPM (Revolutions Per
Minute) and note the reading on the vacuum
gauge:
4.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5.
4.2. If there is little or no vacuum, renew the
vacuum pump.
5. Remove the vacuum gauge from the pump port
and connect it again into the brake vacuum line
using a T-adaptor.
6. Run the engine at 1500 RPM and note the
reading on the vacuum gauge:
6.1. If the vacuum is of the specified value of
mercury (Hg), carry out step 5.
6.2. If there is little or no vacuum, check the
vacuum hose connections for leaks.
6.3. Check the security of the clips and then do
step 7.
7. Switch OFF the engine and monitor the vacuum
gauge reading:
7.1. Make sure that the mercury (Hg) level stays
above the specified value after 60 seconds.
24 - 30 9823/1700-1 24 - 30
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
7.2. Check that the vacuum is sufficient for 3 or 4

pedal operations. The vacuum must decay
slowly with each pedal operation.
8. The brake vacuum pump and brake servo unit
are non-serviceable parts. If they are suspected
as being faulty, install new parts.
Figure 479. Typical Vacuum Pump Installation
A Brake vacuum line

B T-adaptor
24 - 31 9823/1700-1 24 - 31
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Remove and Install
If the brake performance is poor and the brake servo 8. Install a cap on the open ends of the hoses to
vacuum is suspected, do the brake vacuum test prevent the ingress of dirt. Tie the hoses out of
before you install a new servo exhauster unit. Refer the way.
to brakes- service brake. Refer to (PIL 24-03).
9. Remove the screws and carefully take out the
servo exhauster unit from the engine. Discard the
Remove gasket.
1. Make the machine safe. Refer to (PIL 01-03)
Install
Refer to (PIL 01-03). The servo exhauster unit is a non-serviceable part. If
it is suspected as being faulty it must be renewed as
3. Disconnect the battery. Refer to (PIL 33-03). a complete assembly.
The special adaptor is installed with an oil feed
(PIL 06-06).
restrictor orifice (3 mm diameter). Check to make
5. Access to the servo exhauster unit is limited. If sure that the orifice is not blocked before installing
necessary remove the machine cooling pack to the servo exhauster unit.
gain sufficient access. Refer to (PIL 21-03).
6. Remove the clip and release the brake vacuum removal procedure. Additionally do the following
hose from the pipe stub. steps.
7. Disconnect the oil feed hose.
24 - 32 9823/1700-1 24 - 32
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Figure 480.
A
B
A Vacuum hose B Pipe stub

C Oil feed hose D Screw
E Gasket F Adaptor
G Gear
1.1. Make sure that the servo exhauster unit

flange and the engine mating face is clean.
Install a new gasket.
1.2. Carefully align the gear so that the gear
teeth engages with the drive gear in the
engine.
1.3. Tighten the screws to the specified torque
value.
1.4. On completion, test the brakes.

Item Nm
D 47
24 - 33 9823/1700-1 24 - 33
24 - Brake System
03 - Service Brake
50 - Light Switch
50 - Light Switch Diagram

Diagram ......................................................... 24-34 The foot brake pedal switch is connected to the panel
Adjust ............................................................ 24-35 harness.
Figure 481.
3 2 1 3 2 1
24 - 34 9823/1700-1 24 - 34
24 - Brake System
03 - Service Brake
50 - Light Switch
Adjust Brake Light Switch- (Reed Type)

Figure 483.
Brake Light Switch- Proximity Type
Figure 482.
D
E F
F
C
B
D Brake light switch
E Metal vane
F Switch faces
1. This type of switch is not adjustable.
2. If a switch failure is suspected, check all
associated wing and connectors for damage.
3. Make sure the vane moves between the switch
faces when the brake pedal is pressed.
4. If the switch does not work, it must be renewed.

Item Nm
A Proximity sensor C 20
B Brake lever
C Locknut
1. Set the ignition switch to the on position, do not
start the engine.
2. Adjust the proximity sensor to the correct
clearance between the sensor face and the edge
of the brake lever.
3. Tighten the locknut to the correct torque.
4. Press the brake pedal and check that the sensor
operates (brake light illuminates) when the brake
pedal has travelled the correct distance. Check
that the sensor remains on throughout the rest of
the travel.
5. Check that the brake lights illuminate when the
brake pedal is pressed.
24 - 35 9823/1700-1 24 - 35
24 - Brake System
03 - Service Brake
50 - Light Switch
Remove and Install
Remove 4. Disconnect the electrical connector from the

panel harness.
5. Hold the switch and remove the screw.
Refer to (PIL 01-03). 6. Remove the switch from the bracket.
3. Press the brake pedal.
Figure 484.
A Electrical connector B Bracket

C Screw D Switch
24 - 36 9823/1700-1 24 - 36
24 - Brake System
03 - Service Brake
50 - Light Switch
Install
removal procedure.
24 - 37 9823/1700-1 24 - 37
24 - Brake System
03 - Service Brake
57 - Pressure Sensor
57 - Pressure Sensor
Check (Operation)
Special Tools
Servicemaster 892/01033 1*
Electronic Test Kit 892/01174
Data Link Adaptor
(DLA) Kit
*Unless otherwise stated, you can use any of the
tools shown.
Test Procedures
1. Use the applicable Servicemaster diagnostics
tool to identify faults. Ensure that the applicable
control interface operates correctly. Rectify as
required. Refer to (PIL 33-57).
Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
2. Test the applicable wires and connectors for
continuity, shorts to battery and shorts to earth.
Rectify as required.
24 - 38 9823/1700-1 24 - 38
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ........................................................................................................................... 24-41

24-18-03 Switch ............................................................................................................................. 24-46
24-18-06 Cable .............................................................................................................................. 24-48
24-18-15 Pad ................................................................................................................................. 24-54
24-18-18 Caliper ............................................................................................................................ 24-55
24-18-21 Disc ................................................................................................................................ 24-62
24 - 39 9823/1700-1 24 - 39
Notes:
24 - 40 9823/1700-1 24 - 40
24 - Brake System
18 - Park Brake
00 - General
Introduction .................................................... 24-41 The park brake also called the hand brake is a
Technical Data ............................................... 24-42 latching brake usually used to keep the vehicle
Operation ....................................................... 24-43 stationary. It is also used to prevent a vehicle from
Check (Operation) ......................................... 24-43 rolling when the operator needs both feet to operate
the clutch and throttle pedals.
Adjust ............................................................ 24-44
The park brake usually consists of a cable directly
connected to the brake mechanism on one end, and
to a hand-operated lever, on the floor at the side of
the driver.
24 - 41 9823/1700-1 24 - 41
24 - Brake System
18 - Park Brake
00 - General
Technical Data
Table 183. Park Brake

Type Disc brake, manually adjusted caliper
Actuation Cable operated
Location Mounted on the rear axle drive head
24 - 42 9823/1700-1 24 - 42
24 - Brake System
18 - Park Brake
00 - General
(For: PS750 Mk4, PS750 MK4) WARNING! Before testing the park brake make
sure the area around the machine is clear of
The park brake is Independent of the service brakes. people.
It operates on the drive to the front axle by means of
a disc mounted on the gearbox output shaft. 1. Park the machine and make it safe.
2. Follow the care and safety procedures. Refer to
When the operator moves the park brake lever to the
(PIL 01-03).
vertical position, the cable pulls the caliper reaction
lever and pressure is applied to the caliper mounted 3. Apply the park brake fully.
brake pads to hold the brake disc.
4. Start the engine and raise the attachments to the
Figure 485. appropriate travelling position.
B 5. Select the fourth gear on the left hand column
switch.
6. Push down hard on foot brake pedal.
C 7. Select forward drive on the left hand column
D switch.
WARNING! If the machine starts to move during

the park brake test, immediately apply the foot
brake and reduce the engine speed.
A
8. Test the park brake as follows:
8.1. Move the park brake lever slowly forward
A Gearbox output shaft until the warning light is just extinguished.
B Brake pads
C Caliper reaction lever 8.2. Slowly release the foot brake pedal.
D Brake disc 8.3. If the machine has not moved, use the
accelerator pedal to gradually increase the
The lever has a simple system for adjustment of the engine speed to 1500 RPM (Revolutions
cable when necessary. Per Minute). The machine should not move.
An electrical switch senses if the park brake lever 8.4. Do not do this test for longer than 20
is set to the brake on or brake off position. The seconds.
switch controls operator warnings and transmission
8.5. Reduce the engine speed to idle and select
interlocks.
neutral on the left hand columb switch.
8.6. Return the park brake lever to the fully on
position from its partially applied position.
8.7. Lower the attachments and stop the engine.
8.8. If the machine moved during this test, adjust
the park brake and repeat the test. Refer to
brakes- park brake, refer to (PIL 24-18).
WARNING! Do not use a machine with a faulty park
brake.
WARNING! Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
If you have any queries concerning this test

procedure or park brake adjustment, consult your
local JCB distributor.
24 - 43 9823/1700-1 24 - 43
24 - Brake System
18 - Park Brake
00 - General
Figure 486. Adjust

D D
(For: PS750 MK4)
12 WARNING The park brake must not be used to
P slow the machine from travelling speed, except
9 3
10 15
in an emergency, otherwise the efficiency of the

RPM x 100
20
5
0 25
B brake will be reduced. Whenever the park brake

has been used in an emergency the brake pack
must be renewed.
working on it. Park the machine on level ground
535 530

C is engaged. Disconnect the battery to prevent the
Notice: Over adjustment or failure to disengage
the park brake properly will cause excessive wear
of the park brake mechanism.
A Before you try to adjust the park brake after an

emergency stop, remove and install new brake
friction components. Install other new components if
A Park brake lever necessary.
B Left hand column switch
C Foot brake pedal The park brake must be engaged fully when the
D Warning light lever is vertical. The park brake indicator light should
illuminate when the brake is engaged with the
forward and reverse lever away from neutral (starter
switch at IGN).
Do the park brake adjustment as follows:

2. Pull and turn the handle grip clockwise, half a
turn.
4. If the brake fails the test, repeat steps 1, 2 and 3.
5. If no more adjustment is possible and the pin is
at the end of its travel, then adjust the cable at
the calliper. Refer to brakes- service brake, refer
to (PIL 24-18).
24 - 44 9823/1700-1 24 - 44
24 - Brake System
18 - Park Brake
00 - General
Figure 487.
A
A Handle grip
B Pin
24 - 45 9823/1700-1 24 - 45
24 - Brake System
18 - Park Brake
03 - Switch
03 - Switch Adjust
Adjust ............................................................ 24-46 The park brake switch is reed type. It operates when
Remove and Install ....................................... 24-47 the metal vane moves between the switch faces. The
switch is not adjustable.
If switch failure is suspected, then check all the

related wires and connectors for damage. Make sure
that the vane moves between the switch faces when
the park brake is operated. If the switch fails, then
install a new switch.
Figure 488.
C
A
C
A Park brake switch

B Vane
C Switch faces
24 - 46 9823/1700-1 24 - 46
24 - Brake System
18 - Park Brake
03 - Switch

Remove removal procedure.
1. Park the machine and make it safe. Follow all 2. When installing do the following steps also:
safety precautions. Please see (PIL 01-03). 2.1. To align the switch correctly, engage the
2. Put chocks on both sides of the wheels to prevent switch location dowel with the hole in the
the machine rolling. Release the park brake. mounting bracket.
3. Remove the rubber gaiter.

switch connector.
5. Hold the switch and remove the screw.
6. Remove the switch.
Figure 489.
B G D
F
C
A Rubber gaiter
B Switch
D Switch connector
E Screw
F Dowel
G Mounting bracket
24 - 47 9823/1700-1 24 - 47
24 - Brake System
18 - Park Brake
06 - Cable
06 - Cable Adjust
Adjust ............................................................ 24-48
Lubricate ........................................................ 24-50
(For: PS750 Mk4, PS750 MK4)
Remove and Install ....................................... 24-51 If the adjustment of the park brake lever is not
sufficient, then adjust the cable at the calliper.
If it is not possible to adjust at the lever or at the

calliper, then change the brake pads.
Make sure that you install a new cable if the cable is

worn or damaged.
1. Park the machine and make it safe.

2. Follow the care and safety procedures. Refer to
(PIL 01-03).
4. Turn the hand grip anti-clockwise to centre the
pin in its slot.
5. Release the two locknuts and adjust the cable
length as required.
6. If you install a new cable, make sure to put the
threaded section of the cable with approximately
four threads visible below the bottom adjusting
nut.
7. Make sure there is enough freedom of movement
of the operating lever to ensure a positive brake
application. The lever must return to the rest
position when the park brake is released.
8. Make sure that the clearance between the brake
pad and the brake disc is within the specified
range.
Length/Dimension/Distance: 0.5 –0.75 mm
Make final adjustments at the park brake lever if

the brake fails the test. Refer to operator station-
controls, refer to (PIL 09-27).
24 - 48 9823/1700-1 24 - 48
24 - Brake System
18 - Park Brake
06 - Cable
Figure 490.
C
A Hand grip
B Pin
C Locknuts
Figure 491.
D
D Operating lever
24 - 49 9823/1700-1 24 - 49
24 - Brake System
18 - Park Brake
06 - Cable
Lubricate
WARNING Oil on the brake disc will reduce
brake effectiveness. Keep oil away from the
brake disc. Remove any oil from the disc with
a suitable solvent. Read and understand the
solvent manufacturer's safety instructions. If the
pads are oily, install with the new pads.
Apply a thin layer of engine oil on the clevis end of

the park brake cable. Refer to Figure 492.
Figure 492.
A
A Clevis end - Park brake cable
24 - 50 9823/1700-1 24 - 50
24 - Brake System
18 - Park Brake
06 - Cable
Remove and Install
(For: PS750 Mk4, PS750 MK4) Remove

Consumables 1. Make the machine safe. Obey all care and safety
Description Part No. Size procedures Refer to (PIL 01-03).
and Sealer (Medium 2. Release the park brake lever (lever horizontal).
4101/0251 0.05 L
Strength)
Figure 493.
A
A Clevis pin B Actuating lever

C Locknut 1 D Bracket
3. Remove the clevis pin from the park brake 9. Remove the lever fixing bolts.
caliper.
10. Remove the lever assembly together with the
4. Make sure you note which of the three holes on cable.
the actuating lever is used.
11. Measure and record the dimension between the
5. Remove the clip or loosen the locknut 1 as sleeve and the locknut.
applicable.
12. Remove both the buffer bracket fixing bolts.
6. Disconnect the cable from the bracket ad note
the cable routing located underside the cab. 13. Remove the cable nipple from the clevis and then
remove the cable sideways from the lever.
7. Remove the gaiter fixings and pull up the gaiter.
14. Disengage the cable nipple from the clevis.
8. Disconnect the park brake switch electrical
connector. 15. Remove the buffer assembly from the cable.
24 - 51 9823/1700-1 24 - 51
24 - Brake System
18 - Park Brake
06 - Cable
Figure 494.
K
K
N L
M
P
Install
Table 184. Installation is opposite of the removal procedure and
Item Description additionally do the steps below.
E Park brake lever (hori-
1. Make sure you correctly route the cable.
zontal)
F Electrical connector 2. Make sure that the locknut is screwed fully down.
G Lever fixing bolts
3. Adjust the sleeve to allow cable location to the
H Clevis lever assembly.
J Buffer assembly
K Bracket fixing bolts 4. Apply threadlocker to the buffer bracket fixing
bolts.
L Sleeve
M Locknut 2 Consumable: JCB Threadlocker and Sealer
(Medium Strength)
N Dimension between the
sleeve and locknut 2 5. Make sure that the buffer bracket assembly is
P Cable located correctly.
24 - 52 9823/1700-1 24 - 52
24 - Brake System
18 - Park Brake
06 - Cable
7. Adjust the sleeve and the locknut 2 until you get

the dimension measured between the sleeve and
the locknut at the time of removal.
8. If a new cable is installed make sure that the
dimension between the sleeve and the locknut
will be of the specified value.
Dimension: 15 mm
9. Tighten the locknut 2.
10. Make sure that the cable clevis is is connected at
the correct hole in the caliper actuating lever.
11. Make sure that the actuating lever is not being
pulled by the cable when the park brake lever is
in the off (horizontal) position.
12. If necessary adjust sleeve until the actuating
lever is allowed to return fully to its off position.
13. Adjust the cable. Refer to (PIL 24-18-06).

Item Description Nm
K Bracket fixing bolts 3
24 - 53 9823/1700-1 24 - 53
24 - Brake System
18 - Park Brake
15 - Pad
15 - Pad
Check (Condition)

WARNING Oil on the brake disc will reduce
brake effectiveness. Keep oil away from the
brake disc. Remove any oil from the disc with
a suitable solvent. Read and understand the
solvent manufacturer's safety instructions. If the
pads are oily, install with the new pads.
1. Follow the brake pad removal instructions. refer

to (PIL 24-03).
2. Make sure that the minimum thickness of the
friction material on either pad is 1mm (0.04 in),
but it is recommended to install new pads as it
may not be possible to adjust pads worn to this
limit.
3. Check the condition of the disc surface. Install a
new disc if the surface is badly warped, pitted or
worn.
4. Install a new park brake cable if it is worn or
damaged.
24 - 54 9823/1700-1 24 - 54
24 - Brake System
18 - Park Brake
18 - Caliper
18 - Caliper Component Identification

Check (Condition) .......................................... 24-56
Disassemble and Assemble .......................... 24-59
Figure 495.
R
M
M
L
N
F S
E
C
M
D G
Q B A
H P
K J

Q Bearing ring
Item Description
R Housing
A Carrier side pad
S Shaft seal
B Lever side pad
C Screw
D Washer1
E Washer2
F Lever
G Spring
H Rotor
J Ball spacer
K Ball bearings
L Mounting bushes
M Dust seals
N O-rings
P Rotor Seal
24 - 55 9823/1700-1 24 - 55
24 - Brake System
18 - Park Brake
18 - Caliper
Check (Condition)

Refer to Component Identification, (PIL 24-18-18).
1. Clean and dry all parts.

2. Check that all the parts are free from excessive
wear, damage or corrosion. Light scores or stains
should be removed. Renew corroded or deeply
scored parts.
3. Check rotor for damage or distortion.
4. Install new if necessary. Make sure to change
both the brake pads if the park brake has been
used in an emergency.
5. Check the ball pockets in housing for signs of
scoring, pitting, damage or corrosion.
6. Install new housing if damaged. Check that the
spring is not broken or distorted.
7. Check the condition of the disc surface.
8. Install new disc if badly warped, pitted or worn.
Refer to brakes- park brake, refer to (PIL 24-18).
24 - 56 9823/1700-1 24 - 56
24 - Brake System
18 - Park Brake
18 - Caliper
Remove and Install
(For: PS750 Mk4, PS750 MK4) 2. Release the park brake lever (horizontal).
Safety Critical Installation 3. Remove the pin and disconnect the clevis joint,
This is a safety critical installation. Do not attempt note which of the three holes on the lever is used.
to do this procedure unless you are skilled and 4. Remove the clip and disconnect the cable from
competent to do so. the bracket.
Installation and mounting of the park brake caliper
requires tightening of the mounting bolts to a specific 5. Support the caliper and remove the two mounting
torque figure. Do not attempt to do this job unless you bolts and hardened washers.
have the correct tools available. 6. Lift the caliper clear of the brake disc.
Remove 7. Do not remove transmission mounting bracket,
unless it is necessary to be replaced.
Figure 496.
A B C D
E
B
A Clip B Mounting bolts

C Clevis joint D Pin
E Operating lever F Transmission mounting bracket
24 - 57 9823/1700-1 24 - 57
24 - Brake System
18 - Park Brake
18 - Caliper
Install
Installation is the opposite of the removal procedure
but additionally do the below steps.
1. Locate the caliper on the brake disc.

2. Install new mounting bolts with hardened
washers.
3. Tighten the mounting bolts to the correct torque
value.
4. Attach the cable to the mounting bracket and
secure in place with the clip.
5. Install the clevis joint and the pin into the relevant
hole in the operating lever.
6. Make sure there is enough space for the
movement of the operating lever, to make sure
that positive brake application, and that the lever
returns to the rest position when the park brake
is released.
7. Adjust the park brake cable. Do not remove the
he clevis to adjust the cable.

Item Description Nm
B Mounting bolts 255
24 - 58 9823/1700-1 24 - 58
24 - Brake System
18 - Park Brake
18 - Caliper
(For: PS750 Mk4, PS750 MK4) 7. Push out the rotor the remove the ball spacer and
the ball bearings.
Safety Critical Installation
This is a safety critical installation. Do not attempt 8. Make sure you keep the ball bearings properly in
to do this procedure unless you are skilled and a container.
competent to do so. 9. Push out the mounting bushes and then remove
Installation and mounting of the park brake caliper the dust seals.
requires tightening of the mounting bolts to a specific
torque figure. Do not attempt to do this job unless you 10. Remove the O-rings.
have the correct tools available. 11. Remove the rotor seal and then the bearing ring.
Disassembly 12. Note that the rotor seal may be located on the
rotor shaft or may have been left in the calliper
1. Remove the caliper and the brake pads. Refer to housing.
remove and install (PIL 24-18-18).
13. It is not necessary to replace the shaft seal
2. Hold the lever against the tension of the spring. unless it is excessively worn or damaged.
3. Remove the screw and both the washer 1, 13.1. If removal is necessary, use a suitable
washer 2. spacer block and a bench press to push
the seal out from inside the housing.
4. Note the position of the lever with respect to the
splines of the rotor shaft. 13.2. Clean out any remains of the seal after
removal.
5. Mark the end of the shaft and lever to assist in
assembly. Before assembly make sure all parts are clean
and serviceable. Refer to park brake caliper-check
6. Remove the lever and the spring. condition (PIL 24-18-18).
24 - 59 9823/1700-1 24 - 59
24 - Brake System
18 - Park Brake
18 - Caliper
Figure 497.
R
M
M
L
N
F S
E
C
M
D G
Q B A
H P
K J
1. If removed, Install a new shaft seal. Use a

Table 188. suitable spacer block and bench press to push
the seal into the housing.
Item Description
A Carrier side pad 2. Apply silicon grease on the shaft, the outer
B Lever side pad diameter and ball pockets of rotor and the ball
pockets of housing.
C Screw
D Washer 1 3. Install the three ball bearings into the pockets in
E Washer 2 the housing. Install the ball spacer.
F Lever 4. Apply silicon grease on the bearing ring and
G Spring install the ring to the inner diameter on rotor seal.
H Rotor
5. Assemble the rotor seal to the rotor.
J Ball spacer
K Ball bearings 6. Move the rotor through the casting and seat the
L Mounting bushes ball pockets against the bearings.
M Dust seals 7. Position the spring over the shaft of rotor.
N O-rings
8. Put the large diameter end of the spring into hole
P Rotor Seal
in the face of the housing. Refer to Figure 498.
Q Bearing ring
R Housing
S Shaft seal
Assembly
Before assembly make sure all parts are clean and
serviceable.
24 - 60 9823/1700-1 24 - 60
24 - Brake System
18 - Park Brake
18 - Caliper
Figure 498.
T U
T Spring hole
U Lever outside edge
9. Locate the small diameter end of spring around
the outside edge of lever. Refer to Figure 498.
10. Install the lever and align the lever to the mark
made at the time of disassembly.
11. Hold the lever against the tension of the spring
and install the washer 1 and washer 2.
12. Install the screw and tighten the screw to the
13. Install the brake pads.
14. Apply silicon grease to the dust seals and the
bushes.
15. Install the dust seals to the housing and put
mounting bushes.
16. Make sure that the dust seals locate in their
location grooves on the bushes and housing.
17. Lubricate and install new O-rings. Wipe off any
excess grease.
18. Before you install the caliper, make sure that the
lever rotates smoothly and that the lever side
pad returns to the off position when the lever is
released.
19. Install the brake caliper.
20. Install and adjust the park brake cable.

Item Torque value
Screw 13 –16 N·m
24 - 61 9823/1700-1 24 - 61
24 - Brake System
18 - Park Brake
21 - Disc
21 - Disc Introduction
Introduction .................................................... 24-62 A disc brake is a wheel brake that slows the rotation
Check (Condition) .......................................... 24-63 of the wheel by the friction caused by pushing brake
Remove and Install ....................................... 24-64 pads against a brake disc with a set of calipers.
24 - 62 9823/1700-1 24 - 62
24 - Brake System
18 - Park Brake
21 - Disc
Check (Condition)

1. Inspect the thickness of the park brake disc.
Renew the disc if it is below the minimum
thickness. Refer to (PIL 24-18-00).
2. Inspect the condition of the disc. If the disc is
deeply pitted or scored, replace it with a new one.
24 - 63 9823/1700-1 24 - 63
24 - Brake System
18 - Park Brake
21 - Disc
Remove and Install
(For: PS750 MK4) 7. Do not use a steel hammer, damage can occur
to the output shaft bearing.
Special Tools
Description Part No. Qty. 8. If necessary remove the oil seal. Do not damage
Flange Spanner 992/04800 1 the seal housing.
Remove Install
1. If installed remove the park brake caliper. 1. Make sure that the oil seal interface on the brake
disc is clean and free from wear or damage.
2. Bend back the stake nut locking ring.
2. If necessary install a new oil seal. Lubricate the
3. Clean the brake disc and the gearbox around the lips of the seal.
brake disc. Make sure no contamination enters
the gearbox when the brake disc is removed. 3. Install the brake disc onto the output shaft.
4. Hold the brake disc with the service tool and 4. Install the washer.
remove the output shaft stake nut. Discard the 5. Hold the brake disc with the service tool.
stake nut.
Special Tool: Flange Spanner (Qty.: 1) 6. Install a new stake nut.
5. Remove the washer. 7. Progressively tighten the nut to the correct torque
value.
6. Lift off the brake disc. If necessary use a soft
faced mallet to remove the brake disc. 8. Stake the nut to the shaft with a square ended
staking tool.
24 - 64 9823/1700-1 24 - 64
24 - Brake System
18 - Park Brake
21 - Disc
Figure 499.
E
D
C
B
A Brake disc B Stake nut

C Washer D Output shaft
E Oil seal F Bearings
G Oil seal interface H Stake nut locking ring

Item Nm
B 300
24 - 65 9823/1700-1 24 - 65
Notes:
24 - 66 9823/1700-1 24 - 66
Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-00-03 Manual Steer Mode System .......................................................................................... 25-15
25-01 Pump
25-01-00 General ........................................................................................................................... 25-25
25-03 Priority Valve
25-03-00 General ........................................................................................................................... 25-27
25-06 Steer Unit/Valve
25-06-00 General ........................................................................................................................... 25-35
25-09 Mode Valve
25-09-03 Manual Mode Valve ....................................................................................................... 25-47
25-12 Column
25-12-00 General ........................................................................................................................... 25-55
25-15 Proximity Switch
25-15-00 General ........................................................................................................................... 25-59
25-18 Front Track Rod
25-18-00 General ........................................................................................................................... 25-65
25-33 Link Arm
25-33-00 General ........................................................................................................................... 25-75
9823/1700-1
2018-06-28
Acronyms Glossary
2WS Two Wheel Steer

4WS Four Wheel Steer
LS Load Sense
9823/1700-1
2018-06-28
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3

25-00-03 Manual Steer Mode System .......................................................................................... 25-15
25 - 1 9823/1700-1 25 - 1
Notes:
25 - 2 9823/1700-1 25 - 2
00 - General
Introduction ...................................................... 25-3 Your machine may be installed with either manual
Health and Safety ........................................... 25-4 or auto steer mode systems depending on the
Technical Data ................................................. 25-4 specification of the machine.
Operation ......................................................... 25-5
Fault-Finding .................................................... 25-7 Manual Steer Mode System
Check (Leaks) ............................................... 25-10 In a manual steer system, there are three steering
Check (Pressure) .......................................... 25-11 modes available:
Adjust ............................................................ 25-12
Bleed ............................................................. 25-13 1. 2WS (Two Wheel Steer) (front axle only)- only
the front wheels are steered.
2. 4WS (Four Wheel Steer) both axles are steered,
giving a smaller turning circle
3. Crab steer- allows the machine to be driven
diagonally
Auto Steer Mode System

In an auto steer system, there are three steering
modes available:
1. 2WS (front axle only)- only the front wheels are

steered.
2. 4WS both axles are steered, giving a smaller
turning circle
3. Crab steer- allows the machine to be driven
diagonally
The operation of the steer mode switch, solenoids

and proximity switches is controlled by an ECU
(Electronic Control Unit).
On some machines a separate Steer Mode Control

ECU is used - refer to (PIL 33-45-18).
Other machines the steer modes are controlled by

either the hydraulic control ECU or the transmission
control ECU. For details of the ECU operation refer
to (PIL 33-45).
25 - 3 9823/1700-1 25 - 3
00 - General

Engine/Steering Failure Table 191. Hydraulic steer unit
If the engine or steering fails, stop the machine as
Item Description
quickly as possible. Do not operate the machine until
the fault has been corrected. Model TBA
Volumetric displacement 95cc/rev (2:1 ratio)
gerotor 1:
Make the machine safe before getting beneath it. Volumetric displacement -
Make sure that any attachments on the machine are gerotor 2:
Relief valve operat- 195 –200 bar ( 2,826.1 –
ing pressure (at 1500 2,898.5 psi)
RPM (Revolutions Per
movement.
Minute))
Fluid Under Pressure Shock valve operating 255 bar ( 3,695.6 psi)
Fine jets of fluid at high pressure can penetrate the pressure- if installed
skin. Keep face and hands well clear of fluid under
pressure and wear personal protective equipment.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help
immediately.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be
started while the hoses are open.
WARNING! When getting access for maintenance
work, make sure no-one is in a position to be caught
and/or crushed by the wheels when the steering
wheel is turned.
25 - 4 9823/1700-1 25 - 4
00 - General
Operation
The main components of the steering system are the steer unit, which in turn directs the flow to the steer
priority valve (PIL 25-03) , the load sensing steer rams on the axles.
unit (PIL 25-06), the steer mode control valve (PIL
25-09) (if installed) and the double acting steer rams When the steering lock is achieved, the pressure
or power track rods as applicable (PIL 25-18 and or signal in the load sense line ceases. The priority
19). valve then directs the oil from the hydraulic pump
into the main hydraulic system for operation of the
When the you turn the steering wheel, a pressure hydraulic services.
signal (demand) is generated in the load sense line
from the steer unit to the priority valve. The priority The maximum steering system pressure is set by a
valve then directs oil from the hydraulic pump to the relief valve housed inside the steer unit.
Figure 500. Machine with Power Track Rods
A,B
D
E
C
25 - 5 9823/1700-1 25 - 5
00 - General
Figure 501. Machine with Steer Rams
F
D
A, B
F
C
Table 192.
Item Description
A Hydraulic pump
B Priority valve
C Steer unit
D Control valve
E Power track rods
F Steer rams
25 - 6 9823/1700-1 25 - 6
00 - General
Fault-Finding
Fault
Steering wheel difficult to turn Table 193. Page 25-7
Steering wheel turns on its own. Table 194. Page 25-7
Machine will not turn when the steering wheel turned. Table 195. Page 25-7
Steering 'drifts' out of phase during operation. Table 196. Page 25-8
Steering fails to respond to selected mode (solenoid operated mode valve Table 197. Page 25-8
only).
Table 193. Steering wheel difficult to turn

Cause Remedy
Tyres not inflated to correct pressure. Inflate tyres to correct pressure.
Insufficient hydraulic fluid. Check for leaks and top up the hydraulic tank as
Leaks in the relevant hoses or component Check hoses and connections for leaks. Refer to (PIL
connections. 30-00 ).
Air in the hydraulic system. Bleed system- bleed the load sense line. Refer to
(PIL 30-00).
Low pump flow. Check pump flow, if required service or replace
pump. Refer to (PIL 30-00).
Steer relief valve set incorrectly. Check pressure setting of steer unit relief valve,
adjust as required. Refer to (PIL 25-00).
Worn or damaged parts in the steer control valve. Remove and inspect. Refer to (PIL 25-00).
Priority valve not operating correctly. Check if the priority valve is sticking (contamination)
rectify as required. Check the load sense line from
the steer unit to the priority valve for signs of leaking
or poor connection. Refer to (PIL 25-00).
Steer mode valve not operating correctly (if fitted). Check if spools sticking, rectify as required. Refer
to the Steer Mode Valve topic. Check if solenoids
operating, replace solenoids as required. Refer to
(PIL 25-00).
Mechanical failure. Check for damaged axle components, such as rams,
track rods, linkages, etc. Refer to (PIL 27-00).
Table 194. Steering wheel turns on its own.

Cause Remedy
Dirt in the steer control unit (causing sleeves to stick Clean and inspect unit. Refer to (PIL 25-06).
open).
Steer control valve centring springs damaged, Check steer unit. Refer to (PIL 25-06).
broken or missing.
Steer control valve- position of rotor to shaft slot Correct as required. Refer to (PIL 25-06).
incorrect.
Table 195. Machine will not turn when the steering wheel turned.
Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up the hydraulic tank as
required. Refer to (PIL 30-00)
Leaks in the relevant hoses or component Check hoses and connections for leaks. Refer to (PIL
connections. 30-00).
Air in the hydraulic system. Bleed system- bleed the load sense line. Refer to
(PIL 25-00).
Low pump flow. Check pump flow, if required service or replace
pump. Refer to (PIL 30-00).
25 - 7 9823/1700-1 25 - 7
00 - General
Cause Remedy
Steer relief valve set incorrectly. Check pressure setting of steer unit relief valve,
adjust as required. Refer to (PIL 25-00).
Worn or damaged parts in the steer control valve. Remove and inspect. Refer to (PIL 25-00).
Priority valve not operating correctly. – Check if the priority valve is sticking
(contamination) rectify as required. Check the load
sense line from the steer unit to the priority valve for
signs of leaking or poor connection. Refer to (PIL
25-00).
Steer mode valve not operating correctly (if fitted). Check if spools sticking, rectify as required. Check if
solenoids operating, replace solenoids as required.
Refer to (PIL 25-00)
Mechanical failure. Check for damaged axle components, such as rams,
track rods, linkages, etc. Refer to (PIL 27-00)
Steer column splined shaft not fully engaged in steer Check shaft engagement. Refer to (PIL 25-12)
valve.
Power track rod/Steer Ram failure. Check power track rod/Steer Ram for signs of
damage, leaks etc. Refer to (PIL 30-15).
Table 196. Steering 'drifts' out of phase during operation.

Cause Remedy
(1) Does steering go out of phase in less than four YES = go to (2), NO = Ensure system is rephased
hours of continuous use? after four hours of continuous use (see Operator's
Handbook).
(2) Does steering go out of phase by a small amount YES = go to 3, NO = go to 4.
and drift no further when changing steer modes?
(3) Ensure operator changes steer mode at low YES = done, NO = Ensure power track-rod piston
engine speed and observes 5 second delay between is centralised and wheel tracking is correct. Adjust
modes (see Operator's Handbook), is it OK now? alignment of steer proximity switches to optimise
accuracy.
(4) Bleed steering system to remove air. Is it OK YES = done, NO = go to 5.
now?
(5) Possible leakage through anti-cavitation valve (if YES = done, NO = go to 6.
fitted). Replace Steer Unit. Refer to (PIL 25-06).
(6) Check both front and rear power track rods YES = done, NO = go to 7.
for internal leakage. Check the seal installation is
correct, check the seal damage, scoring or bore
ovality. Re-seal or renew faulty unit(s). Refer to (PIL
30-15). Is it OK now?
(7) Strip steer mode valve and inspect spool for YES = done, NO = go to 8.
scoring or damage. Renew valve if required. Refer to
(PIL 25-06). Is it OK now?
(8) Check for contamination in the hydraulic system. YES = Filter the hydraulic system. Refer to (PIL
30-00), NO = It is likely that one of the preceding
tests was not conclusive. Go to (1).
Table 197. Steering fails to respond to selected mode (solenoid operated mode valve only).
Cause Remedy
Electrical failure. (The steer mode ECU will generate Check relevant electrical connectors, if problem still
a blink code for some fault conditions). Refer to (PIL persists, do a wiring continuity check on relevant
57-90). circuits.
Selector switch faulty. Check selector switch, replace as required.
Proximity switches not operating correctly. Check operation of proximity switches, adjust or
replace switches as required. Refer to (PIL 25-15).
Steer mode relay not operating correctly. Renew relay. Refer to (PIL 33-09).
25 - 8 9823/1700-1 25 - 8
00 - General
Cause Remedy
Steer mode valve not operating correctly. – Check if spools sticking, rectify as required. Refer
to (PIL 25-06). Check if solenoids operating in
accordance with the mode selected. Refer to (PIL
25-06).
Leaks in the relevant hoses or component Check hoses and connections for leaks.
connections.
ECU failure. The ECU is normally a reliable component and
failure is unlikely. Before renewing the ECU make
sure that all relevant electrical connections and
components are functioning correctly. (Make sure
you do not connect a test meter directly to the pins
on the ECU).
25 - 9 9823/1700-1 25 - 9
00 - General
Check (Leaks) 4. Select the machine in 2WS mode and then close
the ball valves. Measure the length of one side of
the track rod and record the value.
Internal hydraulic leakage check 5. Drive the machine, in a circle, in one direction,
several times. Stop the machine and again
If hydraulic leaks at the steer mode valve or power
measure the track rod length. Compare the
track rods, the steering system will go progressively
measurements.
out of phase, the more the steering is operated the
further the front and rear wheels will drift out of phase. 5.1. If the track rod has moved then it can
be assumed that there is internal leakage
Some drifting out of phase is normal over time and across the piston seals in the power track
the system must be routinely re-phased. Refer to rod. This may be due to defective or
(PIL 25-00). incorrectly installed seals, or a defective
cylinder bore. Disassemble and inspect the
If the system goes out of phase over short periods
power track rod.
of time it is probable that there is hydraulic leakage.
External leakage is obvious and may occur at 5.2. If the track rod has not moved it can be
track rod seals, relevant hoses, pipes and adaptors. assumed there is internal leakage at the
Internal leakage can occur across power track rod steer mode valve.
piston seals or within the steer mode valve.
To check the internal leakage follow the below steps.
• 4WS (Four Wheel Steer) mode faults: Both

front and rear track rods and the steer mode
valve must be checked individually for possible
leakage.
• 2WS (Two Wheel Steer) mode faults: It is
possible to identify fault, if internal leakage is
at the rear power track rod, or steer mode
valve without first removing and dismantling
components. Follow the steps below.
2. Disconnect the hydraulic hoses from the rear
power track rod and Install isolating ball valves
at each port on the track rod and then reconnect
the hoses.
3. Open the ball valves. Start the engine and bleed
the system. Refer to (PIL 25-00).
Figure 502.
B C
B
A Hydraulic hoses
B Isolating ball valve
C Track rod
25 - 10 9823/1700-1 25 - 10
00 - General
Check (Pressure) 6. Set the steering to neutral (do not turn

the steering wheel), and start the engine.
Special Tools Gradually increase the engine speed to 1000
Description Part No. Qty. RPM (Revolutions Per Minute) and check the
Pressure Gauge (0-400 892/00279 1 maximum pressure gauge reading, it should be
Bar) within the specified limit.
Pressure Gauge (0-70 892/00346 1 Pressure: 5.9 –8.7 bar ( 85.5 –126.1 psi)
Bar)
6.1. If the pressure is more than the specified
The steer circuit pressure is integrated with operation limit then clean the priority valve. Refer to
of the hydraulic pump and the main hydraulic system (PIL 25-03).
pressures. Refer to (PIL 30-00-00) 6.2. If after cleaning the valve the pressure is
more than the specified limit then check
Gear pump machines the steering pump section flow rate and
pressure.
Hydraulic pressure tests 6.3. If the hydraulic pump flow and pressure
tests are satisfactory, then the priority valve
Standby pressure must be replaced with a new one. Refer to
1. Make the machine safe. Refer to (PIL 01-03). (PIL 25-03).
2. Turn the steering wheel to the left and to the right Steering pressure
several times to discharge the system pressure.
3. Disconnect hose 1 and install a pressure test
2. Turn the steering wheel to the left and to the right
gauge into the valve port.
Special Tool: Pressure Gauge (0-70 Bar) (Qty.: 1)
3. Connect a pressure gauge to the test point
4. Put the open end of hose 1 into a clean container located on the priority valve.
in order to collect any oil drainage.
Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
Figure 503. 1)
G H Figure 504.
E K J F F
D K
F Priority valve
D Hose 2 K Test point
E LS (Load Sense) port adaptor
F Priority valve 4. Run the engine at 1500 RPM and turn the
G Hose 1 steering wheel to full lock.
H Hose 3
5. Hold the wheel on full lock and check the gauge
J Socket head screws
reading. This should be equal to the relief valve
K Test point
operating pressure. Refer to (PIL 25-00).
5. Disconnect hose 2 from load sensing port
6. If necessary, remove the plug on the hydraulic
adaptor and put a plug on the hose opening. Do
steer unit and adjust the pressure setting.
not cap the LS port adaptor.
25 - 11 9823/1700-1 25 - 11
00 - General
7. Use an Allen key to adjust the valve screw until Adjust

the correct pressure is shown on the gauge.
8. You can get access to the pressure adjusting To change the steer mode:
screw through a cut-out at the base of the
steering column after you remove the panels. 1. Stop the machine. Select the neutral position on
the forward/reverse lever.
Figure 505.
2. Turn the steering wheel until all the wheels are
pointing in the straight ahead position.
3. Use the steer mode selector lever to select the
steer mode required.
L Figure 506.
A
M
L Pressure adjusting screw B

M Plug
9. It may be necessary to remove the hydraulic C
steer unit if access is restricted.
D
10. Install the plug.
A Steer mode selector lever

B 4-wheel steer
C 2-wheel steer
D Crab steer
To align the wheels:
1. Stop the machine. Select the neutral position on

the forward/reverse lever.
2. Use the steer mode selector lever to select 4-
wheel steer.
3. Turn the steering wheel until the rear wheels are
4. Use the steer mode selector lever to select 2-
wheel steer.
5. Turn the steering wheel until the front wheels are
6. All wheels are now pointing straight ahead, select
the steer mode required and continue in the
normal manner.
25 - 12 9823/1700-1 25 - 12
00 - General
Bleed Machines with manual steer mode valve

(optional)
Machines with auto steer mode valve Whenever any hydraulic steering component is
disconnected or removed the system must be bled
Whenever any hydraulic steering component is as follows:
disconnected or removed the system must be bled
as follows: This procedure must be carried out in the correct
order that is laid down. You must not change the
With the engine running, the following procedure order of selections and operations.
must be carried out in the correct order that is laid
down. You must not change the order of selections 1. Start the engine.
and operations.
2. Select 2WS.
1. Select 2WS (Two Wheel Steer).
2.1. Turn the steering wheel to left, until front
1.1. Turn the steering wheel to left, until both the wheels are fully locked to the left.
front wheels are fully locked to the left. 2.2. Turn the steering wheel to right, until front
1.2. Turn the steering wheel to right, until both wheels are fully locked to the right.
the front wheels are fully locked to the right. 2.3. Turn the steering wheel to left until front
2. Select 4WS (Four Wheel Steer). wheels are in the straight ahead position.
2.1. Turn the steering wheel to left, until the front 3. Select 4WS.
wheels are fully locked to the left. 3.1. Turn the steering wheel to left, until front
3. Select 2WS. wheels are fully locked to the left.
3.2. Turn the steering wheel to right until front
3.1. Turn the steering wheel to full right lock. wheels are in the straight ahead position.
3.2. Turn the steering wheel to full left lock.
4. Select 2WS.
3.3. Turn the steering wheel to full right lock.
4. Select 4WS.
4.1. Turn the steering wheel to left, until the front 4.3. Turn the steering wheel to full right lock.
wheels are fully locked to the left.
4.4. Turn the steering wheel to left until front
5. Select 2WS. wheels are in the straight ahead position.
5.1. Turn the steering wheel to full right lock. 5. Select 4WS.
5.2. Turn the steering wheel to full left lock. 5.1. Turn the steering wheel to left, until the front
5.3. Turn the steering wheel to full right lock. wheels are fully locked to the left.
6. Select 4WS. 5.2. Turn the steering wheel to right until front
wheels are in the straight ahead position.
6.1. Turn the steering wheel to left, until front
wheels are fully locked to the left. 6. Select 2WS.
7. Select 2WS. 6.1. Turn the steering wheel to full right lock.
6.4. Turn the steering wheel to left until front
7.3. Turn the steering wheel to full right lock. wheels are in the straight ahead position.
8. Select 4WS. 7. Select 4WS.
8.1. Turn the steering wheel to left, until the front 7.1. Turn the steering wheel to left, until front
and rear wheels are fully locked. wheels are fully locked to the left.
9. Stop the engine and fill up the hydraulic tank as 7.2. Turn the steering wheel to right until front
necessary. wheels are in the straight ahead position
25 - 13 9823/1700-1 25 - 13
00 - General
8. Select 2WS.
8.4. Turn steering wheel to left until front wheels
are in the straight ahead position.
9. Select 4WS.
9.1. Turn the steering wheel to left, until the front
and rear wheels are fully locked.
10. Stop the engine and fill up the hydraulic tank as
necessary.
25 - 14 9823/1700-1 25 - 14
03 - Manual Steer Mode System
03 - Manual Steer Mode System Introduction

Introduction .................................................... 25-15 In a manual steer system, there are three steering
Operation ....................................................... 25-16 modes available:
• 2-wheel steer (front axle only) - only the front

wheels are steered
• 4-wheel steer - both axles are steered, giving a
smaller turning circle
• Crab steer - allows the machine to be driven
diagonally
25 - 15 9823/1700-1 25 - 15
Operation
Manual Steer Mode System Figure 507. Right turn shown
Machines with power track rods

A
2-wheel steer selected
With the spool of steer the mode control valve in the

2-wheel steer position there is a hydraulic connection
between the steer unit and the front power track L R
rod. Steer mode control valve ports are internally
connected. The oil feed to the rear axle power track
rod is blocked by the spool assembly and the axle is
held in the straight ahead position by the locked-up
hydraulic oil in the track rod ram.
When the steering wheel is turned, the steering

system only operates the front power track rod. P
If the steering wheel is turned to the left, the oil flow B
E
is reversed and the machine will turn in the opposite T
direction.
D
V
Table 198.
Item Description
A Front power track rod
B Steer unit
C Rear axle power track
rod
D Steer mode control
valve port
E Steer mode control
valve port
L Left side
P Steer mode control
valve port
R Right side
T Steer mode control
valve port
25 - 16 9823/1700-1 25 - 16
Item Description Figure 508. Right turn shown

V Steer mode control
valve
(T and P) (Steer mode valve ports A
connected internally for
2 wheel steer)

L R
With the spool of the steer mode valve in the 4-
wheel steer position there is a hydraulic connection
between the steer unit and the front and rear axle
power track rods. Steer mode control valve ports
are internally connected. When the steering wheel is
turned to the right, oil is fed to the rear power track rod P
and the displaced oil is fed to the front power track
rod through the valve spool. The front power track E
rod turns the wheels in the opposite direction to the B
rear wheels and displaced oil returns to tank.
D T
If the steering wheel is turned to the left, the oil flow
is reversed and the machine will turn in the opposite
direction. V
Table 199.
Item Description
B Steer unit
rod
valve port
valve port
L Left side
valve port
R Right side
valve port
25 - 17 9823/1700-1 25 - 17
Item Description Figure 509. Right turn shown

valve
A
(T and B / A and P) (Steer mode valve ports
4 wheel steer)
Crab steer selected L R

With the spool of the steer mode valve in the
crab steer position there is a hydraulic connection
between the steer unit and the front and rear
axle power track rods. Steer mode valve ports are
internally connected. When the steering wheel is
turned to the right, oil is fed to the rear power track
rod and the displaced oil is fed to the front power
track rod through the valve spool. The front power P
track rod turns the wheels in the same direction as B
the rear wheels, causing the machine to crab to the E
right. Displaced oil returns to tank.

D V T
is reversed and the machine will crab in the opposite
direction.
Table 200.
Item Description
B Steer unit
rod
valve port
valve port
L Left side
valve port
R Right side
valve port
25 - 18 9823/1700-1 25 - 18
Item Description Figure 510.

valve
(T and A / B and P) (Steer mode valve ports
crab steer)
Machines with steer rams

L R
2-wheel steer selected F G
With the spool of the steer mode control valve in the
2-wheel steer position there is a hydraulic connection
between the steer unit and the front steer rams. Steer
mode control valve ports are internally connected.
The oil feed to the rear axle steer rams is blocked by
the spool assembly and the axle is held in the straight P
ahead position by the locked-up hydraulic oil in the B
rams. E
When the steering wheel is turned, only the front axle T

rams are operated by the steering unit. D
V
direction.
H J
Table 201.
Item Description
B Steer unit
valve port
valve port
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
valve port
R Right side
valve port
25 - 19 9823/1700-1 25 - 19
Item Description Figure 511.

valve
(T and P) (Steer mode valve ports
2 wheel steer)
With the spool of steer mode valve in the 4- F L R

wheel steer position there is a hydraulic connection G
between the steer unit and the front and rear axle
steer rams. Steer mode control valve ports are
internally connected. When the steering wheel is
turned to the right, oil is fed to the rear rams and
the displaced oil is fed to the front rams through the P
spool assembly. The front rams turn the wheels in the E
opposite direction to the rear wheels and displaced B T
oil returns to tank.
D
direction. V
H J
Table 202.
Item Description
B Steer unit
valve port
valve port
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
valve port
R Right side
valve port
25 - 20 9823/1700-1 25 - 20
Item Description Table 203.

V Steer mode control Item Description
valve B Steer unit
(T and B / A and P) (Steer mode valve ports D Steer mode control
connected internally for valve port
4 wheel steer)
Crab steer selected valve port
F Front steer ram
With the spool of steer mode valve in the crab steer G Front steer ram
position there is a hydraulic connection between the H Rear steer ram
steer unit and the front and rear axle steer rams.
Steer mode valve ports are internally connected. J Rear steer ram
When the steering wheel is turned to the right, oil is L Left side
fed to the rear rams through the spool assembly. The P Steer mode control
front rams turn the wheels in the same direction as valve port
the rear wheels, causing the machine to crab to the R Right side
right. Displaced oil returns to tank.
If the steering wheel is turned to the left, the oil flow valve port
is reversed and the machine will crab in the opposite V Steer mode control
direction. valve
(T and A / B and P) (Steer mode valve ports
Figure 512. connected internally for
crab steer)
Electrical operation and schematics-

Indicated system (if installed)
526-56 machines have front wheels straight ahead
indicator lights and rear wheels straight ahead
indicator lights. When both the lights are on the front
L R
F G and rear wheels are in the straight ahead position.
The wheels must be set to the straight ahead position

before you change the steer mode.
If the indicator lights do not work correctly re-phase

the road wheels before fault finding the electrical
P system.
B
E When the front and rear wheels are in the straight
T ahead position the axle proximity switches, connect
power to the indicator lights.
D
V
When the transmission is set to neutral the ECU
(Electronic Control Unit) energises relay. The relay
connects the forward and rear lights earth and the
lights come on.
H J
25 - 21 9823/1700-1 25 - 21
Figure 513.
B
REAR AXLE
PROXIMITY
SWITCH
A
FRONT AXLE
PROXIMITY
SWITCH
F R
E
WHEEL ALIGN
INDICATOR LIGHTS
WHEEL ALIGN
INDICATOR LIGHTS
RELAY
ECU
D
IGN
Item Description
G Fuse box
Table 204.
H Indicator light- rear
Item Description wheels straight ahead
A Front axle proximity (1) Refer to (PIL 33-45).
switch
B Rear axle proximity
switch
C Wheel align indicator
light relay
D Drive control ECU
(1)
E Indicator light unit

F Indicator light- front
wheels straight ahead
25 - 22 9823/1700-1 25 - 22
01 - Pump
01 - Pump
Contents Page No.
25-01-00 General ........................................................................................................................... 25-25
25 - 23 9823/1700-1 25 - 23
Notes:
25 - 24 9823/1700-1 25 - 24
01 - Pump
00 - General
00 - General
Introduction
Refer to gear pump, (PIL 30-11-00).
25 - 25 9823/1700-1 25 - 25
03 - Priority Valve
03 - Priority Valve
Contents Page No.
25-03-00 General ........................................................................................................................... 25-27
25 - 26 9823/1700-1 25 - 26
03 - Priority Valve
00 - General

Operation ....................................................... 25-29
Gear pump machines
Clean ............................................................. 25-31 The priority valve is mounted on the side of the gear
Remove and Install ....................................... 25-32 pump.
Figure 514.
LS P EF
EF
LS
EF Return line
P Pressure port
LS Load sense
Variable flow machines

The priority valve is an integral part of the control
valve block priority inlet section. Refer to (PIL 30-00).
Electro servo (Agri Xtra) machines

Figure 515.
A Control valve block priority inlet section
Electro servo (Agri excluding Extra)

machines
The priority valve is an integral part of the control
valve block priority inlet section. Refer to (PIL 30-00).
25 - 27 9823/1700-1 25 - 27
03 - Priority Valve
00 - General
Figure 516.
A Control valve block priority inlet section
25 - 28 9823/1700-1 25 - 28
03 - Priority Valve
00 - General
Operation
Neutral
The priority valve supplies hydraulic oil to the
steering circuit when it is necessary.
Figure 517. Gear pump type valve shown
LS P EF
LS
A
B
P EF
orifice 2, onto the end of the priority valve spool. This

creates a large pressure difference across the spool,
Table 205. causing it to move up against the force of the spring.
Item Description This allows the full pump flow to be directed through
port (EF) back to the tank or join with the main flow
A Pump outlet
to the control valve.
B Orifice 1
C Priority valve spool Turning
D Orifice 2
E Steering unit When the steering wheel is turned, a pressure signal
is generated in the load sense line from the steering
P Pressure line
unit.
LS Load sense line
EF Port Pressure is then applied to the spring end of
the priority valve spool. This reduces the pressure
When the steering is not being operated, flow to the difference across the spool, causing it to move down
steering circuit is dead ended by the closed centre under spring force. This allows some of the pump
steering unit, and no pressure signal (demand) is outlet flow to be directed through the pressure port
generated in the load sense line. Pressure from the to the steering unit, which in turn directs the flow to
pump outlet is directed through the orifice 1 and the corresponding steer rams to turn the wheels.
25 - 29 9823/1700-1 25 - 29
03 - Priority Valve
00 - General
Figure 518. Gear pump type valve shown
LS P EF
LS
A
B
P EF
Table 206.
Item Description
A Pump outlet
B Orifice 1
C Priority valve spool
D Orifice 2
E Steering unit
P Pressure line
LS Load sense line
EF Port
The excess flow goes through the port (EF) back to

the tank or joins with the main flow to the control.
When the steering reaches the required position,

the pressure signal in the load sense line from
the steering unit ceases and restore the pressure
difference across the spool. The spool moves back
up and allow the pump full flow to be directed through
port (EF) back to the tank or joins with the main flow
to the control valve.
The maximum steering system pressure is set by a

relief valve located inside the steering unit.
25 - 30 9823/1700-1 25 - 30
03 - Priority Valve
00 - General
Clean 10. Reconnect the hose to the LS port, and bleed the
LS line as described below.
The priority valve spool and spring may be removed 10.1. Start the engine.
for cleaning with the pump in the machine. 10.2. Loosen the connection on the valve, then
turn and hold the steering wheel fully in
1. Make the machine safe. Refer to (PIL 01-03). either direction.
2. Follow the general health and safety procedure. 10.3. When bubble free oil seeps from the joint,
Refer to (PIL 01-03). tighten the connection.
3. Discharge the hydraulic pressure. Refer to (PIL Table 207.
30-00).
Item Description
4. Turn the steering wheel to the left and to the right B 100 –105 N·m
several times to discharge system pressure.
C 75 –81 N·m
5. Disconnect the hose from the LS (Load Sense)
port. Blank off the hose to prevent loss of fluid.
6. Remove the adaptor and extract the priority valve
spring.
6.1. Remove the blanking plug and extract the
priority valve spool. Make sure that the bore
of the valve is not damaged.
7. Clean these components paying particular
attention to the orifices at each end of the spool.
Dry off and lubricate with clean hydraulic fluid.
Figure 519.
B D C
A Hose
B Adaptor
C Blanking plug
D Priority valve
8. Install the priority valve spool and make sure that
the spring seat end of the spool faces towards
the LS port.
9. Install the blanking plug and tighten it to the
25 - 31 9823/1700-1 25 - 31
03 - Priority Valve
00 - General

B C
Consumables
Special HP Grease 4003/2020 0.5 kg
4003/2017 0.4 kg
4003/2006 12.5 kg
4003/2005 50 kg
The priority valve assembly is not serviceable,

only the removal of foreign matter is possible. For
instructions on cleaning the valve refer to (PIL
25-03).
A faulty unit must be replaced with a new one.

D
Remove A

A Hose 1
2. Discharge the hydraulic pressure. Refer to (PIL B Hose 2
30-00). C Hose 3
D Socket head screws
several times to discharge system pressure. Install
4. Make sure that the steering wheel is in the
straight ahead position.
5. Put a label on the hoses to help installation. steps.
6. Disconnect the hose 1, hose 2 and hose 3 from 1.1. Apply grease and install new O-rings
the valve. between the mounting faces.
contamination. 1.2. Tighten the socket head screws evenly and
progressively to the correct torque value.
8. Remove the socket head screws (x3) and lift the
priority valve assembly away from the pump. 1.3. Before you drive the machine, make sure
you bleed the steering system. Refer to (PIL
9. Remove and discard all O-ring seals between the 25-00).
mounting faces of the priority valve assembly and 1.4. Check the hydraulic oil level and top up as
the pump. required. Refer to (PIL 30-00).

Item Description Value
D Socket head 30 ± 4 N·m
screw
25 - 32 9823/1700-1 25 - 32
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ........................................................................................................................... 25-35
25 - 33 9823/1700-1 25 - 33
Notes:
25 - 34 9823/1700-1 25 - 34
00 - General
Introduction .................................................... 25-35 The steer unit valve controls the amount of hydraulic
Component Identification ............................... 25-36 fluid flow in the steering system.
25 - 35 9823/1700-1 25 - 35
00 - General
Figure 521.
D E
C C
A
B
G D
G K J F
J
F E
Item Description
Table 209. H Steer valve
J Load sense port
Item Description
K Steering system relief
A Hydraulic steer unit valve
B Shock Valves (if in-
stalled)
C Check valve
D Left feed/ return port
E Right feed/ return port
F Valve inlet
G Return line
25 - 36 9823/1700-1 25 - 36
00 - General
Remove and Install
Remove Figure 522.

2. Follow the health and safety procedures. Refer
to (PIL 01-03).
straight ahead position. A
5. Gain access to the steer unit. Remove the front A Front cover
cover from the cab. Refer to (PIL 06-06-12).
7. Disconnect the hydraulic hoses 1 and hoses 2
from the steering unit. On 510-56, 512-56 and
514-56 machines the hydraulic hoses 1 have
specified end fitting angles
Angle: 90 °
Figure 523.
F
E
D E B
B Steer unit C Splined shaft

D Bolts E Hydraulic hoses 1
F Hydraulic hoses 2
8. Plug all the open ports and hoses to prevent Install

contamination.
9. Mark the orientation of the steer unit to the removal procedure. Additionally do the following
splined shaft. steps.
10. Remove the bolts from inside the cab. At the 1.1. Tighten the bolts to the correct torque value.
same time, get help from an assistant and
support the steer unit from under the machine. 1.2. Make sure that the hoses are installed in the
correct locations.
11. Remove the steer unit.
1.3. If the hydraulic adaptors are removed make
sure that they are tightened to the correct
torque value.
25 - 37 9823/1700-1 25 - 37
00 - General
Figure 524.
G Hydraulic adaptor 1 H Hydraulic adaptor 2
1.4. The steer unit is spring loaded to the neutral

position. Make sure the steering wheel is
in the straight ahead position when you
connect the splined shaft.
1.5. Before you drive the machine, bleed the
system. Refer to (PIL 25-00).
1.6. If a new steer unit is installed then the
system relief valve must be tested for
correct pressure setting.
1.7. Check the hydraulic oil level and top up as

Item Description Nm
D Bolts 45
G Hydraulic adaptor 1 22
H Hydraulic adaptor 2 77
25 - 38 9823/1700-1 25 - 38
00 - General
Disassemble 2.3. Teflon seal.

2.4. O-ring 1.
1. Use the alphabetical sequence as a guide to
disassembly. Refer to Figure 525. 2.5. Back-up ring.
2. Before you remove the following items, rotate 2.6. Bearing race components.
the spool and sleeve assembly inside the valve
housing until the pin becomes horizontal. 3. Push the spool and sleeve assembly from the
valve housing just far enough to free the gland
2.1. Gland bushing. bushing.
2.2. Dust seal.
25 - 39 9823/1700-1 25 - 39
00 - General
Figure 525.
K
G
M
H
L
F
N
P
Q
C
R
U
T E
W
D
V
X
B
Y
J A
AC AB
AA
AC
S
A Capscrew B End cap

C Meter D Seal 2
E Drive spacer F Drive
G Spacer plate H Seal 1
J Meter end seal K Retaining ring
L Gland bushing M Dust seal
N Teflon seal P O-ring 1
Q Back-up ring R Bearing race component
S Spool T Seal 3
U Setscrew V Check valve seat
W O-ring 2 X O-ring 3
Y Check ball Z Lower check ball retainer
AA Pin AB Spring assembly
25 - 40 9823/1700-1 25 - 40
00 - General
AC Sleeve
25 - 41 9823/1700-1 25 - 41
00 - General
Assemble 3. Assemble the spool and sleeve as follows: Refer

to Figure 527.
1. Check the condition of all the components of the
steering valve. Refer to (PIL 25-06). 3.1. Slide the spool into the sleeve.
2. Assemble the check valve as follows: Refer to Figure 527.

Figure 526.
2.1. Put the lower check ball retainer into the AK
valve housing.
Figure 526.
U S
AC
W S Spool
V AC Sleeve
AK Spring slot
X
3.2. Rotate the spool to make sure it rotates
Y freely.
AE
3.3. Make sure that the spring slots in the spool
Z and the sleeve fully aligns.
4. Install the spring assembly on the sleeve and
spool as follows: Refer to Figure 528.
4.1. Insert the spring installation tool through the
aligned slots in the sleeve and spool.
Figure 528.
AJ
U Setscrew
AH
V Check valve seat
W O-ring 2 AF AF
X O-ring 3 AG AH
Y Check ball AJ
Z Lower check ball retainer
AE Valve housing
S
2.2. Make sure that the lower check ball retainer
is straight in the valve hole and not on its
edge.
2.3. Install the check ball into the valve housing.
AA
2.4. Lubricate the O-ring 2 and O-ring 3 and
AC
install them on the check valve seat.
2.5. Keep the check valve seat on the valve S Spool
housing open end and then push the seat AA Pin
fully into the valve housing. AC Sleeve
AF Low torque spring
2.6. Make sure that you do not twist or damage AG Spring installation tool
the O-ring 2 and O-ring 3. AH Spring spacer
2.7. Install the setscrew. Make sure that the top AJ Centering spring
of the setscrew is slightly below the valve
housing top surface. 4.2. Assemble a set of low torque springs,
extend edge downward, with a pair of spring
2.8. Tighten the setscrew to the correct torque spacers between two sets of centering
valve. springs.
25 - 42 9823/1700-1 25 - 42
00 - General
4.3. Insert one end of the assembled spring set 6.3. Install the seal 3 and bearing race
into the spring installation tool. components into the valve housing. Refer
to Figure 525.
4.4. Press the protruding end of the spring set
together and push it into the slot, at the 6.4. Install the Teflon seal, O-ring 1 and back-up
same time pull out the spring installation ring above the bearing race components.
tool. Refer to Figure 530.
4.5. Move the spring set to the centre of the Figure 530.
spool and sleeve assembly. Make sure
that the spring set pushes down evenly
and is flush with the upper surface of the
assembly.
4.6. Install the pin into the spool through the Q
sleeve. Make sure that the pin is flush with P
N
both sides of the sleeve.
5. Install the spool and sleeve assembly into the T
R
valve housing as follows: Refer to Figure 529.
5.1. Keep the spool and sleeve assembly in
position so that the splined end of the spool
enters the valve housing.
Figure 529.
S
AE AC
N Teflon tape
P O-ring 1
AD Q Back-up ring
R Bearing race components
AE T Seal 3
6.5. Install the dust seal, flat smooth side down,
into the gland bushing. Refer to Figure 531.
S Spool 6.6. Install the gland bushing and dust seal on

AC Sleeve the splined end of the spool. Refer to Figure
AD Insertion end face 531.
AE Valve housing
5.2. Push the assembly slowly into place with a
slight rotating action until the parts are flush
at the insertion end face.
5.3. Apply finger tip force to the spool splined
end to check the spool and sleeve assembly
for free rotation inside the housing.
5.4. Do not move the spool and sleeve assembly
beyond the flush position. If you do this,
the pin can drop into the housing discharge
groove. Refer to Figure 525.
6. Install the drive end seals as follows:
6.1. Keep the valve housing upright on the clean
lint free cloth.
6.2. Lubricate the seals.
25 - 43 9823/1700-1 25 - 43
00 - General

AM
K F
AC H
M
L
G
J
K AE
S AE
L AL
K Retaining ring
L Gland bushing
M Dust seal
S Spool F Drive
AC Sleeve G Spacer plate
AE Valve housing H Seal 1
J Meter end seal
6.7. Make sure that the gland bushing is flat AE Valve housing
against the bearing race. If necessary, tap AL Face line
the bushing with a soft faced hammer. AM Reference line 2
6.8. Install the retaining ring around the sleeve.
7.2. Install the spacer plate with seal1 on the
If necessary, press the retaining ring in
valve housing. Make sure that the bolt holes
position with a screwdriver blade. Refer to
in the valve housing are aligned with the
Figure 531.
holes in the spacer plate.
7. Install the meter end seal and the drive as 7.3. Rotate the spool and sleeve together until
follows: Refer to Figure 532. the pin becomes parallel to the face line of
the valve housing.
7.1. Insert the meter end seal into the valve
housing. 7.4. Install the drive on the pin. Make sure that
the drive is fully engaged with the pin. Refer
to Figure 525.
7.5. Mark the drive head to show the reference
line 2. Refer to Figure 532.
8. Install the meter as follows: Refer to Figure 533.
8.1. Install the seal 2 into the groove on the
meter.
25 - 44 9823/1700-1 25 - 44
00 - General

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

D Seal 2
F Drive Table 211. Torque Values
AE Valve housing
AL Face line Item Description Nm
AM Reference line 2 A Capscrew 31
AN Reference line 1 U Setscrew 11
8.2. Keep the meter in position so that the seal is
away from the valve housing and align the
meter valleys as shown at the reference line
1. Refer to Figure 533.
8.3. Make sure that the reference line 1,
reference line 2 and face line are parallel.
8.4. Install the meter on the drivehead. Align the
bolt holes and make sure that the drive does
not disengage.
9. Install the end cap as follows:
9.1. Install the drive spacer as necessary. Refer
to Figure 525.
9.2. Keep the end cap on the meter and align
the bolt holes.
9.3. Install the capscrews and pre-tighten to the
Torque: 17 N·m
9.4. Tighten the capscrews to the final torque
value in the given sequence viewed from
the face as shown. Refer to Figure 534.
25 - 45 9823/1700-1 25 - 45
09 - Mode Valve
09 - Mode Valve
Contents Page No.
25-09-03 Manual Mode Valve ....................................................................................................... 25-47
25 - 46 9823/1700-1 25 - 46
09 - Mode Valve
03 - Manual Mode Valve
03 - Manual Mode Valve Remove and Install

Remove
30-00).
several times to discharge the system pressure
fully.
straight ahead position.
8. Disconnect the hydraulic hoses from the steer
mode valve.
contamination.
10. Remove the nuts and bolts that secure the steer
mode valve to the chassis.
11. Remove the steer mode selector control handle
located inside the cab.
12. Before you remove the steer mode valve
assembly from the machine, observe the routing
of the operating cable.
13. Remove the nuts securing the steer mode
selector unit to the cab.
14. The steer mode selector unit, operating cable
and valve can now be removed from the machine
as a complete assembly.
15. Make sure to collect the two washers to the rear
of the valve block which may fall out when screws
are removed.
16. Retain the spacer plate.
25 - 47 9823/1700-1 25 - 47
09 - Mode Valve
Figure 535.
A C
A B
A
A Hoses B Bolts
C Steer mode valve
25 - 48 9823/1700-1 25 - 48
09 - Mode Valve
Figure 536.
D Steer mode selector control handle
25 - 49 9823/1700-1 25 - 49
09 - Mode Valve
Figure 537.
E E
E Nuts F Steer mode selector unit
Figure 538.
G A B
H C
A Spacer plates B Bolts

C Steer mode valve G Chassis side plate
H Washer
25 - 50 9823/1700-1 25 - 50
09 - Mode Valve
Install
steps.
1.1. Make sure that the hoses are installed in the
correct position.
1.2. Bleed the steering system. Refer to (PIL
25-00).
1.3. Install the two washers between the valve
block, spacer and the chassis side plate.
25 - 51 9823/1700-1 25 - 51
09 - Mode Valve
Consumables travel away from the valve) until they disengage

Description Part No. Size the operating cable thread.
JCB Threadlocker 4101/0250 0.01 L 4. Remove the locknut 2 and disconnect the
and Sealer (Medium 4101/0251 0.05 L operating cable from valve adaptor.
Strength)
5. Remove the screws 2 from the end cap 2.
Disassemble
6. Remove the locknut 3. Rotate the locknut 3 and
1. Remove the steer mode valve assembly from the the end cap 2 counterclockwise (so that the parts
machine. Refer to (PIL 25-09). travel away from the valve) until they disengage
the operating cable thread.
2. Remove the screws 1 from the end cap 1.
7. Disengage the operating cable from the steer
3. Remove the locknut 1. Rotate the locknut 1 and mode selector.
the end cap 1 counterclockwise (so that the parts
Figure 539.
H K
E
A
C D
A Screws 1 B End cap 1

C Locknut 1 D Locknut2
E Operating cable F Adaptor
G Screws 2 H End cap 2
J Locknut 3 K Steer mode selector
25 - 52 9823/1700-1 25 - 52
09 - Mode Valve
Assemble
the disassembly procedure. Additionally do the
following steps.
Figure 540.
F
D
10 mm
D Locknut 2 F Adaptor
1.1. Before you connect the operating cable to

the valve, set the locknut 2 as shown in the
figure. Refer to Figure 540. In this position,
the locknut can be used as a guide as to
how far to wind the operating cable into the
valve adaptor.
2. Apply the specified sealant to the screws 1 and
the screws 2.
(Medium Strength)
25 - 53 9823/1700-1 25 - 53
12 - Column
12 - Column
Contents Page No.
25-12-00 General ........................................................................................................................... 25-55
25 - 54 9823/1700-1 25 - 54
12 - Column
00 - General
00 - General Figure 541.

X Y
Remove and Install
There are two types of steering column. Type X is

tilt adjustable and type Y is tilt and height adjustable.
The removal and installation procedures are the
same for both types.
Remove
3. Remove the steering wheel and steering column
surround. Refer to (PIL 09-36).
4. Remove the column switches. Refer to (PIL
33-27). H H
5. The electrical connector 1 and electrical
connector 2 are the same. Record the position of D E
the connectors.
6. Disconnect the electrical connector 1 and the
electrical connector 2.
7. Align the marks on the steering shaft and the C
steering column.
8. Remove the clips and the pins.
9. Hold the steering column assembly and remove
the lever lock (if installed).
10. Lift the column assembly away from the cab. A B
A Electrical connector 1
B Electrical connector 2
C Lever lock
D Steering shaft
E Steering column
F Clips
G Pins
H Steering shaft splines
25 - 55 9823/1700-1 25 - 55
12 - Column
00 - General
Install
steps.
1.1. Align the marks on the steering shaft and
the steering column put during removal.
1.2. Engage the steering shaft splines with the
steer valve internal spline.
1.3. Put the electrical connector 1 and the
electrical connector 2 in the correct
positions.
25 - 56 9823/1700-1 25 - 56
15 - Proximity Switch
Contents Page No.
25-15-00 General ........................................................................................................................... 25-59
25 - 57 9823/1700-1 25 - 57
Notes:
25 - 58 9823/1700-1 25 - 58
00 - General
Introduction .................................................... 25-59 These are installed on machines with auto steer
Adjust ............................................................ 25-60 mode system or manual (indicated) mode system.
25 - 59 9823/1700-1 25 - 59
00 - General
Adjust Figure 543.
A
If the proximity switch is defective, replace it. Refer
to steering system- proximity switch, refer to (PIL
25-15).
For electrical operation and testing, refer to electrical

system- electronic diagnostic, refer to (PIL 33-57).
B
The proximity switch setting procedure is the same
for both the front and rear axles. Y
1. Align the wheels in the straight ahead position.

D
2. Check the alignment as shown in the figure. Set
the steering so that the dimension X is of the
specified value. D C
Figure 542.
A Target disc
B Proximity switch
X C Bracket
D Bolts
Y Distance between the sensor tip and the end of
the target disc
5. If the dimension is not correct, adjust the switch
as follows:
5.1. Loosen the bolts.
5.2. Move the bracket up or down to make
dimension Y correct.
5.3. Tighten the bolts.
5.4. Repeat the step 4 again.
X Wheel alignment dimension

3. Remove the proximity switch cover.
4. Measure the dimension Y between the sensor tip
and the edge of the target disc and make sure
that it is to the specified value.
25 - 60 9823/1700-1 25 - 60
00 - General
Remove and Install
Working Under the Machine 2. Disconnect the harness electrical connector from
the switch electrical connector.
Make sure that any attachments on the machine are 3. Remove the proximity switch cover.
the ignition key, disconnect the battery. If the machine 4. Remove the bolt and nut that secure the
has wheels use blocks to prevent unintentional proximity switch to the support bracket.
movement.
5. Remove the proximity switch from the support
The following procedure applies to each of the steer bracket.
proximity switches on the front and rear axles.
Remove
1. Make the machine safe. Follow all the general
safety procedures. Refer to (PIL 01-03).
Figure 544.
C B
A Proximity switch B Nut

C Support bracket D Proximity switch electrical connector
25 - 61 9823/1700-1 25 - 61
00 - General
Install
Installation is the opposite of the removal procedure.
During the installation procedure do this below step
also.
1. Make sure to set the proximity switch air gap.
25 - 62 9823/1700-1 25 - 62
18 - Front Track Rod
Contents Page No.
25-18-00 General ........................................................................................................................... 25-65
25 - 63 9823/1700-1 25 - 63
Notes:
25 - 64 9823/1700-1 25 - 64
00 - General
00 - General Check (Condition)

Check (Condition) .......................................... 25-65
Check Energiser Seals
Disassemble and Assemble .......................... 25-70 If there is difficulty in steering the machine and
routine fault finding indicates power track rod
leakage, it is possible that the rectangular section
piston head seal on the power track rod piston head
is installed incorrectly i.e. twisted.
Check the front and rear power track rods as follows:
1. Disassemble the ram. Refer to Steering System-

Track Rod. Refer to (PIL 25-18).
2. Remove the piston seal and check to see if
the energiser seal has been installed twisted or
rolled.
3. Inspect the cylinder bore and piston rod for
scoring, nicks and burrs.
Figure 545.
A
B
A Piston seal
B Energiser seal
4. Assemble the ram with new seals. Make sure that
the energiser seal is not twisted or rolled. Check
the white installation marks.
Figure 546.
B
B Energiser seal
5. To prevent damage to the seals, clamp the
cylinder in a vertical position and lower the piston
rod assembly into the cylinder during installation.
25 - 65 9823/1700-1 25 - 65
00 - General
6. Install new wiper seals (not shown).

7. Install the power track rod assembly again.
8. Check the tracking. Refer to Driveline - Front
Wheel. Refer to (PIL 27-29).
9. Check for correct operation and steer phasing.
10. Check the hydraulic oil level and top up as
Figure 547.
25 - 66 9823/1700-1 25 - 66
00 - General
Remove and Install
Remove 10.5. Remove the adaptor 2.

10.6. Plug all the open ports and hoses to
2. Follow the general health and safety procedures
11. At this point, if the power track rod is to be
for the hydraulic system. Refer to (PIL 30-00).
dismantled, loosen the track rod link arms while
3. Discharge the hydraulic pressure. Refer to (PIL the track rod is still securely clamped. Refer to
30-00). steering system, Arm. Refer to (PIL 25-33).
4. Turn the steering wheel to the left and to the right 12. Remove the screw and the pin at each end
several times to discharge the system pressure. of the axle and separate the link arms from
Make sure that the steering wheel is in the their mounting points. Discard the two web seals
straight ahead position. seated in the eye of each link arm.
5. Before you start work, clean the area around the 13. Make alignment marks on the cylinder flange,
axle and the power track rod. the end cover of the power track rod and on the
housing flange of the axle.
6. Raise the front or the rear wheels from the
ground with suitable lifting equipment. 14. Remove the mounting screws 2 (x4).
7. Block the chassis. 15. If you work on the front axle, do the following
steps:
8. Remove the front left or the rear right wheel as
applicable. 15.1. Use suitable jacks to support both ends
of the axle and then remove the mounting
9. If you work on the front axle, do the following nuts from both ends. Leave the bolts in
steps: position.
9.1. Put a label on the hoses to help installation. 15.2. Lower the jack at the left end so that there
is sufficient room for removal of the power
9.2. Disconnect hose 1 and hose 2 and then track rod.
remove the adaptor 1.
15.3. Use a soft-faced hammer to gently tap the
9.3. Plug all the open ports and hoses to prevent closed end of the track rod cylinder to the
contamination. left and out of its mounting.
10. If you work on the rear axle, do the following 16. If you work on the rear axle, do the following
steps: steps:
10.1. Put a label on the hoses to help 16.1. Use a suitable jack to raise the left end of
installation. the axle so as to swivel the right end down
10.2. Disconnect the pipe assembly from the to make room for removal of the power
power track rod at the end point 1 and the track rod.
end point 2. 16.2. Use a soft-faced hammer to gently tap the
10.3. Remove the mounting screw 1. closed end of the track rod cylinder to the
right and out of its mounting.
10.4. Remove the pipe assembly.
25 - 67 9823/1700-1 25 - 67
00 - General
Figure 548.
B
A
P
L
K N
F
E
H
D
M
A Hose 1 B Hose 2
C Adaptor 1 D Pipe assembly
E End point 1 F End point 2
G Mounting screw 1 H Adaptor 2
J Screw K Pin
L Link arm M Mounting screw 2
N Nuts P Bolt
25 - 68 9823/1700-1 25 - 68
00 - General
Install
steps.
1.1. Apply grease and install the two new web
seals in each link arm eye. Make sure that
they are installed correctly and fully seated.
1.2. Apply grease to the machined external
shoulders of the power track rod. Install by
tapping with a soft-faced hammer on the
mounting flange.
1.3. Take care to align the marks made during
removal.
1.4. Check the steer proximity switch setting.
steering system. Refer to (PIL 25-00).

Item Description Nm
G Mounting screw 56
H Adaptor 2 56
J Screw 56
M Mounting screw 166
N Mounting nut 600
P Bolts 600
25 - 69 9823/1700-1 25 - 69
00 - General
Consumables 3. Remove the end cap and then pull the piston rod
Description Part No. Size assembly from the cylinder.
Cleaner/Degreaser 4104/1557 0.4 L 4. Do not allow the piston rod to come into contact
- General purpose with the cylinder bore. The cylinder bore may be
solvent based parts damaged by careless dismantling.
cleaner
JCB Multi-Gasket 4102/1212 0.05 L 5. Position the piston rod assembly on the bench in
place of the ram cylinder.
Use the alphabetical sequence shown on the
illustration as a guide to disassembly. Refer to Figure 6. Remove and discard the wear rings and the seal/
549. energising ring.
7. The piston head cannot be removed from the
Disassemble rod, if there is damage to the rod or piston head,
replace the complete assembly.
1. Fix the ram assembly on a locally manufactured
strip/ rebuild bench. 8. Carefully inspect the bore of the cylinder and the
piston rod outer diameter for scoring, nicks and
2. Remove the steering link arm 1 and the steering burrs. If damaged, install a new component.
link arm 2. Refer to steering system- track rod,
25 - 70 9823/1700-1 25 - 70
00 - General
Figure 549.
AA
K C
E
G
J H L
A
D
F J
CC
B
BB
K
A Screw B End cap

C Cylinder D Piston head
E Wear ring 1 F Wear ring 2
G Seal H Energising seal
J Piston rod seals K Wiper rings
L Cover seal AA Steering link arm 1
BB Steering ring arm 2 CC Piston sleeve
25 - 71 9823/1700-1 25 - 71
00 - General

F G E
H
E Wear ring 1
F Wear ring 2
G Seal
Figure 551. H Energising seal
8. Apply grease to the piston seal and to the
surfaces of the piston rod.
9. Install the piston rod assembly.
10. Clamp the cylinder vertically.
11. Lower the piston rod assembly from the top.
Make sure its orientation is correct so that the
piston sleeve is nearest to the closed end of the
cylinder. Refer to Figure 551.
12. Make sure that the piston rod does not touch the
cylinder bore.
13. Engage the new piston head wear rings and
Assemble seals carefully into the cylinder.
1. Make sure all threads are free of grease, 14. If the piston head wear rings or the seals
hydraulic oil and sealant with the degreaser. are damaged during this stage, they must be
replaced.
purpose solvent based parts cleaner 15. When operating in conditions which are
consistently below freezing, it is recommended
2. Allow the degreaser to dry for 15 minutes and that the track rod is operated slowly to its full
then apply the sealant. extent in both directions before you start normal
Consumable: JCB Multi-Gasket working.
3. Make sure that the lubricants used during 16. Check the energiser seals. Refer to Front Track
assembly do not come into contact with the JCB Rod - Check Condition (PIL 25-18).
multi-gasket.
4. Install the piston rod seals and the wiper rings
correctly into the closed end of cylinder and into
the cover along with the cover seal.
5. Make sure that the energiser ring is not twisted.
6. If the installation is not correct, it may lead to
leakage of the hydraulic fluid between the two
sides of the power track rod and will cause
steering problems.
7. Make sure that three white marks are visible on
the outside diameter arrowed before install the
seal.Refer to Figure 552.
25 - 72 9823/1700-1 25 - 72
33 - Link Arm
33 - Link Arm
Contents Page No.
25-33-00 General ........................................................................................................................... 25-75
25 - 73 9823/1700-1 25 - 73
Notes:
25 - 74 9823/1700-1 25 - 74
33 - Link Arm
00 - General
00 - General
Remove and Install

Strength)
Remove
If you have to dismantle the power track rod or
replace the link arms, do the following steps:
Remove
1. Fix the assembly on a locally made strip/rebuild 2. Use suitable open ended spanners (x2) at point
bench. Refer to Figure 553. 1 and point 2 and turn against each other until
one ball joint unscrews as shown. Refer to Figure
554.
3. For this explanation, assume the ball joint at point
1 is now loose, do as follows:
25 - 75 9823/1700-1 25 - 75
33 - Link Arm
00 - General
Figure 554.
A
B
A Point 1 B Point 2
25 - 76 9823/1700-1 25 - 76
33 - Link Arm
00 - General
C Point 3 D Point 4
3.1. Unscrew the ball joint until you can install Install
an open ended spanner on the rod at point
3. Turn the ball joint towards the spanner to If the you have to dismantle the power track rod
secure it and to prevent damage to the rod. ram, carry out the procedure before you remove and
install the link arms. Refer to (PIL 30-15).
3.2. The piston rod operates at full length. Any
damage to the surface will cause fluid leaks. 1. The installation procedure is the opposite of the
Make sure you do not damage it or attempt removal procedure.
to grip the rod diameter with pipe grips etc.
3.3. Hold the spanner at point 3 and remove the 2. When you install, also do the following steps:
ball joint at point 4 by moving it against the 2.1. Install the target disc (where applicable).
spanner at point 3.
2.2. Apply threadlocker and sealer on the first
4. Remove the target disc where applicable. three threads of the inner ball joint where it
screws into the end of the track rod.
5. If you replace the inner or outer ball joints, make
sure you install a replacement link arm assembly. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
Figure 555.
2.3. If the link arms have been renewed, make
sure you check the wheel alignment.
2.4. Bring the wheels to straight ahead position.
J 2.5. Measure the distance 1 and distance 2

between the outer edges of the wheel hub
as shown.
2.6. Make sure that the difference between the
distance 1 and the distance 2 is of the
specified value for correct alignment.
E F G H 2.7. To adjust the wheel alignment, remove
the lock nuts. Turn the threaded adjusters
equally to get the correct alignment. Tighten
E Lock nut the lock nuts.
F Threaded adjuster 2.8. Check the target disc and proximity switch
G Spanner flat on ball joint setting (where applicable). Refer to steering
H Spanner flat on the rod system- track rod, refer to (PIL 25-18).
J Target disc
25 - 77 9823/1700-1 25 - 77
33 - Link Arm
00 - General
Figure 556.
X Distance 1 Y Distance 2

Item Description Nm
G Ball joint 250
G Rod 250
E Lock nut 250
F Adjuster 250
25 - 78 9823/1700-1 25 - 78
27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-06 Semi-Automatic Gearbox
27-06-00 General ............................................................................................................................. 27-7
27-06-06 Clutch - Reverse ............................................................................................................ 27-64
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-68
27-06-08 Clutch - Layshaft ............................................................................................................ 27-96
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-105
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-114
27-06-11 Clutch - Forward (Input) ............................................................................................... 27-121
27-06-12 Clutch - Ratio ............................................................................................................... 27-130
27-06-13 Clutch - Master ............................................................................................................ 27-134
27-06-14 Clutch - 5 Speed .......................................................................................................... 27-152
27-06-15 Solenoid Control Valve ................................................................................................. 27-157
27-06-18 Pressure Relief Valve ................................................................................................... 27-166
27-06-21 Pressure Maintenance Valve (PMV) ............................................................................ 27-167
27-06-24 Oil Pump ...................................................................................................................... 27-169
27-06-27 Speed Sensor .............................................................................................................. 27-171
27-06-30 Oil Pressure Sensor ..................................................................................................... 27-178
27-06-39 Filter ............................................................................................................................. 27-181
27-06-40 Suction Strainer ............................................................................................................ 27-183
27-06-45 Piston Ring Seal .......................................................................................................... 27-185
27-06-47 Oil Seal ........................................................................................................................ 27-187
27-06-52 Driveshaft ..................................................................................................................... 27-189
27-06-54 Main Shaft .................................................................................................................... 27-190
27-06-56 Layshaft ........................................................................................................................ 27-193
27-06-57 Input Shaft .................................................................................................................... 27-194
27-06-58 Output Shaft ................................................................................................................. 27-195
27-06-60 Idler Shaft ..................................................................................................................... 27-206
27-06-70 4WD Unit ...................................................................................................................... 27-207
27-06-81 Mount ........................................................................................................................... 27-212
27-06-85 Oil Feed Pipe ............................................................................................................... 27-213
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-214
27-06-90 Front Case ................................................................................................................... 27-215
27-06-91 Rear Case .................................................................................................................... 27-225
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-227
27-12 Transfer Gearbox
27-12-00 General ......................................................................................................................... 27-231
27-14 Torque Converter
27-14-00 General ......................................................................................................................... 27-257
27-14-06 Control Valve ................................................................................................................ 27-266
9823/1700-1
2018-06-29
27-14-09 Relief Valve .................................................................................................................. 27-268
27-20 Axle(s)
27-20-00 General ......................................................................................................................... 27-271
27-20-15 Breather ........................................................................................................................ 27-290
27-20-81 Mount ........................................................................................................................... 27-291
27-22 Drivehead
27-22-00 General ......................................................................................................................... 27-293
27-22-06 Crownwheel .................................................................................................................. 27-313
27-22-09 Pinion Gear .................................................................................................................. 27-315
27-24 Differential
27-24-00 General ......................................................................................................................... 27-319
27-27 Hub
27-27-00 General ......................................................................................................................... 27-341
27-27-60 Swivel ........................................................................................................................... 27-353
27-27-66 Wheel Stud ................................................................................................................... 27-354
27-29 Wheel
27-29-00 General ......................................................................................................................... 27-357
27-29-15 Wheel Nuts ................................................................................................................... 27-361
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-363
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-367
27-51 Driveshaft
27-51-00 General ......................................................................................................................... 27-373
27-51-15 Shaft Hub Side ............................................................................................................. 27-376
9823/1700-1
2018-06-29
Acronyms Glossary
2WD Two Wheel Drive

4WD Four Wheel Drive
LSD Limited Slip Differential
LSRV Load Sense Relief Valve
PMV Pressure Maintenance Valve
PTFE Polytetrafluoroethylene
PTO Power Take-Off
RAS Rear Axle Stabilization
9823/1700-1
2018-06-29
Notes:
9823/1700-1
2018-06-29
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9823/1700-1 27 - 1
Notes:
27 - 2 9823/1700-1 27 - 2
27 - Driveline
00 - Driveline
00 - General

Health and Safety ........................................... 27-3 Working Under the Machine
Technical Data ................................................. 27-4 Make the machine safe before getting beneath it.
Operation ......................................................... 27-5 Make sure that any attachments on the machine are
movement.
WARNING! A raised and badly supported machine
can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on the
machine hydraulics or jacks to support the machine
when working under it. Disconnect the battery, to
prevent the machine being started while you are
beneath it.
WARNING! Before disconnecting any propshaft,
make sure you block both sides of all wheels to
prevent machine movement. The park brake will
become ineffective or may only operate on 2 wheels
(depending on machine specification).
WARNING! If a 4 wheel drive machine is to be
raised and the engine/transmission run, make sure
all four wheels are raised off the ground. Make sure
the machine is correctly supported by the correct
axle stands. If only one pair of wheels is raised, the
machine could move and fall off the stands.
WARNING! Under no circumstances must the
engine be run with the transmission in gear and only
one driving wheel jacked clear of the ground, since
the wheel on the ground will move the machine.
27 - 3 9823/1700-1 27 - 3
27 - Driveline
00 - Driveline
00 - General
Technical Data
Table 214.
Component 506-36 507-42, 509-42, 510-42, 510-56,
512-56, 514-56, 516-42
Transmission PS750 PS750
Front Axle SD 70 Pivot Mount, 3 Piece SD 80 Pivot Mount, 3 Piece
Rear Axle SD 55 Pivot mount 1 piece SD 80 Pivot mount 3 piece
Front drive head 80 Series 3 piece 80 Series 3 piece
Front differential Maxtrac Maxtrac
Rear drive head SD 55 Series 1 piece SD 80 Series 3 piece
Rear differential Maxtrac Maxtrac
Front hub 55 Series 80 Series
Front swivels and drive shafts 55 Series 55 Series
Front axle brakes 70 Series integral brakes 70 Series integral brakes centre
mounted
Rear swivels and drive shafts 55 Series 1 piece 55 Series
Rear axle brakes . 70 Series integral brakes centre
mounted
27 - 4 9823/1700-1 27 - 4
27 - Driveline
00 - Driveline
00 - General
Operation
The transversely mounted engine drives a The bevel gearbox and the gearbox share the same
permanently engaged 90 ° bevel gearbox. A torque lubricating oil. The transmission has dedicated oil
converter is mounted on the output end of the bevel filtering and cooling systems.
gearbox. The output from the torque converter drives
an electro hydraulically controlled gearbox. Drive Drive is taken from the bevel gearbox to the main
from the gearbox is transmitted to the steer drive hydraulic pump via a short splined tube.
front axle and to the steer drive rear axle via the
propshafts. The engine has a vibration damper bolted to the
flywheel.
Figure 557.
A Engine B Bevel gearbox

C Output end of the bevel gearbox D Electro hydraulically controlled gearbox
E Steer drive front axle F Steer drive rear axle
G Propshafts J Hydraulic pump
K Flywheel
27 - 5 9823/1700-1 27 - 5
27 - Driveline
06 - Semi-Automatic Gearbox
Contents Page No.
27-06-00 General ............................................................................................................................. 27-7

27-06-06 Clutch - Reverse ............................................................................................................ 27-64
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-68
27-06-08 Clutch - Layshaft ............................................................................................................ 27-96
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-105
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-114
27-06-11 Clutch - Forward (Input) ............................................................................................... 27-121
27-06-12 Clutch - Ratio ............................................................................................................... 27-130
27-06-13 Clutch - Master ............................................................................................................ 27-134
27-06-14 Clutch - 5 Speed .......................................................................................................... 27-152
27-06-15 Solenoid Control Valve ................................................................................................. 27-157
27-06-18 Pressure Relief Valve ................................................................................................... 27-166
27-06-21 Pressure Maintenance Valve (PMV) ............................................................................ 27-167
27-06-24 Oil Pump ...................................................................................................................... 27-169
27-06-27 Speed Sensor .............................................................................................................. 27-171
27-06-30 Oil Pressure Sensor ..................................................................................................... 27-178
27-06-39 Filter ............................................................................................................................. 27-181
27-06-45 Piston Ring Seal .......................................................................................................... 27-185
27-06-47 Oil Seal ........................................................................................................................ 27-187
27-06-52 Driveshaft ..................................................................................................................... 27-189
27-06-54 Main Shaft .................................................................................................................... 27-190
27-06-56 Layshaft ........................................................................................................................ 27-193
27-06-57 Input Shaft .................................................................................................................... 27-194
27-06-58 Output Shaft ................................................................................................................. 27-195
27-06-60 Idler Shaft ..................................................................................................................... 27-206
27-06-70 4WD Unit ...................................................................................................................... 27-207
27-06-81 Mount ........................................................................................................................... 27-212
27-06-85 Oil Feed Pipe ............................................................................................................... 27-213
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-214
27-06-90 Front Case ................................................................................................................... 27-215
27-06-91 Rear Case .................................................................................................................... 27-225
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-227
27 - 6 9823/1700-1 27 - 6
27 - Driveline
00 - General
Introduction ...................................................... 27-7 Semi-automatic gearboxes are a form of
Technical Data ................................................. 27-8 transmission where an integrated control system
Component Identification ................................. 27-9 handles manipulation of the gear clutches
Operation ....................................................... 27-19 automatically, but the driver can still take manual
control of gear selection.
Diagram ......................................................... 27-27
Fault-Finding .................................................. 27-36 Many of these transmissions allow the driver to fully
Drain and Fill ................................................. 27-43 delegate gear shifting choice to the control system,
Clean ............................................................. 27-44 which then effectively acts as if it is an automatic
transmission. An automatic transmission uses a
Check (Condition) .......................................... 27-44 torque converter instead of a straight friction clutch
Check (Level) ................................................ 27-45 to manage the connection between the transmission
Check (Pressure) .......................................... 27-46 gearing and the engine.
A typical JCB semi-automatic transmission is called
Disassemble and Assemble .......................... 27-62 Powershift, it has an (A) on the gearshift to signify
Automatic. In this mode the machine will gear change
automatically according to road speed. The following
types exist:
• PS750
• PS764
• PS766
Not all types of transmission are available on all

types of machine. Check the operators manual or
transmission dataplate for the type of transmission
installed on your machine.
Table 215. Transmissions

Machine Transmission Option Transmission Option Transmission Option
526-56 PS750 - -
536-60 PS750 PS764 PS766
536-70 PS750 PS764 PS766
531-70 PS750 PS764 PS766
541-70 PS750 PS764 PS766
535-95 PS750 PS764 PS766
550-80 - PS764 -
560-80 - PS764 -
533-105 PS750 - -
535-v125 PS750 - -
540-v140 PS750 - -
540-140 PS750 PS764 -
540-170 PS750 PS764 -
540-v180 PS750 - -
540-200 PS750 PS764 -
550-140 PS750 PS764 -
550-170 PS750 PS764 -
27 - 7 9823/1700-1 27 - 7
27 - Driveline
00 - General
Technical Data
(For: PS750 MK4)

Table 216. PS 750 4- Speed 2/4 Wheel Drive
Designation PS 750 MkIV Powershift
Description Full electro-hydraulic transmission unit with input, reverse, layshaft and main-
shaft drive clutch packs giving 4 forward and 4 reverse speeds. Electrically (re-
lay) controlled gear selection. Permanent 4 wheel drive or selectable 2/4 wheel
drive variants.
Weight (dry) 2/4 wheel drive 215 kg
Permanent 4 wheel drive TBA
Gearbox Specifications
Table 217. Oil Pressures
Converter Pressures (in neutral) Pressure
Converter In at 50 °C ( 121.9 °F) 1000 RPM (Revolutions Per 1.5 –4 bar ( 21.7 –58.0 psi)
Minute)
2000 RPM 5 –7 bar ( 72.5 –101.4 psi)
Converter Out at 50 °C ( 121.9 °F) 1000 RPM TBA
2000 RPM TBA
Converter inlet relief pressure 6.5 bar ( 94.2 psi)
(max.)
Lubrication pressure (in neutral)
Oil at 50 °C ( 121.9 °F) 1000 RPM 0.14 –0.28 bar ( 2.0 –4.1 psi)
2000 RPM 0.28 –0.55 bar ( 4.1 –8.0 psi)
Main Line Pressure (in neutral)
Oil at 50 °C ( 121.9 °F) 1000 RPM 11 –13 bar ( 159.4 –188.4 psi)
2000 RPM 12 –14.5 bar ( 173.9 –210.1 psi)
Clutch pressure All clutch pressures should be the same as mainline pressure to within
0.7 bar ( 10.1 psi).
Table 218. Oil Flow Rates

Flow Rates (in Flow Rate
neutral)
Cooler oil 1000 RPM 8 –13 L/min
flow at 50 °C
( 121.9 °F)
2000 RPM 19 –25 L/min
Pump oil flow at 1000 RPM 11 –15 L/min
50 °C ( 121.9
°F)
2000 RPM 22.5 –29.5 L/
min
For new gearboxes (i.e. under 100 hours service),

or gearboxes that have been fully serviced, the
pressures will be slightly higher than those shown
(approximately 0.7 –1 bar ( 10.1 –14.5 psi)).
27 - 8 9823/1700-1 27 - 8
27 - Driveline
00 - General
For: PS750 MK3 ......................... Page 27-9 Figure 558.

For: PS750 MK4 ....................... Page 27-11
(For: PS750 MK3)
Unit Identification
The gearbox serial number is stamped on the
unit identification plate as shown. When you make
an order for parts replacement, always quote the
details on the unit identification plate. In the case of
gear replacements, always check the part number
stamped on the gear, and the number of teeth.
A Identification plate
Sectional Drawing
Figure 559. Sectional drawing sheet 1
5A 5B 5C 19 5 21 31 8 1
32
12
11 7
30
6
10
29
25
28
24
23
26
9
2
14
15
22 20 3 18
13
17 16 4 27
27 - 9 9823/1700-1 27 - 9
27 - Driveline
00 - General
Item no Description
15 Bolt (If installed)
Table 219.
16 4WD clutch assembly (if
Item no Description installed)
1 Front case 17 4WD oil feed pipe (if in-
2 Torque converter hous- stalled)
ing 18 Layshaft clutch assem-
3 Rear case bly
4 4WD housing/cover 19 Pressure maintenance
5 Solenoid control valve valve
manifold block 20 Main shaft clutch as-
5A Solenoid control valve sembly
(Reverse high/low) 21 Input clutch assembly
5B Solenoid control valve 22 Output shaft assembly
(Main shaft/Layshaft) 23 Spacer
5C Solenoid control valve 24 Oil seal
(Forward high/low)
25 Stake nut
6 Oil pump assembly
26 Main shaft oil feed pipe
7 Oil seal
27 Spacer
8 Oil filter
28 Spacer
9 Brake disc
29 Spacer
10 Brake caliper
30 Spacer
11 Brake caliper bracket
31 O-rings
12 4WD solenoid control
32 Torque converter relief
valve (If installed)
valve assembly
13 4WD yoke (If installed)
14 Oil seal (If installed)
27 - 10 9823/1700-1 27 - 10
27 - Driveline
00 - General
Figure 560. Sectional drawing sheet 2
6 9
8 5 7
12
1 4
15 8
13 14
9
3
11 10 1
(For: PS750 MK4)

Table 220.
Item no Description Unit Identification
1 Front case
2 Torque converter hous- The gearbox serial number is stamped on the
ing unit identification plate as shown. When you make
an order for parts replacement, always quote the
3 Rear case details on the unit identification plate. In the case of
4 Solenoid control valve gear replacements, always check the part number
manifold block stamped on the gear, and the number of teeth.
5 Oil filter
6 4WD solenoid control
valve (if installed)
7 Brake caliper bracket
8 Speed sensor (if in-
stalled)
9 4WD oil feed pipe (if in-
stalled)
10 Oil strainer
11 Oil drain plug
12 Reverse clutch assem-
bly
13 Spacer
14 Sealing plug and washer
15 Main shaft oil feed pipe
27 - 11 9823/1700-1 27 - 11
27 - Driveline
00 - General
Figure 561.
27 - 12 9823/1700-1 27 - 12
27 - Driveline
00 - General
Main Component Identification
Figure 562. External components
27 - 13 9823/1700-1 27 - 13
27 - Driveline
00 - General
Item Description
13 Oil pump
Table 221.
14 Park brake caliper
Item Description bracket
1 Front case with integral 15 Park brake disc and dri-
torque converter hous- ve shaft coupling
ing
16 Suction strainer
2 Rear case
17 Speed sensor 1
3 Torque converter relief
18 Road speed sensor (if
valve
installed)
4 Pressure maintenance
19 Oil transfer pipe
valve
20 Oil filler / dipstick port
5 Oil pressure switch
21 Oil filter
6 Oil outlet port- to oil
cooler 22 2/4 wheel drive solenoid
control valve (if installed)
7 Oil inlet port- from oil
cooler 23 Input (forward) clutch
solenoid control valves
8 Clutch shaft inspection
port- reverse clutch 24 Main shaft / layshaft
clutch solenoid control
valves
port- main shaft clutch
25 Reverse clutch solenoid
control valves
port- layshaft clutch
26 Oil drain plug
11 Input shaft
12 Yoke- drive shaft cou-
pling
27 - 14 9823/1700-1 27 - 14
27 - Driveline
00 - General
Figure 563. Internal component
19 2
1 18
11 10 4
17 3
12
13
4
7 4
6
12
4
9
6 5
16 15
7
10.5
4
14
8
Item Description
5 Yoke - drive shaft cou-
Table 222.
pling
Item Description 6 Oil seal
1 Rear case 7 Locking nut (stake nut)
2 Front case 8 Oil feed pipe
3 Gearbox oil pump 9 Park brake disc
4 Shim
27 - 15 9823/1700-1 27 - 15
27 - Driveline
00 - General
Item Description Item Description

10 Park brake caliper 18 Input shaft clutch as-
bracket sembly
11 Park brake caliper 19 Reverse shaft clutch as-
12 Output shaft support sembly
bearings (1) Permanent 4 wheel drive variants have a one-
13 Spacer piece shaft in place of the 2/4 wheel drive clutch
14 2/4 wheel drive clutch
(1) assembly.
15 Layshaft clutch assem- The internal component drawing is not a true
bly sectional view. It is drawn to show the main
16 Main shaft clutch as- components as clearly as possible
sembly
17 Output shaft
27 - 16 9823/1700-1 27 - 16
27 - Driveline
00 - General
Figure 564. Test Point
1 4
Test point Description

4 Forward high ratio clutch
Table 223.
pressure
Test point Description 5 Forward low ratio clutch
1 Mainline pressure pressure
2 Main shaft clutch pres- 6 Reverse high ratio clutch
sure pressure
3 Converter inlet and con- 7 Reverse low ratio clutch
verter relief valve pres- pressure
sure
27 - 17 9823/1700-1 27 - 17
27 - Driveline
00 - General
Test point Description Clutch Control Solenoids

8 Layshaft clutch pressure
Figure 565.
9 2/4 wheel drive clutch
pressure
3022
3021
3033
3041
3029
3040
Table 224.
Gear Clutches engaged Solenoids energised Refer to
Figure 565.
1st gear forward Forward Low 3022
Layshaft 3029
2nd gear forward Forward high 3021
Layshaft 3029
3rd gear forward Forward low 3022
Mainshaft 3033
4th gear forward Forward high 3021
Mainshaft 3033
1st gear reverse Reverse Low 3041
Layshaft 3029
2nd gear reverse Reverse high 3040
Layshaft 3029
3rd gear reverse Reverse low 3041
Mainshaft 3033
4th gear reverse Reverse high 3040
Mainshaft 3033
27 - 18 9823/1700-1 27 - 18
27 - Driveline
00 - General
Operation
(For: PS750 MK4) control solenoid. The transmission automatically

selects 4 wheel drive when the service brakes are
Operation Overview applied.
The Powershift gearbox is an electro-hydraulic Drive paths

transmission unit. Input from the engine is by
means of a torque converter. Gear shifting and Forward
direction selection are controlled by engaging and
disengaging multi-disc clutch packs. Figure 566. 1st gear forward
Electric solenoid valves divert pressurised oil A

(provided by the gearbox oil pump) to the selected
clutch packs.
Drive direction and gear ratio are selected by means

of electrical control switches (typically a steering
column mounted lever and swivel switch). E
The electrical control interface by use of electrical
relays.
Start up
Electrical interlocks prevent the engine being started,
unless the transmission is set to neutral.
Table 225.
Drive select Clutches engaged Solenoids energised
A column switch controls the drive selection, Forward low ratio (A) 3022
forward, neutral or reverse. The switch energises Layshaft (E) 3029
the applicable relays which in turn energise the
applicable gearbox control solenoids.
Figure 567. 2nd gear forward
Manual gear select
B
A rotating barrel switch controls selection of the
gear ratios (1,2,3 or 4). The switch energises
the applicable relays which in turn energise the
applicable gearbox control solenoids.
Park brake on E
When the park brake is on, an electrical switch sets

the transmission to neutral even if forward or reverse
is selected. A warning sound will be audible.
Transmission dump
A transmission dump switch on the hydraulic control
lever de-selects the transmission drive when the Table 226.
switch is operated. Clutches engaged Solenoids energised
Forward high ratio (B) 3021
2/4 Wheel drive select Layshaft (E) 3029
A cab mounted switch controls 2 or 4 wheel drive
selection. The switch energises the applicable relay
which in turn energises the applicable gearbox
27 - 19 9823/1700-1 27 - 19
27 - Driveline
00 - General
Figure 568. 3rd gear forward Reverse

Figure 570. 1st gear reverse
A
C
Table 227.
Clutches engaged Solenoids energised
Forward low ratio (A) 3022 Table 229.
Mainshaft (F) 3033 Clutches engaged Solenoids energised
Reverse low ratio (C) 3041
Figure 569. 4th gear forward Layshaft (E) 3029
B Figure 571. 2nd gear reverse
Table 228. D
Forward high ratio (B) 3021
Table 230.
Mainshaft (F) 3033
Reverse high ratio (D) 3040
Layshaft (E) 3029
27 - 20 9823/1700-1 27 - 20
27 - Driveline
00 - General
Figure 572. 3rd gear reverse Valve), which maintains pressure to the solenoid
valves for clutch selection. Excess oil from the
maintenance valve flows back through the case to
the torque converter. A relief valve controls pressure
in the converter and dumps oil from the converter line
F back to the sump.
Oil from the torque converter flows out of the gearbox

to the external oil cooler (if installed) and again
comes back to the converter. Oil then flows through
internal oil ways providing lubrication for clutches
and bearings before it goes back to the gearbox
sump.
The torque converter is a fluid coupling bolted to

C a drive plate which in turn is bolted to the engine
drive. As the engine starts to rotate, the converter
gives smooth power take off and gradually increases
Table 231. the torque transmitted. This torque is transferred
from the converter assembly to the clutch/gear
Clutches engaged Solenoids energised assemblies through the input shaft on the forward
Reverse low ratio (C) 3041 clutch assembly.
Mainshaft (F) 3033
The forward clutch assembly contains two
hydraulically operated clutches: one clutch gives a
Figure 573. 4th gear reverse forward low ratio drive and the other gives a forward
high ratio drive. The clutches are controlled by a
three position solenoid valve. When the applicable
solenoid is energised, pressurised oil is directed to
either the forward low (solenoid 3022) or forward high
F (solenoid 3021) clutch.
The reverse clutch assembly is also similar to the

forward clutch assembly. It contains two hydraulically
operated clutches: one clutch gives a reverse low
ratio drive and the other gives a reverse high ratio
drive. The reverse clutches are controlled by a
three position solenoid valve. When the applicable
solenoid is energised, pressurised oil is directed to
either the reverse low (solenoid 3041) or reverse high
(solenoid 3040) clutch.
D
Both the mainshaft and the layshaft assemblies have
a single clutch each. Both clutches are controlled
Table 232. by a three position solenoid valve. When energised,
Clutches engaged Solenoids energised solenoid 3029 directs pressurised oil to the layshaft
clutch and solenoid 3033 directs pressurised oil the
Reverse high ratio (D) 3040
mainshaft clutch.
Mainshaft (F) 3033
When a gear is selected through the control switch
Hydraulic operation and schematics in the cab, two clutches are always engaged.
When you select different pairs of clutches different
The engine directly drives the oil pump through the gear ratios are engaged. Relays electrically control
torque converter. the solenoids. All the clutches work on the same
principle.
Oil from the pump is fed through an internal passage
via the filter to the PMV (Pressure Maintenance
27 - 21 9823/1700-1 27 - 21
27 - Driveline
00 - General
Figure 574.
K
U J Q
L
D C
V N
R
W P
B A
M
X
H
Y S1
F
S2 G S
Z 4
3
2
E
1
Table 233.
Item Description
A Forward low ratio clutch
B Forward high ratio clutch
C Reverse low ratio clutch
D Reverse high ratio clutch
E Layshaft assembly
F Mainshaft assembly
G Layshaft clutch
H Mainshaft clutch
J Pressure maintenance valve
K Relief valve
L Oil filter
M Forward clutch assembly
N Reverse clutch assembly
P Pump
Q Oil flows to the external oil cooler from the torque
converter
R External oil cooler
S Torque converter
T Oil flows back to the torque converter from the exter-
nal oil cooler
U Solenoid 3040
V Solenoid 3041
W Solenoid 3021
27 - 22 9823/1700-1 27 - 22
27 - Driveline
00 - General
Item Description
X Solenoid 3022
Y Solenoid 3029
Z Solenoid 3033
Forward and Reverse Clutch Operation The counter plates and friction plates are pressed
together by a hydraulically actuated piston. Drive
The forward and reverser clutch assembly transfers is then transmitted from the input shaft to the gear
drive from the input shaft to either gear 1 or gear 2 1. Clutch for gear 2 is disengaged and no drive is
depending on which of the two clutches is engaged, transmitted to gear 2 plate carrier. The gear is also
giving forward or reverse drive. free to rotate on the input shaft assembly.
When neither clutch is engaged, neutral is selected. Actuation of the hydraulic pistons and is controlled
via three position solenoid control valve. When
The clutches are of the wet, multi plate type. neutral is selected both solenoids are deactivated
and the flow of pressurised oil to the clutches is
The clutch housings and input shaft are a one piece blocked. The gear springs 1 and 2 move the pistons
assembly. The assembly is permanently driven by away from the clutch plates and oil from both pistons
the engine via the torque converter. is vented to the sump.
Clutch counter plates are also permanently driven When either forward or reverse is selected, the
via meshing teeth inside the clutch housings. Clutch solenoid control valve diverts pressurised oil via
friction plates are meshed with the gear plate cross drillings inside the input shaft to the appropriate
carriers. clutch piston in the unit. Pressure from the other
clutch is vented to the sump via the solenoid valve
In the diagram, clutch for gear 1 is engaged. spool. Oil is prevented from leaking by seals on the
pistons and ring seals on the input shaft.
27 - 23 9823/1700-1 27 - 23
27 - Driveline
00 - General
Figure 575.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q
A Input shaft assembly B Gear 1 clutch

C Gear 1 piston D Piston external seal
E Gear 2 piston F Gear 2 clutch
G1 Gear 1 G2 Gear 2
H Input shaft ring seals J Gear 2 spring
K Gear 1 spring L Piston internal seal
M Clutch friction plates N Clutch counter plates
P Solenoid - gear 1 Q Solenoid - gear 2
R Solenoid control valve
27 - 24 9823/1700-1 27 - 24
27 - Driveline
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Mainshaft and Layshaft Clutch Operation The clutch is engaged and disengaged by
introducing or dumping pressurised oil behind the
The mainshaft and layshaft units incorporate one piston via a solenoid valve. The solenoid valve is
clutch and not two, as in the forward and reverse operated by a switch in the cab.
units. The operation of the single clutches is the
same as for one clutch in the forward or reverse units. When the switch is in the 4WD position, the solenoid
valve is de-energised. With the solenoid 1 de-
2 and 4 Wheel Drive Clutch Operation energised, the valve spool moves under the force of
the spring. The oil supply to the piston is blocked. At
the same time oil vents from the back of the piston to
4 Wheel Drive Operation the sump via ports 1 and 2.
This clutch is of the Spring-ON (4WD (Four Wheel Because there is no pressure behind the piston, the
Drive))/Pressure-OFF (2WD (Two Wheel Drive)) clutch friction/counter plates of the clutch pack are
type. forced together by the disc springs, thus driving the
output yoke.
Figure 576.
D B E
A A1
3 2
1
A2 C
A Solenoid control valve A1 Solenoid 1

A2 Solenoid 2 B Clutch pack
C Piston D Springs
E Output yoke
27 - 25 9823/1700-1 27 - 25
27 - Driveline
00 - General
2 Wheel Drive Operation and then the pressure plate against the force of the
springs, thus releasing the spring force on the clutch
When the switch is in the 2WD position, the solenoid friction/counter plates of the clutch pack.
valve is energised. The energised solenoid 1 causes
the valve spool to move and form a connection Because there is no spring force, the friction/counter
between ports 3 and 2. plates of the clutch pack now freely rotate on the
output shaft, thus disengaging drive to the front axle.
Pressurised oil is directed to the piston via ports
3 and 2. The piston moves the actuating sleeve
Figure 577.
D G B F E
A A1
3 2
1
A2
A Solenoid control valve A1 Solenoid 1

A2 Solenoid 2 B Clutch pack
C Piston D Springs
E Output yoke F Actuating sleeve
G Pressure plate
27 - 26 9823/1700-1 27 - 26
27 - Driveline
00 - General
Diagram
(For: PS750 MK4) Key Description

2048 Transmission dump re-
Electrical Operation and Schematics lay
3021 Forward high solenoid
The 4-speed PS750 powershift gearbox is controlled 3022 Forward low solenoid
using conventional relays.
3029 Layshaft solenoid
This section explains how the electrical system works 3033 Mainshaft solenoid
when the following gearbox functions are operated: 3040 Reverse high solenoid
3041 Reverse low solenoid
Forward Gears
7014 Diode gate- gearbox
8004 Panel harness to chas-
Table 234. sis harness connector A
Key Description 8010 Panel harness to rear
cab harness connector
-006 Rear cab harness
ground 8016 Transmission harness to
chassis harness connec-
-003 Panel harness ground A tor
-001 Chassis harness ground 9003 Fuse box C
1013 Column switch - left
1068 Dump switch The circuit is shown with 3rd gear forward selected.
1057 Park brake switch Refer to Figure 578.
2008 Drive relay
The harness connector pin numbers are shown on
2009 Driveshaft relay the schematic. For harness connector details refer to
2017 Forward High / Low re- electrical system- harness, refer to (PIL 33-12).
lay
2018 Forward relay The immobiliser connection is not shown for security
reasons.
2028 Park brake relay
2031 Reverse High / Low re- The table shows the electrical device status for all
lay forward gears. Refer to Figure 579.
2032 Reverse relay
27 - 27 9823/1700-1 27 - 27
27 - Driveline
00 - General
Figure 578.
27 - 28 9823/1700-1 27 - 28
Gearbo x Column Switch L/ Relay 204 8 Relay 202 8 Relay 201 8 Relay 203 2 Relay 200 8 Diode Gat e Relay 201 7 Relay 200 9 Gearbox
27 - 29
Function H 1013 Dump Park brake Forward Reverse Drive - Gearbox Forward Hi/ Driveshaft Solenoids
7014 Lo
1st GEAR 14-12 1-4 6-9 8 6-9 8-10, 6-7 3022 ,3029
FORWARD 7-4 3-5, 1-2 1-4 4-1
1F
8 4
10 8 5 3 10 8 10 8
7 2 7 7
1 6 1 1 1 6 6
4 9 4 4 4 9 9
2nd GEAR 14-9 1-4 6-9 2-6, 1-5 8-10, 6-7 8-10, 6-7 3021 ,3029
FORWARD 7-4 3-5, 1-2 1-4 4-1
2F
4 8
10 8 5 3 10 8 10 8
7 2 7 7
1 6 1 1 1 3 7 6 6
4 9 4 4 4 9 9
Figure 579.
9823/1700-1
3rd GEAR 1-4 6-9 6 -9 6-9 3022 ,3033
FORWARD 7-4 3-5, 1-2 1-4 4-1
3F
10 8 5 3 10 8 10 8
7 2 7 7
1 6 1 1 1 6 6
4 9 4 4 4 9 9
4th GEAR 14-13 1-4 6-9 3-7, 6 8-10, 6-7 6-9 3021, 3033
FORWARD 7-4 3-5, 1-2 1-4 4-1
4F
7 3
10 8 5 3 10 8 10 8
7 2 7 7
1 6 1 1 1 6 6
4 9 4 4 4 9 9
27 - 29
00 - General
27 - Driveline
27 - Driveline
00 - General
Reverse gears Key Description

3033 Mainshaft solenoid
Table 235. 3040 Reverse high solenoid
3041 Reverse low solenoid
Key Description
7014 Diode gate- gearbox
-006 Rear cab harness
ground 8004 Panel harness to chas-
sis harness connector
-003 Panel harness ground A
8010 Panel harness to rear
-001 Chassis harness ground cab harness connector
1013 Column switch - left A
1068 Dump switch 8016 Transmission harness to
1057 Park brake switch chassis harness connec-
2008 Drive relay tor
2009 Driveshaft relay 9003 Fuse box C
2017 Forward High / Low re-
The circuit is shown with 3rd gear reverse selected.
lay
2018 Forward relay
2028 Park brake relay The harness connector pin numbers are shown on
2031 Reverse High / Low re- the schematic. For harness connector details refer to
lay electrical system- harness, refer to (PIL 33-12).
2032 Reverse relay The immobiliser connection is not show for security
2048 Transmission dump re- reasons.
lay
3021 Forward high solenoid The table shows the electrical device status for all
3022 Forward low solenoid reverse gears. Refer to Figure 581.
27 - 30 9823/1700-1 27 - 30
27 - Driveline
00 - General
Figure 580.
27 - 31 9823/1700-1 27 - 31
Gearbo x Column Switc h Relay 204 8 Relay 202 8 Relay 201 8 Relay 203 2 Relay 200 8 Diode Gat e Relay 203 1 Relay 200 9 Gearbox
27 - 32
Function 1013 Dump Park brake Forward Reverse Drive 7014 Reverse Hi/ Driveshaft Solenoids
Lo
1st GEAR 14-12 1-4 6-9 8 1-4 8-10, 6-7 3041 ,3029
REVERSE 7-10 1-4 8-10, 6-7 3-5, 2-1
1R
8 4
10 8 10 8 5 3 10 8
7 7 2 7
1 6 1 6 1 1 6
4 9 4 9 4 4 9
2nd GEAR 14-9 1-4 6-9 2-6, 1-5 3-5, 1-2 8-10, 6-7 3040 ,3029
REVERSE 7-10 1-4 8-10, 6-7 3-5, 2-1
2R
4 8
10 8 10 8 5 3 5 3 10 8
7 7 2 2 7
1 6 1 6 1 3 7 1 6
4 9 4 9 4 4 9
Figure 581.
9823/1700-1
3rd GEAR 1-4 6-9 1 -4 6-9 3041 ,3033
REVERSE 7-10 1-4 8-10, 6-7 3-5, 2-1
3R
10 8 10 8 5 3 10 8
7 7 2 7
1 6 1 6 1 1 6
4 9 4 9 4 4 9
4th GEAR 14-13 1-4 6-9 3-7, 6 3-5, 1-2 6-9 3040 ,3033
REVERSE 7-10 1-4 8-10, 6-7 3-5, 2-1
4R
7 3
10 8 10 8 5 3 5 3 10 8
7 7 2 2 7
1 6 1 6 1 1 6
4 9 4 9 4 4 9
27 - 32
00 - General
27 - Driveline
27 - Driveline
00 - General
Neutral to the gearbox solenoid relays A and no gearbox

solenoids B are energised. There is no drive from the
Power is connected to the forward and reverse relays gearbox.
2018 and 2032 via dump relay 2048 and park brake
relay 2028. When the column switch 1013 is set to N, The harness connector pin numbers are shown on
both the forward relay 2018 and the reverse relays the schematic. For harness connector details refer to
2032 are de-energised. There is no power supply electrical system- harness, refer to (PIL 33-12).
Table 236.
Gearbox Function Column Switch L/H Relay 2018 Forward Relay 2032 Reverse
1013
Neutral 1-4 6-9
N
10 8
7
1 6
4 9
9003
2048
2028
2018
A B
2032
1013
Transmission Dump relay common switch contacts, there is no power

supply to the gearbox solenoid relays A. Hence no
Operation of the transmission dump switch (1068) gearbox solenoids B are energised. There is no drive
energises relay 2048. There is no power supply to the from the gearbox.
common switch contacts of the forward and reverse
relays 2018 and 2032. With the column switch in The harness connector pin numbers are shown on
the F or R position the forward or reverse relay is the schematic. For harness connector details refer to
energised. Since the power supply is isolated at the electrical system- harness, refer to (PIL 33-12).
27 - 33 9823/1700-1 27 - 33
27 - Driveline
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Table 237.
Gearbox Function Relay 2048 Transmission Dump Dump Switch 1068
Transmission Dump 5-3, 1-2 1-2
5 3
2
1
4
9003 8004
-001
48
1068
2048
2028
2018
A B
2032
1013
Park Brake ON is no power supply to the gearbox solenoid relays A

and no gearbox solenoids B are energised. There is
When the park brake is set to the ON position the no drive from the gearbox.
switch 1057 closes and energises relay 2028. If the
column switch 1013 is in the F or R position, there will The harness connector pin numbers are shown on
be no power supply to the common switch contacts of the schematic. For harness connector details refer to
the forward and reverse relays 2018 and 2032. There electrical system- harness, refer to (PIL 33-12).
27 - 34 9823/1700-1 27 - 34
27 - Driveline
00 - General
Table 238.
Gearbox Function Relay 2028 Park Brake Park Brake Switch 1057
Park brake ON 10-8, 6-7 1-3
10 8
7
6
9
9003
2048
8020 8020
-006
1057
2028
2018
A B
2032
1013
27 - 35 9823/1700-1 27 - 35
27 - Driveline
00 - General
Fault-Finding
Fault
Machine drives but lacks power in all gears. Gearbox oil may also be Table 239. Page 27-36
overheating.
Machine does not drive in any gear. Table 240. Page 27-37
Some gears fail to engage or lack power. Table 241. Page 27-38
Gearbox oil overheating. Table 242. Page 27-38
Noisy operation. Table 243. Page 27-39
Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch). Table 244. Page 27-39
Cannot engage 2WD (Spring ON clutch). Table 245. Page 27-39
Gearbox oil contaminated with water. Table 246. Page 27-40
Consequential Faults (Gearbox faults caused typically by water Table 247. Page 27-40
contamination and other factors related to the gearbox oil.)- Pressurisation
of gearbox casing. Dipstick blows out and oil escapes from dipstick tube.
contamination and other factors related to the gearbox oil.)- Clutch failure
due to friction lining separation.
contamination and other factors related to the gearbox oil.)- Badly worn or
noisy bearings.
Machine does not achieve maximum speed when travelling on the highway Table 250. Page 27-41
(Lock-up torque converter variants only).
Gear shifts fail to function normally- Sychroshuttle gearboxes only. Table 251. Page 27-41
Gear shifts fail to function normally or shifts occur at the incorrect road Table 252. Page 27-41
speed.
The gear fails to autoshift (Note that on 6 speed gearboxes, 4th, 5th and Table 253. Page 27-41
6th gears utilise clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or 6th
gears fail to engage, check that the lower 3 gears function correctly before
investigating a possible Shiftmaster fault, refer to `Fault Table- Some gears
fail to engage or lack power').
Table 239. Machine drives but lacks power in all gears. Gearbox oil may also be overheating.
Cause Remedy
Gearbox oil level low. Check for leaks and top up oil level as required.
Gearbox oil contaminated or wrong grade. Investigate the reason for the contamination and
rectify as required. Drain the oil and flush the
gearbox. Refer to driveline- semi automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or install new
as applicable. Refer to driveline- semi-automatic
gearbox, refer to (PIL 27-06).
Pressure maintenance valve defective. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Remove the pressure maintenance valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the torque converter relief valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
27 - 36 9823/1700-1 27 - 36
27 - Driveline
00 - General
Cause Remedy
Oil cooler lines restricted or blocked. Internal Carry out oil pressure and flow tests. Refer to
blockage within the oil cooler matrix due to driveline- semi-automatic gearbox, refer to (PIL
contamination. 27-06).
Clear the restriction. Inspect the hose routing
and install new the hoses or oil cooler matrix as
applicable.
Faulty torque converter. Carry out torque converter stall tests to confirm stall
speeds are within specification. Refer to driveline-
Torque converter, refer to (PIL 27-14).
Remove the gearbox and install new the torque
converter. Note that the torque converter assembly is
a non serviceable item.
Failure of oil pump assembly. Carry out the oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect the oil pump for
signs of damage or excessive wear. Install new oil
pump as applicable.
Gearbox internal leakage fault. Carry out oil pressure and flow tests. Refer to
27-06).
Remove and disassemble the gearbox. Inspect all
components for signs of damage or excessive wear.
In particular, check the seals and install new as
applicable.
Table 240. Machine does not drive in any gear.

Cause Remedy
Park brake switch or transmission dump switch Check the function of the park brake switch and
defective. transmission dump switch.
Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Gear selector column switch defective. Check the function of the gear selector column
switch.
Clutch solenoid wiring defective Inspect the condition of the associated electrical
Low mainline oil pressure. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of oil pump assembly. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect oil pump for signs
of damage or excessive wear. Install new oil pump as
applicable.
27 - 37 9823/1700-1 27 - 37
27 - Driveline
00 - General
Table 241. Some gears fail to engage or lack power.

Cause Remedy
Gear selector column switch defective. Check the function of the gear selector column
switch.
The relevant solenoid valve is not being energised. Inspect the condition of the associated electrical
Solenoid coil faulty. Check the solenoid for open or short circuits.
Measure the solenoid coil resistance. If required,
install new solenoid coil.
Clutch operating oil pressure low. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of clutch assembly. Check for clutch internal leakage. Carry out oil
pressure and flow tests. Refer to driveline- semi-
automatic gearbox, refer to (PIL 27-06).
Check for clutch slippage. Carry out torque
converter stall tests to confirm stall speeds are within
specification. Refer to driveline- Torque converter,
Remove and disassemble the gearbox. Inspect
relevant clutch components for signs of damage or
excessive wear. Install new as applicable.
Table 242. Gearbox oil overheating.

Cause Remedy
Oil cooler heat exchanger matrix clogged with dirt Clean the oil cooler matrix. Refer to operators
particles or chaff. (Air blast coolers only. Some manual.
machines have liquid to liquid type coolers.)
gearbox. Refer to driveline- semi-automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or renew
Oil cooler hoses kinked or trapped. Clear the restriction. Inspect the hose routing and
reroute or renew the hoses as applicable.
Machine being operated incorrectly i.e. Incorrect gear Educate the operator.
ratio.
Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of oil pump assembly. Carry out oil pressure and flow tests. Refer to
27-06).
Remove the gearbox and inspect oil pump for signs
of damage or excessive wear. Install new the pump
as applicable.
27 - 38 9823/1700-1 27 - 38
27 - Driveline
00 - General
Table 243. Noisy operation.

Cause Remedy
gearbox. Refer to driveline- semi-automatic gearbox,
Suction strainer restricted or blocked. Remove the suction strainer and clean or install new
Low lubrication oil pressure. Carry out oil pressure and flow tests. Refer to
27-06).
Gearbox components damaged or excessively worn. Remove and disassemble the gearbox. Inspect all
the components for signs of damage or excessive
wear. In particular, check shaft seals and bearings.
Install new as applicable.
Table 244. Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch).
Cause Remedy
4 wheel drive solenoid valve spool is sticking in Remove and inspect the solenoid valve cartridge.
the 2WD (Two Wheel Drive) drive position due to Clean the valve or renew as applicable.
contamination.
Solenoid coil permanently energised. Check the function of the 4WD selector switch.
Failure of clutch assembly Remove the 4WD clutch assembly. Inspect the clutch
Renew as applicable.
Table 245. Cannot engage 2WD (Spring ON clutch).

Cause Remedy
4WD selector switch defective. Check the condition of the 4WD selector switch.
4WD solenoid valve is not being energised. Inspect the condition of the associated electrical
Solenoid coil faulty. Check the solenoid for open or short circuits.
install a new solenoid coil.
4WD solenoid valve spool is sticking in the 4WD Remove and inspect the solenoid valve cartridge.
position due to contamination. Clean the valve or install new as applicable.
Clutch operating oil pressure low. Carry out oil pressure and flow tests. Refer to
27-06).
Failure of clutch assembly. Check for clutch internal leakage. Carry out oil
pressure and flow tests. Refer to driveline- semi-
Remove the 4WD clutch assembly. Inspect the clutch
Install new as applicable.
27 - 39 9823/1700-1 27 - 39
27 - Driveline
00 - General
Table 246. Gearbox oil contaminated with water.

Cause Remedy
Water ingress during filling or topping-up. Drain the oil and flush the gearbox. Refer to
27-06).
Missing or incorrect dipstick. Damaged filler tube. Install new parts as required. Drain the oil and flush
the gearbox.
Machine operated in deep water. Drain the oil and flush the gearbox. Refer to
27-06).
Gearbox oil cooler faulty, gearbox oil contaminated Remove and test the oil cooler. Refer to cooling
with engine coolant. (Liquid to liquid oil coolers only.) system- cooling pack, refer to (PIL 21-03-09).
Gearbox casings damaged. Inspect the gearbox casing. Renew missing or
damaged parts. Drain the oil and flush the gearbox.
Refer to driveline- semi-automatic gearbox, refer to
(PIL 27-06).
Gearbox oil circuit pipework or hoses damaged. Inspect the pipework and hoses. Renew missing or
damaged parts. Drain the oil and flush the gearbox.
Refer to driveline- semi-automatic gearbox, refer to
(PIL 27-06).
Table 247. Consequential Faults (Gearbox faults caused typically by water contamination and other
factors related to the gearbox oil.)- Pressurisation of gearbox casing. Dipstick blows out and oil escapes
from dipstick tube.
Cause Remedy
Water in the oil combined with heat from torque Replace or renew the dipstick.
converter causes steam. Drain the oil and flush the gearbox. Refer to
27-06).
factors related to the gearbox oil.)- Clutch failure due to friction lining separation.
Cause Remedy
Water ingress. Remove and dismantle gearbox. Inspect relevant
clutch components for signs of damage or excessive
wear. Install new as applicable.
Overheating transmission oil. Drain the oil and flush the gearbox. Refer to
27-06).
factors related to the gearbox oil.)- Badly worn or noisy bearings.
Cause Remedy
Water ingress. Remove and dismantle the gearbox. Inspect all
Install new components as applicable.
Insufficient lubrication. Drain the oil and flush the gearbox. Refer to
27-06).
Carry out oil pressure and flow tests. Refer to
27-06).
27 - 40 9823/1700-1 27 - 40
27 - Driveline
00 - General
Table 250. Machine does not achieve maximum speed when travelling on the highway (Lock-up torque
converter variants only).
Cause Remedy
Operator error. Educate the operator. Ensure operator fully
understands the characteristics of the lock up
function.
Lock up torque converter solenoid not being Inspect the condition of the associated electrical
energised. wiring, plugs and connectors for damage and check
Lock up torque converter solenoid coil faulty. Check the solenoid for open or short circuits.
renew the solenoid coil.
Engine or transmission speed sensor faulty. Use the applicable JCB Diagnostics software to
check the ECU (Electronic Control Unit) inputs
and outputs. Refer to electrical system- electronic
diagnostic, refer to (PIL 33-57).
wiring, plugs and connectors or damage and check
that the relevant fuses are intact. If required, install a
new speed sensor.
Faulty lock up torque converter. Remove the gearbox and renew the lock up torque
converter. Note that the torque converter assembly is
a non serviceable item.
Table 251. Gear shifts fail to function normally- Sychroshuttle gearboxes only.
Cause Remedy
Cable shift mechanism faulty Adjust or replace gear shift cables as necessary.
Table 252. Gear shifts fail to function normally or shifts occur at the incorrect road speed.
Cause Remedy
Gear selector column switch faulty Check the function of the gear selector column
switch. Also Inspect the condition of the associated
electrical wiring, plugs and connectors for damage
and make sure that the relevant fuses are intact.
Table 253. The gear fails to autoshift (Note that on 6 speed gearboxes, 4th, 5th and 6th gears utilise
clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or 6th gears fail to engage, check that the lower 3
gears function correctly before investigating a possible Shiftmaster fault, refer to `Fault Table- Some
gears fail to engage or lack power').
Cause Remedy
Transmission speed sensor faulty. Check the function of the speed sensor.
If required, install a new speed sensor.
27 - 41 9823/1700-1 27 - 41
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Cause Remedy
Gearbox ECU defective. (In response to certain Use the ECU Diagnostics software to check the
faults the ECU will enter a `Limp Mode'. For a ECU inputs and outputs. Refer to electrical system-
detailed description of the Limp Modes, refer electronic diagnostic, refer to (PIL 33-57).
to `Service Procedures - Powershift Gearbox, Inspect the condition of the associated electrical
Electronic Control Unit'.) wiring, plugs and connectors for damage and check
Install new ECU. (The ECU is inherently reliable.
It is protected internally from electrical damage.
It is housed in a rugged case for protection from
mechanical damage and ingress of dirt and moisture.
Faults with associated systems are more likely to be
caused by wiring or other input and output device
failure. Before renewing the ECU make sure beyond
reasonable doubt that it is faulty.)
27 - 42 9823/1700-1 27 - 42
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Drain and Fill 13. Continue this procedure for the specified
duration, if possible during machine operation.
Duration: 30 min
Transmission Oil and Filter
14. Allow the machine to cool then drain the
Refer to driveline, semi-automatic gearbox, Filter, transmission oil through the suction strainer
(PIL 27-06-39). aperture. Refer to (PIL 27-06-40).
15. Test the oil for contamination. If the oil is still
Transmission Oil Suction Strainer contaminated, repeat the flushing procedure
Refer to driveline, semi-automatic gearbox, Suction from step 3
Strainer, (PIL 27-06-40). 16. If the oil is clean:
Flushing the Transmission Oil 16.1. Replace the suction strainer. Refer to (PIL
27-06-40).
1. If the transmission oil has been contaminated
with water or incorrect oil types, the transmission 16.2. Install a new oil filter. Refer to (PIL
must be flushed to effectively remove the 27-06-39).
contaminated oil. 16.3. Fill the transmission with the correct grade
of fresh oil. Refer to (PIL 75-00)
2. Park the machine and make it safe.
16.4. Check the oil level and top up as required.
3. Drain the oil from the gearbox. Refer to (PIL Refer to (PIL 27-06-00).
27-06-40).
4. Remove the suction strainer. Refer to (PIL
27-06-40).
5. Clean the suction strainer and install. Refer to
(PIL 27-06-40).
6. Replace the oil filter. Note that the filter may be
remotely mounted on some installations. Refer to
(PIL 27-06-39).
7. Fill the transmission with the correct grade of
fresh oil. Refer to (PIL 75-00).
8. Check the oil level and top up as required. Refer
to (PIL 27-06-00).
9. Start the engine and run the machine until the
normal operating temperature is as specified.
Temperature: 50 –100 °C ( 121.9 –211.9 °F)
10. Stall the torque converter for the specified
duration. Refer to (PIL 27-14).
Duration: 5 s
10.1. Do not stall the torque converter for
longer than the maximum duration or the
transmission oil will overheat.
Duration: 10 s
11. Continue running the engine under normal
conditions for the specified duration.
Duration: 5 min
12. Repeat step 10.
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Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4 L JCB Threadlocker 4101/0250 0.01 L
- General purpose and Sealer (Medium 4101/0251 0.05 L
solvent based parts Strength)
cleaner
Before assembling the gearbox, make sure that a
1. Carefully remove all traces of the gasket thorough inspection of all components is carried out.
or gasket compound from the following Remember that although a failed component may
components: be easy to identify, the cause of that failure may be
less easy to trace. It is also possible that a failed
1.1. Front and rear case mating faces component may have caused damage to other areas
1.2. Front case and torque converter housing of the gearbox.
mating faces
1. Cleaning: Refer to Semi-Automatic Gearbox -
1.3. Solenoid control valve manifold and case Clean, refer to (PIL 27-06).
mating faces
2. General Inspection:
1.4. 4WD case mating faces (if applicable)
1.5. Layshaft cover and rear case mating faces. 2.1. Carefully inspect all gears, bearings and
shafts for signs of excessive wear or
2. Clean the inside of the cases using a suitable damage. If wear or damage is evident, the
degreasing agent. components must be renewed.
Consumable: Cleaner/Degreaser - General 2.2. Make sure that all oil way cross drillings are
purpose solvent based parts cleaner clear and free from debris. Blocked oil ways
are a common cause of bearing failure. If
necessary use an air line to blow through
the oil ways.
3. Clutch Units:
3.1. If a clutch failure is suspected see the
relevant clutch dismantling and assembly
procedure, refer to (PIL 27-06).
4. Gearbox Oil Pump-Renew:
4.1. If tests have shown the pump performance
to be unacceptable, the pump must be
renewed as a complete unit.
4.2. Make sure that the pump mating face on the
gearbox front cover is clean and free from
surface damage.
5. Gearbox Oil Pump-Replace: If the existing pump
is to be re-installed proceed as follows:
5.1. Undo the security screw and separate
the pump body. Carefully inspect the gear
teeth, white metal bearing and gear/body
mating faces for signs of wear and damage,
(If either is evident, the pump must be
renewed).
5.2. Carefully remove and discard the oil seal.
Take care not to damage the seal housing.
5.3. Install a new seal. Install the seal the correct
way around. Push the seal flush with the
front of the housing.
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5.4. Re-assemble the pump. Check (Level)

Figure 582.
2. Start the engine and operate at low idle for the
specified time. This allows the oil to fill the filter,
pump, torque converter, oil cooler and hoses.
Duration: 4 min
3. Stop the engine.
5. Gain access to the dipstick. Refer to (PIL 06-06).
A
B 6. Before you complete a check of the oil level, you
must wait as shown on the instructional label.
The instructional label shows the waiting time in
seconds.
7. Make sure that the area around the dipstick and
tube are clean and free of debris before removing
B the dipstick.
8. Check the gearbox oil level on the dipstick. The
C oil level must be between the end of the dipstick
and maximum mark on the dipstick.
A Security screw
B Oil seal 9. Clean the dipstick with a clean lint free cloth.
C Housing Make sure that no debris remain on the dipstick
or enters the transmission via the dipstick tube.
6. Cases:
10. If necessary add clean new oil through the
6.1. If the gearbox cases are to be renewed, be dipstick tube.
sure to install blanking plugs and adaptors
as required. Inspect the original cases Water Contamination
and identify the blanking plug and adaptor
positions. Transfer the plugs and adaptors Carefully inspect the gearbox oil for signs of water
to the new cases. Apply JCB Threadlocker contamination. Contaminated oil will contain water
and Sealer to the threads. Note that new droplets or be visibly emulsified.
plugs may be supplied with a sealant patch,
in which case sealant need not be applied. Water droplets may be visible on the dipstick or
Consumable: JCB Threadlocker and Sealer inside the filler tube. For oil analysis purposes, the
(Medium Strength) maximum permissible water content of the oil is
0.10%. If the gearbox oil has been contaminated
with water, faults or damage to the gearbox may
be apparent as a result. Before trying to remedy,
thoroughly investigate and rectify the cause of the
water contamination.
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Check (Pressure)
Special Tools Before you start any of the transmission pressure/

Description Part No. Qty. flow test, make sure that the oil level is correct and
Flowmeter 892/00229 1 at normal operating temperature (not less than 50
°C ( 121.9 °F)).
Pressure Gauge (0-40 892/00278 1
Bar) Do the these test procedures:
To help with fault identification, record the test results • Pump flow test
on a check list. The check list will help the engineer to • Mainline pressure test
identify the cause of a gearbox fault and if needed it • Converter in pressure
can be sent to JCB Technical Service by email. Refer • Converter relief (safety) valve pressure
to Figure 589. • Converter out pressure and oil cooler flow rate
• Lubrication pressure
Make sure you follow all safety procedures before • Clutches- Isolating a suspect clutch
working on the machine. Refer to (PIL 01-03). • Clutches- Individual clutch leakage test
27 - 46 9823/1700-1 27 - 46
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Figure 583. Test points
A D
H
Item Description
F Reverse high ratio clutch
Table 254. Test points
pressure
Item Description G Reverse low ratio clutch
A Mainline pressure pressure
B Mainshaft clutch pres- H Layshaft clutch pressure
sure J 2/4 wheel drive clutch
C Converter inlet and con- pressure
(1)
verter relief valve pres-

sure (1) Machines with selectable 2/4 wheel drive option.
D Forward high ratio clutch
pressure
E Forward low ratio clutch
pressure
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Mainline pressure 2.1. A low reading can be caused by either

a faulty pressure maintenance valve or a
1. Stop the engine, connect a pressure gauge of the worn pump. Refer to Figure 584.
specified limit to the mainline pressure test point.
2.2. A high or low reading may indicate a
faulty pressure maintenance valve. Refer to
Pressure: 0 –20 bar ( 0.0 –289.9 psi) Figure 584.
2. Start engine and run at 1000 RPM (Revolutions 3. Do the 2 again with engine running at 2000 RPM
Per Minute). With the transmission in neutral the note the gauge readings. Refer to Figure 584.
pressure gauge will show the main line pressure.
Refer to Figure 584. 4. Stop engine and remove the test gauge. Refer to
Figure 584.
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Figure 584. Pump flow test
A
L
X Y Z
P
Q
N
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Special Tool: Flowmeter (Qty.: 1)
Table 255. 4. Start engine and run at 1000 RPM. With the
transmission in neutral the flowmeter will show
Item Description
the pump flow. Refer to Figure 584.
A Mainline pressure test
point 4.1. A low reading indicates a worn pump or
K Transmission oil filter blocked suction strainer. Refer to Figure
L Flowmeter 584.
M Male adapter 5. Again do step 4 and note gauge readings with
N Female adapter engine running at 2000 RPM. Refer to Figure
P Banjo bolt 584.
Q Fitting adapter 6. Stop engine and remove test adapters. Remove
R Pressure test adapter the gearbox adapter and install the filter. Refer to
Figure 584.
Pump flow (machines with direct mount
oil filter) Converter in pressure
1. Stop the engine. Clean the area around the Note that the converter in pressure is affected by
transmission oil filter. Refer to Figure 584. the transmission oil temperature, cooler circuit back
pressure and torque converter relief valve operation.
2. Remove the filter and the adapter installed to the Before carrying out tests check the operation of the
gearbox. Refer to Figure 584. relief valve.
3. Install one of the three alternative pump flow 1. Stop the engine, connect a pressure gauge of the
test adapters in place of the oil filter. The choice specified limit to the converter inlet and converter
of adapter is best determined by the ease of relief valve pressure test point. Refer to Figure
installation and/or accessibility. Refer to Figure 585.
584.
Pressure: 0 –20 bar ( 0.0 –289.9 psi)
3.1. Note that adapter type 'z' is installed as Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
standard on machines with a remote oil
filter. Refer to Figure 584. 2. Start engine and run at 1000 RPM. With the
transmission in neutral the pressure gauge will
3.2. Type 'x': Install the female adapter in the show the converter in pressure. Refer to Figure
gearbox case. Install the male adapter in 585.
the female adapter. Install the pressure test
adapter over the female and male adapter. 2.1. A low reading could indicate a worn pump,
Install the oil filter to clamp the pressure test a worn pump would also be evident during
adapter in place.Refer to Figure 584. a pump flow test. Refer to Figure 585.
3.3. Type 'y': With the component parts 2.2. A high pressure together with low flow could
assembled, install and secure with banjo be caused by a blocked oil cooler. Refer to
bolt screwed into the gearbox and tightened Figure 585.
to the correct torque value. Refer to Figure 2.3. Low pressure could be caused by a faulty
584. pump or internal leakage. Refer to Figure
3.4. Type 'z': With the component parts 585.
assembled, install and secure with fitting
adapter screwed into the gearbox, and 3. Stop the engine and remove the pressure test
tightened to the correct torque value. Refer gauge. Refer to Figure 585.
to Figure 584.
3.5. Connect the flowmeter to the flow and
return adapters (shown with arrows). Refer
to Figure 584.
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Figure 585. Converter in, converter relief valve pressure tests

S
C Converter inlet and converter relief valve S Load valve

pressure test point
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Converter relief (safety valve) pressure does not indicate a fault. If necessary reset the
load valve and perform the test again, carefully
The purpose of the torque converter relief valve is watch the pressure gauge. Refer to Figure 585.
to protect the torque converter from excessive oil
pressure. Excessive oil pressure can be generated 6. If the converter relief valve opens at a pressure
when the transmission oil temperature is below 50 higher than specified then the valve is faulty.
°C ( 121.9 °F) and/or the engine is run at over 2000 Refer to Figure 585.
RPM. 7. A low opening pressure indicates a leaking pump
to casing seal or a faulty converter relief valve.
In this event the relief valve opens and returns
oil directly to the transmission sump, bypassing
the torque converter, cooler and clutch lubrication 8. Stop engine, remove test gauges and the load
circuits, protecting against damage due to excessive valve. Refer to Figure 585.
pressure.
9. Install hoses to their original position. Refer to
For this reason it is essential that the transmission Figure 585.
oil should be more than 50 °C ( 121.9 °F) and the
engine should run between idle and 1000 RPM when Bypassing the converter relief valve
you test the relief valve.
During some powershift pressure and oil flow tests
1. Connect a pressure gauge of the specified limit
it is advisable to temporarily bypass the converter
to the converter inlet and converter relief valve
relief valve. If the relief valve opens at the time of the
pressure test point. Refer to Figure 585.
following tests it will cause false results.
Pressure: 0 –20 bar ( 0.0 –289.9 psi)
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) • Converter out pressure/Oil cooler flow rate
• Converter in pressure
2. Install a load valve into the converter out line. • Lubrication pressure
Make sure the load valve is fully open before • Torque converter stall test
starting the test. Refer to Figure 585.
Before you bypass the torque converter relief valve
3. Do not allow the pressure to exceed more than make sure that the mainline pressure is correct and
the specified value, or else it can damage the that the transmission oil filter is fitted.
converter seals. Refer to Figure 585.
Pressure: 8.3 bar ( 120.3 psi) To temporarily bypass the relief valve (prevent the
valve from opening) proceed as follows:
4. Start the engine and run at 1000 RPM. With the
transmission in neutral, slowly screw down the 1. Stop the engine and remove the relief valve.
load valve and monitor the gauge reading which Refer to Figure 586.
should increase to the converter relief (safety)
valve pressure setting. Refer to Figure 585. 2. Carefully remove the spring. Refer to Figure 586.
5. The gauge pressure will fall, once the valve has 3. Obtain a suitable plug, drill and tap the centre
opened. This is normal relief valve operation and then install a locking bolt. Refer to Figure 586.
27 - 52 9823/1700-1 27 - 52
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Figure 586. Bypass the converter relief valve
U
T
T Spring U Locking bolt

V Spool
4. Install the plug assembly to the relief valve 2. Do not run the engine at more than 2000 RPM
housing and tighten the bolt to hold the spool on for more than the specified time. Refer to Figure
its seat. Refer to Figure 586. 586.
5. Do not damage the spool and its seat. Refer to Duration: 1 min
Figure 586.
When the check is complete make sure to remove
The torque converter can be damaged when the the plug assembly and install the spring and cover/
converter relief valve is bypassed. To prevent the plug.
torque converter from damage follow the below
steps. Converter out pressure and oil cooler
flow rate
1. Before you start the engine make sure that
the transmission oil temperature is above the Note that the converter out pressure and oil cooler
specified value. Refer to Figure 586. flow rate are affected by the torque converter relief
Temperature: 50 °C ( 121.9 °F) valve operation. Before you carry out the test check
the operation of the relief valve.
27 - 53 9823/1700-1 27 - 53
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1. Stop the engine. Connect a pressure gauge cooler flow rate. Make sure that the readings are
of the specified limit and flowmeter into the correct. Refer to Figure 587.
converter out line. Refer to Figure 587.
4.1. A high pressure together with low flow could
Pressure: 0 –20 bar ( 0.0 –289.9 psi) be caused by a blocked oil cooler. Low
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) pressure could be caused by a faulty pump
Special Tool: Flowmeter (Qty.: 1) or internal leakage. Refer to Figure 587.
2. The flowmeter may cause back pressure, so 5. Do the steps 3 and 4 with engine running at 2000
bypass the torque converter relief valve or else RPM and note gauge readings. Refer to Figure
it may open and cause false readings. Refer to 587.
Figure 587.
6. Stop the engine. Remove test gauges and install
3. Run the engine at 1000 RPM with transmission hoses to original position. Refer to Figure 587.
in neutral. Refer to Figure 587.
7. Make sure you remove the torque converter
4. The pressure gauge indicates the converter out relief valve by-pass assembly and install the
pressure and the flowmeter indicates the oil relief valve (ball, spring and cover/plug). Refer to
Figure 587.
Figure 587. Converter out, Lubrication pressure tests
W
L
AA
L Flowmeter W Pressure gauge

AA Pressure gauge connected to the return line
from the oil cooler
27 - 54 9823/1700-1 27 - 54
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00 - General
Lubrication pressure park brake on. Therefore, so that we can

complete the test, move the park brake lever
Note that the lubrication pressure is affected by fractionally forward until the warning light is just
the torque converter relief valve operation and back extinguished; hold the lever in this position for the
pressure in the oil cooler circuit. Before you carry out duration of the test.
the test check the operation of the relief valve.
4. Do not move the lever too far forward, otherwise
1. Stop the engine, connect a suitable pressure the park brake will not be fully operational.
gauge into the return line from the oil cooler to Alternatively, disconnect the switch at the park
the transmission. Refer to Figure 587. brake.
2. Start the engine and run at 1000 rev/min. 5. Start engine and run at 1000 RPM, engage1st
With the transmission in neutral the pressure gear forward. Record the pressure reading.
gauge will indicate the lubrication pressure which Repeat the test for all gears in forward drive and
should be correct. Refer to Figure 587. record the pressure readings. Refer to Refer to
Table 256.
3. Do step 2 and note gauge readings with engine
running at 2000 RPM. If the pressure is high the 5.1. Readings should not vary between clutches
oil cooler may be blocked. Refer to Figure 587. by more than the specified value.
4. Stop the engine and remove the pressure gauge.
5.2. In the table of examples shown, we can
Isolate a suspect clutch see that pressure is low when 2nd and 4th
gear forward is selected, indicating clutch
1. Stop the engine. Connect a pressure gauge of leakage. Refer to Table 256.
the specified to the mainline pressure test point. 5.3. From the table we can see that the forward
Refer to Figure 588. high clutch is used for selection of both 2nd
Pressure: 0 –20 bar ( 0.0 –289.9 psi) and 4th gear forward.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
5.4. We know from the table that the mainshaft
2. Make sure that both sides of all four wheels are and layshaft clutches are working normally
chocked. Apply the foot brake and park brake. (1st and 3rd gear selection show normal
operating pressure). So we can assume
3. When fully engaged, the park brake electrically that the forward high clutch is leaking.
disconnects the transmission drive, this prevents
the machine from being driven with the 6. If necessary, do the above test again using
reverse clutch ratios.
Table 256.
Gear select Ratio clutch Mainshaft or layshaft Value (Examples Only)
clutch
1st Forward low Layshaft 9.65 bar ( 139.9 psi)
2nd Forward high Layshaft 8.62 bar ( 124.9 psi)
3rd Forward low Mainshaft 9.65 bar ( 139.9 psi)
4th Forward high Mainshaft 8.62 bar ( 124.9 psi)
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Figure 588.
A D
AB
A Mainline pressure (test point) D Forward high ratio clutch pressure (test point)
AB Layshaft clutch solenoid (3029)
Before you carry out individual clutch leakage tests, 4. Make sure that both sides of all four wheels are
we can confirm that the forward high clutch is leaking: chocked. Apply the foot brake and park brake.
Individual clutch leakage test 5. When fully engaged, the park brake electrically
In the following procedures the forward high clutch disconnects the transmission drive, this prevents
is tested, therefore in step 2 a pressure gauge is the machine from being driven with the
connected to the forward high clutch test point. park brake on. Therefore, so that we can
complete the test, move the park brake lever
When you test the other suspect clutches, connect fractionally forward until the warning light is just
a gauge to the relevant suspect clutch test point. extinguished; hold the lever in this position for the
Because the forward high clutch is suspect, a gear duration of the test. Refer to Figure 588.
must be selected that will use the forward high clutch, 6. Do not move the lever too far forward, otherwise
in this instance 2nd gear forward. the park brake will not be fully operational.
Alternatively, disconnect the switch at the park
1. Stop the engine. Connect a pressure gauge of
brake. Refer to Figure 588.
the specified to the mainline pressure test point.
Refer to Figure 588. 7. Start engine and run at 1000 RPM, select 2nd
Pressure: 0 –20 bar ( 0.0 –289.9 psi) gear forward. Note the pressure readings on both
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) gauges, which should not vary more than the
specified value. If the difference on the gauges is
2. Connect a pressure gauge of the specified vale greater than the specified value do the following.
to the forward high ratio clutch test point. Refer Refer to Figure 588.
to Figure 588.
Pressure: 0 –20 bar ( 0.0 –289.9 psi)
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) 7.1. Stop the engine and interchange the
gauges. Refer to Figure 588.
3. Remove the electrical connector from the
layshaft clutch solenoid. This will ensure that only 7.2. Start the engine and run at 1000 RPM,
the forward high clutch is energised when 2nd select 2nd gear forward. If the difference on
gear forward is selected. Refer to Figure 588. the gauges is still greater than the specified
27 - 56 9823/1700-1 27 - 56
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00 - General
value then disassemble the forward high 7.3. If after interchanging the gauges, the
clutch. Refer to Figure 588. readings are different than the value
mentioned in step 7 then calibrate the
gauges and again do the check. Refer to
Figure 588.
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Figure 589. Transmission Technical Data Checklist
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Remove and Install
Remove 7. Carefully remove the gearbox from the torque

converter, keep the assemblies square to each
1. Because of the configuration of the engine and other.
transmission mounting system, the powershift
gearbox should be removed from the machine Figure 590.
together with the engine, bevel gearbox, torque
converter and hydraulic pump as a full assembly.
Refer to Engine- General. Refer to (PIL 15-00).
2. Support the engine and transmission assembly
on a suitable frame. Remove the engine lifting
beam.
3. Make sure that the engine is safely supported
when the transmission components are
removed.
5. Disconnect the following external oil hoses and
pipes, typically as follows.
5.1. Oil cooler hose 1 and hose 2.
5.2. Bevel gearbox drain pipe.
5.3. Remote oil filter pipes (if installed). x
6. Support the gearbox with suitable lifting gear and

remove the bolts that connect the gearbox to the X Hole
torque converter housing.
27 - 59 9823/1700-1 27 - 59
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Figure 591.
E C F
B D
A Frame B Cooler hose 1

C Cooler hose 2 D Drain pipe
E Oil filter pipes F Bolts
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Install
steps.
1.1. Before you install the powershift gearbox,
make sure that the pressure test points are
installed at the clutch pressure test points.
Refer to driveline- semi-automatic gearbox.
1.2. Make sure you align the gearbox square to
the torque converter housing.
1.3. Insert the torque converter drive shaft in to
the opening of the pump, make sure that
the drive shaft engages correctly with the
pump. Take care not to damage the oil seal.
1.4. Do not use the housing bolts or any other
device to pull the assemblies together.
1.5. Make sure you install any cable tie locators
retained by the bolts.
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For: PS750 MK3 ....................... Page 27-62 have been replaced. However, after assembly, the
For: PS750 MK4 ....................... Page 27-62 clutch shaft end floats must be checked to confirm
correct assembly and tolerances. This is particularly
important if components such as clutch shafts or
(For: PS750 MK3) gearbox cases have been replaced. If the end float is
found to be outside the permissible limits, new shims
Disassemble must be installed. Make sure that the correct shim
kits are available.
With the gearbox removed from the machine, place
suitable wooden blocks to securely support the 1. Install the output shaft.
assembly.
2. Install the front case and the clutch shafts.
1. Separate the front and rear cases, and remove
the clutch shafts. (For: PS750 MK4)
2. Remove the output shaft. Before following some of the procedures, remove
the gearbox from its machine installation. Refer to
Disassembly the correct machine service documentation. The
table lists all the service procedures for the gearbox.
Clutch shaft end float is controlled using spacers. For some procedures it is necessary to do other
Usually these spacers can be installed again to procedures first, these are shown in the table.
achieve the correct end float, even if components
Table 257. Service Procedures List

Serial No. Procedure Name Do these procedures first
1 Oil Filter - Removal and Replace- -
ment. Refer to (PIL 27-06-39).
2 Suction Strainer - Removal and -
Replacement. Refer to (PIL
27-06-40).
3 4 Wheel Drive Yoke and Oil Seal - -
Removal and Replacement. Refer
to (PIL 27-06-95).
4 Brake Disc - Removal and Re- -
placement Refer to (24-18-21).
5 Solenoid Control Valves - Re- -
moval and Replacement. Refer to
(27-06).
6 Torque Converter Relief Valve - -
Removal and Replacement. Refer
to (27-14).
7 Pressure Maintenance Valve - Re- -
(27-06-21).
8 Speed Sensors - Removal and Re- -
placement.
9 Oil Pressure Switch - Removal and -
Replacement. Refer to (27-06-30).
10 Oil Pump - Removal, Inspec- -
tion and Replacement. Refer to
(27-06-24).
11 Clutches - Removal. Refer to 1, 2, 3, 5, 8, 9, 10
(1)
(27-06).
12 Clutches - Replacement. Refer to -
(27-06).
27 - 62 9823/1700-1 27 - 62
27 - Driveline
00 - General
Serial No. Procedure Name Do these procedures first

13 Output Shaft and Bearing - Re- 11
(27-06-58).
14 Input Clutch, Forward and Revers- 11
er Clutch - Disassemble. Refer to
(27-06).
15 Input Clutch, Forward and Revers- -
er Clutch - Assemble. Refer to
(27-06).
16 Layshaft Clutch - Disassemble. 11
Refer to (27-06-08).
17 Layshaft Clutch - Assemble. Refer -
to (27-06-08).
18 Main shaft Clutch - Disassemble. 11
Refer to (27-06-54).
19 Main shaft Clutch - Assemble. Re- -
fer to (27-06-54).
20 2 and 4 Wheel Drive Clutch (4WD 11
Pressure ON) - Disassemble. Re-
fer to (27-06-07).
21 2 and 4 Wheel Drive Clutch (4WD -
Pressure ON) - Assemble. Refer to
(27-06-07).
21 2 and 4 Wheel Drive Clutch S1 11
(4WD Spring ON) - Disassemble.
Refer to (27-06-07).
23 2 and 4 Wheel Drive Clutch S1 -
(4WD Spring ON) - Assemble. Re-
fer to (27-06-07).
24 2 And 4 Wheel Drive Clutch (4WD 11
Spring ON) - Pressure Testing. Re-
fer to (27-06-07).
25 PTFE Piston Ring Seals. Refer to 11
(27-06-45).
(1) The components depicted in the procedures 5, 8, and 9 are to be removed to prevent component damage
during the disassembly of the gearbox.
27 - 63 9823/1700-1 27 - 63
27 - Driveline
06 - Clutch - Reverse
06 - Clutch - Reverse Introduction

Introduction .................................................... 27-64 The clutch is a mechanical device that engages
Check (Condition) .......................................... 27-65 and disengages the transmission, from driving shaft
Check (Pressure) .......................................... 27-65 to driven shaft. The clutch is located between the
Remove and Install ....................................... 27-66 engine and the gearbox, as disengaging it is required
to change gear.
The clutch is operated by a pedal using a hydraulic
or cable connection from the pedal to the clutch
mechanism.
The default state of the clutch is engaged, that is

the connection between the engine and gearbox is
always on unless the driver presses the pedal and
disengages it.
If the engine is running with the clutch engaged

and the transmission in neutral, the engine spins
the input shaft of the transmission, but no power
is transmitted to the wheels. Although the gearbox
does not stop rotating during a gear change, there
is no torque transmitted through it, thus less friction
between gears and their engagement gears.
27 - 64 9823/1700-1 27 - 64
27 - Driveline
Check (Condition) Check (Pressure)

Special Tools
Carry out a visual inspection of the friction and Description Part No. Qty.
counter plates: Hand Pump Pressure 892/00223 1
Test
Counter plates Pressure Test Adaptor 993/59300 1
1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored 1. Assemble the 2 and 4 wheel drive clutch. Refer to
must be replaced with a new set. the relevant Clutch- Disassemble and Assemble
procedure (PIL 27-06).
Friction plates 2. Check the clutch pack end float and adjust
as required. Refer to the relevant Clutch -
1. The cross hatching should be clearly visible, Disassemble and Assemble procedure (PIL
plates that are not flat, have friction material 27-06).
damage or scoring must be replaced with a new
set. 3. Use the service tool (993/59300), insert the
adaptor into the oil gallery in the end of the 2
2. DO NOT mix old and new plates, if a plate is and 4 wheel drive clutch shaft as shown. Hold the
damaged or worn install a complete new set. adaptor in position with clamp.
3. Needle roller bearings should slide into position Special Tool: Pressure Test Adaptor (Qty.: 1)
freely, do not bend or distort the cage to install. If
the cage has been distorted install new bearings. 4. Use the hand pump (892/00223) to pressurise
the clutch assembly until the gear can be turned
4. Take care when handling disc springs to avoid by hand. Note the pressure gauge reading. Do
marking or damage, which could result in stress not exceed the given value.
cracking. If in doubt install a new disc spring.
Special Tool: Hand Pump Pressure Test (Qty.: 1)
5. If the pressure gauge reading is between
the given values, then the clutch is operating
correctly and can be installed in the gearbox.
Pressure: 8.6 –9.3 bar ( 124.6 –134.8 psi)
6. If the pressure gauge reading is above the
given value, then check the clutch for assembly
defects, especially the clutch pack end float (the
shim may not be to the correct thickness). Re-
test after checking and rectify assembly defects.
27 - 65 9823/1700-1 27 - 65
27 - Driveline
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

(Four Wheel Drive) clutch, reverse clutch, main shaft
clutch and forward / input clutch are all part of the
main shaft assembly.
Refer to the main shaft remove and install procedure.

A Adaptor (Part of 993/59300)

B Clamp (Part of 993/59300)
27 - 66 9823/1700-1 27 - 66
27 - Driveline
Refer to Clutch-Input, Disassembly and Assembly

(PIL 27-06-11).
27 - 67 9823/1700-1 27 - 67
27 - Driveline
07 - Clutch - 2WD/4WD
07 - Clutch - 2WD/4WD Introduction

Introduction .................................................... 27-68 Refer to Driveline, Semi-Automatic Gearbox, Clutch-
Component Identification ............................... 27-69 Reverse, Introduction (PIL 27-06-06).
Check (Condition) .......................................... 27-74
Check (Pressure) .......................................... 27-74
27 - 68 9823/1700-1 27 - 68
27 - Driveline
For: PS750 MK3 ....................... Page 27-69

For: PS750 MK4 ....................... Page 27-71
For: PS750 MK4 ....................... Page 27-72
(For: PS750 MK3)
Figure 593. Pressure ON
N P
L N
K
U
T
S
R AA
Q
Y
AB H
X
W
V AC
A
E
D
C
B G
F
A Yoke B Bolt
C Gasket D Nut
E Washer F Housing
27 - 69 9823/1700-1 27 - 69
27 - Driveline
G Oil seal H Bearing 1

J Piston ring seal K Bearing 2
L Thrust washer 1 M Gear and splined hub
N Needle roller bearings (x2) P Thrust washer 2
Q Circlip 1 R Shim (if installed)
S Pressure end plate T Friction plates
U Counter plates V Circlip 2
W Spring retaining plate X Spring
Y Piston Z O-ring 1 (Piston)
AA O-ring 2 (Shaft) AB Oil baffle
AC Shaft
Figure 594. Spring ON
E F
L
F
D
C G N
M
U
H2
K
J
S
T
H1
Y
R
W
V
A Bearing 1 B Piston ring seal

C Bearing 2 D Thrust washer
E 4WD gear F Needle roller bearing
G Circlip 1 H1 Disc spring 1
H2 Disc spring 1 J Pressure end plate
K Shim L Friction and counter plates
M Circlip 2 N Support washer
P Clutch drum Q Actuating sleeve
27 - 70 9823/1700-1 27 - 70
27 - Driveline
R Disc spring 2 S Piston

T Spring steel ring U O-ring 1
V O-ring 2 W Piston housing
X Shaft Y Spacer
(For: PS750 MK4)
Figure 595. Pressure ON

G
F
E
F
D
C
M
L
K
J
H U
S
Q
P
N
A

C Bearing 2 D Thrust washer 1
E 4WD (Four Wheel Drive)gear and splined hub F Needle roller bearing
G Thrust washer 2 H Circlip 1
J Shim K Pressure end plate
L Friction plate M Counter plate
N Circlip 2 P Spring retaining plate
Q Piston spring R Oil baffle
S Piston T O-ring 1 (Piston)
U O-ring 2 (Shaft)
27 - 71 9823/1700-1 27 - 71
27 - Driveline
(For: PS750 MK4)
Figure 596. S1 Spring ON
E F
L
F
D
C G N
M
U
H2
K
J
S
T
H1
Y
R
W
V

X Shaft Y Spacer
27 - 72 9823/1700-1 27 - 72
27 - Driveline
Figure 597. S2 Spring ON

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16
1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9A Disc spring 1 9B Disc spring 1
10 Pressure end plate 11 Shim(s)
12 Friction plates and counter plates 13 Bearing 2
14 Thrust washer 3 15 Piston housing
16 O-ring 1 17 O-ring 2
18 Piston 19 Spring steel ring
20 Disc spring 2 21 Actuating sleeve
22 Clutch drum 23 Shaft
27 - 73 9823/1700-1 27 - 73
27 - Driveline
Check (Condition) Check (Pressure)

Special Tools
Do a visual check of the friction and counter plates Description Part No. Qty.
and gears: Hand Pump Pressure 892/00223 1
Test
Counter plates Pressure Test Adaptor 993/59300 1
that are not flat, worn or heavily marked or scored 1. Assemble the 2 and 4 wheel drive clutch. Refer to
must be replaced with a new one. the relevant Clutch- Disassemble and Assemble
Friction plates 2. Check the clutch pack end float and adjust
as required. Refer to the relevant Clutch -
1. The lubrication slots should be clearly visible, Disassemble and Assemble procedure (PIL
plates that are not flat, have friction material 27-06).
one. 3. Use the service tool (993/59300), insert the
adaptor into the oil gallery in the end of the 2
2. Do not change individual plates, if a plate is and 4 wheel drive clutch shaft as shown. Hold the
damaged or worn install a complete new set. adaptor in position with clamp.
3. Needle roller bearings should slide into position Special Tool: Pressure Test Adaptor (Qty.: 1)
the cage has been distorted install new bearings. 4. Use the hand pump (892/00223) to pressurise
the clutch assembly until the gear can be turned
The piston consists of a small check valve. Visually by hand. Note the pressure gauge reading. Do
check the piston to make sure that the ball is in not exceed the given value.
place and that the seat is free from contamination. Pressure: 13.8 bar ( 200.0 psi)
If necessary clean the valve by blowing through with Special Tool: Hand Pump Pressure Test (Qty.: 1)
an air line. Do not use a wire rod (or screwdriver) as
it can damage the valve seat. 5. If the pressure gauge reading is between
the given values, then the clutch is operating
Gears correctly and can be installed in the gearbox.
Pressure: 8.6 –9.3 bar ( 124.6 –134.8 psi)
1. Check the gear teeth for wear, cracking or
damage. 6. If the pressure gauge reading is above the
given value, then check the clutch for assembly
defects, especially the clutch pack end float (the
shim may not be to the correct thickness). Re-
test after checking and rectify assembly defects.
27 - 74 9823/1700-1 27 - 74
27 - Driveline
(For: PS750 MK3)

Special Tools
Drive Coupling 892/00812 1
Spanner
Consumables
Strength)
Remove
1. The following 2/4 wheel drive variants may be
installed:
1.1. Selectable 2/4 wheel drive. Gearbox
installed with a 4WD clutch unit.
1.2. Permanent 4 wheel drive. Gearbox installed
with a 4WD output shaft.
1.3. Permanent 2 wheel drive. Gearbox installed
A Adaptor (Part of 993/59300) with a blanking cover over the 4WD
B Clamp (Part of 993/59300) housing.
2. If applicable remove the 4WD clutch shaft
assembly or 4WD output shaft assembly
(permanent 4 wheel drive variant) as follows:
2.1. Remove the 11 bolts that attach the 4WD
clutch assembly.
2.2. Remove the 4WD clutch and shaft
assembly from the housing.
2.3. If the 4WD clutch assembly is to be
disassembled then hold the yoke with the
service tool.
Special Tool: Drive Coupling Spanner (Qty.:
1)
2.4. Loosen the retaining nut before you remove
the complete assembly.
2.5. Note: If the flywheel housing flange is the
SAE (circular) type, it will be necessary to
remove the SAE flange before the 4WD
clutch unit can be removed. Install the SAE
flange after removing the 4WD clutch unit.
27 - 75 9823/1700-1 27 - 75
27 - Driveline
Figure 599.
A
A Bolt (x11)
Install
1. Install the 4WD clutch assembly or output
shaft assembly (permanent 4WD variant) (if
applicable).
1.1. Use a new gasket and install the 4WD
clutch and shaft assembly.
1.2. Apply sealant to the threads of bolts.
(Medium Strength)
1.3. Tighten the bolts to the correct torque value.
1.4. Install the 4WD output shaft oil seal and
yoke if removed.
Note: On 2WD machines, the 4WD housing may be

sealed with either a blanking plate or by installing a
2WD type case.
27 - 76 9823/1700-1 27 - 76
27 - Driveline
For: PS750 MK3, Pressure ON Description Part No. Qty.

................................................... Page 27-77 Drive Coupling 892/00812 1
For: PS750 MK3, Spring ON ..... Page 27-81 Spanner
For: PS750 MK4, Pressure ON
................................................... Page 27-85 Consumables
For: PS750 MK4, S1, Spring ON Description Part No. Size
................................................... Page 27-89 JCB Threadlocker 4101/0250 0.01 L
For: PS750 MK4, S2, Spring ON and Sealer (Medium 4101/0251 0.05 L
................................................... Page 27-92 Strength)
(For: PS750 MK3, Pressure ON) Before you disassemble the 2 wheel drive (2WD) and
4wheel drive (4WD) clutch units, drain the gearbox
Special Tools oil.
Hand Pump Pressure 892/00223 1
Test
27 - 77 9823/1700-1 27 - 77
27 - Driveline
Disassemble
Figure 600.
N P
L N
K
U
T
S
R AA
Q
Y
AB H
X
W
V AC
A
E
D
C
B G
F
A Yoke B Bolt
C Gasket D Nut
E Washer F Housing
L Thrust washer 1 M Gear and splined hub
N Needle roller bearings (x2) P Thrust washer 2
Q Circlip 1 R Shim (if installed)
S Pressure end plate T Friction plates
U Counter plates V Circlip 2
27 - 78 9823/1700-1 27 - 78
27 - Driveline
W Spring retaining plate X Spring

Y Piston Z O-ring 1 (Piston)
AA O-ring 2 (Shaft) AB Oil baffle
AC Shaft
1. Hold the output yoke with the service tool and Figure 601.
loosen the nut.
Special Tool: Drive Coupling Spanner (Qty.: 1)
2. Remove the housing bolts and remove the unit
from the gearbox.
3. Remove the nut, washer, and yoke from the
shaft.
4. Remove the housing cover.
5. Remove the bearing 1 outer cup and the spacer
from the inside of the housing cover.
6. Remove the oil seal.
7. Remove the bearing 1, only if it is required to be
replaced. 15. Lift off the spring retaining plate.
8. Carefully remove the piston ring seal. 16. Remove the spring and the oil baffle.
8.1. If the piston ring seal is damaged or 17. Turn the assembly over and knock the clutch
excessively worn then check for burrs or shaft on a piece of aluminium (or wood) to loosen
damage on the shaft grooves. If necessary the piston.
remove burrs with a fine grade abrasion
paper and oil. 17.1. If the piston does not loosen, then hand
pump air down the shaft oil inlet hole.
9. With a puller or press, remove the 4WD gear and
Special Tool: Hand Pump Pressure Test
splined hub, together with its bearing 2, needle
(Qty.: 1)
roller bearing and thrust washer 1.
Figure 602.
10. Remove the thrust washer 2.
10.1. The thrust washer 1 and thrust washer 2
are not interchangeable.
11. Remove the circlip 1 that retains the friction and
counter plates.
12. Remove the pressure end plate and shim (If
applicable).
13. Remove the friction plates and the counter
plates.
13.1. Keep them together in sets, do not mix the
plates with those from other clutches.
CAUTION! The spring (or springs) apply

considerable force. Make sure you take care to 18. Remove the piston.
avoid damage or injury. 19. Remove and discard the piston O-ring 1.
14. Put the clutch assembly in a suitable press. 20. Remove and discard the shaft O-ring 2.
14.1. With a cut away tube compress the piston
spring and remove the circlip 2. Assemble
If only the clutch pack has been removed, begin at
step 7.
27 - 79 9823/1700-1 27 - 79
27 - Driveline
1. Install the new O-ring 1 onto the piston. 12. Adjust as necessary, by adding or removing
shims 2.
2. Install the new O-ring 2 onto the shaft.
13. Install the thrust washer 2.
3. Lubricate the piston with oil and press fully into
the bore of the clutch housing. 14. Carefully align the teeth of the clutch plates with
a thin rod (or screwdriver) and install the 4WD
CAUTION! The spring (or springs) apply gear and splined hub, needle roller bearings and
considerable force. Make sure you take care to thrust washer 1.
avoid damage or injury.
15. Apply gearbox oil on the clutch end bearing 2 and
4. Install the oil baffle and piston spring. Make sure press the bearing onto the shaft to seat on the
that the spring is positioned properly in the piston. thrust washer 1.
5. Install the spring retaining plate. 15.1. Take care not to exert any force on the
housing i.e. rest the unit on the opposite
6. Compress the spring with a cut away tube and shaft end, not the housing.
install the circlip 2.
16. Install the new piston ring seals.
7. Build up the clutch pack. Install one counter plate
followed by one friction plate. 17. If required, install the new bearing 1 onto the
shaft.
7.1. Continue to install alternate counter and
friction plates, finishing with a friction plate. 18. Before pushing the outer cup of the bearing1
into the housing cover, make sure you install the
8. Install the pressure end plate and the shim (If spacer.
applicable).
Figure 604.
9. Install the friction and counter plate retaining
circlip 1.
H
10. Use an air line to blow air down the shaft oil inlet
hole and check the piston and clutch pack is free
to operate smoothly.
11. Use screwdrivers to measure the clutch pack end
float. The value should be within the specified
range.
Dimension: 1 –2.3 mm
Figure 603.
AF
H Bearing 1
AB AF Spacer
19. Install the 4WD clutch to the gearbox with a new
gasket.
20. Apply sealant to the threads of the bolts.
(Medium Strength)
22. Install the output yoke, the washer, and the
AB retaining nut.
23. Tighten the nut to the correct torque value.
23.1. Some gearboxes use a flanged bolt in
place of the nut and washer (the 4WD
shaft has an internal thread). This bolt
27 - 80 9823/1700-1 27 - 80
27 - Driveline
must be tightened to the correct torque 29. Stake the nut to the shaft with a square ended
value. staking tool.
Torque: 395 N·m Figure 605.
23.2. The end float of the clutch shaft is
controlled without the use of shims.
This is achieved by using a `set-right'
tolerancing system during manufacture.
After assembly the clutch shaft end
floats must be checked to confirm
correct assembly and tolerances. This is
particularly important if components such
as clutch shafts or gearbox casings have
been renewed.
24. Measure the shaft end float. The value should be
within the specified limit.
29.1. Some gearboxes use a flanged bolt in
place of the nut and washer (the 4WD
24.1. Rotate the shaft when you measure the shaft has an internal thread). This bolt
end float to fully seat the bearings. must be tightened to the correct torque
value.
25. Remove the retaining nut, the washer, and the Torque: 395 N·m
output yoke.
26. Install a new oil seal. Table 258. Torque Values
Item Nm
B 56
retaining nut.
D 400
28. Tighten the nut to the correct torque value.
(For: PS750 MK3, Spring ON)

Special Tools Consumables
Description Part No. Qty. Description Part No. Size
Drive Coupling 892/00812 1 JCB Threadlocker 4101/0250 0.01 L
Spanner and Sealer (Medium 4101/0251 0.05 L
Strength)
27 - 81 9823/1700-1 27 - 81
27 - Driveline
Disassembly
Figure 606.
M N
T
N
L
K P V
U
AB
Q2
S
R
Z
AA
Q1
AF
Y
AE
AD
AC
A
E
D
C
B G
F
A Yoke B Bolt
C Gasket D Nut
E Washer F Housing
L Thrust washer M 4WD gear
N Needle roller bearing P Circlip 1
Q1 Disc spring 1 Q2 Disc spring 1
27 - 82 9823/1700-1 27 - 82
27 - Driveline
R Pressure end plate S Shim

T Friction and counter plates U Circlip 2
V Support washer W Clutch drum
X Actuating sleeve Y Disc spring 2
Z Piston AA Spring steel ring
AB O-ring 1 AC O-ring 2
AD Piston housing AE Shaft
AF Spacer
1. Hold the output yoke with the service tool and 14. Remove the clutch drum and the actuating
loosen the nut. sleeve.
Special Tool: Drive Coupling Spanner (Qty.: 1) 15. Remove the disc spring 2.
2. Remove the housing bolts and remove the unit 16. Remove the piston and its spring steel ring.
from the gearbox.
17. Remove and discard the piston O-ring 1 and O-
3. Remove the nut, washer, and yoke from the ring 2.
shaft.
18. If necessary, remove the piston housing. The
4. Remove the housing cover. piston housing is a press fit on the shaft.
5. Remove the bearing 1 outer cup and the spacer
from the inside of the housing cover. Assembly
6. Remove the oil seal. 1. Lubricate the shaft.
7. Remove the bearing 1 from the shaft only if it is 2. Install the piston housing by pressing the shaft
to be replaced. squarely into the housing (make sure the housing
is securely supported).
8. Carefully remove the piston ring seal.
3. Install the O-ring 1 and O-ring 2 onto the piston.
8.1. Note: If the piston ring seal is damaged
or excessively worn then check for burrs 4. Lubricate the piston with oil and press fully into
or damage on shaft grooves. If necessary the bore of the housing.
paper and oil. 5. Install the spring steel ring. Make sure that the
seal seats properly in its groove.
9. With a suitable puller, remove the 4WD gear
together with its bearing 2, thrust washer, and the 6. Put the disc spring 2 into the housing.
needle roller bearings (x2). 7. Put the actuating sleeve onto the disc spring.
CAUTION! The spring (or springs) apply 8. Install the clutch drum in the housing.
considerable force. Make sure you take care to
avoid damage or injury. 9. Install the support washer and drum retaining
circlip 2.
10. Use a suitable press and compress the disc
springs to remove the circlip 1. 10. Build up the clutch pack. Install one friction plate
followed by one counter plate.
10.1. There is considerable force applied by the
springs. 10.1. Continue to install alternate counter and
friction plates, finish with the pressure
Weight/Force: 26,700 N plate.
11. Remove the disc springs 1 (x4), pressure end 11. Use the 4WD gear to align the clutch plate
plate and the shims. splines. Make sure that all the plates are
12. Remove the clutch pack friction plates and engaged with the gear shaft splines.
counter plates. 12. Rotate the 4WD gear back and forth to create
12.1. Keep them together in sets, do not mix the maximum backlash then remove the gear taking
plates with those from other clutches. care not to disturb the pack.
13. Remove the clutch drum retaining circlip 2 and CAUTION! The spring (or springs) apply
support washer. considerable force. Make sure you take care to
27 - 83 9823/1700-1 27 - 83
27 - Driveline
13. Put the first two disc springs 1 with their convex 18. Install the 4WD gear onto the shaft.
sides uppermost, onto the clutch pack. (There
are four disc springs 1, which are identical). Put 19. Install the thrust washer.
the other two disc springs 1, with their convex
sides down, onto the first two. 20. Apply gearbox oil on the clutch end bearing 2 and
press the bearing onto the shaft to seat on the
Figure 607. thrust washer.
21. Install the new piston ring seal.
22. If required, install the new bearing 1 onto the
shaft.
23. Before pushing the outer cup of bearing 1 into the
housing cover make sure you install the spacer.
Figure 609.
14. Use a suitable press to compress the disc spring

and install the circlip 1.
15. Use levers to remove free play.
Figure 608.
AF
H Bearing 1
AF Spacer
24. Do an operational test of the clutch assembly.
25. Install the 4WD clutch to the gearbox with a new
gasket.
(Medium Strength)
16. Measure the gap between the pressure end plate
and the actuating sleeve. 27. Tighten the bolts to the correct torque value.
16.1. The gap should be within the range 28. Install the output yoke, the washer, and the
specified. retaining nut.
Length/Dimension/Distance: 0.75 –1.5 29. Tighten the nut to the correct torque value.
mm
16.2. If necessary, install a new shim to get the 29.1. The end float of the clutch shaft is
correct gap. controlled without the use of shims.
This is achieved by using a `set-right'
16.3. The shim can be a combination of a tolerancing system during manufacture.
single counter plate, shim (thinner than the After assembly the clutch shaft end
counter plate) or both counter plate and floats must be checked to confirm
shim. correct assembly and tolerances. This is
16.4. Make sure that the clutch pack splines are particularly important if components such
still aligned. as clutch shafts or gearbox cases have
been renewed.
17. Install the two needle roller bearings into 4WD
gear.
27 - 84 9823/1700-1 27 - 84
27 - Driveline
30. Measure the shaft end float. The value should be Figure 610.
30.1. Rotate the shaft while you measure the
end float to fully seat the bearings.
31. Remove the retaining nut, the washer, and the
output yoke.
32. Install a new oil seal.
retaining nut.
34. Tighten the nut to the correct torque value. Table 259. Torque Values
35. Stake the nut to the shaft with a square ended Item Nm
staking tool. B 56
D 400
(For: PS750 MK4, Pressure ON)

Special Tools
Test
27 - 85 9823/1700-1 27 - 85
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Disassemble
Figure 611.
G
F
E
F
D
C
M
L
K
J
H U
S
Q
P
N
A

C Bearing 2 D Thrust washer 1
E 4WD gear and splined hub F Needle roller bearing
G Thrust washer 2 H Circlip 1
J Shim K Pressure end plate
L Friction plate M Counter plate
N Circlip 2 P Spring retaining plate
Q Piston spring R Oil baffle
S Piston T O-ring 1 (Piston)
U O-ring 2 (Shaft)
1. Remove the bearing 1, only if it is required to be or damage on shaft grooves. If necessary

replaced. remove burrs with a fine grade abrasion
paper and oil.
2. Carefully remove the piston ring seal.
2.1. Note: If the piston ring seal is damaged
or excessively worn then check for burrs
27 - 86 9823/1700-1 27 - 86
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3. With a puller or press, remove the 4WD gear and Figure 613.
splined hub, together with its bearing 2, needle
roller bearing and thrust washer 1.
4.1. Note the thrust washer 1 and thrust washer
2 are not interchangeable.
5. Remove the circlip 1 that retains the friction and
counter plates.
6. Remove the pressure end plate and shim (If
applicable).
plates.
7.1. Keep them together in sets, do not mix the 12. Remove the piston.
13. Remove and discard the piston O-ring 1.
8. Put the clutch assembly in a suitable press.
14. Remove and discard the shaft O-ring 2.
spring and remove the circlip 2.
Assemble
Figure 612.
1. Install the new O-ring 1 onto the piston.
2. Install the new O-ring 2 onto the shaft.
the bore of the clutch housing.
4. Install the oil baffle and piston spring. Make sure
that the spring is positioned properly in the piston.
5. Install the spring retaining plate.
6. Compress the spring with a cut away tube and
7. Install one counter plate followed by one friction
plate.
9. Lift off the spring retaining plate. 7.1. Continue to install alternate counter and
friction plates, finishing with a friction plate.
10. Remove the spring and oil baffle.
8. Install the pressure end plate. Make sure the
11. Turn the assembly over and knock the clutch chamfered face of the pressure end plate faces
shaft on a piece of aluminium (or wood) to loosen the clutch pack.
the piston.
9. Make sure that the teeth are not aligned with the
11.1. If the piston does not loosen, then hand lubrication slots in the housing.
pump air down the shaft oil inlet hole.
10. Do not install the shim at this stage.
(Qty.: 1) 11. Install the friction and counter plate retaining
circlip 1.
12. With a DTI (Dial Test Indicator) measure the end
float of the pressure end plate. The value should
be within the specified range.
Dimension: 1.9 –2.5 mm
27 - 87 9823/1700-1 27 - 87
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Figure 614. end plate, with either a shim or an extra counter

plate between the retaining circlip 1 and the
pressure end plate.
14. Use an air line to check the operation of the
clutch.
15. Install the thrust washer 2.
16. Carefully align the teeth of the clutch plates with
a thin rod (or screwdriver) and install the 4WD
gear and splined hub, needle roller bearings and
thrust washer 1.
13. If it is necessary to adjust the end float to bring it thrust washer 1.
within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure 18. Install the new piston ring seals.
27 - 88 9823/1700-1 27 - 88
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(For: PS750 MK4, S1, Spring ON)
Disassemble
Figure 615.
E F
L
F
D
C G N
M
U
H2
K
J
S
T
H1
Y
R
W
V

X Shaft Y Spacer
1. Remove the bearing 1 from the shaft only if it is 2. Carefully remove the piston ring seal.
to be replaced.
27 - 89 9823/1700-1 27 - 89
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2.1. Note: If the piston ring seal is damaged 8. Install the clutch drum in the housing.
or excessively worn then check for burrs
or damage on shaft grooves. If necessary 9. Install the support washer and drum retaining
remove burrs with a fine grade abrasion circlip 2.
paper and oil.
10. Build up the clutch pack. Install one friction plate
3. With a suitable puller, remove the 4WD gear followed by one counter plate.
together with its bearing 2, thrust washer, and the
needle roller bearings (x2). 10.1. Continue to install alternate counter and
friction plates, finish with the pressure
CAUTION! The spring (or springs) apply plate.
considerable force. Make sure you take care to 11. Use the 4WD gear to align the clutch plate
avoid damage or injury. splines. Make sure that all the plates are
engaged with the gear shaft splines.
4. Use a suitable press and compress the disc
springs to remove the circlip 1. 12. Rotate the 4WD gear back and forth to create
maximum backlash then remove the gear taking
4.1. There is considerable force applied by the
care not to disturb the pack.
springs.
Weight/Force: 26,700 N 13. Put the first two disc springs 1 with their convex
5. Remove the disc springs 1 (x4), pressure end are four disc springs 1, which are identical). Put
plate and the shims. the other two disc springs 1, with their convex
sides down, onto the first two.
6. Remove the clutch pack friction plates and
counter plates. Figure 616.
6.1. Keep them together in sets, do not mix the
7. Remove the clutch drum retaining circlip 2 and
support washer.
8. Remove the clutch drum and the actuating
sleeve.
9. Remove the disc spring 2.
10. Remove the piston and its spring steel ring.
11. Remove and discard the piston O-ring 1 and O-
ring 2.
12. If necessary, remove the piston housing. The
piston housing is a press fit on the shaft.
Assemble 14. Use a suitable press to compress the disc spring
and install the circlip 1.
1. Lubricate the shaft.
15. Use levers to remove free play.
2. Install the piston housing by pressing the shaft
squarely into the housing (make sure the housing
is securely supported).
3. Install the O-ring 1 and O-ring 2 onto the piston.
the bore of the housing.
5. Install the spring steel ring. Make sure that the
seal seats properly in its groove.
6. Put the disc spring 2 into the housing.
7. Put the actuating sleeve onto the disc spring.
27 - 90 9823/1700-1 27 - 90
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Figure 617. 16.3. The shim can be a combination of a

single counter plate, shim (thinner than the
counter plate) or both counter plate and
shim.
16.4. Make sure that the clutch pack splines are
still aligned.
17. Install the two needle roller bearings into 4WD
gear.
18. Install the 4WD gear onto the shaft.
19. Install the thrust washer.
16. Measure the gap between the pressure end plate thrust washer.
and the actuating sleeve.
16.1. The gap should be within the range
specified. 22. If required, install the new bearing 1 onto the
shaft.
Length/Dimension/Distance: 0.75 –1.5
mm 23. Before pushing the outer cup of bearing 1 into the
housing cover make sure you install the spacer.
16.2. If necessary, install a new shim to get the
correct gap. 24. Do an operational test of the clutch assembly.
27 - 91 9823/1700-1 27 - 91
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(For: PS750 MK4, S2, Spring ON)
Disassemble
Figure 618.
8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16
1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9 Disc spring 1 (x4) 10 Pressure end plate
11 Shim(s) 12 Friction plates and counter plates
13 Bearing 2 14 Thrust washer 3
15 Piston housing 16 O-ring 1
17 O-ring 2 18 Piston
19 Spring steel ring 20 Disc spring 2
27 - 92 9823/1700-1 27 - 92
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21 Actuating sleeve 22 Clutch drum

23 Shaft
1. Carefully remove the piston ring seal from the Figure 619.
shaft. AA
1.1. If the piston ring seal is damaged or
excessively worn then check for burrs or
damage on the shaft grooves. If necessary
paper and oil.
2. Use a suitable puller to remove the 4WD gear
with its related bearing 1, thrust washer 1, needle
roller bearing 1, and needle roller bearing 2. AB
AA Rounded profile
CAUTION! The spring (or springs) apply AB Flat profile
avoid damage or injury. 1.2. Install the needle roller bearings on the
4WD gear with the flat end profiles facing
3. Use a suitable press to compress the disc spring out (nearest the ends of the shaft).
1 and remove the circlip.
1.3. Use a suitable press to press the needle
3.1. There is considerable clamping force acting roller bearings into the 4WD gear.
on the springs.
2. Install the O-rings 1 and O-rings 2 onto the
Weight/Force: 26,700 N piston.
4. Remove the disc spring 1 (x4), pressure end 3. Lubricate the piston with oil and press fully into
plate and shim(s). the bore of the piston housing.
5. Remove the clutch pack friction plates and 4. Install the spring steel ring onto the piston. Make
counter plates. sure that the seal seats firmly in its groove.
5.1. Keep them together in sets, do not mix the Figure 620.
7. Use a suitable press on the output end of the
shaft and push the clutch drum with its related
bearing 2, thrust washer 3, piston housing, and
actuating sleeve.
8. Remove the disc springs 2.
18 19
9. Remove the piston and its spring steel ring.
18 Piston
10. Remove and discard the piston O-ring 1 and O- 19 Spring steel ring
ring 2.
5. Use a suitable press to assemble the shaft to the
Assemble piston housing and clutch drum as follows:
1. Install the needle roller bearing 1 and needle 5.1. Place the thrust washer 3 on the press.
roller bearing 2 to the 4WD gear in the correct Arrange the press so that the shaft can
orientation. pass through the thrust washer a sufficient
distance during assembly.
1.1. One end of the bearing has a rounded 5.2. Put the piston housing and piston assembly
profile and the other end has a flat profile. centrally on the thrust washer.
5.3. Put the disc spring 2 in position.
27 - 93 9823/1700-1 27 - 93
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Figure 621. 5.7. The shaft will approximately drop to

the specified distance when the splines
engage.
Distance: 3 mm
5.8. Important: Make sure that the shaft and
clutch drum splines align and engage
correctly. If the splines are not aligned
the force from the press will damage the
components.
5.9. Put a suitable bushing at the top of the shaft
18 Piston and use the press to push the shaft fully
20 Disc spring 2 onto the piston housing and clutch drum.
Make sure that there are no splines visible.
5.4. Put the actuating sleeve over the clutch
drum and then put the clutch drum in the 6. Install the thrust washer 2. Make sure that the
piston housing. thrust washer 2 is positioned over the collar on
the shaft correctly.
Figure 622.
Figure 624.
AD
7 Thrust washer 2
23 Shaft
15 Piston housing AD Collar
20 Disc spring 2
21 Actuating sleeve 7. Build the clutch pack. Install one friction plate
22 Clutch drum followed by one counter plate.
5.5. Put the shaft on the clutch drum and piston 7.1. Continue to install alternate counter and
housing. friction plates.
Figure 623. 7.2. Install the friction plates so that the cross
hatching pattern aligns with each adjacent
plate.
Figure 625.
AC
22 Clutch drum
23 Shaft
AC Splines
5.6. Hold the clutch drum and carefully rotate the AE
shaft until the splines engage. 24 Cross hatching pattern
27 - 94 9823/1700-1 27 - 94
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7.3. Install the shim or shims as applicable after 14. Measure the gap between the pressure end plate
you install the final counter plate. and actuating sleeve.
8. Install the pressure plate with its chamfer side 14.1. The gap should be within the specified
facing down. range.
9. Use the 4WD gear to align the clutch plate Distance: 0.75 –1.5 mm
splines. 14.2. If necessary install a new shim to achieve
the correct gap.
9.1. Make sure that all the plates are engaged
with the gear shaft splines. 14.3. The shim can be a combination of a
single counter plate, shim (thinner than the
9.2. Rotate the 4WD gear back and forth to counter plate) or both counter plate and
create maximum backlash then remove the shim.
gear taking care not to disturb the pack.
15. Make sure that the clutch pack splines are still
10. Place the first two disc springs 1 with their convex aligned and install the 4WD gear.
are four disc springs 1, which are identical). 16. Install the thrust washer 1.
11. Place the other two disc springs 1, with their 17. Apply oil on the bearing 1 and press the bearing
convex sides down, onto the first two. onto the shaft to seat on the thrust washer 1.
Figure 626. 18. Install the thrust washer 2.
19. Apply oil on the bearing 2 and press the bearing
onto the shaft to seat on the thrust washer 2.
21. Do an operational test of the clutch assembly.

12. Use a suitable press to compress the disc springs

1 and install the retaining circlip.
13. Use levers to remove the free play.
Figure 627.
27 - 95 9823/1700-1 27 - 95
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08 - Clutch - Layshaft
08 - Clutch - Layshaft Component Identification

Check (Condition) .......................................... 27-99
Calibrate ........................................................ 27-99
27 - 96 9823/1700-1 27 - 96
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Figure 628.
AA
D AB X
C
AC
P
Z L
J
R
Q B
N
K
H A
G
F
U S
W
V
T
A Piston ring seals B Taper roller bearing 1

C 4 wheel drive transfer gear D Taper roller bearing 2
E Piston housing F Spring retaining plate
G Spring H Oil baffle
J O-ring 1 K O-ring 2
L Circlip 1 M Gear and splined hub
27 - 97 9823/1700-1 27 - 97
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N Thrust washer 1 P Thrust bearing 1

Q Thin thrust washer 1 R Needle roller bearings
S Thin thrust washer 2 T Thrust bearing 2
U Circlip 2 V Outer pressure end plate
W Shim (if installed) X Friction plates
Y Counter plates Z Inner pressure end plate
AA Piston AB O-ring 3 (Piston)
AC Thrust washer 2
27 - 98 9823/1700-1 27 - 98
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Do a visual check of the friction and counter plates: End float measurement
Counter plates 1. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate.
that are not flat, worn or heavily marked or scored 2. The end float should be within the specified limit.
must be replaced with a new one. Dimension: 1.9 –2.5 mm
Friction plates Figure 629.
1. The cross hatching should be clearly visible,

plates that are not flat, have friction material
one.
2. Do not change individual plates, if a plate is A
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
the cage has been distorted install new bearings.
The piston consists of a small check valve. Visually

check the piston to make sure that the ball is in
place and that the seat is free from contamination.
If necessary clean the valve by blowing through with
it can damage the valve seat.
A DTI
3. If the end float is more than the specified value
then install a 6.0mm (0.23in) or 6.5mm (0.25in)
thick pressure end plate, with either a shim or an
extra counter plate between the retaining circlip
and the pressure end plate.
clutch.
27 - 99 9823/1700-1 27 - 99
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Remove and Install
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

(Four Wheel Drive) clutch, reverse clutch, mainshaft
clutch and forward / input clutch are all part of the
mainshaft assembly.
Refer to the mainshaft remove and install procedure.

27 - 100 9823/1700-1 27 - 100

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Disassemble
Figure 630.
AA
D AB X
C
AC
P
Z L
J
R
Q B
N
K
H A
G
F
U S
W
V
T
27 - 101 9823/1700-1 27 - 101

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C 4 wheel drive transfer gear D Taper roller bearing 2

E Piston housing F Spring retaining plate
G Spring H Oil baffle
J O-ring 1 K O-ring 2
L Circlip 1 M Gear and splined hub
N Thrust washer 1 P Thrust bearing 1
Q Thin thrust washer 1 R Needle roller bearings
S Thin thrust washer 2 T Thrust bearing 2
U Circlip 2 V Outer pressure end plate
W Shim (if installed) X Friction plates
Y Counter plates Z Inner pressure end plate
AA Piston AB O-ring 3 (Piston)
AC Thrust washer 2
1. Carefully remove the piston ring seals. 11. Remove the thin thrust washer 2 and thrust
bearing 2.
1.1. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft 12. Remove the circlip 2 that retains the friction
grooves. If necessary remove burrs with a plates and counter plates.
fine grade abrasion paper and oil.
13. Remove the outer pressure end plate and shim
2. Remove the taper roller bearing 1 with a suitable (if installed).
puller and press.
2.1. This bearing would not normally be plates.
removed unless it was damaged. It is
permissible to use a standard bearing 14.1. Keep them together in sets, do not mix the
puller, although damage to the bearing cage plates with those from other clutches.
may be incurred which will require a new
bearing. 15. Remove the inner pressure end plate.
3. From the opposite side of the shaft, use a 16. Remove the piston.
suitable puller to remove the 4WD transfer gear 17. Remove and discard the O-ring 3 from the piston.
(if applicable) and the taper roller bearing 2.
3.1. The gear and bearing 1 are under pressure Assemble
from the spring, make sure you proceed
with caution. 1. Install the O-ring 3 onto the piston.
3.2. Make sure to remove the thrust washer 2. 2. Lubricate the piston with oil and press fully into
3.3. Make a record of the orientation of the gear
for ease during assembly. 3. Install the inner pressure end plate. Make sure
3.4. The 2 wheel drive machines have a spacer that the teeth are not aligned with the lubrication
installed instead of a gear. slots in the housing.
4. Lift off the piston housing complete with clutch 3.1. Note: The inner pressure end plate is 4 mm
pack. (0.157 in) thick and should not be confused
with the outer pressure end plate which is
5. Lift off the spring retaining plate. either 6 mm (0.23 in) or 6.5 mm (0.25 in)
thick.
6. Remove the spring and the oil baffle.
4. Install one friction plate followed by one counter
7. Remove and discard the O-ring 1 and O-ring 2 plate.
from the shaft.
4.1. Continue to install alternate friction and
8. Remove the circlip 1. counter plates, finishing with a friction plate.
9. Remove the gear and the splined hub together 5. Install the outer pressure plate.
with the thrust washer 1, thrust bearing 1, and
thin thrust washer 1. 5.1. Make sure that the flatter of the two faces is
installed outermost. It will face against the
10. Remove the two needle roller bearing retaining circlip 2 when this is installed.
assemblies.
27 - 102 9823/1700-1 27 - 102

27 - Driveline
5.2. Make sure that the teeth are not aligned with 17.1. Note: Always check that the oil baffle plate
the lubrication slots in the housing. and spring retaining plate are in the correct
order.
18. Carefully align the teeth of the clutch plates using
7. Install the friction and counter plates retaining a thin rod (or screwdriver).
circlip 2.
18.1. Wedge the plates together by inserting two
8. With a DTI (Dial Test Indicator) measure the end blunt tools (small rounded screwdrivers)
float of the pressure end plate. The value should through the bottom holes in the side of the
be within the specified range. clutch housing.
Figure 632.
Figure 631.
A A
A DTI
A Screwdrivers
9. If it is necessary to adjust the end float to bring
it within tolerance, there is a choice to install a 18.2. Position the clutch assembly onto the shaft
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure and splined hub.
end plate, with either a shim or an extra counter
plate between the retaining circlip 2 and pressure 19. Position the 4 wheel drive transfer gear onto the
end plate. shaft spline.
10. Install the thrust bearing 2 and thin thrust washer 19.1. Make sure that the gear is installed in the
2. correct position.
19.2. The 2 wheel drive machines have a spacer
11. Install the two needle roller bearings. installed instead of a gear.
12. Install the gear and splined hub. 20. Install the thrust washer 2 over the shaft.
13. Install the thin thrust washer 1, thrust bearing 1, 21. Apply gearbox oil onto the taper roller bearing
and thrust washer 1. 2 and install the bearing and the 4 wheel drive
14. Install the circlip 1. transfer gear into position with a bench press.
15. Install the spring and spring retainer. 21.1. When the taper roller bearing and the 4
wheel drive transfer gear have been fully
16. Install the new o-ring 1 and o-ring 2 onto the installed on the shaft, remove the two blunt
shaft. tools (small rounded screwdrivers) used to
wedge the clutch plates.
17. Install the oil baffle.
21.2. Rotate the gear to make sure that the
clutch has been correctly installed.
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21.3. Use an air line to check the operation of

the clutch.
22. Apply gearbox oil onto the taper roller bearing 1
and install the bearing onto the shaft.
23. Install the new piston ring seals.
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09 - Clutch - Main Shaft
09 - Clutch - Main Shaft Component Identification

Check (Condition) ........................................ 27-108
Calibrate ...................................................... 27-108
27 - 105 9823/1700-1 27 - 105

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Figure 633.
M
N
P J
K
L
Q
G
B
A
Item Description
Table 260. D Circlip 1
Item Description E Pressure plate
A Piston ring seals F Shim (if installed)
B Taper roller bearing 1 G Friction plates
C Taper roller bearing 2 H Counter plates
27 - 106 9823/1700-1 27 - 106

27 - Driveline
Item Description
J Circlip 2
K Spring retaining plate
L Spring
M Oil baffle
N Piston
P O-ring 1 (Piston)
Q O-ring 2 (Shaft)
27 - 107 9823/1700-1 27 - 107

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Do a visual check of the friction and counter plates: End float measurement
Counter plates 1. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate.
that are not flat, worn or heavily marked or scored 2. The end float should be within the specified limit.
must be replaced with a new one. Dimension: 1.9 –2.5 mm
Friction plates Figure 634.

one.
2. Do not change individual plates, if a plate is A

A DTI
3. If the end float is more than the specified value
then install a 6.0mm (0.23in) or 6.5mm (0.25in)
thick pressure end plate, with either a shim or an
extra counter plate between the retaining circlip
clutch.
27 - 108 9823/1700-1 27 - 108

27 - Driveline
Remove and Install
The layshaft clutch, 2WD / 4WD clutch, reverse

clutch, mainshaft clutch and forward / input clutch are
all part of the mainshaft assembly.

27 - 109 9823/1700-1 27 - 109

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Special Tools
Test
27 - 110 9823/1700-1 27 - 110

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Disassemble
Figure 635.
M
N
P J
K
L
Q
G
B
A

C Taper roller bearing 2 D Circlip 1
E Pressure plate F Shim (if installed)
G Friction plates H Counter plates
J Circlip 2 K Spring retaining plate
L Spring M Oil baffle
27 - 111 9823/1700-1 27 - 111

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N Piston P O-ring 1 (Piston)

Q O-ring 2 (Shaft)
1. Carefully remove the piston ring seals. 10.1. Note: If the piston does not loosen, then
hand pump air down the shaft oil inlet hole.
1.1. Note: If the piston ring seals are excessively
worn then check for burrs or damage on the Special Tool: Hand Pump Pressure Test
shaft grooves. If necessary remove burrs (Qty.: 1)
with a fine grade abrasion paper and oil. Figure 637.
2. Remove the taper roller bearing 1 with a suitable
puller and press.
2.1. Note: This bearing would not normally
be removed unless it was damaged. It
is permissible to use a standard bearing
puller, although damage to the bearing cage
may be incurred which will require a new
bearing.
3. Remove the taper roller bearing 2 from the
opposite of the shaft.
4. Remove the retaining circlip 1 of the friction and
counter plates.
5. Remove the pressure end plate and shim if
installed. 11. Remove the piston.
6. Remove the friction plates and counter plates. 12. Remove and discard the piston O-ring 1.
6.1. Keep them together in sets, do not mix the 13. Remove and discard the shaft O-ring 2.
Assemble
spring and then remove the circlip 2. 2. Install the new O-ring 2 onto the shaft.
Figure 636. 3. Lubricate the piston with oil and press fully into
4. Install the oil baffle and piston spring. Make sure
that the spring is positioned properly in the piston.
6. Compress the spring with a cut away tube and
plate.
8. Install the pressure end plate. Make sure that the
chamfered face of the pressure end plate faces
8. Lift off the spring retaining plate. the clutch pack.
9. Remove the spring and oil baffle. 9. Make sure the teeth are not aligned with the
10. Turn the assembly over and knock the clutch lubrication slots in the housing.
shaft on a piece of aluminium (or wood) to loosen 10. Do not install the shim at this stage.
the piston.
27 - 112 9823/1700-1 27 - 112

27 - Driveline

circlip 1.
12. With a DTI (Dial Test Indicator) measure the end
float of the pressure end plate. The value should
be within the specified range.
Figure 638.
13. If it is necessary to adjust the end float to bring it

within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
end plate, with either a shim or an extra counter
plate between the retaining circlip 1 and the
pressure end plate.
14. Use an airline to check the operation of the
clutch.
15. Apply gearbox oil to the taper roller bearings 1
and 2.
16. Install the bearings onto the shaft.
17. Install new piston ring seals.
27 - 113 9823/1700-1 27 - 113

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10 - Clutch - 6 Speed
10 - Clutch - 6 Speed Component Identification

Check (Condition) ........................................ 27-116
Figure 639.
AA
C N
Q
P
B
A
R
S
U
V
A
D
F
G
H
L
J
M
E
K
A Piston ring seal B Taper roller bearing

C Gear 1 D Clutch end bearing
27 - 114 9823/1700-1 27 - 114

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E Splined hub F Thick thrust washer 1

G Thrust bearing 1 H Thin thrust washer 1
J Needle roller bearing K Thin thrust washer 2
L Thrust bearing 2 M Thick thrust washer 2
N Circlip 1 P Pressure end plate
Q Shim R Friction plates
S Counter plates T Disc spring
U Circlip 2 V Spring retaining plate
W Spring X Oil baffle
Y Piston Z Piston O-ring
AA Shaft O-ring
27 - 115 9823/1700-1 27 - 115

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Check (Condition)
Do a visual check of the friction and counter plates:
Counter Plates
1. Counter plates- light scoring or polishing is
permissible, plates that are not flat, worn or
heavily marked or scored must be replaced with
a new one.
Friction Plates
one.
2. Do not change individual plates, if a plate is

27 - 116 9823/1700-1 27 - 116

27 - Driveline
Disassembly 11. Remove the friction plates and the counter

plates. Keep them together in a set.
1. Carefully remove the piston ring seals from each
end of the shaft. 12. Do not mix the plates with those from other
clutches assemblies.
2. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft 13. Remove the disc spring.
grooves. If necessary remove burrs with a fine
grade abrasion paper and oil. 14. Put the clutch assembly in a suitable press to
compress the piston spring, then remove the
3. Use a collet tool to push and remove the taper circlip 2.
roller bearing.
15. Lift off the spring retaining plate.
4. Remove the gear and make a note of, in which
orientation the gear is installed. 16. Remove the spring and the oil baffle.
5. Use a puller to remove the clutch end bearing 17. Turn the assembly over and hit the clutch shaft
from the opposite end. gently on a piece of aluminium (or wooden) block
to loosen the piston.
6. Remove the gear and the splined hub together
with the thick thrust washer 1, thin thrust washer 18. If the piston does not loosen when you hit the
1 and the thrust bearing 1. clutch shaft then hand pump air down the shaft
oil inlet hole.
7. Remove the needle roller bearing.
19. Remove the piston.
8. Remove the thin thrust washer 2, thrust bearing
2 and the thick thrust washer 2. 20. Remove the piston O-ring and the shaft O-ring.
9. Remove the friction and the counter plate Before you assemble the clutch assembly check
retaining circlip 1. the condition of the clutch assembly. Refer to
Semi- Automatic Gearbox, Clutch- 6 Speed, Check
10. If installed, remove the pressure end plate and Condition (PIL 27-06-10).
shims.
27 - 117 9823/1700-1 27 - 117

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Figure 640.
AA
C N
Q
P
B
A
R
S
U
V
A
D
F
G
H
L
J
M
E
K
A Piston ring seal B Tapper roller bearing

C Gear 1 D Clutch end bearing
E Splined hub F Thick thrust washer 1
G Thrust bearing 1 H Thin thrust washer 1
J Needle roller bearing K Thin thrust washer 2
L Thrust bearing 2 M Thick thrust washer 2
N Circlip 1 P Pressure end plate
Q Shim R Friction plates
27 - 118 9823/1700-1 27 - 118

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S Counter plates T Disc spring

U Circlip 2 V Spring retaining plate
W Spring X Oil baffle
Y Piston Z Piston O-ring
AA Shaft O-ring
27 - 119 9823/1700-1 27 - 119

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Assembly 16. Use an air line to check the operation of the

clutch.
1. Install both the piston O-ring and the shaft O-ring.
17. Install the thick thrust washer 2, thrust bearing 2,
2. Lubricate the piston with hydraulic oil and push and the thin thrust washer 2.
fully into the bore of the clutch housing.
18. Install the needle roller bearing.
3. Install the oil baffle and the piston spring. Make
sure that the spring seats in the piston. 19. Carefully use a thin rod (or screwdriver) to align
the teeth of the clutch plates.
20. Install the gear and splined hub.
5. Compress the spring and install the circlip 2.
21. Install the thin thrust washer 1, thrust bearing 1
6. If applicable, install the disc spring assembly. and the thick thrust washer 1.
7. Make sure that the disc spring is installed with 22. Smear the clutch end bearing with gearbox oil
the teeth facing towards the clutch pack. and push the bearing onto the shaft.
8. Make sure that the teeth are not aligned with the 23. At the opposite end, push the gear onto the shaft
lubrication slots in the housing. spline. Make sure that the gear is installed in the
correct orientation.
9. Install the counter plates and friction plates
alternately, starting with a counter plate and finish 24. Smear the tapper roller bearing with gearbox oil
with a friction plate. and push the bearing onto the shaft.
10. Install the pressure end plate. Do not install the 25. Install new piston ring seals at each end of the
shims at this stage. shaft.
11. Make sure that the chamfered face is installed, Refer to: PIL 27-06-45.
facing the clutch pack.
lubrication slots in the housing.
13. Install the clutch friction and counter plate
retaining circlip 1.
14. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate and it should
be within the specified limit.
Figure 641.
15. If it is necessary to adjust the end float to bring

it within specified limit mentioned in step 14,
Install a 6.0mm (0.23in) or 6.5mm (0.25in) thick
pressure end plate together with a shim or an
extra counter plate, between the retaining circlip
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11 - Clutch - Forward (Input)
11 - Clutch - Forward (Input) Component Identification

Clean ........................................................... 27-123
Check (Condition) ........................................ 27-123
Figure 642.
L
J X Y
W
C E
A
P
H
K
A
G F V
D U
T R
S
B
R
N
S
Y T
U H
V J
W P
Q
M
X
L
M
N
Q
Z
AB
AA
AC
G
AD
AE
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Table 261.
Item Description
A Piston ring seal 1
B Clutch end bearing
C Gear
D Needle roller thrust bearing 1
E Thrust washer 1
F Gear and splined hub 1
G Needle roller bearing 2
H Thrust washer 2
J Needle roller bearing thrust washer
K Thrust washer 3
L Friction/counter plates retaining circlip
M Shim
N Pressure end plate
P Friction plates
Q Counter plates
R Disc spring assembly
S Circlip 1
T Spring retaining plate
U Spring
V Oil baffle
W Piston
X O-ring 1
Y O-ring 2
Z Piston seal rings 2
AA Bearing 1
AB Thrust washer 4
AC Needle roller bearing 3
AD Thrust washer 5
AE Gear and splined hub 2
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Consumables
Description Part No. Size Carry out a visual inspection of the friction and
Surface Cleaning Fluid 4103/1204 1L counter plates:
1. Carefully remove all traces of gasket or gasket Counter plates

compound from the front and rear case mating
faces. 1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored
1.1. Use a gasket removal product such as must be replaced with a new set.
Loctite Chisel when you remove the gasket
compound. Friction plates
1.2. Make sure that the mating faces are not 1. The cross hatching should be clearly visible,
damaged. plates that are not flat, have friction material
1.3. Clean the mating faces with a fine damage or scoring must be replaced with a new
carborundum paper. set.
1.4. Use a solvent cleaner and a clean cloth to 2. DO NOT mix old and new plates, if a plate is
finally remove all traces of oil or debris. damaged or worn install a complete new set.
Consumable: Surface Cleaning Fluid 3. Needle roller bearings should slide into position
2. Use a suitable degreasing agent to clean the freely, do not bend or distort the cage to install. If
inside of the case. the cage has been distorted install new bearings.
4. Take care when handling disc springs to avoid
marking or damage, which could result in stress
cracking. If in doubt install a new disc spring.
27 - 123 9823/1700-1 27 - 123

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Remove and Install
The layshaft clutch, 2WD / 4WD clutch, reverse

clutch, mainshaft clutch and forward / input clutch are
all part of the mainshaft assembly.

27 - 124 9823/1700-1 27 - 124

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Special Tools Description Part No. Qty.

Description Part No. Qty. Spring Compressor 892/00916 1
Hand Pump Pressure 892/00223 1 Tool
Test
27 - 125 9823/1700-1 27 - 125

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Disassemble
Figure 643.
H
X
K Y
W
L
E
P
J
B F
G
V
A D U
T
S
C
R
S
N
R
Y T
U
V
H
W P J
Q
M
X
L
M
N
Z
Q
AA
AC
AF
AE
AB
AD
A Piston ring seals 1 B Clutch end bearing 1

C Gear D Thrust bearing 1
E Thin thrust washer 1 F Gear and splined hub 1
G Needle roller bearing 1 H Thrust bearing 2
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J Thick thrust washer 1 K Thin thrust washer 2

L Circlip 1 M Pressure end plate
N Shim (If installed) P Friction plates
Q Counter plates R Disc spring
S Circlip 2 T Spring retaining plate
U Spring V Oil baffle
W Piston X O-ring 1 (Piston)
Y O-ring 2 (Shaft) Z Piston ring seals 2
AA Clutch end bearing 2 AB Thrust bearing 3
AC Thick thrust washer 2 AD Thin thrust washer 3
AE Gear and splined hub 2 AF Needle roller bearing 2
1. Carefully remove the piston ring seals1. Figure 644.

then check for burrs or damage on the shaft
grooves. If necessary remove burrs with a
fine grade abrasion paper and oil.
2. Remove the clutch end bearing 1 and gear with
a suitable puller and press.
3. Remove the thrust bearing 1 and thin thrust
washer 1.
4. Remove the gear and splined hub 1 assembly
with the needle roller bearing 1.
5. Remove the thrust bearing 2, thick thrust washer
1 and thin thrust washer 2.
10.2. If a press is not available use the spring
6. Remove the retaining circlip 1 of the friction and compressor tool A (892/00916) to remove
counter plates. the circlip 2.
7. Remove the pressure end plate and shim (if Special Tool: Spring Compressor Tool
installed). (Qty.: 1)
8. Remove the friction plates and counter plates. 11. Lift off the spring retaining plate.
8.1. Keep them together in sets, do not mix the 12. Remove the spring and oil baffle.
13. Turn the assembly over and knock the clutch
9. Remove the disc spring assembly shaft on a piece of aluminium (or wood) to loosen
the piston.
considerable force. Make sure you take care to 13.1. If the piston does not loosen, then hand
avoid damage or injury. pump air down the shaft oil inlet hole.
10. Put the clutch assembly in a suitable press. (Qty.: 1)
spring and then remove the circlip 2.
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Figure 645. 8. Install one counter plate followed by one friction

plate.
9. Install the pressure end plate. Make sure the
chamfered face of the pressure end plate faces
the clutch pack.
lubrication slots in the housing.
circlip 1.
14. Remove the piston. 13. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate. The value
15. Remove and discard the piston O-ring 1. should be within the specified range.
16. Remove and discard the shaft O-ring 2. Length/Dimension/Distance: 1.9 –2.5 mm
17. To disassemble the opposite clutch, carefully Figure 646.

remove the piston ring seals 2.
18. Remove the bearing 2 with a suitable puller.
19. Remove the thrust bearing 3, thick thrust washer
2 and thin thrust washer 3.
20. Remove the gear and splined hub 2 assembly
with the needle roller bearing 2.
21. Do the steps 5 to 16 to disassemble the clutch
assembly.
Assemble
14. If it is necessary to adjust the end float to bring it
1. Install the new O-ring 1 onto the piston. within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
2. Install the new O-ring 2 onto the shaft. end plate, with either a shim or an extra counter
3. Lubricate the piston with oil and press fully into plate between the retaining circlip 1 and the
the bore of the clutch housing. pressure end plate.
4. Install the oil baffle and piston spring. Make sure 15. Use an airline to check the operation of the
that the spring is positioned properly in the piston. clutch.
5. Install the spring retaining plate. 16. Install the thick washer 1, thin washer 2, and the
thrust bearing 2.
CAUTION! The spring (or springs) apply 17. Carefully align the teeth of the clutch plates using
considerable force. Make sure you take care to a thin rod (or screwdriver) and install the gear and
avoid damage or injury. splined hub 1.
6. Compress the spring with a cut away tube and 18. Install the needle roller bearing 1.
19. Install the thrust bearing 1 and thin thrust washer
7. Install the disc spring assembly. 1.
7.1. Make sure that the disc spring is installed 20. Apply gearbox oil on the clutch end bearing 1 and
with the teeth towards the clutch pack. install the gear and bearing 1 onto the shaft.
7.2. Make sure that the teeth are not aligned with
the lubrication slots in the housing. 21. Install the new piston ring seals 1.
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22. To assemble the opposite clutch do the steps 1

to 19.
23. Carefully align the teeth of the clutch plates using
a thin rod (or screwdriver) and install the gear and
splined hub 2.
24. Install the needle roller bearing 2.
25. Install the thrust bearing 3, thick washer 2, and
thin washer 3.
install the gear and bearing 2 onto the shaft.
27. Install the new piston ring seals 2.
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12 - Clutch - Ratio
12 - Clutch - Ratio

Circlip Assembly Tool 998/11334 1
Main shaft clutch A

Disassembly
The numerical sequence is a guide to the
disassembly procedure.
1. Remove and discard the O-ring seals 1.

2. To check the clutch plates.
2.1. Remove the circlip1 from the clutch drum.
2.2. Lift off the thick pressure counter plate then
the seven friction plates and seven counter
plates.
A Tube
3. Remove and check the roller bearing race. If
necessary discard it. 5. Cut out a small portion of the tube, to allow
access, to release the circlip 2.
4. Use either the circlip assembly tool or a tube of
suitable diameter to install over the top spring 6. With the clutch drum located in the press,
cup. compress the spring sufficiently to allow the
circlip 2 to be released.
Special Tool: Circlip Assembly Tool (Qty.: 1)
7. When the circlip 2 is released, remove it from the
shaft with the spring cup, spring and the lower
spring cup.
8. If necessary the clutch operating piston may be
removed by compressed air blown through the
drilling in the end of the clutch shaft.
9. Remove and discard the clutch piston O-ring seal
2 and seal 3.
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12 - Clutch - Ratio
Figure 648.
B C
H G
J
K
L N
M R
Item Description
Table 262.
G Upper spring cup
Item Description H Circlip 2
B Circlip 1 J Spring
C Thick pressure counter K Lower spring cup
plate
L Piston
D Friction plate
M Clutch shaft
E Counter plate
N O-ring seal 2
F Roller bearing race
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12 - Clutch - Ratio
Item Description Ratio Clutches

P O-ring seal 3
Q Housing Disassembly
R Gallery port 1. For the remaining two ratio clutches follow the
S O-ring seal 1 same disassembly procedure as above.
Assembly 2. The only difference is the retention of the support

taper roller bearing which for each clutch is held
Assembly is the opposite of the disassembly in place by a machined cap.
procedure with the following precautions.
Assembly
1. Install the new clutch piston O-ring seals 2 and
seal 3 to the piston. 1. Clutch 1 and clutch 2 assembly.
2. Lubricate the new seals and push the piston into 1.1. Use a mandrel to carefully push the taper
the housing by hand. bearing 1 into its position.
1.2. Rotate the roller cage as the bearing is
3. Put the lower spring cup over the central spigot pushed into place to make sure that the
of the piston. mandrel does not foul and distort the cage.
4. Replace the spring and the top spring cup. 1.3. Put the new O-ring seal 4 into the grooves
in the cap 1.
5. Keep the circlip 2 on the top cup ready for
installation. Figure 649.
6. Use the tube with a cutout to compress the W
spring.
X
7. Locate the cutout to give access for circlip 2.
V
8. Install the circlip 2 and make sure that it is seated
correctly in the groove.
U
9. New clutch friction plates must be soaked in oil
before assembly. T
10. Install the first counter plate to the clutch drum

followed by the friction plate.
11. Alternately install all fourteen plates.
12. Use a scrap splined drive hub to align the splines
of the friction plates.
13. Install the thick counter plate at the top of the
assembly followed by the circlip 1.
14. Check the free play clearance of the clutch plates
and it must be within the specified limit.
Dimension: 3 –3.5 mm
15. You can adjust the clearance by either changing T Taper bearing 1
the thick pressure plate from 6.0mm (0.24in) U O-ring seal 4
thick version to 6.5mm (0.26in) thick or by V Cap 1
the addition of a shim counter plate installed W Capscrews 1
immediately under the thick pressure plate. X O-ring seals 5
16. Once the clutch is assembled completely then 1.4. Two capscrews 1 hold the cap 1 in place.
apply compressed air to the gallery port in the 1.5. Tighten the capscrews 1 to the correct
end of the shaft to check the clutch operation. torque value.
1.6. Put two new O-ring seals 5 into the groves
in cap 1.
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12 - Clutch - Ratio
2. Clutch 3 and clutch 4 assembly.

2.1. Use a mandrel to carefully push the taper
bearing 2 into its position.
2.2. Rotate the roller cage as the bearing is
pushed into the place to make sure that the
mandrel does not foul and distort the cage..
2.3. Put the new O-ring seal 6 into the grooves
in the cap 2.
Figure 650.
Y
AA
AC
AB
Y Taper bearing 2
Z O-ring seal 6
AA Cap 2
AB Capscrews 2
AC O-ring seals 7
2.4. Two capscrews 2 hold the cap 2 in place.
2.5. Tighten the capscrews 2 to the correct
torque value.
2.6. Put two new O-ring seals 7 into the groves
in cap 2.

Item Description Nm
W Capscrews 1 18
AB Capscrews 2 45
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13 - Clutch - Master
13 - Clutch - Master Remove and Install

Special Tools
Clutch Pack Retainers 892/01048 2
Mandrel 892/01050 1
Locking Plates 892/01052 2
Consumables
JCB Multi-Gasket 4102/1212 0.05 L
Remove
1. Put the gearbox on a suitable manipulator.
Rotate the gearbox until the clutch is in the top
position.
2. Remove all the cover attaching bolts and then
install the M10 jacking bolts 1 (x3).
3. Screw all the jacking bolts evenly until the cover
is clear of its spigot.
Figure 651.
E
C B
A
D
G B
A Cover attaching bolts (x18)

B M10 jacking bolts 1 (x3)
C Cover
D M10 threaded lifting eye (x2)
E Oil seal 2
F Cover O-ring seal
G O-ring 1 seal
4. Install the M10 threaded lifting eyes to lift the
cover.
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27 - Driveline
5. Carefully lift off the cover and make sure that you 9. Prise out and discard the oil seal 2 carefully and
keep it square to the housing. make sure that the seal housing in the cover is
not damaged.
6. Make sure that you remove and discard all the
O-ring 1 seals. 10. Install the special locking plates to prevent the
clutch assembly from rotating.
7. Remove the jacking bolt.
Special Tool: Locking Plates (Qty.: 2)
8. Remove and discard the cover O-ring seal.
Figure 652.
H A
A Cover attaching bolts (x18) H Special screws

J Clutch assembly K Special locking plate
L Housing
11. Use the cover attaching bolts and the special

screws that are supplied with the locking plates,
to lock the clutch assembly to the housing.
12. Remove all the clutch drum bolts.
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T R
N
M
U S
P Q
M Clutch drum bolts (x12)

N Plug 1
P M8 threaded lifting eye (x2)
Q Clutch drum
13. Remove the locking plate. R Special pack retainers (x2)
S Clutch plates
14. Install the M8 threaded lifting eyes to the clutch T Thrust washer 1
drum. U Plate carrier
V Thrust washer 2
15. Attach suitable lifting equipment to the clutch
drum. 18. Remove the carrier together with the clutch
plates and the thrust washer 1.
16. Carefully remove the clutch drum, hub and the
pressure plate assembly. 19. Remove the thrust washer 2.
17. Install the special pack retainers to the clutch 20. Remove the button head capscrews.
plate carrier.
21. Remove the oil baffle plate.
Special Tool: Clutch Pack Retainers (Qty.: 2)
22. Rotate the drum carrier to align the five holes with
countersunk capscrews.
23. Remove the countersunk capscrews.
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27 - Driveline
AB
W
X
L
M
AC
Y Z
Z AD
M
AA
Z AB
M Clutch drum bolts (x12) L Housing

L Housing Z JCB multi gasket
W Button head capscrews (x5) AB Verbus-ripp bolts (x12)
X Oil baffle plate AC O-ring 2
Y Countersunk capscrews AD Cross drilling blanking plug 2
Z JCB multi-gasket
AA Drum carrier 28. The clutch house removal.
AB M10 jacking bolts2 (x3)
28.1. Remove and discard all the Verbus-ripp
24. Install the M10 jacking bolts 2 and jack the drum bolts.
carrier to remove it from the housing. 28.2. Use a soft faced hammer to separate the
housing from the PTO/splitter gearbox.
25. Make sure that you install the drum bolts that
will assist you to lift the drum carrier clear of the 28.3. Remove the clutch housing.
housing.
29. After you remove the clutch from the housing
26. The drum carrier will be removed completely with there will be three main sub assemblies.
the PTO (Power Take-Off) input gear and the
bearing. 29.1. Remove the clutch drum, hub and
pressure plate sub-assembly. Refer to
27. It is not necessary to remove the clutch housing Figure 657.
unless it is damaged or the PTO/splitter gearbox
needs to be disassembled.
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Install
steps.
29.2. Remove the clutch plates and plate carrier 2. If it is necessary to replace the clutch housing
sub-assembly. Refer to Figure 658. with a new one then make sure that the cross
drilling blanking plug 2 is installed into the new
Figure 658. housing.
3. Tighten the plug 2 to the correct torque value.
4. Make sure that the oil feed cross drillings are
clear.
5. Carefully clean all the traces of the sealing
compound from the clutch and the smoothshift
gearbox housing mating surfaces.
6. Lightly lubricate with oil and install a new O-ring
2.
7. Apply even beads of JCB Multi-gasket to the
Smoothshift Gearbox housing (around the outer
diameter and around each threaded bolt hole).
Consumable: JCB Multi-Gasket
8. Make sure that you install new Verbus-ripp bolts.
29.3. Remove the clutch drum carrier and input
gear PTO sub-assembly. 9. Tighten the Verbus-ripp bolts to the correct
torque value.
10. Make sure that the clutch components are
carefully checked for any signs of wear or
damage.
11. If any of the friction or counter plates are
damaged or if any of the friction plates are
excessively worn (thickness less than 3.5 mm or
oil grooves less than 0.1 mm deep) replace the
complete set of plates.
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27 - Driveline
12. Make sure that the new friction plates are soaked
in transmission oil before you install them.
13. Check the thrust washer 2 for any signs of wear.
14. If the thickness (3.9mm) or the outside diameter
(110.0mm) is less then the mentioned value then
install a new thrust washer 2.
15. Before you install the new thrust washer 2 soak
it in the transmission oil for at least an hour.
16. Do not apply any kind of thread locking
compound to any of the bolts or screws.
17. Tighten the plugs 1 to the correct torque value to
prevent oil gallery leakage.
18. It is not possible to locate the clutch drum over
the clutch plates and carrier assembly inside the
housing.
19. First sub-assemble the components on the
bench and then use the retainers to hold the
assembly together.
20. Before you replace the drum, plates, carrier and
hub assembly install the two guide pins to the
M10 threaded holes in the drum carrier.
21. Use a special mandrel to install the new oil seal 2.
Special Tool: Mandrel (Qty.: 1)
22. If the clutch plates are replaced with new ones,
check to make sure that the clutch is disengaged
before installing the cover 2.
23. Lightly apply oil and install a new O-ring 1 and
the cover O-ring.

Item Description Nm
A Cover attaching bolt 56
M Clutch drum bolt 52
W Button head capscrews 12
Y Countersunk capscrews 38
N Plug1(Black) 22
N Plug1(Gold) 12
AB Verbus-ripp bolt 75
AD Cross drilling blanking plug2 15
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Special Tools 8. Use M6 bolt (x2) and suitable levers to help in

Description Part No. Qty. removal of the piston.
Peg Socket 892/01045 1 9. Remove and discard the outer seal from the
Mandrel 892/01046 1 piston.
Clutch Jig 892/01047 1
10. Remove the socket head capscrews (x8).
Clutch Pack Retainers 892/01048 2
Guide Rods 892/01049 2 11. Use a suitable bar to prevent drum rotation.
12. Use a soft faced hammer to tap out the hub from
Consumables the drum.
Description Part No. Size 13. Remove and discard the O-ring 1 from the drum.
and Sealer (Medium 4101/0251 0.05 L 14. Remove the circlip.
Strength)
15. Use a suitable drift to tap out the blanking disc
together with the inner bearing.
Master Clutch- Clutch Drum and Hub
16. Remove and discard the O-ring 2.
Disassembly
17. Remove and discard the iron sealing ring.
1. Remove the lubrication nozzles.
18. Remove and discard the inner piston seal from
2. Remove the bolts. the hub.
3. Remove the release springs and the spring 19. Do not remove the outer bearing unless it is to be
pillars then discard the springs. replaced with a new one.
4. Remove the oil baffle plate from the locating 20. At the time of removal the bearing can be
dowel 1. damaged. When the bearing is removed it must
be replaced.
5. Remove the pressure plate.
21. To remove the outer bearing, screw in two jacking
6. Make sure that you do not lose the dowel 1 and bolts at their correct location on the hub.
dowel 2
22. If the bronze bush is to be replaced, then remove
7. Remove the piston from the drum. it with a suitable puller and slide hammer.
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Figure 660.
L
A K
K
M H
L
G
J W
C
Y
D
W
B
Y
Z S
T U
L
P Z
R
Q
N
V
27 - 141 9823/1700-1 27 - 141

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Item Description
T Inner piston seal
Table 265.
U Outer bearing
Item Description
V Bronze bush
A Lubrication nozzles
W M8 bolt (x2)
B Bolts
X Dowel 1
C Springs
Y Dowel 2
D Spring pillars
Z Jacking bolts (x2)
E Oil baffle plate
F Pressure plate Assembly
G Piston
H Drum Assembly is the opposite of the disassembly
procedure but additionally follow the steps below.
J Outer seal
K Socket head capscrews 1. Check that the oil feed slots and drillings are
(x8) clear.
L Hub
2. Check the condition of the pressure plate, if it is
M O-ring 1
excessively scored then replace with a new one.
N Circlip
P Blanking disc 3. If it is necessary to replace the pressure plate,
Q Inner bearing dowel 1 and dowel 2 must be installed to the plate
before assembly.
R O-ring 2
S Sealing ring
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Figure 661.
A K
M H
L
G
J W
C
Y
D
W
B
Y
A Lubrication nozzles B Bolts

C Springs D Spring pillars
E Oil baffle plate F Pressure plate
G Piston H Drum
J Outer seal K Socket head capscrews (x8)
L Hub M O-ring 1
W M8 bolt (x2) X Dowel 1
Y Dowel 2
4. The larger dowel 2 must be tapped into the blind 7.1. Put a drop of paraffin in the orifice of the
holes on one face of the plate and the smaller valve.
dowel 1 must be tapped onto the through holes
on the opposite face so that they reach through
the plate but do not protrude.
5. Check the faces of the drive tangs on the drum
and if you find any small burrs then carefully use
a file to remove the small burrs.
6. Check the pressure relief ball valve in the piston,
the ball should be free to move against its spring.
7. Check the pressure relief valve for leakage.
27 - 143 9823/1700-1 27 - 143

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Figure 662. 12. Keep the hub square to the drum to avoid
damage to the O- ring 1.
AC 13. Install the socket head capscrews.

14. Gradually tighten the capscrews to the correct
torque value.
15. Align the threaded holes in the piston with the
guide hole in the hub. Refer to Figure 664.
Figure 664.
G L
AB AA
AA AB
AC Valve orifice
G Piston
7.2. There should not be any leakage on the L Hub
other side of the ball. AA Threaded holes in piston
AB Guide holes in hub
7.3. If there is leakage then the piston or the
valve assembly must be replaced with a 16. Locate the piston inside its groove.
new one.
17. Locate the larger dowel (dowel2) pins on the
8. If the bronze bush is to be replaced then make pressure plate into the drilled holes in the piston.
sure that the oil grooves must align with the oil
feed drillings in the hub. 18. Use a suitable press to push the pressure plate
and the plate will push the piston down.
9. Use a suitable mandrel to push the bush until it
is 0.5mm below the end face of the hub. 19. Remove the pressure plate and make sure that
there is no evidence of damaged seals in the
Special Tool: Mandrel (Qty.: 1) form of small slices of seal material.
10. Lubricate and install a new O-ring 1 to the drum. 20. If damage is suspected, remove the piston, install
11. Align the oil feed holes in the hub with the oil feed new seals and then assemble again.
slots in the drum. Refer to Figure 663. 21. Make sure that the pressure plates are aligned
Figure 663. correctly.
22. Replace the oil baffle plate on the locating dowel
1.
23. Install new springs.
24. Remove any debris that may have been pushed
from the bolt holes into the hub.
25. If the drum and the hub are separated then
the outer bearing and the capscrews must be
replaced with a new one.
26. Before you install the outer bearing make sure
that the spring is installed already.
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27. Use a suitable press to install the outer bearing Consumable: JCB Threadlocker and Sealer
and apply force only on to the inner race. (Medium Strength)
28. Note that the piston rings cannot be installed 30. Install new piston rings with extreme care, as the
before the outer bearing. rings can break very easily.
29. Apply one drop of JCB Threadlocker and Sealer 31. Note the interlocking end of the piston rings.
to one or two threads from the end, on the
lubrication nozzles.
Figure 665.
AD
Z S
T U
L
P Z
R
Q
N
V
N Circlip P Blanking disc

Q Inner bearing R O-ring 2
S Sealing ring T Inner piston seal
U Outer bearing V Bronze brush
L Hub Z Jacking bolts (x2)
AD Piston ring interlocking end

Item Description Torque value
A Lubrication nozzles 15 N·m
B Bolts 28 N·m
K Socket head capscrews 85 N·m
Master Clutch- Clutch Plates and Plate 2. The plates can only be removed from one end of
Carrier the carrier. There are six friction plates and five
counter plates.
Disassembly 3. If the thrust washer is not removed at the time of
removal then remove it now.
1. Remove the friction plates and counter plates
from the plate carrier.
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Figure 666.
A
B
B C
D
A
C G
F
B
G
Item Description
Table 267. F Guide rods
Item Description G Threaded hole
A Friction plates H Clutch pack retainers
B Counter plates
C Plate carrier Assembly
D Thrust washer 1. Before you assemble the friction and the counter
E Clutch drum and hub as- plates check them for any signs of damage or
sembly wear.
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2. Friction plates should not be less than 3.5 mm Figure 668.

thick or have oil grooves less than 0.1 mm deep. E
If the friction plate thickness is less then 3.5 mm
then it needs to be changed for a new one.
3. Replace the plates in a set, not as a single piece.
4. Check the thrust washer for wear.
5. If the thickness is less than 2.9mm or the outside
diameter is less than 90mm then replace the
thrust washer.
6. Before you install new friction plates and a new C G
thrust washer soak them in transmission oil for at
least one hour. F
7. Start the assembly with a friction plate followed B
by a counter plate and so on. G
8. Note the correct orientation of oil slots in the
friction plates relative to the plate carrier. Refer
to Figure 667.
Figure 667.
A
B Counter plates
C Plate carrier
E Clutch drum and hub assembly
F Guide rods
G Threaded hole
10. It is not possible to replace the clutch drum and
hub assembly inside the clutch housing unless
it is first installed to the plates and plate carrier
assembly.
11. Install the thrust washer to the plate carrier.
12. Install two suitable guide rods to the threaded
C holes in the plate carrier.
Special Tool: Guide Rods (Qty.: 2)
A Friction plate
C Plate carrier 13. Use suitable lifting equipment to carefully lower
the drum and hub sub-assembly over the plates.
9. The counter plates should be positioned relative
to the two threaded holes. Refer to Figure 668. 14. Make sure that the guide rods locate through the
corresponding holes in the drum.
15. Make sure that the drive tangs on the counter
plates engage with the cut-outs in the drum.
16. It may be necessary to rotate the drum and plates
slightly to align them.
17. With the drum and hub fully lowered, remove the
guide rods and install two special pack retainers
to temporarily hold the assembly together.
Special Tool: Clutch Pack Retainers (Qty.: 2)
18. Do not use bolts or screws, mistakenly they may
be left in the place which can make the clutch
inoperative.
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19. The special retainers prevent further assembly 23.3. Make sure that the bolts are tightened and
until they are removed. the splitter input shaft is engaged in the
clutch plate carrier.
20. The drum, hub, plates and plate carrier can
now be replaced inside the clutch housing as a 23.4. Turn the clutch drum/hub assembly and, at
complete assembly. the same time hold the splitter shaft so it
does not rotate. Some drag is normal.
21. Remove the special retainers and install plugs to Master Clutch- Clutch Drum Carrier and
the holes in the clutch drum. Power Take Off Input gear
22. If the clutch plates are replaced, the plate stack Disassembly
height is changed.
1. To remove the stake nut follow the steps below.
23. If the stack height is too high then the clutch
will be permanently engaged. Do the following 1.1. Use a vice and a suitable jig to position the
check. assembly as shown.
23.1. Assemble the clutch components inside Special Tool: Clutch Jig (Qty.: 1)
the housing.
23.2. Do not install the cover.
Figure 669.
J
E Clutch drum and hub assembly

J Cover
K Bolt
L Splitter input shaft
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Figure 670.
C
A
A Stake nut B Input gear

C Drum plate carrier D Clutch jig
E Hacksaw
1.2. To avoid damage to the input gear threaded 1.3. Make sure that the gear shaft is not
shaft, use a hacksaw to carefully cut-away damaged.
the staked portion of the collar on the stake
1.4. The staked portion can now be easily bent
nut. Refer to Figure 671.
clear of the shaft. Refer to Figure 672.
Figure 671.
A E
A Stake nut
E Hacksaw
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Figure 672. 1.5. Use a special peg socket to loosen the

stake nut. The nut is very tight.
F Special Tool: Peg Socket (Qty.: 1)
1.6. Make sure that the gear shaft is not
damaged.
1.7. Support the input gear and then remove the
stake nut.
1.8. Remove the gear and the bearing retainer
plate from the drum carrier.
A
1.9. Discard the stake nut.
2. Use a suitable press to push off the bearing and
then remove the loose bearing rib.
A Stake nut
F Bent on the stake
Figure 673.
K B
A
C

Item Description H Bearing
A Stake nut J Bearing rib
B Input gear K Attaching screw holes
C Drum plate carrier
G Gear and bearing retain-
er plate
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27 - Driveline
Assembly 2. Note the position of the loose bearing rib.
Assembly is the opposite of the disassembly 3. Note the orientation of the retainer plate.
procedure, additionally note the following steps.
4. The counter sunk side of the attaching screw
1. Make sure that the bearing is installed in the holes must face the drum carrier plate.
correct orientation as shown. Refer to Figure 5. Lightly apply oil to the threads of the new stake
674. nut.
Figure 674. 6. Install the stake nut.
G
7. Use a torque multiplying wrench and a peg
socket to tighten the stake nut to the correct
C torque value.
8. Stake the nut into the two positions on the shaft.
J B
B Input gear
C Drum plate carrier
G Gear and bearing retainer plate
H Bearing
J Bearing rib

Item Description Torque value
A Stake nut 1,000 N·m
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14 - Clutch - 5 Speed Component Identification

Figure 675.
J N
H
L
F
M
D
Z
K
X
G
E
AA
V
C
S
Q
Y
W B
U
T A
P
AB
Item Description
Table 270. D Transfer gear
Item Description E Taper roller bearing 2
A Piston ring seals F Spacer
B Taper roller bearing 1 G Circlip 1
C Transfer gear retaining H Thrust washer
bolt
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Item Description
J Gear and splined hub
K Needle roller bearing
L Thick thrust washer
M Thrust bearing
N Thin thrust washer
P Friction and counter
plates retaining circlip
Q Shim
R Pressure end plate
S Counter plates
T Friction plates
U Circlip 2
V Spring retaining plate
W Spring
X Piston
Y Liner
Z O-ring 1
AA Oil baffle
AB O-ring 2
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Special Tools 14.1. With a cut away tube compress the piston
Description Part No. Qty. spring.
Hand Pump Pressure 892/00223 1 Figure 676.
Test
Disassembly
1. Carefully remove the piston ring seals 1.
then check for burrs or damage on the shaft
grooves. If necessary remove the burrs with
a fine grade abrasion paper and oil.
2. Use a collet tool and press to remove the taper
roller bearing 1.
3. Remove the transfer gear retaining bolt.
4. Remove the transfer gear. Make a note in which 14.2. Remove the circlip 2.
orientation the gear is installed. 15. Lift off the spring retaining plate.
4.1. The transfer gear and the retaining bolt are 16. Remove the spring and the oil baffle.
shown only for reference. These items must
be removed while the clutch assembly is 17. Turn the assembly over and knock the clutch
located in the gearbox to facilitate removal shaft on a piece of aluminium (or wood) to loosen
of the clutch. the piston.
5. Remove the taper roller bearing 2 with a puller 17.1. If the piston does not loosen when the
tool. clutch shaft is knocked on aluminium, then
hand pump air down the shaft oil inlet hole.
6. Remove the spacer.
7. Remove the circlip 1 and the thrust washer 1. (Qty.: 1)
8. Remove the gear and the splined hub. Figure 677.
9. Remove the needle roller bearing.
10. Remove the thin thrust washer, thrust bearing
and the thick thrust washer.
10.1. Note the shape and positions of the thrust
washers so you can correctly assemble
them.
11. Remove the friction and counter plates retaining
circlip.
12. Remove the pressure end plate and shim, if
installed.
plates. 18. Remove the piston.
13.1. Keep them together in sets. Do not mix the 19. Remove and discard the O-ring 1 from the piston.
20. Remove and discard the O-ring 2 from the shaft.
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Figure 678.
J N
H
L
F
M
D
Z
K
X
G
E
AA
V
C
S
Q
Y
W B
U
T A
P
AB
Item Description
Table 271.
H Thrust washer
Item Description J Gear and splined hub
A Piston ring seals K Needle roller bearing
B Taper roller bearing 1 L Thick thrust washer
C Transfer gear retaining M Thrust bearing
bolt N Thin thrust washer
D Transfer gear P Friction and counter
E Taper roller bearing 2 plates retaining circlip
F Spacer Q Shim
G Circlip 1
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Item Description plate between the retaining circlip and the

R Pressure end plate pressure end plate.
S Counter plates Figure 679.
T Friction plates
U Circlip 2
V Spring retaining plate
W Spring
X Piston
Y Liner
Z O-ring 1
AA Oil baffle
AB O-ring 2
Assembly
10.2. Use an air line to check the operation of
2. Install the new O-ring 2 onto the shaft. the clutch.
3. Lubricate the piston with oil and push fully into 11. Install the thick thrust washer, thrust bearing and
the bore of the clutch housing. the thin thrust washer.
4. Install the oil baffle and the piston spring. Make 12. Install the needle roller bearing.
sure that the spring is positioned properly in the
piston. 13. Use a thin rod (or screwdriver) to carefully align
the teeth of the clutch plates and install the gear
5. Install the spring retaining plate. and splined hub assembly.
6. Compress the spring with a cut away tube and 14. Install the circlip 1 and the thrust washer 1.
secure with the circlip 2.
15. Install the spacer.
plate. 16. Apply gearbox oil to the taper roller bearing 2 and
push the taper roller bearing 2 on to the shaft.
friction plates, finishing with a friction plate. 17. Install the transfer gear onto the shaft spline.
8. Install the pressure end plate. 17.1. Make sure that the gear is installed in the
8.1. Do not install the shim at this stage.
8.2. Make sure that the chamfered face of the 18. Install the transfer gear retaining bolt.
pressure end plate faces the clutch pack. 18.1. Tighten the bolt to the correct torque value.
8.3. Make sure that the teeth are not aligned with
the lubrication slots in the housing. 19. Check the shaft end float. This can only be
done when the clutch assembly is installed in the
9. Install the friction and counter plates retaining gearbox.
circlip.
20. At the opposite end, apply gearbox oil to the taper
10. Use a DTI (Dial Test Indicator)DTI (Dial Test roller bearing 1 and push the taper roller bearing
Indicator) to measure the end float of the 1 on to the shaft.
pressure end plate. The value should be within
the specified range. 21. Install the new piston ring seals.
Dimension: 0.7 –2 mm Refer to: PIL 27-06-45.
10.1. If it is necessary to adjust the end float Table 272. Torque Values
to bring it within the specified value, then Item Description Nm
you can choose either a 6.0mm (0.23in)
C Transfer gear retaining bolt 396
or a 6.5mm (0.25in) thick pressure end
plate, with either a shim or an extra counter
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15 - Solenoid Control Valve
15 - Solenoid Control Valve Introduction

Introduction .................................................. 27-157 The solenoid control valves provides the switching
Check (Condition) ........................................ 27-158 for forward drive and reverse drive to select the
Remove and Install ..................................... 27-158 direction of travel.
On some transmission systems the solenoid control
valves are also used for gear selection and 2WD
(Two Wheel Drive) / 4WD (Four Wheel Drive)
selection.
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For: PS750 MK4 ..................... Page 27-158
If damage to any component or distortion of the
For: PS750 MK3 ..................... Page 27-160
spool is evident the complete valve assembly must
be renewed. Great care should be taken when
dismantling and assembling the valve to avoid the (For: PS750 MK4)
following: Consumables
• Contamination Description Part No. Size
• Damage to spools JCB Transmission Fluid 4000/2601 5L
• Damage to seal grooves EP SAE 30 4000/2605 20 L
4000/2603 200 L
Any of the above may result in possible problems
with the operation of the valve. There are two types of solenoid installed.
Solenoid valve - nut retained - this has a nut securing

the solenoid coil to the stem.
Solenoid valve - bolt retained - the solenoid is

enclosed in a metal casing and the casing is bolted
to the transmission housing.
Solenoid Valve - Nut retained

The procedure for the solenoid control valves is
the same. The following procedure is for one valve.
The gearbox shown has three solenoid valves, other
gearbox variants may contain a different quantity of
valves.
Remove
1. Put a label on the harness connector to help
installation.
2. Disconnect the electrical harness connector (if
installed) at the solenoid coil 1 and coil 2.
3. Record the position of the solenoid coil electrical
connectors on the valve stem.
4. Clean the area around the solenoid valves. Do
not allow particles of grit to fall into the gearbox..
5. Remove the nut, coil 1, spacer and coil 2. Make
sure that you record the orientation of the spacer
for correct installation.
6. Clean the area around the valve stem and the
gearbox case to prevent contamination of the
gearbox. Plug all the open ports and hoses to
7. Remove the valve stem from the gearbox case.
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Figure 680. gauze is defective, replace the valve with a new

one.
4. Inspect the O-ring seals for damage. Refer to
Check Condition (PIL 27-06-15).
5. Put some clean gearbox oil on the O-ring seals.
Consumable: JCB Transmission Fluid EP SAE
30
6. Use an extended socket to tighten the valve stem
to the correct torque value. Refer to Table 273.
7. Install the solenoid coils and spacer in the correct
orientation.
8. Put the solenoid coil electrical connectors in the
correct position on the valve stem.
9. Tighten the nut to the correct torque value. Refer
to Table 273.
10. Connect the electrical harness connectors at the
solenoid coils in the correct positions.
Solenoid Valve - Bolt retained

Remove
1. Put a label on the harness connector to help
installation.
2. Disconnect the electrical harness connector.
3. Clean the area around the solenoid valve. Do not
allow particles of grit to fall into the gearbox.
4. Remove the bolts and valve from the gearbox
housing. Make sure that you record the
orientation of the solenoid for correct installation.
A Valve 1 4.1. Take care not to grip the unit by its electrical
B Valve 2 connector block. The connector block is not
C Valve 3 designed as a leverage point.
D Solenoid coil 1 4.2. Slowly rotate and at the same time pull
E Solenoid coil 2 the valve to remove it from the gearbox
F Nut housing.
G Spacer
H O-ring 5. Plug all the open ports and hoses to prevent
J Valve stem contamination.
Install
steps.
2. Inspect the gauze filters (if installed) on the valve
stem for contamination and damage.
3. Do not touch the gauze. Remove contamination
by rinsing the valve stem in clean gearbox oil.
If this fails to remove the contamination or the
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Figure 681. Table 273. Torque Values

Item Nm
L F 6
J 27
K L 6
M (For: PS750 MK3)

Consumables
L Strength)
Remove
1. Remove the solenoid control valves as follows:
Figure 682.
A B C D
E
N
K Electrical harness connector
L Retaining bolts
M Valve
N O-ring seals
A Screws
Install B Reverse high-low clutch solenoid valve
C Main shaft-layshaft clutch solenoid valve
1. The installation procedure is the opposite of the D High-low clutch solenoid valve
steps. 1.1. Remove the plastic sealing plugs to get
access to the capscrews below them.
2. Replace the O-ring seals. 1.2. Remove the screws and remove the
3. Put some clean gearbox oil on the O-ring seals. solenoid valves given in steps 1.3 to 1.5 .
Consumable: JCB Transmission Fluid EP SAE 1.3. Reverse high-low clutch solenoid valve.
30 1.4. Main shaft and layshaft clutch solenoid
valve.
4. Install the solenoid in the correct orientation.
1.5. Forward high-low clutch solenoid valve.
Refer to Table 273. 1.6. Discard the surface mounted O-ring (x4)
from the each valve body.
2. If installed remove the 4WD oil feed pipe. Refer
to Figure 683.
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L H
M
F
F 4WD oil feed pipe

3. If a pipe guard is installed, remove the two fixing
bolts and remove the guard before you remove
the oil feed pipe. Refer to Figure 684. P N
Figure 684.
H Nut
J 4WD clutch solenoid
K 4WD solenoid valve spool
L Plug
M Pressure maintenance valve spool
N Bolt
P Valve manifold block
4.1. Remove the nut that attaches the 4WD
clutch solenoid (if installed).
4.2. Remove the 4WD clutch solenoid (if
installed).
4.3. Remove the 4WD solenoid valve spool (if
installed).
4.4. Remove the bolts (x16) that attach the valve
manifold block.
F
4.5. Do not use a screwdriver to remove the
G
valve block, the sealing faces will get
F 4WD oil feed pipe damaged.
G Pipe guard 4.6. If the valve block is difficult to remove, lightly
4. Remove the valve manifold block as follows: tap the block with a soft faced hammer.
Refer to Figure 685. 4.7. Remove and discard the valve block sealing
gasket. The gasket may disintegrate on
removal, make sure that all traces are
removed and discarded.
4.8. If required, remove the plug and remove
the pressure maintenance valve spool and
spring.
Install
1. Install the M8 oilway blanking plug as follows:
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L H
M
S P N
Q Blanking plug
R 122 mm H Nut
S 65 mm J 4WD clutch solenoid
K 4WD solenoid valve spool
1.1. Install the plug at the position shown below L Plug
the manifold block face at the specified M Pressure maintenance valve spool
distance. N Bolt
Distance: 1 mm P Valve manifold block
2. Install the valve manifold block as follows: Refer 3. Install the 4WD clutch assembly oil feed pipe.
to Figure 687. Make sure that the pipe is not twisted or strained.
2.1. Put the manifold block against the gearbox
case with a new sealing gasket. 4. Tighten the oil feed pipe nuts to the correct torque
value.
2.2. Attach the manifold block with the bolts.
Figure 688.
2.3. Tighten the bolt to the correct torque value.
2.4. Install the 4WD solenoid valve spool (if
applicable).
F
2.5. Install the 4WD solenoid coil.
2.6. Install the nut that attaches the 4WD clutch
solenoid.
2.7. Tighten the nut to the correct torque value.
Do not overtighten as damage to the valve
could result.
2.8. Install the pressure maintenance valve
spool and spring into the manifold block.
F 4WD oil feed pipe
2.9. Install the plug to secure the pressure
maintenance valve. Do not overtighten as 5. A pipe guard is available as a service option. The
damage to the aluminium housing could guard is installed using two bolts. Refer to Figure
result. 689.
6. Apply sealant to the threads of the bolts and
tighten to the correct torque value.
Torque: 56 N·m
(Medium Strength)
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27 - Driveline
Figure 689. 7.6. After assembly, make sure that the plastic
sealing plugs are inserted into the mounting
screw counter-bores to prevent the ingress
of water and dirt. This will prevent corrosion
of the screw heads and avoid problems
removing the screws in the future.

Item Nm
A 5
F 56
H 7
N 27
F
G
F 4WD oil feed pipe
G Pipe guard
7. Install the solenoid control valves as follows:
Figure 690.
A B C D
E
A Screws
B Reverse high-low clutch solenoid valve
C Main shaft-layshaft clutch solenoid valve
D High-low clutch solenoid valve
7.1. Replace the surface mounted o-rings in
each valve body.
7.2. Put the forward high-low clutch solenoid
valve in position against the manifold block.
7.3. Attach the forward high-low clutch solenoid
valve with the screws.
7.4. Tighten the screws to the correct torque
value.
7.5. Do the steps 7.2 to 7.4 main shaft-layshaft
clutch solenoid valve and reverse high-low
clutch solenoid valve.
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Disassemble and Assemble Figure 691.
(For: PS750 MK3)

Consumables
Strength)
It is not normally recommended to remove the spool

from the valve body. None of the component parts
of the valve assembly can be renewed individually.
The extent of permissible servicing is cleaning and
the consequential renewal of O-ring seals. Refer to
Check Condition.
Disassemble
1. Remove the surface mounted O-rings 1.
2. Unscrew the knurled nut and remove O-ring 3,
withdraw the solenoid and O-ring 5.
3. Hold the solenoid valve body in a vice, using the
spanner flats, remove spindle and O-ring 8.
4. Pull out the actuating pin, spring, spring retainer
and spool.
5. Dismantle the opposite solenoid in the same
sequence as described above.
6. Inspect the spool and spool bore for signs of
wear, nicks scratches etc.
1 O-rings
2 Knurled nut
3 O-ring
4 Solenoid
5 O-ring
6 Solenoid valve body
7 Spindle
8 O-ring
9 Actuating pin
10 Spring
11 Spring retainer
12 Spool
A Spanner flats
Assemble
1. Renew all O-rings.
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2. Lightly lubricate all parts with clean transmission

fluid before assembling.
3. Apply a small quantity of JCB Threadlocker and
Sealer to the threads in the knurled nut before
installation.
(Medium Strength)

Item Nm
2 12.5
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18 - Pressure Relief Valve
18 - Pressure Relief Valve
Introduction
The pressure relief valve is a type of valve used to

control or limit the pressure which can build up due
to a fault in the system.
The pressure is relieved by allowing the pressurised

fluid to flow from an auxiliary passage out of the
system. The relief valve is designed to open at
a predetermined set pressure to protect pressure
vessels from being subjected to pressures that
exceed their design limits.
27 - 166 9823/1700-1 27 - 166

27 - Driveline
21 - Pressure Maintenance Valve (PMV)
21 - Pressure Maintenance Valve

(PMV)
Remove and Install
(For: PS750 MK4) 2. Do not allow particles of grit to fall into the
gearbox.
Remove 3. Remove the plug then the sealing washer, the
spring and the valve spool.
1. Clean the area around the valve and the gearbox
case.
Figure 692.
B
C
D
A Plug B Sealing washer

C Spring D Valve spool
27 - 167 9823/1700-1 27 - 167

27 - Driveline
21 - Pressure Maintenance Valve (PMV)
Install
At the time of installation do the following step.
1. Tighten the plug to the correct torque value.

Item Description Nm
A Plug 56
27 - 168 9823/1700-1 27 - 168

27 - Driveline
24 - Oil Pump
24 - Oil Pump Check (Condition)

Check (Condition) ........................................ 27-169
Check (Condition)
A pump which is damaged or worn can cause
damage to the gearbox.
1. Remove the screws and then remove the pump

body.
2. Carefully check for any signs of wear or damage
on the gear teeth, white metal bearing and gear
mating faces. If any signs of wear or damage is
visible then you must replace the pump with a
new one.
3. Carefully remove and discard the oil seal.
Figure 693.
A
B
C
A Screw
B Oil seal
C Pump housing
4. Make sure that the seal housing is not damaged.
5. Install a new seal.
6. Install the seal the correct way around. Push the
seal flush with the front of the housing.
7. Assemble the pump again.
8. Make sure that the pump and the mating face on
the gearbox front cover is clean and free from
surface damage.
27 - 169 9823/1700-1 27 - 169

27 - Driveline
24 - Oil Pump
Remove and Install 5. Install the bolts together with the new sealing
washers.
Consumables
Description Part No. Size 6. Progressively tighten the bolts to the correct
torque value.
and Sealer (Medium 4101/0251 0.05 L 7. Put some clean, new, oil into the pump at the
Strength) location shown.
Remove Table 277. Torque Values

Item Nm
1. Clean the area around the pump. Do not allow
any dirt or contamination to fall into the gearbox. A 28
2. Remove the fixing bolts and lift the pump

assembly off the input shaft.
3. Remove the sealing washers and the pump
sealing ring.
4. Discard the washers and sealing ring.
Figure 694.
B A
F
D
E
A Bolt
B Oil pump
C Sealing washer
D Input shaft
E Sealing ring
F Oil filling location
Install
1. If the existing pump is to be installed then inspect
the pump for damage.
2. Install a new sealing ring.
3. Install the pump over the input shaft. Make sure
that the bolt holes are aligned.
(Medium Strength)
27 - 170 9823/1700-1 27 - 170

27 - Driveline
27 - Speed Sensor
27 - Speed Sensor Introduction

Introduction .................................................. 27-171 The sensor sends a varying frequency signal to
Component Identification ............................. 27-172 the Transmission ECU to determine the current
Operation ..................................................... 27-173 rotational speed of the input shaft or torque
Remove and Install ..................................... 27-174 converter. The ECU uses the input shaft speed to
determine the slippage across the torque converter
and potentially to determine the rate of slippage
across the clutches. This information is vital to
regulate the application of the torque converter lock-
up clutch smoothly and effectively.
27 - 171 9823/1700-1 27 - 171

27 - Driveline
27 - Speed Sensor
(For: PS750 MK4)

Figure 695. Location
A
A Ground speed sensor
Wires and Connectors
Figure 696. Ground Speed Sensor
6 1
5 2
4 3
1 Signal A - power (red) 2 Signal A - earth (black)

3 Signal A - output (white) 4 Signal B - power (orange)
5 Signal B- earth (brown) 6 Signal B - output (yellow)
27 - 172 9823/1700-1 27 - 172

27 - Driveline
27 - Speed Sensor
Operation
(For: PS750 MK4)

Machines with PS766 and PS750 transmission have
a Ground Speed Sensor and an Input Speed Sensor.
Machines with PS750 transmission only use the

Ground Speed Sensor.
Ground Speed Sensor Operation

The ground speed sensor is a magnetic induction
type. The sensor detects the passing of gear teeth as
the gear rotates inside the gearbox. The installation
ensures the correct air gap between the gear teeth.
When the gear rotation speed changes the frequency

of the output signal from the sensor changes.
The ground speed sensor installation senses the

rotation of the gearbox output gear.
The speed sensor incorporates two sensor elements

and a dual output signal to enable diagnosis if there
is a disagreement between the two sensor outputs.
Input Speed Sensor Operation

The input speed sensor is a magnetic induction type.
The sensor detects the passing of gear teeth as
the gear rotates inside the gearbox. The installation
ensures the correct air gap between the gear teeth.
When the gear rotation speed changes the frequency

of the output signal from the sensor changes.
The input speed sensor senses the rotation of the

gearbox input shaft via the reverse clutch driven
gear.
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27 - Driveline
27 - Speed Sensor
Remove and Install
For: PS750 MK3 ..................... Page 27-174 1.2. Remove the spacer 1.
For: PS750 Mk4, PS750 MK4 1.3. Remove the sensor guard.
................................................. Page 27-175
2. Remove the capscrew 2.
(For: PS750 MK3)
3. Remove the speed sensor.
Remove 4. Remove the spacer 2
1. If installed remove the sensor guard as follows: 5. Remove and discard the O-ring.
1.1. Remove the capscrews 1 (x2).
Figure 697.
B
C
E G
A Sensor guard B Capscrew 1 (x2)

C Spacer 1 D Sensor
E Capscrew 2 F Spacer 2
G O-ring
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27 - Driveline
27 - Speed Sensor
Install 2. Clean the area around the speed sensor.
1. Put the spacer 2 and O-ring into position on the 3. Do not allow particles of grit to fall into the
sensor. gearbox.
2. Put the sensor in position. 4. Remove the screw 1.
3. Attach the sensor with the capscrew 1. 5. Remove the speed sensor 1 from the housing.
4. If applicable install the sensor guard. Install

4.1. Attach the sensor guard with the spacer 1 1. Installation is the opposite of the removal
and capscrews 1 (x2). procedure. At the time of installation do the
following steps.
2. If the O-ring 1 is damaged replace it with a new
Speed sensors are installed depending on the one.
machine application. The gearbox has provision for
3. Install the screw 1.
two speed sensors.
4. Tighten the screw 1 to the correct torque value.
Speed sensor 1
Remove
1. If connected, disconnect the speed sensor
electrical connector.
27 - 175 9823/1700-1 27 - 175

27 - Driveline
27 - Speed Sensor
Figure 698.
B
A
G B
3. Do not allow particles of grit to fall into the

gearbox.
Table 278.
4. Remove the screw 2.
Item Description
A Speed sensor 1 5. Remove the speed sensor 2 from the housing.
B Speed sensor 2
6. If installed remove the shims or the spacers with
C Screw 1 the sensor 2.
D O-ring 1
E Screw 2 Install
F O-ring 2
G Shims or spacers procedure. At the time of installation do the
following steps.
Speed sensor 2
2. If the O-ring 2 is damaged replace it with a new
Remove one.
1. If connected, disconnect the speed sensor 3. If the spacers or the shims were removed replace
electrical connector. them correctly.
2. Clean the area around the speed sensor.
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27 - Driveline
27 - Speed Sensor
4. The speed sensor may be damaged or fail to

operate correctly if it is not at the correct distance
inside the housing.
5. Install the screw 2.
6. Tighten the screw 2 to the correct torque value.

Item Description Nm
C Screw 1 28
E Screw 2 12
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27 - Driveline
30 - Oil Pressure Sensor
30 - Oil Pressure Sensor Introduction

Introduction .................................................. 27-178 The transmission pressure sensor is a form of switch
Component Identification ............................. 27-179 that closes an electrical contact when a certain
Remove and Install ..................................... 27-179 set pressure has been reached on its input. The
switch may be designed to make contact either on a
pressure rise or on a pressure fall.
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27 - Driveline
Component Identification Remove and Install
(For: PS750 MK4) (For: PS750 MK4)

Figure 699. Location
Remove
1. Clean off all debris, dirt and grit from around the
pressure switch.
A
2. There must be no signs of debris, dirt or grit
inside the gearbox.
3. Remove the pressure switch and discard the
sealing washer.
4. Put caps on all the open ports of the gearbox.
Figure 701.
A Transmission Oil Pressure Switch

Figure 700. Wires and Connectors
A B
2 1
A Instrument panel
B Transmission Oil Pressure Switch
A Pressure switch
B Sealing washer
Install
procedure. At the time of installation do the
following steps.
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27 - Driveline
2. The oil pressure switch is non serviceable. If it is

faulty or damaged, it must be replaced with new
one.
3. Replace the sealing washer.
4. Tighten the pressure switch to the correct torque
value.

Item Description Nm
A Pressure switch 16
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27 - Driveline
39 - Filter
39 - Filter Introduction
Introduction .................................................. 27-181 The transmission filter is designed to filter all the
Remove and Install ..................................... 27-182 contamination that is generated through use to
the required level of cleanliness. The filter must
be serviced to the requirements of the machine
maintenance schedules.
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27 - Driveline
39 - Filter
Remove and Install Consumable: JCB Transmission Fluid EP SAE

30
Special Tools
Description Part No. Qty. 2. Screw the filter on until it just contacts the filter
head.
Oil Filter Removal Tool 892/00292 1
3. Turn the filter at least another 3/4 of a turn.
Consumables
JCB Transmission Fluid 4000/2601 5L
EP SAE 30 4000/2605 20 L
4000/2603 200 L
For draining the gearbox, refer to Gearbox, Drain and

Fill (PIL 27-06).
Remove
1. Clean the area around the filter. Do not allow
particles of grit to fall into the gearbox.
2. If required, use a strap wrench to loosen the oil
filter.
Special Tool: Oil Filter Removal Tool (Qty.: 1)
3. Remove and discard the filter.
Figure 702.
A Gearbox filter
B Seal
Assemble
1. Smear the seal with transmission oil.
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27 - Driveline
40 - Suction Strainer
40 - Suction Strainer Introduction

Introduction .................................................. 27-183 The suction strainer is a component used for trapping
Remove and Install ..................................... 27-184 large and coarse particles entering the transmission
system.
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27 - Driveline
Remove and Install Table 281. Torque Values

Item Nm
Consumables
Description Part No. Size B 12
Strength)
Remove
1. Clean the area around the strainer. Do not allow
2. Place a container, of suitable size beneath the
suction strainer. Remove the bolts. Remove the
strainer and the gasket. Allow the oil to drain into
the container. Be aware that the oil may be hot.
Refer to Gearbox, Drain and Fill (PIL 27-06).
3. Clean the strainer with a suitable solvent. Follow
the solvent manufacturer's instructions on safety.
Figure 703.
A Strainer
B Bolts
D Gasket
Install
1. Install the strainer and a new gasket.
2. Apply JCB Threadlocker and Sealer to the
threads of the bolts. Tighten the bolts to the
(Medium Strength)
27 - 184 9823/1700-1 27 - 184

27 - Driveline
45 - Piston Ring Seal
45 - Piston Ring Seal Introduction

Introduction .................................................. 27-185 A piston ring is a split ring that fits into a groove on
Remove and Install ..................................... 27-186 the outer diameter of a piston
27 - 185 9823/1700-1 27 - 185

27 - Driveline
45 - Piston Ring Seal
Remove and Install
Remove
1. Refer to the relevant Clutch - Disassemble and
Assemble procedure (PIL 27-06).
Install
1. Wind the PTFE (Polytetrafluoroethylene) piston
ring seal around your finger as shown, so that the
seal forms a coil.
Figure 704.
2. Lubricate the seal and then install the seal to the

shaft. Make sure that the seal sits below or flush
with the outer diameter of the shaft. If necessary,
use finger pressure as shown to make the seal
flush with the shaft.
Figure 705.
3. If the seal is not set below or flush with the outer

diameter of the shaft, then the seal will cut when
the shaft is installed to its mating component.
27 - 186 9823/1700-1 27 - 186

27 - Driveline
47 - Oil Seal
47 - Oil Seal Introduction

Introduction .................................................. 27-187 Oil seals close spaces between components in
Remove and Install ..................................... 27-188 mechanical systems, they are designed to:
• Prevent lubricant escape

• Prevent harmful contaminants from entering a
system
• Prevent corrosive moisture from entering a
system
• Prevent mixture of two different mediums e.g.
lubricating oil and water.
27 - 187 9823/1700-1 27 - 187

27 - Driveline
47 - Oil Seal

1. Make sure that the oil seal interface on the yoke
Remove is clean and free from wear or damage.
1. Bend back the stake nut locking ring. 2. Install a new oil seal. Locate the seal in the
position shown, the seal does not locate to the
2. Remove the yoke and the washer, refer to back of the housing.
Gearbox, Yoke- Remove and Install (27-06-95).
3. Lubricate the lips of the oil seal.
3. Remove the oil seal. Do not damage the seal
housing. 4. Install the yoke, refer to Gearbox, Yoke- Remove
and Install (27-06-95).
Figure 706.
5. Install a NEW stake nut. Tighten to the correct
torque value.
6. Stake the nut to the shaft using a square ended
staking tool, as shown.

Item Nm
B 400
A Yoke
B Stake nut
C Oil seal
D Oil seal interface
E Washer
F Locking ring
27 - 188 9823/1700-1 27 - 188

27 - Driveline
52 - Driveshaft
52 - Driveshaft
Introduction
The driveshaft is a mechanical component for

transmitting torque and rotation, it is used to connect
other components of the driveline that cannot be
connected directly because of the distance or the
need to allow for relative movement between them.
27 - 189 9823/1700-1 27 - 189

27 - Driveline
54 - Main Shaft
54 - Main Shaft Introduction

Introduction .................................................. 27-190 The main shaft receives its power from the engine
Check (Condition) ........................................ 27-191 and transmits the power to other components in the
Remove and Install ..................................... 27-191 gearbox.
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 190 9823/1700-1 27 - 190

27 - Driveline
54 - Main Shaft

1. Carefully inspect all gears, bearings and shafts
for signs of excessive wear or damage. If wear
(For: PS750 MK4)
or damage is evident, the components must be
renewed. Remove
2. Make sure that all oil way cross drillings are clear 1. Carefully lift out the clutch/shaft assemblies in the
and free from debris. Blocked oil ways are a following order.
common cause of bearing failure. If necessary
use an air line to blow through the oil ways. 1.1. Layshaft clutch assembly.
1.2. 2/4 wheel drive clutch or the permanent
4WD (Four Wheel Drive) shaft, as
applicable.
Figure 707.
P
K
M
N
L
K Layshaft clutch assembly

L 2/4 wheel drive clutch
M Reverse clutch assembly
N Main shaft clutch assembly
P Input clutch assembly
Q Bearing outer cups 1
R Shims
1.3. Reverse clutch assembly.
1.4. Main shaft clutch assembly.
1.5. Input clutch assembly.
2. Remove the bearing outer cups 1 and shims from
the rear case. Record the position of the cups
and shims to make sure the correct assembly.
27 - 191 9823/1700-1 27 - 191

27 - Driveline
54 - Main Shaft
Clutch Disassemble and Assemble 2.3. With the help of an assistant slightly raise
Procedures and tilt the input clutch and main shaft
clutch, install the reverse clutch.
For detailed disassemble and assemble procedures 2.4. Install the 2/4 wheel drive clutch or
refer to the following procedures: permanent 4WD shaft, as applicable.
• Reverse clutch - refer to (PIL 27-06-06) 2.5. Install the layshaft clutch.
• 2WD (Two Wheel Drive) / 4WD clutch - refer to
(PIL 27-06-07) 3. Install the correct bearing outer cups 2 to the
• Layshaft clutch - refer to (PIL 27-06-08) clutch shaft bearings.
• Mainshaft clutch - refer to (PIL 27-06-09) 4. Install the main shaft bearing outer cup to the
• Forward / input clutch - refer to (PIL 27-06-11) centre of the output shaft.
Install
1. Install the shims and the bearing outer cups 1 at
their correct locations in the rear case.
2. Install the clutch assemblies as follows.
2.1. Lubricate the clutch shaft bearings.
2.2. Install the input clutch and at the same time
install the main shaft clutch into the front
case.
Figure 708.
P
V
K
V
M V
V
N
L
K Layshaft clutch assembly

L 2/4 wheel drive clutch
Q Bearing outer cups 1
R Shims
V Bearing outer cups 2
W Main shaft bearing outer cup
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27 - Driveline
56 - Layshaft
56 - Layshaft
Introduction
The layshaft is an intermediate shaft within a gearbox

that carries gears, but does not transfer the primary
drive of the gearbox either in or out of the gearbox.
27 - 193 9823/1700-1 27 - 193

27 - Driveline
57 - Input Shaft
57 - Input Shaft
Introduction
Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).
27 - 194 9823/1700-1 27 - 194

27 - Driveline
58 - Output Shaft
58 - Output Shaft Introduction

Introduction .................................................. 27-195 In the gearbox, the input and output shafts lie along
Calibrate ...................................................... 27-196 the same line, and are sometimes combined into a
Remove and Install ..................................... 27-197 single shaft within the gearbox. This single shaft is
called the main shaft.
The input and output ends of this combined shaft

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

of the main shaft can be locked together to create a
1:1 gear ratio, causing the power flow to bypass the
layshaft. The main shaft then behaves like a single,
solid shaft: a situation referred to as direct drive.
27 - 195 9823/1700-1 27 - 195

27 - Driveline
58 - Output Shaft
Calibrate
Refer to the individual Remove and Install tasks of

the Output Shaft for the calibration procedure.
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27 - Driveline
58 - Output Shaft
Remove and Install
For: PS750 MK3 ..................... Page 27-197 Remove

For: PS750 MK4 ..................... Page 27-201
Figure 709.
(For: PS750 MK3)
B
Special Tools A
Spacer Kit 921/52600 1
Flange Spanner 992/04800 1
End Float Setting Tool 993/70100 1
Kit
D
(10-100Nm) H E
G
C
A Brake Disc
B Output shaft nut
C Output shaft
D Oil seal
E Outer taper roller bearing
F Spacer
G Inner taper roller bearing
H Bolt 1
J Park brake bracket
K Rear case
1. Remove the output shaft as follows:
1.1. Hold the brake disc with the service tool.
Special Tool: Flange Spanner (Qty.: 1)
27 - 197 9823/1700-1 27 - 197

27 - Driveline
58 - Output Shaft
1.2. Remove the output shaft nut. 1.4. Drill a hole of the specified diameter at the
location shown to enable the installation of
1.3. Support the output shaft from inside the
the service tool for checking the end float.
case and remove the brake disc.
Dimension: 12.5 mm
1.4. Remove the output shaft. Special Tool: End Float Setting Tool Kit
1.5. Remove and discard the oil seal. (Qty.: 1)
1.6. Remove the outer taper roller bearing. 2. Pre-assemble the output shaft as follows:
1.7. Remove the spacer and keep for assembly. Figure 711.
1.8. Use a suitable puller to remove the output
shaft inner bearing. D
1.9. If required, the parking brake bracket can E
be removed at this stage. Before removal,
mark the position of the bracket with respect
to the case.
1.10. Note: Due to different ratio options, some
gearboxes may have a larger diameter K
output gear. When you remove the output
shaft the gear may touch the gearbox
housing, preventing removal. Refer to the
Section - Output Shaft Removal - Larger
Diameter Gears, within this procedure.
Install
1. If removed, the park brake bracket must be
installed at this stage as follows:
Figure 710.
F
H
M
C
J G
L
C Output shaft
D Oil seal
K E Outer taper roller bearing
F Service spacer
H Bolt 1 K Rear case
K Rear case 2.1. Apply oil on the inner bearing and cup and
L 82 mm install on the output shaft.
M 75 mm
2.2. Install the bearing cups into the case.
1.1. Put the bracket in the position marked 2.3. Install the service spacer onto the output
during disassembly. shaft and install the output shaft into the
1.2. Attach the park brake bracket with the bolts case.
1. Special Tool: Spacer Kit (Qty.: 1)
1.3. Tighten the bolts to the correct torque value. 2.4. Apply oil on the outer bearing and cup and
install onto the output shaft.
2.5. Do not install the oil seal at this stage.
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27 - Driveline
58 - Output Shaft
3. Measure the output shaft assembly end float. Figure 713.

3.1. Install the service tool sleeve (which
temporarily replaced the disc brake) and S
secure it with the service nut.
3.2. Tighten the service tool nut to the correct
torque value.
Torque: 50 N·m
3.3. Install the service tool support pillar so that
the fork end engages in the service tool nut.
3.4. Tighten the bolt 2.
T
Figure 712.
S DTI
Q T Torque wrench
R 3.7. Select the right size spacer based on the
example given in the table. Refer to Table
283.
P 3.8. Note: If the measurement obtained is
outside the spacer kit range, then check the
assembly of the bearings.
N
3.9. Disassemble the service tools and install
the correct size spacer. Assemble the
transfer gear output shaft.
3.10. Install the service tool sleeve and secure
it with the service nut.
3.11. Tighten the service tool nut to the correct
torque value.
Torque: 50 N·m
3.12. Make sure that there is no end float and
the rolling torque is less than the specified
value.
N Service tool sleeve
P Service tool nut Torque: 1.5 N·m
Q Support pillar 3.13. If the rolling torque exceeds the specified
R Bolt 2 value then check that the output shaft is
installed correctly.
3.5. Install the DTI (Dial Test Indicator).
3.14. If the rolling torque is too high, install the
3.6. Set the torque wrench to the specified value next largest spacer.
and measure the end float while you rotate
the output shaft. 3.15. If the rolling torque is too low, install the
next smallest spacer.
Torque: 35 N·m
Special Tool: Torque Wrench (10-100Nm) 3.16. Remove the service tool nut and the
(Qty.: 1) service tool sleeve.
4. Output shaft final assembly.
27 - 199 9823/1700-1 27 - 199

27 - Driveline
58 - Output Shaft
Figure 714. 4.4. Install the brake disc with reference to the
alignment marks made during disassembly.
A B
4.5. Note: Do not excessively hammer the disc
during assembly or damage to the shaft
bearings could occur. If necessary, press
fit the parts. Fully support the shaft during
D assembly.
4.6. Install the new retaining nut and washer.
4.7. Progressively tighten the nut to the correct
torque value.
4.8. The combined seal and bearing rolling
torque should not exceed the specified
value when fully torque tightened provided,
the correct size spacer has been selected.
Torque: 2 N·m
A Brake Disc
B Output shaft nut 4.9. If the rolling torque is too high, install the
F Oil seal next largest spacer.
4.10. If the rolling torque is too low, install the
4.1. Lubricate the seal lips of a new oil seal.
next smallest spacer.
4.2. Install the new oil seal.
4.11. Stake the nut into the slot in the shaft.
4.3. Make sure that the seal is pushed square to
the housing.
Table 283. Spacer Selection Example

Service spacer 13.7
Subtract end float 0.41
Total 13.29
Subtract bearing tolerance and pre-load 0.12
Result 13.17
Use next smallest spacer i.e. 13.15

Item Nm
B 300
Output Shaft Removal - Larger Diameter partially up the output shaft, it will not be possible
Gears to remove them at this stage.
2. Pull the output shaft up and position suitable
In the event that the output gear fouls against
spacers between the taper rollers and bearing
the gearbox housing at position 1 when attempting
outer cup as shown.
removal of the output shaft, proceed as follows:
3. Push the output shaft down again, the inner cup
Note: The following procedure will be required and taper rollers will be forced further up the shaft
when dismantling the gearbox, and also after initial allowing them to be removed.
assembly, since the output shaft will need to be
removed when setting the end float. 4. If the inner cup and taper rollers are still engaged
on the output shaft repeat steps 2 and 3 using
To enable the output shaft removal past the case at thicker spacers.
position 1, the bearing inner cup and taper rollers
must first be removed from the output shaft. 5. With the bearing inner cup and taper rollers
removed, the output shaft and gear can be
1. Push the output shaft down until the gear lowered and tilted to one side, allowing the gear
contacts the housing at position 1, take care not to clear the housing and the shaft to be removed.
to damage the housing or gear. Although the
bearing inner cup and taper rollers will be forced
27 - 200 9823/1700-1 27 - 200

27 - Driveline
58 - Output Shaft
Figure 715. 1. Remove the output shaft as follows: Refer to

Figure 716.
1.1. Hold the brake disc (or output yoke) with the
service tool.
C C
1 1.2. Remove the output shaft nut.
Special Tool: Flange Spanner (Qty.: 1)
2
1.3. Support the output shaft from inside the
case and remove the brake disc (or output
yoke).
1.4. Remove the output shaft.
3 1.5. Remove and discard the oil seal.
1.6. Remove the outer taper roller bearing.
1.7. Remove the spacer and keep for assembly.
A 1.8. Use a suitable puller to remove the output
shaft inner bearing.
1.9. If required, the park brake bracket can
B be removed at this stage. Before removal,
mark the position of the bracket with respect
1 Output shaft
to the case.
2 Taper rollers
3 Bearing outer cup 1.10. Note: Due to different ratio options, some
A Gear gearboxes may have a larger diameter
B Position 1 output gear. When you remove the output
C Spacers shaft the gear may touch the gearbox
housing, preventing removal. Refer to
Note: If the output shaft is being removed after initial Section- Output Shaft Removal- Larger
assembly, typically to set the end float, take extreme Diameter Gears within this procedure.
care to avoid damage to the bearing outer cup and
inner cup and taper rollers. Use only soft spacers
such as aluminium, do not use hardened steel items
such as screwdrivers.
If the bearing is damaged a new bearing must be

installed. The tolerance difference between the new
bearings is expected to be less than the difference
between the solid spacer sizes so changing a
bearing should not affect the end float.
(For: PS750 MK4)

Special Tools
Setting Tool Kit 892/00918 1
Flange Spanner 992/04800 1
End Float Setting Tool 993/70100 1
Kit
(10-100Nm)
Remove
Before removing the output shaft and its bearings
remove all the clutch assemblies.
27 - 201 9823/1700-1 27 - 201

27 - Driveline
58 - Output Shaft
B
A
H
M
J
L
D
H E
K
J
H Bolt 1
K J Park brake bracket
K Rear case
L 82 mm
M 75 mm
1.1. Put the bracket in position marked during
disassembly.
1.2. Attach the park brake bracket with the bolts
1.
1.4. Drill a hole of the specified diameter at the
location shown to enable the installation of
the service tool for checking the end float.
F Dimension: 12.5 mm
Special Tool: End Float Setting Tool Kit
(Qty.: 1)
G
C 2. Pre-assemble the output shaft as follows: Refer
to Figure 718.
A Brake disc
B Output shaft nut
C Output shaft
D Oil seal
E Outer taper roller bearing
F Spacer
H Bolt 1
K Rear case
Install
1. If removed, the park brake bracket must be
installed at this stage as follows: Refer to Figure
717.
27 - 202 9823/1700-1 27 - 202

27 - Driveline
58 - Output Shaft
Figure 718. 3.2. Tighten the service tool nut to the correct
torque value.
D Torque: 50 N·m
E 3.3. Install the service tool support pillar so that
the fork end engages in the service tool nut.
3.4. Tighten the bolt 2.
Figure 719.
K
Q
R
C
G
C Output shaft
D Oil seal
E Outer taper roller bearing N Service tool sleeve
F Service spacer P Service tool nut
G Inner taper roller bearing Q Support pillar
K Rear case R Bolt 2
2.1. Apply oil on the inner bearing and cup and 3.5. Install the DTI. Refer to Figure 720.
install on the output shaft. 3.6. Set the torque wrench to the specified value
2.2. Install the bearing cups into the case. and measure the end float while you rotate
the output shaft.
2.3. Install the service spacer onto the output
shaft and install the output shaft into the Torque: 35 N·m
case. Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
Special Tool: Spacer Kit (Qty.: 1)
2.4. Apply oil on the outer bearing and cup and
install onto the output shaft.
2.5. Do not install the oil seal at this stage.
3. Measure the output shaft assembly end float.
3.1. Install the service tool sleeve (which
temporarily replaced the disc brake) and
secure it with the service nut. Refer to
Figure 719.
Special Tool: Setting Tool Kit (Qty.: 1)
27 - 203 9823/1700-1 27 - 203

27 - Driveline
58 - Output Shaft
A B
S
S DTI A Brake Disc

T Torque wrench B Output shaft nut
F Oil seal
3.7. Select the right size spacer based on the
example given in the table. Refer to Table 4.1. Lubricate the seal lips of a new oil seal.
285.
4.2. Install the new oil seal.
3.8. Note: If the measurement obtained is
outside the spacer kit range, then check the 4.3. Make sure that the seal is pushed square to
assembly of the bearings. the housing.
3.9. Disassemble the service tools and install 4.4. Install the brake disc (or output yoke) with
the correct size spacer. Assemble the reference to the alignment marks made
transfer gear output shaft. during disassembly.
3.10. Install the service tool sleeve and secure 4.5. Note: Do not excessively hammer the disc
it with the service nut. during assembly or damage to the shaft
bearings could occur. If necessary, press
3.11. Tighten the service tool nut to the correct fit the parts. Fully support the shaft during
torque value. assembly.
Torque: 50 N·m 4.6. Install the new retaining nut and washer.
3.12. Make sure that there is no end float and 4.7. Progressively tighten the nut to the correct
the rolling torque is less than the specified torque value.
value.
4.8. The combined seal and bearing rolling
Torque: 1.5 N·m torque should not exceed the specified
3.13. If the rolling torque exceeds the specified value when fully torque tightened, provided
value then check that the output shaft is the correct size spacer has been selected.
installed correctly. Torque: 2 N·m
3.14. If the rolling torque is too high, install the 4.9. If the rolling torque is too high, install the
next largest spacer. next largest spacer.
3.15. If the rolling torque is too low, install the 4.10. If the rolling torque is too low, install the
next smallest spacer. next smallest spacer.
3.16. Remove the service tool nut and the 4.11. Stake the nut into the slot in the shaft with
service tool sleeve. a square ended staking tool.
4. Output shaft final assembly. Refer to Figure 721.

Service spacer 13.7
Total 13.29
Subtract bearing tolerance and pre-load 0.12
27 - 204 9823/1700-1 27 - 204

27 - Driveline
58 - Output Shaft
Result 13.17
Use next smallest spacer i.e. 13.15

Item Nm
B 300
H 166
Output Shaft Removal - Larger Diameter Figure 722.

Gears
In the event that the output gear fouls against the
gearbox housing at position 1 when attempting to C C
remove the output shaft, proceed as follows: 1
Note: The following procedure will be required 2
when dismantling the gearbox, and also after initial
assembly, since the output shaft will need to be
removed when setting the end float.
To enable the output shaft removal past the case at

position 1, the bearing inner cup and taper rollers 3
must first be removed from the output shaft.
1. Push the output shaft down until the gear

contacts the housing at position 1, take care not A
to damage the housing or gear. Although the
bearing inner cup and taper rollers will be forced
partially up the output shaft, it will not be possible
to remove them at this stage.
B
2. Pull the output shaft up and position suitable 1 Output shaft
spacers between the taper rollers and bearing 2 Taper rollers
outer cup as shown. 3 Bearing outer cup
A Gear
3. Push the output shaft down again, the inner cup B Position 1
and taper rollers will be forced further up the shaft C Spacers
allowing them to be removed.
Note: If the output shaft is being removed after initial
4. If the inner cup and taper rollers are still engaged assembly, typically to set the end float, take extreme
on the output shaft repeat steps 2 and 3 using care to avoid damage to the bearing outer cup and
thicker spacers. inner cup and taper rollers. Use only soft spacers
5. With the bearing inner cup and taper rollers such as aluminium, Do not use hardened steel items
removed, the output shaft and gear can be such as screwdrivers.
lowered and tilted to one side, allowing the gear
to clear the housing and the shaft to be removed. If the bearing is damaged a new bearing MUST be
installed. The tolerance difference between the new
bearings is expected to be less than the difference
between the solid spacer sizes so changing a
bearing should not affect the end float.
27 - 205 9823/1700-1 27 - 205

27 - Driveline
60 - Idler Shaft
60 - Idler Shaft
Introduction
The idler shaft carries one or more gearwheels, the

shaft idles between a driver shaft and a driven shaft,
usually to reverse the direction of rotation or provide
different spacing of gearwheels in a gearbox.
27 - 206 9823/1700-1 27 - 206

27 - Driveline
70 - 4WD Unit
70 - 4WD Unit Introduction

Introduction .................................................. 27-207 Machines with permanent 4 wheel drive (4WD)
Component Identification ............................. 27-208 feature a gear and output shaft in place of the 2WD
Check (Condition) ........................................ 27-209 and 4WD clutch on selectable 4WD machines. The
Remove and Install ..................................... 27-209 shaft is driven from the layshaft in the same way as
the 2WD and 4WD clutch.
27 - 207 9823/1700-1 27 - 207

27 - Driveline
70 - 4WD Unit
Figure 723.
1 Output yoke 2 Retaining nut

3 Housing bolts 4 Washer
5 Shaft 6 Housing
7 Oil seal 8 Bearing
9 Bearing 11 Spacer
27 - 208 9823/1700-1 27 - 208

27 - Driveline
70 - 4WD Unit

1. Carefully inspect the components for signs of Refer to Driveline, Semi-Automatic Gearbox,
damage or excessive wear. In particular inspect Permanent 4WD Unit- Disassemble and Assemble
the oil seal interface surface on the output yoke (PIL 27-06-70).
for signs of scoring. Renew as required.
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27 - Driveline
70 - 4WD Unit
Special Tools 2. Remove the housing bolts and withdraw the unit
Description Part No. Qty. from the gearbox.
Drive Coupling 892/00812 1 3. Remove the retaining nut, washer (if installed)
Spanner and the yoke. Withdraw the shaft from the
housing.
Consumables
Description Part No. Size 4. Remove the oil seal from the housing.
5. If the bearings are to be renewed, remove the
inner cups from the shaft. Remove the outer cup
Disassemble of the bearing 8 from the housing and retrieve the
spacer (if installed). Remove the outer cup of the
1. Use the tool 892/00812 to hold the output yoke, bearing 9 from the main gearbox housing.
loosen the retaining nut.
Figure 724.
1 Output yoke 2 Retaining nut

3 Housing bolts 4 Washer
5 Output shaft 6 Housing
7 Oil seal 8 Bearing
9 Bearing 11 Spacer
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27 - Driveline
70 - 4WD Unit
Assemble
1. Install the bearing outer cup to the main gearbox
case.
2. Install the spacer and then the bearing outer cup
to the housing.
3. Install the bearing inner cups to the shaft.
4. Assemble the shaft to the housing. Install the
yoke and nut. Do not fully tighten the nut at this
stage.
5. Apply JCB Multi-gasket to the main gearbox case
and housing. Use the bolts to secure the 4WD
unit to the gearbox.
6. Hold the yoke using tool 892/00812 and tighten
the nut to the correct torque value, Do not stake
the nut at this stage.
7. Measure the end float of the output shaft. It must
be between the given tolerances.
8. Finally remove the nut, yoke and install the new
oil seal. Carefully install the yoke, make sure
you avoid damage to the seal. Install a new
stake nut (with integral washer), tighten the nut
to the correct torque value and then use a square
ended staking tool to stake the nut to the shaft.
Figure 725.

Item Nm
2 400
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27 - Driveline
81 - Mount
81 - Mount
Check (Condition)
2. Get access to the mounting(s).
3. Make sure that the entire mounting(s) system is
in good condition.
3.1. Inspect brackets and casings for cracks,
damage and security.
3.2. Inspect rubber mountings (if installed) for
wear and tears and too much movement.
3.3. Make sure that all fastenings are there and
they are tightened to the correct torque.
Refer to (PIL 72).
4. Install new components if any are defective.
Refer to the correct section in the service manual
as necessary.
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27 - Driveline
85 - Oil Feed Pipe
85 - Oil Feed Pipe
Remove and Install
Remove
1. Remove the adaptor bolts 1.
2. Remove all the sealing washers 1 (x4).
3. Remove the external oil feed pipe.
Figure 726.
C
B
B External oil feed pipe

C Adaptor bolts 1 (x2)
D Sealing washers 1 (x4)
Install
1. Install the external oil feed pipe with the adaptor
bolts 1 and the sealing washers 1.
2. Tighten the bolts 1 to the correct torque value.

Item Description Nm
C Adaptor bolts 1 26.5
27 - 213 9823/1700-1 27 - 213

27 - Driveline
86 - Oil Transfer Pipe
86 - Oil Transfer Pipe
Remove and Install
The oil transfer pipe is located on the rear case, if

the pipe is damaged or the gearbox is contaminated
then the pipe must be removed for cleaning or
replacement.
Remove
1. Remove the adaptor bolts 2.
2. Remove all the sealing washers 2.
3. Remove the oil transfer pipe.
Figure 727.
S
T
U
U
S Adaptor bolts 2 (x2)

T Oil transfer pipe
U Sealing washers 2 (x4)
Install
1. Install the oil transfer pipe with the adaptor bolts
2 and sealing washers 2.
2. Tighten the bolts 2 to the correct torque value.

Item Description Nm
S Adaptor bolts 2 26.5
27 - 214 9823/1700-1 27 - 214

27 - Driveline
90 - Front Case
90 - Front Case Clean

Consumables
Clean ........................................................... 27-215
Check (Condition) ........................................ 27-216
Cleaner/Degreaser 4104/1557 0.4 L
Remove and Install ..................................... 27-216 - General purpose
solvent based parts
cleaner
1. Carefully remove all traces of gasket or gasket

compound from the front and rear case mating
faces. When removing gasket compound use a
gasket removal product such as Loctite Chisel.
Take care not to damage the mating faces. Clean
the faces with a fine carborundum paper. Use
a solvent cleaner and a clean cloth to finally
remove all traces of oil or debris
2. Clean the inside of the cases using a suitable
degreasing agent.
purpose solvent based parts cleaner
27 - 215 9823/1700-1 27 - 215

27 - Driveline
90 - Front Case

Consumables For: PS750 MK3 ..................... Page 27-216
Description Part No. Size For: PS750 MK4 ..................... Page 27-222
and Sealer (Medium 4101/0251 0.05 L (For: PS750 MK3)
Strength)
Special Tools
1. If the gearbox cases are to be renewed, be Description Part No. Qty.
sure to install blanking plugs and adaptors as End Float Setting Tool 993/70100 1
required. Inspect the original cases and identify Kit
the blanking plug and adaptor positions. Transfer
the plugs and adaptors to the new cases. Apply
(10-100Nm)
JCB Threadlocker and Sealer to the threads
before installation. Adaptor 993/78200 1
Consumable: JCB Threadlocker and Sealer Consumables
(Medium Strength) Description Part No. Size
Strength)
Remove
With the gearbox removed from the machine, place
suitable wooden blocks to securely support the
assembly.
1. Remove the suction strainer.

2. Remove the drain plug and discard its sealing
washer.
3. Remove and discard the oil filter.
3.1. Note: Some gearbox installations may have
a remotely situated oil filter.
4. Remove the main shaft lubrication oil pipe. Refer
to Figure 728.
4.1. The pipe is connected at the rear case and
at the torque converter housing.
5. Remove the mainline pressure switch and
pressure test point assembly. Refer to Figure
728.
27 - 216 9823/1700-1 27 - 216

27 - Driveline
90 - Front Case
C A J H
B
A Oil filter
B Oil pipe F
C Pressure switch and pressure test point
6. If required remove the speed sensor.
E
7. Remove the torque converter housing as follows:
Refer to Figure 729. E Torque converter housing
F Torque converter relief valve
7.1. Remove the bolts 1 that attach the torque G Bolt 2
converter housing. H Rear case
7.2. Lift the torque converter housing from the J Brake disc
gearbox.
11.1. Temporarily install the torque converter
Figure 729. housing with 2 bolts.
11.2. Put the gearbox in the vertical position
such that the torque converter housing
D faces down.
E 11.3. Remove the torque converter relief valve
ball, spring and sealing washer.
11.4. Remove the bolts 2 (x20) and lift the rear
case.
11.5. Make sure you remove the bearing outer
cups from inside the case.
11.6. Keep the cups together with their
associated bearing.
D Bolt 1 11.7. Note: Make sure that the internal
E Torque converter housing components remain installed in the front
case. If necessary, rotate the brake disc on
8. Remove the gearbox oil pump.
the output shaft back and forth slightly to
9. Remove the solenoid control valves. dislodge the internal components.
11.8. Remove and discard the sealing O-rings
10. Remove the applicable 4WD (Four Wheel Drive) from the front case. Refer to Figure 731.
clutch shaft assembly.
12. Remove the clutch and shaft assemblies in the
11. Separate the front and rear cases as follows: sequence that follows: Refer to Figure 731.
27 - 217 9823/1700-1 27 - 217

27 - Driveline
90 - Front Case

L
P R
L
M N
P
K O-ring (x3)
L Layshaft clutch assembly K
12.1. Layshaft clutch assembly.
12.2. Reverse clutch assembly.
M N
12.3. Main shaft clutch assembly.
12.4. Input clutch assembly.
K O-ring (x3)
13. Note the positions of the end shaft spacers. L Layshaft clutch assembly
Remove and put labels on the spacers to enable M Reverse clutch assembly
assembly in their original locations. Be sure N Main shaft clutch assembly
to remove the bearing outer cups from inside P Input clutch assembly
the case. Keep the cups together with their R Screwdrivers
associated bearing.
2.1. Lubricate all the bearings.
Install 2.2. Make sure that the piston ring seals have
been replaced, lubricated and installed in
1. Install the clutch shaft spacers (x4) in their their correct positions.
original positions inside the front case. Refer to
Figure 732. 2.3. Install the input clutch and the main shaft
together into the front case.
Figure 732. 2.4. With the help of a second person slightly
Q raise the input clutch and the main shaft.
With the two units raised, install the reverse
clutch.
Q Q 2.5. Install the layshaft assembly.
2.6. Make sure that all bearings are correctly
installed and that the relevant gears are
engaged correctly.
2.7. With two small rods (or screwdrivers) align
all the friction and counter plates of the main
shaft clutch.
Q 3. Assemble the front and rear cases as follows:
Q Clutch shaft spacers (x4)

2. Install the clutch shaft assemblies as follows:
27 - 218 9823/1700-1 27 - 218

27 - Driveline
90 - Front Case
Figure 734. and tolerances. This is particularly important if

components such as clutch shafts or gearbox cases
have been replaced.
J H
1. The main shaft airline adaptor 993/78200 can be
used to hold the clutch pack with air pressure, the
pack needs to be aligned with the transfer gear
assembly first.
G Special Tool: Adaptor (Qty.: 1)
2. Use the service tool to measure the end float of
all clutch shafts.
Special Tool: End Float Setting Tool Kit (Qty.: 1)
3. Measure the input shaft end float. Refer to Figure
735.
Figure 735.
G Bolt 2 W
H Rear casing
J Brake disc
V
3.1. Install the new o-rings (x3) in the front case.
Lubricate the O-rings. Make sure they stay T
in position. U
3.2. Apply liquid gasket to the front case mating
face. X S
3.3. Before you install the rear case make sure
that the bearings are lubricated and the
piston ring seals are lubricated and installed
at their correct position.
3.4. Make sure that the clutch bearing outer S Base plate
cups are installed to the rear case and the T Support pillar
output shaft assembly. U Adaptor
V Torque wrench
3.5. Make sure that all the friction and counter
W DTI
plates in the main shaft clutch are aligned.
X Splined wrench
3.6. Carefully lower the rear case into position,
take care to align the output gear splines 3.1. Assemble the adaptor to the end of the
with the main shaft clutch friction and shaft.
counter plates. 3.2. Install the base plate to the gearbox with a
3.7. Gently rotate the brake disc back and forth bolt.
to enter the plates, if the case does not drop 3.3. Install a splined wrench (which can be
down onto the dowels, do not use the bolts manufactured from an old torque converter
or force as the plates will be damaged. hub) over the shaft.
3.8. Apply sealant to the threads of the bolts that 3.4. Assemble the DTI (Dial Test Indicator) and
attach the front and rear cases. the torque wrench.
Consumable: JCB Threadlocker and Sealer Special Tool: Torque Wrench (10-100Nm)
(Medium Strength) (Qty.: 1)
3.9. Tighten the bolts to the correct torque value. 3.5. Set the DTI to zero and the torque wrench
to the specified torque value.
Note: The end float of the clutch shafts is controlled
without the use of shims. This is achieved by using Torque: 35 N·m
a `set-right' tolerancing system during manufacture. 3.6. Rotate the input shaft back and forth with
After assembly the clutch shaft end floats must the splined wrench, to seat the bearings,
be checked to make sure correct assembly and lift and depress the torque wrench.
27 - 219 9823/1700-1 27 - 219

27 - Driveline
90 - Front Case
3.7. Make a record of the reading on the DTI. Figure 737.

3.8. The end float must be within the range
specified. W
mm V
4. Measure the reverse shaft end float. Refer to
Figure 736.
Figure 736.
Z W
S U
Y
S Base plate
U U Adaptor
V V Torque wrench
W DTI
5.1. Assemble the adaptor to the end of the
S shaft.
5.2. Install the base plate to the gearbox with a
bolt.
S Base plate
U Adaptor 5.3. Assemble the DTI and the torque wrench.
V Breakback torque wrench 5.4. Set the DTI to zero and the torque wrench
W DTI to the specified torque value.
Y Sealing plug
Z Washer Torque: 35 N·m
5.5. Rotate the reverser shaft back and forth
4.1. Remove the sealing plug and the washer.
with the brake disc on the output shaft, to
4.2. Assemble the adaptor to the end of the seat the bearings, and lift and depress the
shaft. torque wrench.
4.3. Install the base plate to the gearbox with a 5.6. Record the reading on the DTI.
bolt.
4.4. Assemble the DTI and the torque wrench. specified.
4.5. Set the DTI to zero and the torque wrench Length/Dimension/Distance: 0.02 –0.16
to the specified torque value. mm
Torque: 35 N·m 6. Measure the main shaft shaft end float. Refer to
4.6. Rotate the reverse shaft back and forth with Figure 738.
the splined wrench on the input shaft, to
seat the bearings, and lift and depress the
torque wrench.
4.7. Record the reading on the DTI.
specified.
mm
5. Measure the layshaft shaft end float. Refer to
Figure 737.
27 - 220 9823/1700-1 27 - 220

27 - Driveline
90 - Front Case
Figure 738. are engaged with the torque converter

housing.
9.3. Apply sealant to the threads of the bolts that
attach the torque converter.
W
(Medium Strength)
S V
9.5. Install the torque converter relief valve ball
and tapered spring. Refer to Figure 739.
9.6. Make sure that the larger diameter of the
tapered spring is located securely over the
spigot on the plug.
9.7. Use a new sealing washer, then install and
U
tighten plug.
S Base plate
U Adaptor Figure 739.
V Torque wrench
W DTI
6.1. Assemble the adaptor to the end of the
shaft. F
6.2. Install the base plate to the gearbox with a
bolt.
6.3. Assemble the DTI and the torque wrench.
6.4. Set the DTI to zero and the torque wrench
to the specified torque value.
Torque: 35 N·m
6.5. Gain access through the 4WD cover to
rotate the main shaft. For 2WD (Two Wheel
Drive) transmissions use an airline and the
adaptor tool.
6.6. Rotate the main shaft back and forth to seat
the bearings, and lift and depress the torque
wrench.
6.7. Record the reading on the DTI.
6.8. The end float must be within the range F Torque converter relief valve
specified. 10. Install the solenoid valve manifold block and the
Length/Dimension/Distance: 0.02 –0.18 solenoid valves.
mm
11. Install the suction strainer.
7. Install the 4WD clutch assembly or output
shaft assembly (permanent 4WD variant) (if 12. Install the drain plug with a new sealing washer.
applicable). 13. Tighten the drain plug to the correct torque value.
8. Install the gearbox oil pump. Torque: 203 N·m
9. Install the torque converter housing as follows: 14. Install the main line pressure switch and pressure
test point assembly with a new sealing washer.
9.1. Apply liquid gasket to the mating face of the
torque converter housing. 15. Tighten the locknut to the correct torque value.
Consumable: JCB Multi-Gasket 16. Install a new oil filter.
9.2. Put the torque converter in position against
the front case. Make sure that the dowels 17. Install the main shaft lubrication oil pipe at the
gearbox case and torque converter housing.
27 - 221 9823/1700-1 27 - 221

27 - Driveline
90 - Front Case
18. If removed, install the speed sensor. Figure 740.

Item Description Nm
C Mainline pressure switch and 28
pressure test point locknut
D Bolt 1 56
G Bolt 2 56
(For: PS750 MK4)

Consumables
Before removal
A
Before splitting the front and rear case do the
following procedures.
• Remove the oil filter. Refer to (PIL 27-06-39). A Cradle

• Remove the suction strainer. Refer to (PIL
27-06-40) Remove the external oil feed pipe. Refer to (PIL
27-06-85).
• Remove the solenoid control valves. Refer to
(PIL 27-06). Remove
• Remove the 4WD yoke and seal. Refer to (PIL
27-06-95). Front and rear case
• Remove the speed sensors. Refer to (PIL 1. Remove all the case fixing screws.
27-06-27).
• Remove the torque converter relief valve. Refer Figure 741.
to (PIL 27-14-09).
Cleanliness is of the utmost importance when you

service the gearbox. All precautions to prevent any
ingress of dirt, grit etc. must be taken.
F
• Remove deposits of dirt, grit and oil from the
outer cases and components.
• Prevent dirt, grit and debris falling into the
gearbox.
• Put caps on all open ports, hoses, pipes and
orifices.
E
Use lifting equipment to locate the gearbox in a
work cradle as shown. Do not try to disassemble the
gearbox further unless it is safely located in a work F
cradle.
E Case fixing screws (x22)

F Rear case
G Front case
27 - 222 9823/1700-1 27 - 222

27 - Driveline
90 - Front Case
2. Use lifting equipment to carefully lift off the rear Before installation
case.
• If you remove the output shaft and bearing then
3. Remove the shaft bearing outer cups. The cups install them. Refer to (PIL 27-06-58).
will be left on the bearings, or inside the front • Make sure the clutch assemblies are correctly
case. assembled and are free from defects. Refer to
(PIL 27-06).
Figure 742. • Replace the clutch shaft piston ring seals with
new ones. Make sure that the piston ring seals
are correctly installed in the shaft grooves.
H
H Use lifting equipment to locate the gearbox in a work
cradle as shown. Do not try to assemble the gearbox
further unless it is safely located in a work cradle.
Figure 743.
H H
H
H Bearing outer cups

J O-ring seals
4. Keep the cups with their associated bearings. A
5. Remove and discard the O-ring seals from the
front case.
A Cradle
After removal
Clean and check the condition of all components
Remove the oil transfer pipe. Refer to (PIL 27-06-86). before you install them.
Remove the clutch assemblies - refer to the following Install the oil transfer pipe. Refer to (PIL 27-06-86).
procedures:
Install the clutch shaft assemblies. Refer to (PIL
• Mainshaft - (including layshaft clutch assembly, 27-06).
2WD / 4WD clutch assembly, reverse clutch
assembly, mainshaft clutch assembly and Install the front and rear case
forward/input clutch assembly) - refer to (PIL
27-06-54). 1. Install new O-ring seals in the front case.
For detailed clutch disassemble and assemble

procedures refer to the following procedures:
• Reverse clutch - refer to (PIL 27-06-06)

• 2WD / 4WD clutch - refer to (PIL 27-06-07)
• Layshaft clutch - refer to (PIL 27-06-08)
• Mainshaft clutch - refer to (PIL 27-06-09)
• Forward / input clutch - refer to (PIL 27-06-11)
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27 - Driveline
90 - Front Case
J
J F
Y G
J O-ring seals E Case fixing screws (x22)

X Friction counter plates F Rear case
Y JCB Multigasket G Front case
2. Apply a continuous bead of JCB Multigasket to 5. If necessary rotate the output shaft a small
the front case mating face. amount to align the splines.
Consumable: JCB Multi-Gasket 6. Apply sealant to the threads of the case fixing
bolts and install them.
3. Use two small rods or screwdrivers to align all the
friction counter plates in the main shaft clutch. 7. Tighten the bolts to the correct torque value.
4. Use suitable lifting equipment to carefully lower
the rear case and to align the output gear splines After installation
with the main shaft clutch friction plates.
Install the external oil feed pipe.

Item Description Nm
E Case fixing screws 56
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27 - Driveline
91 - Rear Case
91 - Rear Case Clean

Clean ........................................................... 27-225 Refer to Front Case - Clean (PIL 27-06-90).
Check (Condition) ........................................ 27-226
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27 - Driveline
91 - Rear Case

For: PS750 MK3 ..................... Page 27-226
Refer to Front Case - Check Condition (PIL
For: PS750 MK4 ..................... Page 27-226
27-06-90).
(For: PS750 MK3)
The front and rear case are separated at the same
time. Refer to the removal procedure of the front
case.
(For: PS750 MK4)

The front and rear case are separated at the same
time. Refer to the removal procedure of the front
case. Refer to (PIL 27-05-90).
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27 - Driveline
95 - Coupling Yoke 4WD
95 - Coupling Yoke 4WD Introduction

Introduction .................................................. 27-227 The drive yoke is an important component of a
Remove and Install ..................................... 27-228 driveshaft assembly. The drive yoke assembly allows
a driveshaft or PTO (Power Take-Off) to flex or slip
with their given application. The drive yoke is also
essential for allowing u-joints to rotate properly with
the driveshaft.
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Special Tools
Spanner
Remove
1. Bend back the stake nut locking ring.
2. Clean the area around the yoke. Do not allow
3. Use service tool 892/00812 to hold the yoke and
at the same time undo the nut. The nut is very
tight, the help of an assistant will be required.
Discard the nut.
4. Remove the yoke and the washer.
5. If necessary remove the oil seal. Do not damage
the seal housing.
A Yoke
B Stake nut
C Oil seal
D Oil seal interface
E Washer
F Locking ring
Install
1. Make sure that the oil seal interface on the yoke
is clean and free from wear or damage.
2. If necessary install a new oil seal. Locate the seal
in the position shown, the seal does not locate to
the back of the housing.
3. Lubricate the lips of the oil seal.
4. Install the yoke.
5. Install the stepped washer the correct way
around with the plan face facing the stake nut as
shown.
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6. Install a NEW stake nut. Tighten to the correct

torque value.
7. Stake the nut to the shaft using a square ended
staking tool, as shown.

Item Nm
B 400
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27 - Driveline
12 - Transfer Gearbox
Contents Page No.
27-12-00 General ......................................................................................................................... 27-231
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27 - Driveline
00 - General
Introduction .................................................. 27-231 The transfer gearbox is a system of gears used in
Component Identification ............................. 27-232 4WD (Four Wheel Drive) vehicles, which transfers
Clean ........................................................... 27-235 torque from the transmission to the front and rear
Check (Condition) ........................................ 27-235 driveshafts or propshafts. Putting a transfer gearbox
in neutral disconnects the transmission from the
Calibrate ...................................................... 27-236 wheels.
Disassemble and Assemble ........................ 27-245 Transfer gearboxes typically have two gear ranges,
High and Low.
• High Range is used for typical road use.

• Low Range is used for off-road conditions.
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00 - General
Unit Identification order for parts replacement, always give the details
mentioned on the unit identification plate. In the case
The gearbox serial number is stamped on the unit of gear replacements, always check the part number
identification plate as shown. When you make an stamped on the gear, and the number of teeth.
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00 - General
Figure 747. Component Identification (For: Bevel Gearbox)
AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
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00 - General
Table 293.
Item Description
A Gearbox case
B Bolt 1
C Pinion gear case
D Extraction holes
E Shim set 1
F Nut 1
G Spacer 1
H O-ring 1
J Pinion gear
K Bearing 1
L Bearing 2
M Spacer 2
N Triple lip seal 1
P O-ring 2
Q Mounting bushes
R Housing bosses
S Bolt 2
T Bevel gear case
U Extraction holes
V Shim set 2
W Nut 2
X Washer
Y Drive flange
Z O-ring 3
AA Bevel gear
AB Bearing 3
AC Bearing 4
AD Spacer 3
AE Triple lip seal 2
AF O- ring 4
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00 - General

Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4 L JCB Threadlocker 4101/0250 0.01 L
- General purpose and Sealer (Medium 4101/0251 0.05 L
solvent based parts Strength)
cleaner
Surface Cleaning Fluid 4103/1204 1L Inspection
1. Carefully remove all traces of the gasket Before you assemble the gearbox, do a full
or gasket compound from the dropbox case inspection of all the components. It may be easy to
mating faces. Note: When removing the gasket find out a component failure but the cause behind
compound use a gasket removal product such the failure may not be as easy to find out. It is also
as Loctite Chisel. Take care not to damage the possible that a failed component may have caused
mating faces. damage to other areas of the gearbox.
2. Clean the faces with a fine carborundum paper. 1. General inspection.
Use a solvent cleaner and a clean cloth to finally
remove all traces of oil or debris. 1.1. Carefully inspect all the gears, bearings and
shafts for any signs of excessive wear or
damage. If you find any damage during the
3. Clean the inside of the dropbox case using a inspection, components must be replaced.
suitable degreasing agent. 1.2. Make sure that all oil way cross drillings
Consumable: Cleaner/Degreaser - General are clear and free from contamination and
purpose solvent based parts cleaner foreign particles. Blocked oil ways are
a common cause of bearing failure. If
necessary use an air line to blow through
the oil ways.
2. Case inspection
2.1. If the gearbox case is to be replaced, then
make sure that all the necessary blanking
plugs and the adaptors are installed.
2.2. Check the original case and locate all the
locations of the blanking plugs and adaptors
on the case.
2.3. Move the plugs and adaptors to the new
cases. Apply sealant to the threads.
(Medium Strength)
2.4. New plugs may be supplied with a sealant
patch, in which case sealant is not
necessary.
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00 - General
Calibrate
Figure 748.
AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
A Gearbox housing B Bolt 1
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00 - General
C Pinion gear housing D Extraction holes

E Shim set 1 F Nut 1
G Spacer 1 H O-ring 1
J Pinion gear K Bearing 1
L Bearing 2 M Spacer 2
N Triple lip seal 1 P O-ring 2
Q Mounting bushes R Housing bosses
S Bolt 2 T Bevel gear housing
U Extraction holes V Shim set 2
W Nut 2 X Washer
Y Drive flange Z O-ring 3
AA Bevel gear AB Bearing 3
AC Bearing 4 AD Spacer 3
AE Triple lip seal 2 AF O-ring 4
End Float Measurement 6. If the pinion gear housing becomes difficult to

turn by hand, then stop tightening the vice and
The end float measurement procedure given below install the next largest spacer.
is applicable for both the pinion drive gear and the
bevel gear. 7. The rolling torque can be measured as a rolling
force. Use a spring balance and a cord wrapped
1. Install the bearings into the pinion gear housing. around the pinion gear housing.
1.1. Note: The taper roller bearings 1 and 2 must Figure 750.
be preloaded 0.01 to 0.06 mm to give a
rolling torque of 0.5 to 1.5 Nm. The correct
pre-load is achieved by selecting a spacer
of the correct thickness.
2. Select the largest spacer and assemble with the
bearings in a vice. Use a suitable socket as a
clamping spacer.
Figure 749.
AQ M,AD
AR
AR 75 mm
8. Pull the spring balance until the pinion gear
housing stops to rotate and then record the
reading.
Weight/Force: 6.9 –19.6 N
9. If the rolling force is too low, assemble again
using the next smallest size spacer.
M Spacer 2
AD Spacer 3 10. When the correct spacer has been selected,
AQ Socket remove the assembly from the vice and measure
the dimension shown.
3. Tighten the vice and measure the end float on the
housing. To select the correct size spacer Refer
to Table 294. for the calculation.
4. Select the nearest size spacer and assemble
again in a vice.
5. Carefully tighten the vice and make sure that the
pinion gear housing is free to rotate.
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00 - General
Figure 751. Table 294. Spacer size calculation

Largest spacer 8
End float (example) 0.42
7.58
Pre-load required 0.04
Spacer required 7.54
Backlash Adjustment
Figure 752.
1. Carefully install the gear assemblies into their (use the bolt and lock nut as a reference point).
correct positions with the shim sets. Refer to Figure 752.
1.1. Note: Do not install the O-rings 2 and 4 at 5. Take measurements at four positions and
this stage. Make sure that the shims are calculate the average. The average should be
correctly aligned with the non-symmetrical between the specified values.
bolt holes. Length/Dimension/Distance: 0.13 –0.2 mm
2. Turn the gear shafts slightly to make sure that the 6. Adjust the shim sets equally from each drive gear
gears mesh with each other. to calculate the correct backlash.
3. Attach each drive gear in position with three
bolts. Gear Meshing Check
4. Hold the pinion drive gear stationary and do a 1. Apply engineers marking compound on the teeth
backlash check at the bevel gear drive flange of the gears.
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27 - Driveline
00 - General
2. With the gearbox under load, rotate the gears in Figure 754.
both directions.
2.1. Note: It is recommended that the gearbox is
secured to the engine to provide a load.
3. When the pinion is too deeply (Refer to Figure
753. ) in mesh with the bevel gear do the
following:
Figure 753.
J
AA
J
AA
4.1. Decrease the shim thickness between the

pinion drive assembly and the main case.
4.2. Increase the shim thickness between the
bevel gear assembly and the main case
equally to maintain backlash.
5. When the correct gear meshing is achieved,
calculate the backlash check.
3.1. Increase the shim thickness between the Shim Selection Methods
pinion drive assembly and the main case.
3.2. Decrease the shim thickness between the Three methods of shim selection are used which
bevel gear assembly and the main case depends on the parts replaced during assembly:
equally to maintain backlash.
• Method A: Assembly using all the original
4. When the pinion is too far (Refer to Figure 754. ) components.
out of mesh with the bevel gear do the following: • Method B: Assembly using complete new gear/
bearing assemblies or gearbox case.
• Method C: Comparing relevant sizes of old and
replacement components and then adjusting
the shim pack accordingly. This method must
be used when you replace the taper roller
bearings. It can also be of use if some deviation
markings are illegible.
Method A
1. As the original gears and bearings are being
installed use the shims that were removed during
disassembly in their original positions.
2. Set the backlash.
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27 - Driveline
00 - General
Method B
Figure 755.
AH AL
V
E
AK
AG
AN AP
AJ AM
E Shim set 1 V Shim set 2

AG Pinion assembly deviation AH Pinion gear deviation
AJ Pinion housing deviation AK Bevel assembly deviation
AL Bevel gear deviation AM Bevel housing deviation
AN When installing replacement pinion drive gear AP When installing replacement bevel drive gear
assemblies, the sum of AG and AH is marked assemblies, the sum of AK and AL is marked
at AN. at AP.
When you assemble the new gear/bearing Table 295. Pinion Drive Gear Assembly
assemblies it is possible to arrive at a nominal shim
Item Description Devia-
stack thicknesses by calculation.
tion/Thick-
Due to component tolerancing some deviation is ness
built up from base dimensions. These deviations AG Pinion assembly deviation 0
are marked on the relevant components during AH Pinion gear deviation +18
manufacture. Typical locations of deviation markings AN
(1)
=18
are shown. Refer to Figure 755.
AJ Pinion housing deviation +19
If some of the markings are not visible then it will Total =37
not be possible to calculate shim thicknesses. In this Constant +40
event start by installing 0.5 mm nominal shims to Shim stack thickness 0.77
each gear assembly, then set the backlash.
(1) When installing replacement pinion drive gear
Calculate the shim stack thickness. Refer to Table assemblies, the sum of AG and AH is marked at AN.
295. and Refer to Table 296.. When you note down Table 296. Bevel Gear Assembly
the pinion gear housing and bevel gear housing
deviations a positive value becomes a negative value Item Description Devia-
and a negative value becomes a positive value, e.g. tion/Thick-
-19 becomes +19 in the pinion gear calculation. Refer ness
to Table 295. AK Pinion assembly deviation 17
AL Pinion gear deviation +60
AP
(1)
=77
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27 - Driveline
00 - General
Item Description Devia- Figure 756.

tion/Thick-
ness
AM Pinion housing deviation +27
Total =104
Constant +20
Shim stack thickness 1.24
(1) When installing replacement pinion drive gear
assemblies, the sum of AK and AL is marked at AP.
Select shims to make up the nearest thickness for

each gear assembly.
Important: In all cases use the calculations as a

starting point. Verify with the backlash and gear tooth
mark checks.
X
Method C
1. When the taper roller bearings are replaced: 1.3. Subtract the value derived in step 1.2 from
the relevant shim stack.
1.1. Measure and record the thickness of the
existing shim stack. Length/Dimension/Distance: 0.33 mm
1.2. Compare the old and new dimension
measured during assembly. Refer to Table
297.
Table 297.
Old = 40.65
New = 40.32
Result = 0.33
1. When the pinion and bevel gears are replaced: 1.3. Subtract the value derived in step 1.2 from
1.2. Compare the old and new gear deviations.

Refer to Table 298.
Table 298.
AH Old (Pinion gear) = 30
AH New (Pinion gear) = 40
Result = + 0.1
1. When the gearbox case is replaced: 1.4. Subtract the value derived in step 1.2 from
1.2. Compare the old and new housing Figure 757.

deviations. Refer to Table 299.
1.3. When you record the housing deviation 0
a positive figure becomes a negative
figure and a negative value becomes a
positive value, e.g. -19 becomes +19 in a -8 + 19
calculation. Refer to Table 299. - 27
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27 - Driveline
00 - General
Table 299.
AJ Old (Pinion gear) = 30
AJ New (Pinion gear) = 40
Result The deviation has altered from +19
to -8, a total of -27 units. Refer to
Figure 757.
If the case deviation markings are not visible it will Figure 758.
not be possible to calculate shim stack adjustment.
In this event start by installing 0.5 mm nominal shims
to each gear assembly, then set the backlash.
1. Replacement of the gear assemblies when the

deviation markings are not visible:
existing shim stack.
1.2. Remove the gear and measure the new
dimension.
1.3. Compare the old and new dimension (old

dimension measured during dismantling,
see gear disassembly procedure).
1.4. Compare the old and new gear deviations.
1.5. Subtract the value derived in step 1.4 from
Table 300.
Old = 40.65
New = 40.32
Result = - 0.33
Table 301.
AH Old (Pinion gear) = 30
AH New (Pinion gear) = 40
Difference = + 0.1
Add difference from Refer to Table = - 0.33
300.
Result = - 0.23
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27 - Driveline
00 - General
Remove and Install
Remove 3. Remove the torque converter. Refer to driveline-

torque converter, refer to (PIL 27-14).
1. Because of the configuration of the engine
and the transmission mounting system, we 4. Remove the hydraulic pump. Refer to hydraulic
recommend to remove the engine and the system- gear pump, refer to (PIL 30-11).
transmission as a full assembly.
5. Support the bevel gearbox with suitable lifting
2. Remove the gearbox. Refer to driveline- semi- equipment and remove the flywheel housing
automatic gearbox, refer to (PIL 27-06). bolts on the engine.
6. Take out the gearbox from the engine.
Figure 759.
A Flywheel housing bolts
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27 - Driveline
00 - General
Install
removal procedure.

Item Nm
A 70
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27 - Driveline
00 - General
Special Tools Special Tool: Reaction Block Fixture (Qty.:

Description Part No. Qty. 1)
Heavy Duty Socket 892/00912 1 1.5. With a heavy duty socket of the specified
46mm A/F value, remove the stake nut 1.
Heavy Duty Socket 892/00914 1 Dimension: 55 mm
55mm A/F Special Tool: Heavy Duty Socket 55mm A/
Reaction Block Fixture 892/00915 1 F (Qty.: 1)
Consumables 1.6. Remove the spacer 1.

Description Part No. Size 1.7. Remove the O-ring 1 and then remove the
Special HP Grease 4003/2020 0.5 kg pinion gear. Make sure you also remove the
4003/2017 0.4 kg bearing 1 and spacer 2.
4003/2006 12.5 kg 1.8. Remove the triple-lip seal 1 and the O-ring
4003/2005 50 kg 2.
1.9. Important: If the bearings or the gear
Machines (Before 2011) assembly is to be replaced, measure and
record the dimension as shown below.
Earlier (before 2011) and later (after 2011) Make sure you use suitable measuring
procedures are shown. Make sure you refer to the equipment with an accuracy of the specified
correct procedures for your machine. value.
Dimension: 0.01 mm
Disassemble
Figure 760.
Remove the gearbox from the machine, place
suitable wooden blocks to securely support the
assembly.
Cleanliness is of the utmost importance when you

service the gearbox. All precautions to prevent any
ingress of dirt, grit etc. must be taken. Wash the
exterior of the gearbox assembly, refer to Transfer
Gearbox-Clean (PIL 27-12).
Make sure you note the orientation of the mounting

bushes if their replacement is required. Use a
suitable tube to press the outer steel ring of the
bushes during removal/installation of the mounting
bushes. Make sure the new bushes are installed in
their correct orientation and are positioned properly
in the housing bosses.
X
Disassemble the gear assembly as follows (For
Machines before 2011).
1.10. Remove the bearing cups from the pinion
1. Remove the pinion drive gear assembly. gear housing.
1.11. Put a suitable drift through the two holes
1.1. Remove the bolts 1 that attach the in the pinion gear and then remove the
pinion drive gear assembly to the gearbox bearing2 from the gear.
housing.
1.2. If necessary, use a jacking bolt in the tapped 2. Remove the bevel gear assembly.
extraction holes on the pinion gear housing. 2.1. Remove the bolts 2 that attach the bevel
1.3. Remove the shim set 1 and put a label as gear assembly to the gearbox housing.
'for use with the pinion gear assembly.' 2.2. If necessary, use a jacking bolt in the tapped
1.4. Use a reaction block to hold the gear extraction holes on the bevel gear housing.
assembly in a vice.
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27 - Driveline
00 - General
2.3. Remove the shim set 2 and put a label as Figure 761.
'for use with the bevel gear assembly.'
2.4. Use a reaction block to hold the gear
assembly in a vice.
Special Tool: Reaction Block Fixture (Qty.:
1)
2.5. With a heavy duty socket of the specified
value, remove the stake nut 2.
Dimension: 46 mm
Special Tool: Heavy Duty Socket 46mm A/
F (Qty.: 1)
2.6. Remove the washer, drive flange 1, and the
O-ring 3.
2.7. Remove the bevel gear. Make sure you also
remove the bearing 3 and spacer 3.
X
2.8. Remove the triple-lip seal 2 and the O-ring
4.
2.10. Remove the bearing cups from the bevel
2.9. Important: If the bearings or the gear gear housing.
assembly is to be replaced, measure and
record the dimension as shown below. 2.11. Put a suitable drift through the two holes
Make sure you use suitable measuring in the pinion gear and then remove the
equipment with an accuracy of the specified bearing 4 from the gear.
value.
Dimension: 0.01 mm
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27 - Driveline
00 - General
Figure 762. Gearbox (Before 2011)

AF
T
U
AD
Z
X
AA
AC
V
AB
AE
Y
W
S
Q L
R
E
C
D
K
H
N
F J
B M
G
A Gearbox housing B Bolt 1

C Pinion gear housing D Extraction holes
E Shim set 1 F Nut 1
G Spacer 1 H O-ring 1
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00 - General
J Pinion gear K Bearing 1

L Bearing 2 M Spacer 2
N Triple lip seal 1 P O-ring 2
Q Mounting bushes R Housing bosses
S Bolt 2 T Bevel gear housing
U Extraction holes V Shim set 2
W Nut 2 X Washer
Y Drive flange 1 Z O-ring 3
AA Bevel gear AB Bearing 3
AC Bearing 4 AD Spacer 3
AE Triple lip seal 2 AF O-ring 4
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00 - General
Assemble Figure 763.
The bevel gear and the pinion drive gear are a

matched pair and must be replaced as a set if
one of the two gears is damaged or excessively
worn. It is recommended that complete built-up gear/
bearing assemblies are installed in the event of gear
replacement.
Important: When you assemble the gearbox with

replacement or original components, the rolling
torques, backlash, shim stacks and gear meshing 2.15. Use the reaction block to hold the
must be checked and adjusted as required. assembly in the vice.
1. Make sure all bearings are lubricated before Special Tool: Reaction Block Fixture (Qty.:
installation. Rotate the bearings while you set 1)
them. Make sure the oil ways in the bearing
2.16. Install the nut 1.
carriers and gearbox housing are clean and
clear. This is particularly important if bearings 2.17. Tighten the nut to the correct torque value
have failed. Make sure you install new o-rings with a socket of the specified dimension.
and stake nuts. Dimension: 55 mm
2. Assemble the pinion drive gear (for machines 2.18. Do not stake the nut 1 at this stage.
before 2011):
2.19. Measure the bearing rolling torque. Make
2.1. Check the pinion drive gear assembly end sure the rolling torque is between the
float. specified value.
2.2. Press the inner bearing 2 onto the pinion Torque: 0.5 –2.5 N·m
gear. 2.20. Excessive rolling torque indicates an
2.3. Install the spacer 2 selected in step 2.1. incorrectly installed seal.
2.4. Install the pinion gear and the bearing 2 into 2.21. Stake the nut 1 with a square ended
the pinion gear housing. staking tool.
2.5. Install the inner bearing 1 onto the pinion Figure 764.
gear.
2.6. Use the reaction block to hold the pinion
gear assembly in a vice.
2.7. Install the spacer 1 and nut 1.
2.8. Tighten the nut to the correct torque value
with a socket of the specified dimension.
Dimension: 55 mm
2.9. Do not stake the nut 1 at this stage.
2.10. Measure the bearing rolling torque. Make F
sure the rolling torque is between the
specified value. 2.22. For figure, Refer to Figure 762.
Torque: 0.5 –1.5 N·m 3. Assemble the bevel gear assembly (for
2.11. Remove the nut 1 and the spacer 1. machines before 2011).
2.12. Install the new O-ring 1. 3.1. Check the bevel gear assembly end float.
2.13. Install a new triple lip seal 1 with a 3.2. Press the inner bearing 4 onto the bevel
suitable mandrel. Make sure that the seal gear.
is installed correctly in its housing.
3.3. Install the spacer 3 selected in step 3.1.
2.14. Carefully install the spacer 1 inside the
triple lip seal 1. Make sure that the outer 3.4. Install the pinion gear and the bearing 4 into
lip of the seal is against the housing. the bevel gear housing.
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27 - Driveline
00 - General
3.5. Install the inner bearing 3 onto the bevel 3.18. Do not stake the nut 2 at this stage.
gear.
3.19. Measure the rolling torque. Make sure
3.6. Use the reaction block to hold the bevel the rolling torque is between the specified
gear assembly in a vice. value.
Special Tool: Reaction Block Fixture (Qty.: Torque: 0.5 –2.5 N·m
1)
3.20. Excessive rolling torque indicates an
3.7. Install the drive flange 1, washer, and the incorrectly installed seal.
nut 2.
3.21. For figure, Refer to Figure 762.
3.8. Tighten the nut 2 to the correct torque value
with a socket of the specified dimension. Table 303. Torques (Before 2011)
Dimension: 46 mm Item Torque
3.9. Do not stake the nut 2 at this stage. B 85
F 300
3.10. Measure the bearing rolling torque. Make
sure the rolling torque is between the S 85
specified value. W 300
Torque: 0.5 –1.5 N·m
Machines (After 2011)
3.11. Remove the nut 2, washer, and the drive
flange 1. Disassemble
3.12. Install the new O-ring 3.
Disassemble the gear assembly as follows (for
3.13. Install a new triple lip seal 2 with a machines after 2011).
suitable mandrel. Make sure that the seal
is installed correctly in its housing. 1. Remove the bolted bevel gear assembly.
3.14. Carefully install the drive flange 1 inside 1.1. Remove the screws that attach the adaptor
the triple lip seal 2. Make sure that the to the drive flange.
outer lip of the seal is against the housing.
1.2. Remove the adaptor.
Figure 765.
assembly in a vice.
1)
1.4. Remove the set screw.
1.5. Remove the drive flange.
1.6. Remove the pinion gear.
1.7. Remove the triple lip seal and the O-ring 2.
3.15. Use the reaction block to hold the 1.8. Remove the O-ring 1.
assembly in the vice.
1.9. Remove the bearing and spacer.
1) 1.10. Put a suitable drift through the two holes
in the pinion gear and then remove the
3.16. Install the washer and the nut 2. bearing 8 from the gear.
3.17. Tighten the nut 2 to the correct torque
value with a socket of the specified
dimension.
Dimension: 46 mm
27 - 250 9823/1700-1 27 - 250

27 - Driveline
00 - General
Figure 766. Bevel Gear Assembly (Bolt)

8
2
9
20
16 17 5 4 2 3 1
1 Bevel gear 2 Bearing

3 Spacer 4 Carrier- bearing
5 Triple lip seal 8 O-ring 1
9 O-ring 2 16 Drive flange
17 Setscrew 20 Adaptor
1. Remove the bevel gear assembly (nut). Refer to

Figure 767.
assembly in a vice.
1)
1.2. Remove the stake nut.
1.3. Remove the pinion gear from the bearing
carrier.
1.4. Remove the triple lip seal 3 and the O-ring
5.
1.5. Remove the O-ring 6.
1.6. Remove the bearing 6 and spacer 5.
1.7. Put a suitable drift through the two holes
in the pinion gear and then remove the
bearing 6 from the gear.
27 - 251 9823/1700-1 27 - 251

27 - Driveline
00 - General
Figure 767. Bevel Gear Assembly (Nut) AM Spacer 4

AN Stake nut 3
AP O-ring 6
AQ O-ring 5
Make sure you do not discard any component at this

stage.
Inspect the gearbox assembly. Refer to (PIL 27-12).
AN
AM
AQ
AL
AK
AP
AJ
AH
AG
AG Pinion gear 2
AH Bearing 6
AJ Spacer 5
AK Bearing 5
AL Triple lip seal 3
27 - 252 9823/1700-1 27 - 252

27 - Driveline
00 - General
Figure 768. Gearbox (After 2011)
4
8
3 2 5 16
17 20
11 2
5 9
6
7
1
8 2
2 3
459-10234-2
1 Bevel gear 2 Bearing- taper roller

3 Kit- bearing spacer 4 Carrier- bearing
5 Seal- triple lip 6 Spacer- seal ring
7 Nut- stake M36 (55 mm head) 8 O-ring seal
9 O-ring seal 11 Bevel gear
16 Flange- drive 17 Setscrew
20 Adaptor
Assemble sure the bearings are rotated whilst being

set.
1. Assemble the bevel gear assembly (bolt). (For
machines after 2011)
1.2. Make sure the lubrication route and seal
1.1. Make sure the bearing rollers are packed vents in the bearing hub are not blocked
with the correct grease before setting. Make by excess grease. Do not overpack the
bearings.
27 - 253 9823/1700-1 27 - 253

27 - Driveline
00 - General
1.3. Pack the cavity between the seal lips with 1.17. Excessive rolling torque indicates an
the correct grease before assembly. incorrectly installed seal. Renew the seal
if it is damaged.
1.4. Select a bearing spacer to achieve the
specified preload. 1.18. Install the adaptor. Tighten the fastenings
to the correct torque. Refer to (PIL 72).
1.5. Press the bearings into the bearing carrier 2. Assemble bevel pinion drive gear (nut). (For
Make sure you install the spacer. Refer to machines after 2011). Refer to Figure 767.
Figure 768. and Refer to Figure 767.
2.1. Make sure the bearing rollers are packed
1.6. Install the triple lip seal. with the correct grease before setting. Make
sure the bearings are rotated whilst being
1.7. Install the pinion gear the bevel gear
set.
bearing housing.
1.8. Carefully install the drive flange 2 inside the
triple lip seal 4. Make sure that the outer lip 2.2. Make sure the lubrication route and seal
of the seal is against the housing. vents in the bearing hub are not blocked
by excess grease. Do not overpack the
Figure 769. bearings.
2.3. Pack the cavity between the seal lips with
the correct grease before assembly.
2.4. Select a bearing spacer to achieve the
specified preload.
2.5. Press the bearings into the bearing carrier.
Make sure you install the spacer. Refer to
Figure 768. and Refer to Figure 767.
1.9. Use the reaction block to hold the bevel 2.6. Install the triple lip seal.
2.7. Install the pinion gear in the bevel gear
bearing housing.
1)
2.8. Install the O-ring 5.
1.10. Take up the free play on the setscrew.
2.9. Carefully install the spacer 4 inside the triple
1.11. Check the seal drag is within specified
lip seal 3. Make sure that the outer lip of the
limits.
seal is against the housing.
Torque: 0.4 –0.75 N·m
Figure 770.
1.12. If the seal drag is within limits, tighten the
setscrew to the specified torque value.
Torque: 395 N·m
the rolling torque is between the specified
value.
1.14. Use the reaction block to hold the bevel
2.10. Install the O-ring 6.
1.15. Install the set screw and tighten it to the
specified torque value. 2.11. Use the reaction block to hold the bevel
Torque: 395 N·m
1.16. Measure the rolling torque. Make sure 1)
value. 2.12. Take up the free play on the stake nut. Do
not stake the nut.
27 - 254 9823/1700-1 27 - 254

27 - Driveline
00 - General
2.13. Check the seal drag is within specified 6. Set the backlash. Refer to driveline, transfer
limits. gearbox, calibrate (PIL 27-12-00).
Torque: 0.4 –0.75 N·m 7. Examine the gear meshing. Refer to driveline,
2.14. If the seal drag is within limits, tighten the transfer gearbox, calibrate (PIL 27-12-00).
stake nut to the specified torque value.
Torque: 395 N·m
value.
2.16. Excessive rolling torque indicates an
incorrectly installed seal. Renew the seal
if it is damaged.
2.17. If the rolling torque is correct, stake the nut.
The nut is to be split axially using a square
ended tool.
Figure 771.
3. Install the bevel gear assemblies into the

gearbox case. Tighten the bolts to the correct
torque value.
4. Measure the correct thickness required for the
bevel gear assembly shim sets 1 and 2.
5. Important: Correct gear meshing and backlash
settings are essential for the reliable operation of
the gearbox. The settings are obtained by means
of variable shim stacks. Three methods of shim
selection are used which depends on the parts
replaced during assembly:
5.1. Method A: Assembly using all the original
components.
5.2. Method B: Assembly using complete
new gear/bearing assemblies or gearbox
casing.
5.3. Method C: Shim pack thickness can be
calculated by comparing relevant sizes of
old and replacement components and then
adjusting the shim pack accordingly. This
method must be used when you replace the
taper roller bearings. It can also be of use if
some deviation markings are not visible.
27 - 255 9823/1700-1 27 - 255

27 - Driveline
14 - Torque Converter
Contents Page No.
27-14-00 General ......................................................................................................................... 27-257

27-14-06 Control Valve ................................................................................................................ 27-266
27-14-09 Relief Valve .................................................................................................................. 27-268
27 - 256 9823/1700-1 27 - 256

27 - Driveline
00 - General
Introduction .................................................. 27-257 The torque converter is a type of fluid coupling that
Technical Data ............................................. 27-258 is used to transfer rotating power from the engine to
Component Identification ............................. 27-258 a rotating driven load.
Operation ..................................................... 27-259
The torque converter normally takes the place of
Check (Operation) ....................................... 27-260 a mechanical clutch in a vehicle with an automatic
Remove and Install ..................................... 27-264 transmission, allowing the load to be separated from
the power source.
It is usually located between the engine flywheel and

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

ability to multiply torque when there is a substantial
difference between input and output rotational
speed, thus providing the equivalent of a reduction
gear. Some torque converters are equipped with a
temporary locking mechanism which rigidly locks the
engine to the transmission when their speeds are
nearly equal, to avoid slippage and a resulting loss
of efficiency.
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27 - Driveline
00 - General
Technical Data Component Identification
Technical data may differ between gearbox variants Figure 772.

and installations. For full data relating to specific
gearboxes refer to the applicable machine Service
Manual. D
G C
F E
A Impeller
B Turbine
C Reaction member
D Drive plate (engine driven bevel gearbox)
E Drive to gearbox input shaft
F Spline location for reaction member
G Direct drive from the engine to the gearbox oil
pump
H Direction of oil flow
27 - 258 9823/1700-1 27 - 258

27 - Driveline
00 - General
Operation
The torque converter is similar to a fluid coupling,

which utilises the centrifugal force exerted in the
transmission oil to transmit power from the engine to
the gearbox. It multiplies the torque from the engine
and functions as a combined clutch and infinitely
variable reduction gearbox.
The torque converter is enclosed in a casing and

consists of three basic parts, the impeller, reaction
member and turbine.
The impeller is driven by the engine.
The reaction member does not rotate. Its hub

engages with a splined tube on the gearbox oil pump
and is held stationary.
The turbine is engaged with the splined end of the

gearbox input shaft.
The impeller driven by the engine, forms one set

of shaped blades, it can be likened to a centrifugal
pump imparting energy to the transmission oil. This
energy is transferred to another set of shaped
blades, which form the turbine. The turbine is
connected to the gearbox and converts the energy
back to a mechanical torque.
When the impeller is rotating faster than the turbine,

the fixed reaction member causes some of the
energy in the oil to be transferred back to the impeller.
This has the effect of multiplying the torque available.
When the impeller (input) is running much faster

than the turbine (output) there is a substantial
circulation of transmission oil around the blades. The
oil circulation is maximum when the turbine (output)
is stalled, and is almost zero when the impeller and
turbine speeds are equal i.e. the ratio is near 1:1.
If the turbine (output) is stalled whilst the impeller
(input) is revolving, all the power is dissipated as
heat.
Because of the absence of a direct mechanical

connection between the engine and the gearbox,
the flexibility of the torque converter drive greatly
reduces wear on the transmission, absorbing shocks
and torsional vibration from the engine. The engine
cannot be stalled due to overload, as the fluid
coupling slips.
For illustration refer to Component Identification (PIL

27-14-00).
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27 - Driveline
00 - General
Check (Operation)
CAUTION Do not stall the converter for longer torque converter. This is the point at which, due to
than 10 seconds or the transmission fluid will torque applied by the engine the torque converter
overheat. Make sure the transmission oil level stops transmitting drive to the gearbox.
is correct before and after carrying out the test.
Make sure you check the oil level at normal The engine speed at which stalling occurs is
operating temperature. compared to speeds recorded for a machine in
normal condition.
Notice: Before starting the stall test, make sure
that the mainline and clutch pressures are correct. Stall tests can be used to diagnose faults with the
If the pressures are not correct, the clutches transmission.
could slip, resulting in premature wear of the
transmission friction plates. Also make sure the
machine neutral circuit and steer circuit pressures Technical Data Check List
are correct.
Record the test results in a check list for easy fault
identification. This section includes a blank check list
Stall Test to copy and use as required. Refer to Figure 773.
The purpose of the stall test is to check the The check list will help the engineer to identify the
performance of the transmission by stalling the cause of a gearbox fault, and if required, can be sent
to the JCB Technical Service Team via e-mail.
27 - 260 9823/1700-1 27 - 260

27 - Driveline
00 - General
Figure 773.
27 - 261 9823/1700-1 27 - 261

27 - Driveline
00 - General
Procedure 4. When fully engaged, the park brake electrically

disconnects the transmission drive. This
The purpose of the stall test is to check the prevents the machine from being driven with
performance of the transmission by `stalling' the the park brake on. Therefore, so that we can
torque converter. This is the point at which, due to complete the test, move the park brake lever
torque applied by the engine, the torque converter fractionally forward until the warning light is just
stops transmitting drive to the gearbox. The engine extinguished.
speed at which `stalling' occurs is compared to
speeds recorded for a machine in normal condition. 5. Hold the lever in this position for the duration of
Abnormal stall speed results can be used to identify the test.
possible faults as follows: 6. Do not move the lever too far forward, otherwise
the park brake will not be fully operational.
1. Poor engine performance
7. Do not disconnect the switch at the park brake.
2. Faulty torque converter
8. Select the 1st speed forward drive and open
3. Faulty gearbox hydraulic clutches
throttle fully. Record the engine speed from the
4. Faulty torque converter relief valve tachometer.
5. Transmission hydraulic leaks 9. Repeat the test in reverse drive.
6. Faulty hydraulic system relief valves 10. Repeat the test with the machine in each
configuration as described in the stall data tables.
For normal stall speed values refer to driveline- semi- Refer to driveline- semi-automatic gearbox, refer
automatic gearbox, refer to (PIL 27-06). to (PIL 27-06).
Do not stall the converter for longer than 10 seconds 11. For the machines with powershift gearboxes,
or the transmission fluid will overheat. Make sure repeat the test in 2nd and 3rd gears in both
that the oil level is correct and at normal operating forward and reverse drive.
temperature.
12. All recorded readings should be as specified.
If the machine is installed with a variflow hydraulic Refer to driveline- semi-automatic gearbox, (PIL
pump, make sure that the hydraulic oil temperature 27-06).
is above 50 °C ( 121.9 °F). Also make sure that
the valve block LSRV (Load Sense Relief Valve) Interpreting the Test Results
pressure and the variflow pump Delta P pressure are
set correctly. If all the engine speeds are below the stated figures
either the engine is losing power and should be
Before completing the following test, remove the serviced/ overhauled or the torque converter reaction
transmission dipstick. If there is any sign of member clutch is slipping. To check the engine,
smoke emitting from the dipstick tube stop the select neutral, open throttle fully and operate a
test immediately and dismantle the transmission for hydraulic service to 'blow off' the main relief valve.
servicing. Engine speed should fall to slightly below the
maximum governed speed. Refer to (PIL 15-00). If
1. Check all engine fluid levels. Run the engine at engine speed is correct the torque converter reaction
maximum speed and check the no load speed. member clutch is slipping.
Refer to Engine, General, General, Technical
Data, (PIL 15-00-00). If all the engine speeds are higher than the stated
figures in all gears the torque converter safety relief
2. Make sure that the engine and transmission are valve may be faulty. Alternatively there may be
at normal working temperature (the transmission internal oil leakage.
oil must be above the specified temperature).
Run engine at maximum speed and check the If the engine speeds are higher than the stated
engine speed is correct (High Idle/ maximum figures in some gears, check the transmission for
governed speed). Refer to engine- general, refer clutch slippage or internal leakage.
to (PIL 15-00).
The example given below shows how the results can
be used to isolate a suspect clutch.
3. Apply the park brake and foot brake firmly.
If necessary, set the machine against a fixed
obstruction.
27 - 262 9823/1700-1 27 - 262

27 - Driveline
00 - General
Table 304.
Stall Test Results- 4 Speed Powershift
Gear Clutches engaged
Forward RPM (Revolutions Reverse RPM
Per Minute)
1st T, Z 1990 W, Z 1980
2nd U, Z 2060 V, Z 1975
3rd T, Y 1985 W, Y 1990
In the example shown, the engine speed is

abnormally high when 2nd gear forward drive is
selected, indicating a slipping clutch, possibly U or
Z. We can now use the results to determine which
clutch is at fault.
As per the details from the table, there is no problem

with clutch Z since it is engaged in other gears,
the stall speeds for those gears are normal. This
indicates that the clutch U is slipping.
Clutches may slip for several reasons. Hydraulic

leakage is possible and this can be confirmed by
carrying out a pressure test. Refer to driveline- semi-
27 - 263 9823/1700-1 27 - 263

27 - Driveline
00 - General
Remove and Install 3.3. Make a note that it is important to protect

the converter drive tube against damage or
Special Tools contamination at all times.
4. Install the drive plate retaining bolt 1 (x4).
Torque Converter 892/01110 1
Alignment Tool 5. Tighten the drive plate retaining bolt to the correct
torque value.
Remove
6. Remove the alignment tool.
1. Due to the configuration of the engine and
7. Install the remaining bolt 1 (x2).
transmission mounting system, we recommend
to remove the engine and the transmission as a 8. Keep the torque converter and drive plate
full assembly. assembly on the flywheel.
2. The torque converter is part of the gearbox 9. Install the bolt 1 (x3) on the drive plate and the
assembly. Remove the gearbox with torque flywheel.
converter.
10. Check the converter run-out as shown.
Install
11. Make sure that the converter run-out is within the
1. Make sure that the flywheel face, drive plate and specified limits.
hardware are clean and free from burrs or other Dimension: 0.38 mm
surface imperfections.
12. If the run-out exceeds the specified limit, do the
2. Keep the drive plate on the torque converter. following.
3. Place the specified torque converter alignment 12.1. Remove the converter.
tool over the torque converter spigot.
12.2. Check the spigot for burrs.
Special Tool: Torque Converter Alignment Tool
(Qty.: 1) 12.3. Remove the drive plate.
3.1. Make a note that the alignment tool is used 12.4. Rotate the specified drive plate to the
one way around for the 12” and the other specified angle on the torque converter.
way round for W300 torque converters. Angle: 180 °
3.2. Make sure that the tool locates in two of the 12.5. Do the steps 3 to 12 again.
torque converter bolt holes as shown. Refer
to Figure 774. Figure 775.
G
Figure 774.
E
D
B A
E
F
A Drive plate
E Bolt 1
F DTI (Dial Test Indicator)
G Bolt 2
B Drive plate retaining bolts 13. Remove the torque converter and drive plate
C Alignment tool assembly from the flywheel.
D Torque converter assembly
14. Install the torque converter with its drive plate
assembly onto the transmission input shaft.
27 - 264 9823/1700-1 27 - 264

27 - Driveline
00 - General
15. Make sure that the converter pump drive shaft

engages with the recesses in the pump.
16. Take care not to damage the oil seal.
17. Rotate the engine flywheel so that one bolt hole
is in a six O' clock position.
18. Rotate the torque converter and drive plate
assembly so that one bolt hole is in a six O' clock
position.
19. Install the transmission/torque converter
assembly to the engine.
19.1. It is very important to install the torque
converter at the gearbox and engine
flywheel correctly.
19.2. Failure to locate the converter correctly will
result in damage to the gearbox oil pump
on engine start up.
20. Remove the access plate from the bottom of the
engine flywheel case.
21. Install the flanged bolt 2 in the six 'O' clock
position through the access hole.
22. Tighten the flanged bolt 2 by hand.
23. Rotate the flywheel until the next bolt 2 hole is
accessible.
24. Install and hand tighten the next bolt 2.
25. Do the steps 21 to 24 for all the bolts 2.
26. Tighten the bolt 2 to the specified torque value.
27. Install the access plate.

Item Nm
B 84
G 44
27 - 265 9823/1700-1 27 - 265

27 - Driveline
06 - Control Valve
06 - Control Valve Figure 776.

E
Remove and Install
C
Gearboxes compatible with a lock-up torque
converter are installed with a control valve and an
interconnecting pipe. Before you disassemble the
gearbox the pipe and valve must be removed.
C
Remove D
1. Remove the pipe nuts and lift off the pipe.
2. Remove the capscrews and remove the solenoid
control valve.
3. Make sure to remove the O-rings (x3) from the
bottom of the valve. D D
C A
B
A Nuts
B Pipe
C Control valve
D Capscrews (x3)
E O-rings (x3)
Install
1. Make sure that the valve sealing interface is not
damaged.
2. Install new O-rings to the valve.
3. Carefully put the valve in position against the
gearbox.
3.1. Make sure that the O-rings are not loose in
their seat.
4. Attach the valve with the capscrews.
5. Tighten the capscrews to the correct torque
value.
27 - 266 9823/1700-1 27 - 266

27 - Driveline
06 - Control Valve
6. Install the pipe and tighten the nuts to the correct

torque value.

Item Nm
A 56
D 9
27 - 267 9823/1700-1 27 - 267

27 - Driveline
09 - Relief Valve
09 - Relief Valve
Remove and Install
(For: PS750 MK4) 2. Do not allow particles of grit to fall into the
gearbox.
Remove 3. Remove the plug, sealing washer, spring and the
poppet.
1. Clean the area around the valve and the gearbox
case.
Figure 777.
B
C
A Plug B Sealing washer

C Spring D Poppet
27 - 268 9823/1700-1 27 - 268

27 - Driveline
09 - Relief Valve
Install
At the time of installation do the following step.
1. Tighten the plug to the correct torque value.

Item Description Nm
A Plug 56
27 - 269 9823/1700-1 27 - 269

27 - Driveline
20 - Axle(s)
20 - Axle(s)
Contents Page No.
27-20-00 General ......................................................................................................................... 27-271

27-20-15 Breather ........................................................................................................................ 27-290
27-20-81 Mount ........................................................................................................................... 27-291
27 - 270 9823/1700-1 27 - 270

27 - Driveline
20 - Axle(s)
00 - General
Introduction .................................................. 27-271 Axles are an integral component of a wheeled
Technical Data ............................................. 27-272 vehicle. The axle transmits a driving torque to the
Component Identification ............................. 27-273 wheel, as well as maintaining the position of the
Check (Level) .............................................. 27-278 wheels relative to each other and to the vehicle body.
27 - 271 9823/1700-1 27 - 271

27 - Driveline
20 - Axle(s)
00 - General
Technical Data Overall Gear Ratio 18.16 : 1

Crownwheel and Pinion 3.364 : 1 (Colour code:
For: 506-36 [T2/T3], Front ....... Page 27-272 Ratio Blue)
For: 507-42 [T2/T3], 509-42 [T2/T3], Hub Reduction 5.4 : 1
510-56 [T2/T3], 512-56 [T2/T3], Front
................................................. Page 27-272
(For: 506-36 [T2/T3], Rear)
For: 506-36 [T2/T3], Rear ........ Page 27-272
For: 507-42 [T2/T3], 509-42 [T2/T3], Table 310. SD55 1 Piece steer drive axle
510-56 [T2/T3], 512-56 [T2/T3], Rear
................................................. Page 27-272 Hubs 55 Series
Hub swivels and drive 55 Series
(For: 506-36 [T2/T3], Front) shafts
Drive head 55 Series 1 piece
Table 308. SD70 3 Piece steer drive axle Type JCB spiral bevel input
Hubs 55 Series with epicyclic hub reduc-
Hub swivels and drive 55 Series tion
shafts Steering Steer rams
Drive head 80 Series 3 piece Weight (dry, with no TBA
Brakes 70 Series Integral steer rams and without
Brakes (3 Piece Axles) wheels)
Overall Gear Ratio 23.625 : 1
Type JCB spiral bevel input
with epicyclic hub reduc- Crownwheel and Pinion TBA
tion Ratio
Brakes Oil immersed multi-plate Hub Reduction TBA
discs, located in centre
section (For: 507-42 [T2/T3], 509-42 [T2/T3],
Steering Steer rams 510-56 [T2/T3], 512-56 [T2/T3], Rear)
Weight (dry, with no -
steer rams and without Table 311. SD80 3 Piece Steer Axle
wheels) Hubs 55 Series
Overall Gear Ratio 18.16 : 1 Hub swivels and drive 55 Series
Crownwheel and Pinion 3.364 : 1 (Colour code: shafts
Ratio Blue) Drive head 80 Series 3 piece
Hub Reduction 5.4 : 1 Brakes 70 Series Integral
Brakes (3 Piece Axles)
(For: 507-42 [T2/T3], 509-42 [T2/T3], Type JCB spiral bevel input
510-56 [T2/T3], 512-56 [T2/T3], Front) with epicyclic hub reduc-
tion
Table 309. SD80 3 Piece Steer Axle Brakes Oil immersed multi-plate
Hubs 55 Series discs, located in centre
Hub swivels and drive 55 Series section
shafts Steering Steer rams
Drive head 80 Series 3 piece Weight (dry, with no TBA
Brakes 70 Series Integral steer rams and without
Brakes (3 Piece Axles) wheels)
Overall Gear Ratio 24.975 : 1
Type JCB spiral bevel input
with epicyclic hub reduc- Crownwheel and Pinion 4.625 : 1
tion Ratio
Brakes Oil immersed multi-plate Hub Reduction 5.4 : 1
discs, located in centre
section
Steering Steer rams
Weight (dry, with no
steer rams and without
wheels)
27 - 272 9823/1700-1 27 - 272

27 - Driveline
20 - Axle(s)
00 - General
For: 70/80-Series, Front .......... Page 27-273 The axle consists of a centre casing (drivehead) and
For: 55-Series, 70-Series, Rear two axle arms and swivel wheel hubs.
................................................. Page 27-273
The drivehead houses the differential gearing and
For: 70/80-Series, Rear ........... Page 27-274
two oil immersed disc brake units. The axle arms
For: 55-Series ......................... Page 27-277 house the driveshafts. Specially shaped spider gears
in the differential provide torque proportioning, which
(For: 70/80-Series, Front) make sure drive power will be kept on one wheel if
the other is slipping. The wheel hubs are connected
3 Piece Axle to the driveshafts through universal joints which drive
sun-and-planet gears inside the hubs.
The illustration shows a typical 3 piece steer drive
front axle. The drive yoke, pinion, crownwheel and differential
unit are all components of the drivehead.
Figure 778.
C D N
M L
E H F
A
B
A Yoke connection to propshaft (axle input) B Pinion

C Crownwheel D Differential unit
E Driveshaft F Universal coupling
G Reduction gear hub H Steer swivel trunnion bearings
L Inboard oil-immersed multi-plate disc brake M Brake actuating piston
pack
N Hydraulic brake lines
(For: 55-Series, 70-Series, Rear) SD55 1 Piece Steer Drive Axle
SD80 3 Piece Steer Drive Axle- Integral The illustration shows a typical steer drive rear axle.
Brakes The axle has a single piece case which houses the
differential and half shafts. The rear axle is pivot
For SD80 3 piece steer axle, refer to (PIL 20-00). mounted to the chassis.
27 - 273 9823/1700-1 27 - 273

27 - Driveline
20 - Axle(s)
00 - General
Figure 779.
A B
E
F
G
J
K
C
D
L
A Yoke connection to propshaft B Pinion

E Drive shaft F Universal coupling
J Axle pivot K Oil fill and level plug
L Oil drain plug
(For: 70/80-Series, Rear) The axle has a single-piece casing which houses the
differential and driveshafts.
1 Piece Axle The axle is mounted to the chassis with a pivot pin to
allow the machine to sway.
The illustration shows a typical 1 piece steer drive
rear axle.
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27 - Driveline
20 - Axle(s)
00 - General
Figure 780.
A B
F
G
J
K
C
D
E
H

J Axle pivot K Oil filler / level plug
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00 - General
3 Piece Axle house the driveshafts. Specially shaped spider gears

in the differential provide torque proportioning, which
The illustration shows a typical 3 piece steer drive make sure drive power will be kept on one wheel if
rear axle. the other is slipping. The wheel hubs are connected
to the driveshafts through universal joints which drive
The axle consists of a centre casing (drivehead) and sun-and-planet gears inside the hubs.
two axle arms and swivel wheel hubs.
The drive yoke, pinion, crownwheel and differential
The drivehead houses the differential gearing and unit are all components of the drivehead.
two oil immersed disc brake units. The axle arms
Figure 781.
C D N
M L
E H F
A
B

L Inboard oil-immersed multi-plate disc brake M Brake actuating piston
pack
N Hydraulic brake lines
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(For: 55-Series)
Figure 782. SD55 1 Piece Steer Drive Axle
A B
F E
J
K
D
C
A Yoke connection to propshaft B Pinion

E Drive shaft F Universal coupling
J Axle pivot K Oil fill and level plug
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00 - General
Check (Level)
Notice: The oil level must be checked with the 4. Remove the plug with its sealing washer.
machine level, otherwise a false indication of the
amount of oil will be given. 5. Make sure the oil is level with the bottom of the
hole.
Notice: It is not recommended that the machine
be driven with the axle partially filled with oil. 6. If necessary add oil.
1. Make the machine safe. Refer to (PIL 01-03). 7. Clean the fill/level plug.
2. Get access to the axle fill/level plug. 8. Install the plug with its sealing washer.
3. Clean the area around the fill/level plug. 9. Tighten the plug to the correct torque value.
Figure 783. 506-36 Machines
A
A
A Axle fill/level plug
Figure 784. 507-42, 509-42, 510-42, 510-56, 512-56, 514-56 and 516-42 Machines
A A
A Axle fill/level plug

Item Nm
A 79
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00 - General
Remove and Install
For: 70/80-Series, 70-Series ... Page 27-279 3. Shims may have been installed on the axle
For: 55 Series (1 Piece Axle), Rear mounts. Make sure to note the position and
................................................. Page 27-281 quantity of these shims before removal. There
may be an uneven number of shims on each side
of the axle as they are used to adjust the machine
(For: 70/80-Series, 70-Series) height and make it level.
Consumables
Description Part No. Size 4. Make sure to collect the shims and replace them
in the correct position when you replace the axle.
Special HP Grease 4003/2020 0.5 kg
4003/2017 0.4 kg 5. If installed, remove the front stabilisers. Refer to
4003/2006 12.5 kg (PIL 06-42-00).
4003/2005 50 kg 6. Remove the bolt 1 and disconnect the propshaft
coupling from the axle.
Raised Machine
7. Disconnect the hydraulic feed hoses from the
Never position yourself or any part of your body
steer rams (one hose on each ram). Cap the
under a raised machine which is not correctly
open ports and hoses to prevent contamination.
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be 8. Loosen the front road wheel retaining nuts then
killed. raise and support the front end of the machine
WARNING! A raised and badly supported machine on support stands or blocks positioned under the
can fall on you. Position the machine on a firm, level chassis. Refer to (PIL 27-29.
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on the 9. Remove the front road wheels.
machine hydraulics or jacks to support the machine 10. If installed, remove the front fenders. Refer to
when working under it. Disconnect the battery, to (PIL 06-54).
beneath it. 11. Disconnect the brake hose. Cap the open ports
WARNING! Before disconnecting any propshaft, and hoses to prevent contamination.
make sure you block both sides of all wheels to
12. Remove the bolt 2 and then remove the pivot pin
prevent machine movement. The park brake will
1.
become ineffective or may only operate on 2 wheels
(depending on machine specification). 13. Support the axle on a trolley jack.
Remove 14. Remove the bolt 3 and then remove the pivot pin
2.
15. Remove the axle from the machine.
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Figure 785. SD80 Pivot sway axle
A B
F
C
Install
Table 313. 1. The installation procedure is the opposite of the
Item Description removal procedure. Additionally do the following
steps.
A Bolt 1
B Hydraulic feed hoses 1.1. Install the road wheels. Refer to (PIL 27-29).
C Brake hose 1.2. Tighten the bolt 2 and bolt 3 to the correct
D Bolt 2 torque value.
E Pivot pin 1 1.3. Make sure that you bleed the brake system.
F Bolt 3 Refer to (PIL 24-00).
G Pivot pin 2, Axle pivot 1.4. Make sure that you bleed the steering
1.5. Make sure that you re-phase the steering
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00 - General
1.6. Apply grease on the axle pivot. Refer to (PIL machine on axle stands or blocks positioned
75-06-00). under the chassis. Remove the rear road wheels.
7. Remove the rear fenders (if installed). Refer to
Table 314. Torque Values (PIL 06-54).
Item Description Nm
8. Disconnect the brake hose. Install caps on the
G Pivot pin 2 118
open connections.
(For: 55 Series (1 Piece Axle), Rear) 9. Support the axle on a trolley jack.
10. Remove the bolt 2 and take out the right side
SD80 3 Piece Steer Drive Axle- Integral RAS (Rear Axle Stabilization) ram pivot pin.
Brakes Repeat the procedure for the left side RAS ram
pivot.
Remove
11. Remove the bolt 3 securing the axle pivot pin and
1. Make the machine safe. Refer to (PIL 01-03). drive out the pivot pin towards the front of the
machine.
12. Lower the axle away from the mounting yoke and
3. Follow the general health and safety procedures. remove from the machine.
4. Remove the bolts 1 and disconnect the propshaft Install
coupling from the axle. Refer to (PIL 27-48). 1. The installation procedure is the opposite of the
5. Disconnect and install the caps on the hydraulic removal procedure. Additionally do the following
feed hoses to the steer rams (one hose on each steps.
ram). 1.1. Install the road wheels. Refer to (PIL 27-29).
6. Slacken off the rear road wheel retaining nuts 2. Before you drive the machine do the following
and then raise and support the rear end of the steps.
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00 - General
Figure 786. SD80 3 Piece Steer Drive Axle- Integral Brakes
C
B
D
F
G
A Bolt 1 B Hydraulic feed hose

C Brake hose D Bolt 2
E RAS ram pivot pin F Bolt 3
G Axle pivot pin
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00 - General
2.1. Bleed the brake system. Refer to (PIL 2.3. Re-phase the steering system. Refer to (PIL
24-03). 25-00).
2.2. Bleed the steering system. Refer to (PIL 2.4. Put grease in the axle pivot. Refer to (PIL
25-00). 25-00).
Table 315. Torques table

Item Nm
F 118
SD55 1 Piece Steer Drive Axle under the chassis. Remove the rear road wheels.
Remove 8. Support the axle on a trolley jack.
9. Remove the bolt 2 securing the axle pivot pin and
2. Install the safety strut. Refer to (PIL 06-69). the drive out the pivot pin towards the front of the
machine.
Refer to (PIL 01-03). 10. Lower the axle away from the mounting yoke and
remove from the machine.
4. Remove the bolts 1 and disconnect the propshaft
coupling from the axle. Refer to (PIL 27-48). Install
5. Disconnect and install caps on the hydraulic feed 1. The installation procedure is the opposite of the
hoses to the steer rams (one hose on each ram). removal procedure. Additionally do the following
steps.
6. Remove the rear fenders (if installed).
1.1. Install the road wheels and do the tightness
7. Slacken off the rear road wheel retaining nuts checks. Refer to (PIL 27-30).
and then raise and support the rear end of the
machine on axle stands or blocks positioned 2. Before you drive the machine, do the following
steps.
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00 - General
Figure 787. SD55 1 Piece Steer Drive Axle
A Bolt 1 B Hydraulic feed hose

C Bolt 2 D Axle pivot pin
2.1. Bleed the steering system. Refer to (PIL 2.3. Put grease in the axle pivot. Refer to (PIL
25-00). 25-00).
2.2. Re-phase the steering system. Refer to (PIL
25-00).
Table 316. Torques table

Item Nm
C 118
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00 - General
(For: 70-Series) 12. Make sure that you do not install new plates
individually.
Consumables
Description Part No. Size 13. Remove all the three reaction pins and check
JCB Gear Oil HP 4000/0505 20 L them for damage.
4000/0503 200 L 14. In the controlled retraction piston type, If new
JCB Multi-Gasket 4102/1212 0.05 L brake and friction plates are installed then a new
JCB Threadlocker 4101/0250 0.01 L brake back off pin 1 and tension bushes also
and Sealer (Medium 4101/0251 0.05 L need to be installed. Failure to do so could result
Strength) in the brake being permanently on.
Brake piston and seals- Controlled

Disassembly
retraction type
It is recommended that axle must be removed from
the machine while you disassemble the rear axle Make sure that only one side at a time is
brake. disassembled to prevent damage to the bearings and
preserve the crownwheel and the backlash settings.
Before you disassemble the rear axle brakes, it is
mandatory to mark the components for alignment Before you remove the brake housing and the piston
and to identify the right hand and left hand side, to assembly make sure that you support the differential
make sure that it is correctly assembled at the time with the driveshaft or any other suitable support.
of assembly.
1. Mark the brake piston housing and the
drivehead.
Brake pack
2. Remove the capscrews.
1. Use a heavy duty (6 point) socket to remove the
bolt 1. 3. Remove the brake housing and the piston
assembly.
2. Carefully remove the axle arm from the
drivehead. 4. Make sure that you do not turn the nut, if it is
turned then the bearing pre-load needs to be
3. If necessary, tap the case with a soft faced reset.
hammer and remove all traces of the old sealant
from the mating faces. 5. Remove the six reaction pin assemblies.
4. The brake pack consist of five friction plates and 5.1. Remove the circlip 2.
six counter plates. There are two counter plates,
one at each end of the brake pack, which are not 5.2. Remove the back off pins 1.
attached to the plate carrier. 5.3. Remove the tension bushes and the spring
1.
5. If it is necessary to install the plates again
then make a note of their position and correct 6. Remove the brake piston from the brake housing.
orientation.
7. Remove and discard the seal 1 and seal 2.
6. Remove the circlip 1.
8. Check the housing bore for damage and scoring.
7. If it is necessary to install the brake pack again
then make a note of their original position before 9. Nicks or cuts in the seals may be the reason for
you remove them. loss of brake fluid.
8. The wear limit of friction plates is to the depth of Brake Piston and Seals- Positive retraction
the cross hatching. type
9. Check all plates for flatness and damage.
Make sure that only one side at a time is
10. Scoring of the counter plates to a certain limit is disassembled to prevent damage to the bearings and
permissible. do the preservation procedure for the crownwheel
and the backlash settings.
11. Install a new brake pack, if it is damaged.
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00 - General
Before you remove the brake housing and the piston 5. Remove the six reaction pin assemblies.
assembly make sure that you support the differential
with the driveshaft or any other suitable support. 5.1. Remove the back off pins 2.
5.2. Remove the spring 2.
1. Mark the brake piston housing and the
drivehead. 6. Remove the brake piston from the brake housing.
2. Remove the capscrews. 7. Remove and discard both the seal 1 and seal 2.
3. Remove the brake housing and the piston 8. Check the housing bore for damage and scoring.
assembly.
9. Nicks or cuts in the seals may be the reason for
4. Make sure that you do not turn the nut, if it is loss of brake fluid.
turned then the bearing pre-load needs to be
reset.
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00 - General
Figure 788.
E J
L
K
M
N Q R
T
B
B
C D
Item Description
Table 317. D Circlip 1
Item Description E Reaction pin
A Bolt 1 F Support for differential
B Counter plate G Brake piston housing
C Plate carrier H Capscrew
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00 - General
Item Description Brake piston and seals- Positive retraction

J Nut type
K Circlip 2 1. Remove all traces of the old sealant from the
L Back off pin 1 mating faces of the drivehead and the brake
M Tension bush piston housing.
N Spring 1
2. Install a new seal 1 and seal 2. Make sure that
P Brake piston they are seated squarely in their grooves.
Q Seal 1
R Seal 2 3. Carefully push the piston all the way into the
housing. Make sure that the brake back off holes
S Back off pin 2 are aligned with the housing.
T Spring 2
U Cross hatching 4. Apply sealant to the threads of the back off pin 2.
Install the spring 2 over the back off pin 2. Screw
V Oil flow holes the back off pin 2 into the brake piston.
W Drivehead housing
(Medium Strength)
Assemble
5. Apply JCB multigasket to the drivehead mating
Brake piston and seals- Controlled surface and then install the brake piston housing
retraction type assembly. Make sure that they are aligned
against the marking, made at the time of
1. Remove all traces of the old sealant from the disassembly.
mating faces of the drivehead and the brake
piston housing.
6. Install the capscrews, tighten the capscrews to
2. Install a new seal 1 and seal 2. Make sure that
they are seated squarely in their grooves.
7. Remove the differential support.
3. Apply sealant to the threads of the back off pin 1.
Screw the back off pin 1 into the brake piston.
Brake pack
(Medium Strength) 1. In the controlled retraction piston type, If new
brake and friction plates are installed then a new
4. Carefully push the piston all the way into the brake back off pin 1 and tension bushes also
housing. Make sure that the brake back off holes need to be installed. Failure to do so could result
are aligned with the housing. in the brake being permanently on.
5. Install the spring 1 over the back off pin 1. 2. Assemble the five friction plates and six counter
plates onto the brake carrier. If the original brake
6. Put the tension bush over the back off pin 1. pack is reinstalled then return the plates to their
7. Use a suitable tool to drive the tension bush onto original positions.
the back off pin 1, use a soft faced hammer until 3. Soak the new friction plates in JCB Special Gear
the circlip 2 is installed. Oil before assembly.
8. Apply JCB multigasket to the drivehead mating Consumable: JCB Gear Oil HP
surface and then install the brake piston housing
assembly. Make sure that they are aligned 4. Install the circlip 1.
against the marking, made at the time of
disassembly. 5. At the time of assembly of the brake packs, the oil
flow holes must be aligned with each other when
Consumable: JCB Multi-Gasket installed to the brake pack carrier.
9. Install the capscrews, tighten the screws to the 6. Put the three reaction pins into their grooves and
correct torque value.Refer to Table 318. lubricate them.
10. Remove the differential support. 7. Push the pins fully into their location holes in the
housing. Makes sure they stay in place.
8. Install one counter plate into the housing,
lubricate it and then the other counter plate.
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00 - General
9. If the old counter plates are re installed then put Consumable: JCB Threadlocker and Sealer
them into their original position. (Medium Strength)
10. Fully press the brake pack in the housing. 13. Put the axle arm on to the drivehead. Make sure
it is aligned correctly.
11. Apply JCB multigasket to the mating surface of
the drive head. 14. Install the bolts 1 and tighten the bolt to the
12. Apply threadlocker and sealer to the bolt thread. 14.1. Check the grade of the installed bolt and
make sure you tighten them to the correct
torque.Refer to Table 318.
Table 318. Torques

Item Torque
If the bolt 1 is 8.8 grade 244
If the bolt 1 is 12.9 grade 400
Item H (capscrew) 56
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27 - Driveline
20 - Axle(s)
15 - Breather
15 - Breather
Check (Condition)
Breathers are installed to axles to release the If the breather is dislodged or removed, make sure
pressure build up due to braking and prolonged that it is installed again with the hole pointing towards
roading. the wheel.
If the breathers are blocked, there can be oil leakage Make sure that the breather is installed on the
past seals and brake problems due to pressure opposite side of the crownwheel (in less turbulent oil
build up. Most of the axles are have long stem type areas) to avoid oil seepage.
breather.
Make sure that the plug is installed on the
Make sure that there is sufficient clearance around crownwheel side.
the breather.
Figure 789.
A Long stem breather B Plug

C Hole
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27 - Driveline
20 - Axle(s)
81 - Mount
81 - Mount
Check (Condition)
2. Get access to the mounting(s).
3. Make sure that the entire mounting(s) system is
in good condition.
3.1. Inspect brackets and casings for cracks,
damage and security.
3.2. Inspect rubber mountings (if installed) for
wear and tears and too much movement.
3.3. Make sure that all fastenings are there and
they are tightened to the correct torque.
Refer to (PIL 72).
4. Install new components if any are defective.
Refer to the correct section in the service manual
as necessary.
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27 - Driveline
22 - Drivehead
22 - Drivehead
Contents Page No.
27-22-00 General ......................................................................................................................... 27-293

27-22-06 Crownwheel .................................................................................................................. 27-313
27-22-09 Pinion Gear .................................................................................................................. 27-315
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22 - Drivehead
00 - General
Introduction .................................................. 27-293 The axle drivehead transmits drive from the input
Component Identification ............................. 27-294 coupling yoke to the driveshafts through the
Disassemble and Assemble ........................ 27-300 differential unit.
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22 - Drivehead
00 - General
For: 55 Series (3 Piece Axle) ... Page 27-294 Figure 790.

For: 55 Series (1 Piece Axle) ... Page 27-296
(For: 55 Series (3 Piece Axle))
Unit Identification
The axle serial number is stamped on the unit
identification plate. When ordering replacement A
parts, always quote the details on the unit
identification plate. In the case of gear replacements,
always check the part number stamped on the gear,
and the number of teeth.
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22 - Drivehead
00 - General
Location Drawing (448/00063)
Figure 791.
1 15 11 10 16
14
13
12
2
3
5 4
6
7
8
Item Description
Table 319. 10 Bolt Verbus-ripp
Item Description 11 Crownwheel and pinion
assembly
1 Drive case
12 Bearing (taper roller)
13 Side nut
3 Shim
14 Brake piston
4 Spacer
15 Differential assembly
16 Brake piston housing
6 Pinion seal
7 Coupling yoke
8 Stake nut
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00 - General
(For: 55 Series (1 Piece Axle)) Figure 793.
Unit Identification
The axle serial number is stamped on the unit
identification plate as shown. When you make an
order for parts replacement, always give the details
of gear replacements, always check the part number
Figure 792.
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22 - Drivehead
00 - General
Figure 794.
4 5
2 3 6 7 8
Item Description
5 Bevel gears
Table 320.
6 Side nut locking pin
Item Description
7 Differential housing
1 Coupling yoke
8 Crownwheel
2 Driveshaft
3 Side nut
4 Pinion
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22 - Drivehead
00 - General
Location Drawing (448/00040)
Figure 795.
15 10
14
12
13
1
2
11
3
4
5
Item Description
Table 321. 4 Spacer
Item Description 5 Bearing (taper roller)
1 Drivehead carrier 6 Pinion seal
2 Bearing (taper roller) 7 Coupling yoke
3 Shim 8 Stake nut
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00 - General
Item Description
10 Bolt-Verbus Ripp
11 Crown wheel and pinion
assembly
13 Side nut
14 Side nut locking pin
15 Differential assembly
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27 - Driveline
22 - Drivehead
00 - General
For: 55 Series (3 Piece Axle) ... Page 27-300 2. Mark the brake piston housing and the drivehead
For: 55 Series (1 Piece Axle) ... Page 27-307 for their correct assembly with respect to each
other. Refer to Figure 796.
(For: 55 Series (3 Piece Axle)) 3. Remove the brake piston housing. Refer to
Description Part No. Qty. 4. Remove the differential side nut locking pin to
Drive Coupling 892/00812 1 allow for readjustment on assembly. Refer to
Spanner Figure 797.
Setting Tool Kit 892/00918 1
Figure 797.
Torque Wrench 993/70111 1 C
(10-100Nm)
Support Bracket 997/11000 1
Disassembly
When the drivehead is installed on the machine it
cannot be disassembled. It is recommended that you
remove the complete axle.
The crownwheel and pinion are matched and should

be replaced as a pair, if either of them are damaged
or excessively worn.
The two differential case halves are also matched as C Side nut locking pin
are the differential side gears and planet gears, do
not use unmatched halves or gears. 5. Remove the other brake piston housing if it is
damaged, but its locking pin must be removed
1. Place the drivehead with the crownwheel at the to allow the side load adjustment on assembly.
top and then remove the capscrews. Refer to Refer to Figure 797.
Figure 796.
6. Lift off the crownwheel/ differential assembly.
Figure 796. Refer to Figure 798.
B A
A Capscrew
B Brake piston housing
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27 - Driveline
22 - Drivehead
00 - General
H
D
J
G
F
E Pinion
F Pinion seal
D Crownwheel/ differential assembly G Outer bearing cone
H Inner bearing cup
7. If it is necessary to remove the brake piston J Shim
housings then mark the crownwheel end of the
drivehead case to make sure that they are 11. If necessary, drive out the pinion inner bearing
correctly assembled at the time of assembly. cup and shims. Refer to Figure 799.
12. Discard the shims. Refer to Figure 799.
8. Use the spanner to lock the drive yoke and then
remove the stake nut and the yoke. Refer to 13. Do the step 11 to remove the outer bearing cup.
Figure 799. Refer to Figure 799.
Special Tool: Drive Coupling Spanner (Qty.: 1) 14. There are no shims for the outer bearing cup.
9. Use a soft faced hammer to hit the pinion end
shaft until the pinion is free from its front bearing 15. Remove the pinion spacer. Refer to Figure 800.
and then remove the pinion. Refer to Figure 799.
Figure 800.
10. Remove the pinion seal and the outer bearing
cone. Refer to Figure 799.
K L
K Inner bearing cone

L Pinion spacer
16. Remove the inner bearing cone. Refer to Figure
800.
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27 - Driveline
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00 - General
17. Disassembly of the differential unit. Refer to 6. Put the top half of the differential housing on
Figure 801. to the differential and make sure that you have
aligned it correctly. Refer to Figure 802.
17.1. Remove the bolts.
Figure 802.
17.2. Lift off the top half housing.
Figure 801.
M
R
N
R
N S
S P
Q
P
Q
M Bolt
N Top half housing
M Bolt P Spherical washer 1
N Top half housing Q Spherical washer 2
P Spherical washer 1 R Differential bearing cone
Q Spherical washer 2 S Differential gear
R Differential bearing cone
7. Apply Loctite 242 to the threads of the bolts and
S Differential gear
then install them. Refer to Figure 802.
17.3. Remove the differential gears, the
8. Tighten the bolt to the correct torque value. Refer
spherical washer 1 and spherical washer
to Figure 802.
2.
17.4. Remove the differential bearing cones. 9. Check the gears for free rotation. Refer to Figure
802.
Assembly 10. Install the new inner bearing cone on to the
pinion. Refer to Figure 803.
1. If necessary, install a new crownwheel to the
differential case half.
2. Install the crownwheel retaining bolt.
3. Tighten the bolt to the specified torque value.
Torque: 94 N·m
4. Assemble the differential gear and the spherical
washer 1 and spherical washer 2 into the bottom
half of the differential housing. Refer to Figure
802.
5. Install the differential bearing cones. Refer to
Figure 802.
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22 - Drivehead
00 - General
H
K L
J
G
F
K Inner bearing cone
L Pinion spacer
11. Install the largest available solid spacer
E Pinion
(14.20mm) from the solid spacer setting kit. Refer
F Pinion seal
to Figure 803.
G Outer bearing cone
Special Tool: Spacer Kit (Qty.: 1) H Inner bearing cup
J Shim
12. Find the correct thickness for the shims. Refer to
Front Drivehead, Pinion Gear- Calibrate. Refer to 17. Before you put the pinion into the bore, make
Figure 803. sure that it is matched with the crownwheel.
Refer to: PIL 27-22-09. Refer to Figure 804.
13. Install the shims behind the pinion inner bearing 18. The code numbers etched on the pinion end
cup. Refer to Figure 804. face and the crownwheel perimeter should be the
same. Refer to Figure 804.
14. Use a puller tool to make sure that the inner
bearing cup is installed in square. Do not use a 19. Install the pinion outer bearing cone. Refer to
hammer. Refer to Figure 804. Figure 804.
15. Install the outer bearing cup. Refer to Figure 804. 20. Do not install the oil seal at this stage. Refer to
Figure 804.
16. Put the pinion into its bore. Refer to Figure 804.
21. Install the special tool sleeve and the special
pinion shaft adapter. Refer to Figure 805.
22. Tighten the adaptor to the correct torque value.
23. Make sure that the pinion is free to rotate and
there is end float. Refer to Figure 805.
24. End float will prevent the bearing from damage.
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27 - Driveline
22 - Drivehead
00 - General
T Z
Y
U
1
T Pinion shaft adaptor X Support pillar
U Special tool sleeve Y DTI
V Special bracket Z Torque wrench
W Bolt (M10x30)
33. Set the torque wrench to the specified value and
25. If the pinion is not free to rotate or there is no end measure the end float while you rotate the shaft.
float at this stage check the bearing is installed Refer to Figure 806.
correctly. Refer to Figure 805. Torque: 35 N·m
26. Make sure that the correct size spacer is Special Tool: Torque Wrench (10-100Nm) (Qty.:
installed. Refer to Figure 805. 1)
27. Use two bolts (M10x30) to install the special 34. Correct size solid spacer selection. Refer to
bracket to the drivehead housing. Refer to Figure Figure 806. Refer to Table 322.
805. 34.1. To select the correct size spacer, subtract
Special Tool: Support Bracket (Qty.: 1) the end float obtained at step 33 from the
solid spacer size (14.20 mm).
28. Install the special tool support pillar to the bracket
so that the fork end engages in adaptor. Refer to 34.2. Also subtract 0.04 mm to allow for
Figure 805. theoretical bearing tolerance and pre load.
34.3. The result is the size of spacer to be
29. Make sure that the fork is centrally located on the
installed from the solid spacer kit.
adaptor. Refer to Figure 805.
34.4. If there is no spacer of this size, fit the next
30. If necessary, align the bracket again. Refer to nearest size spacer from the spacer kit.
Figure 805.
31. Install a DTI (Dial Test Indicator). Refer to Figure
806. 35. Remove the sleeve and the temporary spacer.
32. Make sure that the DTI is installed on the
drivehead not on the bracket. Refer to Figure 36. When you remove the temporary spacer make
806. sure that the outer bearing is not damaged. Refer
to Figure 805.
37. Install the correct size spacer from the spacer kit.
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27 - Driveline
22 - Drivehead
00 - General
38. Install the sleeve. Refer to Figure 805. 49. Gradually tighten the stake nut to the minimum
specified torque value, occasionally rotate the
39. Tighten the adaptor to the specified value, to coupling yoke. Refer to Figure 807.
protect against bearing damage while spacer
selection is verified and make sure that the pinion Torque: 250 N·m
is free to rotate. Refer to Figure 805. 50. If the correct size spacer is selected, the rolling
Torque: 50 N·m torque should be within the specified torque
value including the seal drag. Refer to Figure
40. Check there is no end float and pinion is free to 807.
turn smoothly by hand. Refer to Figure 805.
41. Remove the adaptor and install the stake nut.
Refer to Figure 805. 51. When the torque value is correct, use a square-
ended staking tool to stake the nut to the pinion
42. Check that rolling torque is less than 2.0 Nm. If shaft. Refer to Figure 807.
the rolling torque exceeds 2.0 Nm, check that the
shaft is assembled correctly. Refer to Figure 805. 52. The stake nut tightening torque value can be
increased to a maximum of 300 Nm if the pinion
43. If the pinion is not free to rotate then check the rolling torque does not exceed the maximum of
correct size spacer is installed or not. Refer to 3.4 Nm. Refer to Figure 807.
Figure 805.
Figure 808.
44. If rolling torque measured at step 42 is too high
then install the next larger size spacer. If the
rolling torque is too low then install the next
smallest size spacer. Refer to Figure 805.
45. If a correct spacer is not available from the range,
check that drivehead is assembled correctly.
46. Remove the stake nut and the sleeve. Refer to
Figure 805.
47. Lubricate the seal lips and then install the new oil
seal. Refer to Figure 807.
Figure 807.
AA
AB 53. If the brake piston housing is removed then install
AC one at the opposite end to the crownwheel. Refer
to Figure 810.
54. Apply Loctite 574 to the drivehead mating face,
then install the brake piston housing. Refer to
Figure 810.
55. Make sure that the mark made between the
drivehead and the brake piston housing at the
time of disassembly is aligned. Refer to Figure
AA Oil seal 810.
AB Coupling yoke
AC Stake nut 56. Install the crownwheel/ differential assembly into
the drivehead. Refer to Figure 809.
48. Install the coupling yoke and the new stake nut.
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27 - Driveline
22 - Drivehead
00 - General
Figure 809. 60. Adjust the differential side nuts to give a bearing
pre-load of the specified value.
Torque: 1.13 –2.26 N·m
D
61. Measure the pre-load by taking another rolling
torque reading and subtracting the torque figure
measured at step 50. The difference is the
bearing pre-load.
62. Measure the crownwheel backlash, it should be
63. Adjust the differential side nuts by equal amounts
when you change the backlash.
64. When the backlash and pre-load are both
correct, install the side nut locking pins. Refer to
Figure 810.
65. Check the tooth marks to make sure that
the crownwheel and pinion are set correctly.
D Crownwheel/ differential assembly Refer to Front Drivehead, Crownwheel- Check
(Operation).
57. Install the other side brake piston housing onto Refer to: PIL 27-22-06.
the drivehead. Refer to Figure 810.
Figure 811.
Figure 810.
AD
B A

Value
(1)
Temporary spacer size 14.20

A Capscrew Subtract end float 0.25
B Brake piston housing Total 13.95
C Side nut locking pin
AD Differential side nut Subtract tolerance and 0.04
pre-load
58. Install the capscrews. Refer to Figure 810. Result 13.91
Use next smallest spac- 13.90
59. Tighten the capscrews to the correct torque
er
value. Refer to Figure 810.
(1) All the values are in millimetre (mm).
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22 - Drivehead
00 - General
Table 323. Torque Values 7. Remove the bearing outer race 1 and bearing
outer race 2 from the drivehead carrier bores.
Item Description Nm
M Bolt 46 8. Drive off the taper roller bearing cone 1 from the
T Pinion shaft adaptor 50 crownwheel differential case half.
AC Stake nut 250 9. Remove the differential assembly from the
A Capscrew 56 carrier.
(For: 55 Series (1 Piece Axle)) 10. Mark the position of the drive yoke on the splined
shaft.
Special Tools
Description Part No. Qty. 11. Use the special tool to prevent the drive yoke
from rotating and remove the pinion nut.
Spanner Special Tool: Drive Coupling Spanner (Qty.: 1)
Setting Tool Kit 892/00918 1 12. Remove the drive yoke.
Spacer Kit 921/53300 1 13. Remove the pinion shaft from the drivehead
carrier.
(10-100Nm) 14. Prise the pinion oil seal out of the bore.
Support Bracket 997/11000 1
15. Remove the pinion tail bearing.
Consumables
16. If necessary, remove the bearing outer race 3.
JCB Multi-Gasket 4102/1212 0.05 L 17. If necessary, remove the bearing cup from
JCB Threadlocker 4101/0250 0.01 L the opposite side of the drivehead carrier and
and Sealer (Medium 4101/0251 0.05 L remove the pinion shims.
Strength)
18. Remove the spacer and the taper roller bearing
cone 3 from the pinion.
Disassembly
Disassemble the differential unit (If
The drivehead consists of the drivehead carrier necessary)
and pinion assembly, and the differential unit. A
separate disassembly procedure is given for each 1. For LSD (Limited Slip Differential) Refer to Front
sub assembly. Differential, Disassemble and Assemble.
Disassemble the Drivehead Carrier 2. Remove the differential assembly retaining bolt
and separate the case half 1 and case half 2.
1. Drain the oil from the axle centre case.
3. Remove the side gears and the thrust washer 1
2. Completely remove both hub assemblies with the (2 off each).
driveshafts.
4. Remove the bevel gears and thrust washer 2 (4
3. Mark the installation position of the drivehead off each) from the trunnion pins.
carrier with respect to the axle case.
5. Remove the taper roller bearing cone 2 from the
4. Remove the drivehead carrier retaining bolt and differential case half.
then remove the drivehead carrier from the axle
case. 6. Remove the Verbus-ripp bolts.
5. Clean the drivehead carrier and axle case mating 7. Remove the crownwheel from the differential
faces. case half.
6. Pull out the tension pin 1 and tension pin 2, and

remove the castellated nut 1 and castellated nut
2.
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27 - Driveline
22 - Drivehead
00 - General
Figure 812.
D K L
T
M
Q
G E C
P
R W N
S
F
H J
V
A
B
AG
U
AD
AE
Z
AF
AC
AB
AA
X Y
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27 - Driveline
22 - Drivehead
00 - General
housing halves are also matched. Do not use

unmatched halves.
Table 324.
Item Description Assemble the differential unit (if necessary)
A Drivehead carrier retain- 1. For LSD Refer to Front Differential, Disassemble
ing bolt and Assemble.
B Drivehead carrier
C Tension pin 1 2. Assemble the trunnion pin, bevel gear 1 and the
bevel gear 2 then the thrust washer 1 and thrust
D Tension pin 2 washer 2 into differential half case 2.
E Castellated nut 1
F Castellated nut 2 3. Put the differential half case 1 onto the half case
2. Make sure you align them properly.
G Bearing outer race 1
H Bearing outer race 2 4. Apply sealant to the differential assembly
J Taper roller bearing retaining bolt and then install it.
cone 1 Consumable: JCB Threadlocker and Sealer
K Differential assembly (Medium Strength)
L Differential assembly re-
taining bolt 5. Tighten the bolt to the correct torque value.
M Case half 1 6. Check the gears for free rotation.
N Case half 2
7. Use new Verbus-ripp bolts to install the
P Side gear
crownwheel.
Q Thrust washer 1
R Bevel gear 8. Tighten the bolt to the correct torque value. Refer
S Thrust washer 2 to table1.
T Taper roller bearing Assemble the drivehead carrier
cone 2
U Verbus-ripp bolt 1. Measure the correct thickness for the seam.
V Crownwheel Refer to Front Drivehead, Pinion Gear- Calibrate.
W Trunnion pin Refer to: PIL 27-22-09.
X Pinion nut
2. Install the shim behind the new bearing cup.
Y Drive yoke
Z Pinion shaft 3. Install the new pinion head bearing cone onto the
AA Pinion oil seal pinion.
AB Pinion tail bearing 4. Install the pinion and bearings into the drivehead
AC Bearing outer race 3 case.
AD Bearing cup
5. Install the largest available solid spacer (14.20
AE Drive pinion shim mm).
AF Spacer
AG Taper roller bearing
cone 3 6. Apply a coat of oil and then install the pinion tail
bearing.
Assembly 7. Do not install the oil seal at this stage.
The procedure below refers to the following aspects 8. Install the special tool sleeve and the special
of the drivehead assembly, which are covered pinion shaft adaptor from the setting kit.
separately in detail.
• Pinion depth setting
• Crownwheel and pinion meshing 9. Tighten the adaptor to the correct torque value.
10. Make sure that the pinion is free to rotate and
Both the crownwheel and pinion and the bevel gear
there is end float, this will prevent any damage
1 and bevel gear 2 are matched and should be
to the bearing. If the pinion is not free to rotate
replaced as a set, if any of their components are
or there is no end float at this stage check the
damaged or excessively worn. The two differential
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27 - Driveline
22 - Drivehead
00 - General
bearing is installed properly. Also check that the Figure 814.

correct size spacer is installed.
11. Use two (M10x30) nuts and bolts to install the
special bracket on the drivehead housing.
Special Tool: Support Bracket (Qty.: 1) AN
Figure 813.
AM
AL
AJ
AK
AH
AM DTI
AN Torque wrench
16. Set the torque wrench to the specified value and
measure the end float while you rotate the shaft.
Torque: 35 N·m
1)
AH Special tool sleeve
AJ Adaptor 17. To select the right size spacer do the following
AK Special bracket steps. Refer to Table 327.
AL Support pillar 17.1. Subtract the end float obtained in step
12. Install the special support pillar on the bracket so 16 from the solid spacer thickness value
that the fork end engages with the adaptor. (14.20 mm).
17.2. Subtract 0.04mm to allow for theoretical
13. Make sure that the fork is centrally located on the bearing tolerance and pre-load.
adaptor.
17.3. The result is the size of spacer to be
14. If necessary, align the bracket again. installed from the solid spacer setting kit.
15. Install a DTI. Make sure that the DTI is mounted Special Tool: Spacer Kit (Qty.: 1)
on the drivehead and not on the bracket. 17.4. If there is no spacer of this size, then install
the next nearest size spacer.
18. Remove the sleeve and the temporary spacer.
19. Install the correct size spacer from the solid
spacer setting kit.
20. Make sure that you do not damage the outer
bearing.
21. Again install the sleeve and then install the
adaptor.
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27 - Driveline
22 - Drivehead
00 - General
22. Tighten the adaptor to the correct torque value, 41. Measure the backlash between the crownwheel
to protect against bearing damage while spacer and the pinion and it should be within the
selection is verified making sure the pinion is free specified limit.
to rotate. Length/Dimension/Distance: 0.17 –0.28 mm
23. Check there is no end float and the pinion is free 42. When altering the backlash adjust both the
to turn smoothly by hand. castellated nut in equal amounts.
24. Remove the adaptor and then install the nut. 43. When the backlash and pre-load are both
25. Make sure that the rolling torque is less than 2.0 correct, install the tension pin 1 and tension pin 2.
Nm, if the rolling torque exceeds 2.0 Nm, then 44. Check the tooth marks to verify that the
check that the shaft is assembled correctly or not. crownwheel and the pinion are set correctly.
26. If the pinion is not free to rotate, check the correct 45. Apply JCB Multigasket to the mating faces of the
size spacer has been installed. drivehead carrier and the axle case.
27. If the rolling torque measured at step 25 is Consumable: JCB Multi-Gasket
too high, install the next larger size spacer. If
the rolling torque is too low, install the next 46. Install the drivehead carrier to the axle case with
smallest size spacer. If a correct spacer is not the crownwheel towards the short driveshaft.
available from the range, check that drivehead is
assembled correctly. 47. Install the drivehead carrier retaining bolts.
28. Remove the adaptor and the sleeve. 48. Tighten the bolt to the correct torque value.
29. Lubricate the seal lips and then install the new 49. Reassemble both driveshafts and hub
oil seals. assemblies.
30. Install the coupling yoke and the new stake nut.
Table 325. Torque Settings (55 Series)
31. Gradually tighten the stake nut up to the specified Item Description Nm
torque value, while occasionally rotating the
coupling yoke. A Drivehead carri- 98
er retaining bolt
Torque: 250 N·m U Verbus-ripp bolt 94
32. If the correct size spacer is selected then the
pinion rolling torque should with in the specified
limit. Table 326. Torque Settings (70 and 80 Series)
Torque: 2.3 –3.4 N·m Item Description Nm

A Drive head car- 166
33. The nut tightening torque value can be increased rier retaining
to a maximum of 300 Nm but the pinion rolling bolt
torque does not exceed the maximum of 3.4 Nm. U 'Verbus Ripp' 200
bolt
34. Finally stake the nut into the slot.
35. Install the differential assembly onto the
drivehead carrier. Table 327. Spacer Selection Example
Value
(1)
36. Push the taper roller bearing onto the spigot of

the differential half case2. Temporary spacer size 14.20
37. Install the bearing outer race 1 and bearing outer Total 13.95
race 2.
Subtract tolerance and 0.04
38. Install the castellated nut 1 and castellated nut 2 preload
to the drivehead carrier. Result 13.91
39. Do not install the tension pin 1 and tension pin 2 Use next smallest spac- 13.90
at this stage. er
(1) All the values are in millimetre (mm).
40. Adjust the castellated nut to give an increase in
input pinion rolling torque of between 1.36 and
2.5 Nm more than that specified in Step25.
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27 - Driveline
22 - Drivehead
00 - General

Item Description Nm
L Differential assembly 46
retaining bolt
AJ Adaptor 50
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27 - Driveline
22 - Drivehead
06 - Crownwheel
06 - Crownwheel Introduction
Introduction .................................................. 27-313 A crown wheel is a rotating gear wheel with teeth set
Check (Operation) ....................................... 27-314 at right angles to its plane, it is usually matched with a
pinion gear that meshes with the crown wheel. They
are mainly used in vehicles to maintain a forward
movement.
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27 - Driveline
22 - Drivehead
06 - Crownwheel
Check (Operation) Figure 817.
Crownwheel and Pinion Meshing

Meshing of the gears should be checked by marking
three of the pinion teeth with engineers marking
compound and rotating the pinion. The marking will
then be transferred to the crown wheel teeth.
1. Correct tooth marking.

Figure 815.
2. Pinion too deeply in mesh. Move the crown wheel

towards the pinion to correct the backlash.
Figure 816.
3. Pinion too far out of mesh. Move the crown wheel

away from the pinion to correct the backlash.
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27 - Driveline
22 - Drivehead
09 - Pinion Gear
09 - Pinion Gear Introduction

Introduction .................................................. 27-315 A pinion gear is a small gear that meshes with a
Calibrate ...................................................... 27-316 larger crownwheel. They are mainly used in vehicles
to maintain a forward movement.
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27 - Driveline
22 - Drivehead
09 - Pinion Gear
Calibrate and record the height. The bearing cups and

rollers are matched sets. Always keep the
Special Tools bearing assemblies together. Make sure that you
Description Part No. Qty. measure only the inner bearing.
Shim Kit 921/M0229 1 Figure 820.
Pinion Depth Setting

E
Determine the pinion depth setting shim size as
follows:
E Inner bearing height
1. Note the deviation figure etched on the pinion
and the deviation figure on the drivehead Shim Size Calculation Example
housing. Both figures are in units of 0.01 mm.
Note: The pinion depth may be etched on the Table 329. Calculation 1.
gear face or on the rear of a gear tooth. Actual Drivehead Case Size
Special Tool: Shim Kit (Qty.: 1) Item Typical Fig- Description
ures
Figure 818.
A 187.6 mm Nominal drive-
D head case size,
fixed at the fac-
tory
B -0.14 mm Drivehead
case deviation,
marked on the
case
Sum of A and B 187.46 mm Actual drive-
head case size
Table 330. Calculation 2. -

Actual Pinion and Bearing Size
Item Typical Fig- Description
ures
D Pinion depth C 150.0 mm Nominal pinion
length, fixed at
Figure 819. the factory
D 0.10 mm Pinion devia-
tion, marked on
the pinion
E 36.6 mm Bearing size, in-
ner pinion bear-
ing
Sum of C, D 186.70 mm Actual pinion
and E and bearing
size
Table 331. Calculation 3. Shim

Size = Calculation 1 - Calculation 2
Typical Figures Description
187.46 - 186.70 = Select the nearest shim
0.76mm size from the shim kit.
B Deviation figure
2. Assemble the pinion inner bearing and its
cup on a flat surface. Lightly oil and rotate
the bearing before measurement. Make sure
that the bearing cup is square and measure
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27 - Driveline
24 - Differential
24 - Differential
Contents Page No.
27-24-00 General ......................................................................................................................... 27-319
27 - 317 9823/1700-1 27 - 317

Notes:
27 - 318 9823/1700-1 27 - 318

27 - Driveline
24 - Differential
00 - General
Introduction .................................................. 27-319 A differential is a particular type of simple planetary
Technical Data ............................................. 27-320 gear train.
Check (Condition) ........................................ 27-326 The differential couples the drive shaft to half-shafts
that connect to the rear driving wheels. The purpose
Disassemble and Assemble ........................ 27-327 of the differential is to allow a speed differential
between the inner and outer wheel while being driven
by the input shaft. In its most common form, the
differential consists of a pinion and ring and planetary
bevel gears to connect the output shafts.
The axle can have the following type of differentials.
1. Open Differential.
2. LSD (Limited Slip Differential).
Open Differential
A standard differential, or what is referred to as an
open carrier. A conventional open differential always
supplies close to equal (because of limited internal
friction) torque to each side. The differential gearing
allows the outer drive wheel to rotate faster than the
inner drive wheel during a turn. This is necessary
when the vehicle turns, making the wheel that is
travelling around the outside of the turning curve roll
farther and faster than the other.
In a standard [open type] differential, the rotational

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

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

In the most basic sense, a LSD equalizes the
difference in either speed between output shafts or
applied torque between output shafts to maintain
traction in adverse or performance conditions. The
benefits of installing an LSD are:
1. Enhanced traction in snow, gravel, and sand.
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27 - Driveline
24 - Differential
00 - General
2. More predictable handling at the limits of grip. Technical Data

This type behaves as an open differential unless one
wheel begins to spin and exceeds that threshold. Technical data may differ between axle variants and
The LSD will remain open unless enough torque is installations. For full data relating to specific axles
applied to cause one wheel to lose traction and spin, refer to the applicable machine Service Manual.
at which point it will engage.
An LSD can use clutches when engaged, or may

also be a solid mechanical connection like a locker
or spool. It is called limited slip because it does just
that; it limits the amount that one wheel can slip.
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27 - Driveline
24 - Differential
00 - General
For: 55 Series (3 Piece Axle), Front, Limited

Slip Differential (LSD) .............. Page 27-321
For: Front, Max-Trac ............... Page 27-322
For: Front, Limited Slip Differential (LSD)
................................................. Page 27-323
For: 55 Series (1 Piece Axle), Front, Limited
Slip Differential (LSD) .............. Page 27-324
................................................. Page 27-325
(For: 55 Series (3 Piece Axle), Front, Limited Slip Differential (LSD))
Figure 821. Limited Slip Differential (LSD)
E
F
H
J
K
N P
A M
G K
C J
H
G
A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates
L Side gears M Trunnion pins
N Bevel gears P Thrust washers
27 - 321 9823/1700-1 27 - 321

27 - Driveline
24 - Differential
00 - General
(For: Front, Max-Trac)

Figure 822. JCB Maxtrac Differential
E C
B
D
A Capscrews
B Side gears
C Thrust washers
D Bevel gears
E Spherical washers
F Differential bearing cones
27 - 322 9823/1700-1 27 - 322

27 - Driveline
24 - Differential
00 - General
(For: Front, Limited Slip Differential (LSD))
Figure 823.
AA
R M
N
L
H
T
G1 Q S
S Q
T
K
G2
J X
AE
AB
C
AD
AC
D1
F C
E
Y
Z
W
F
U
AA A B D2
A Bolt 1 B Drivehead carrier

C Roll pin D1 Castellated nut 1
D2 Castellated nut 2 E Bearing cup
F Bearing cone G1 Differential case half
G2 Differential case half H Verbus-ripp bolt
J Crownwheel K Bolt 2
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27 - Driveline
24 - Differential
00 - General
L Trunnion pin M Planet gear

N Thrust washer P Side gear
Q Shim 1 R Counter plate
S Friction plate T Pressure plate
U Stake nut V Washer
W Drive flange X Pinion
Y Collapsible spacer Z Oil seal
AA Pinion tail bearing AB Pinion head bearing cone
AC Pinion head bearing cap AD Shim 2
AE Bush
(For: 55 Series (1 Piece Axle), Front, Limited Slip Differential (LSD))
Figure 824.
E
F
H
J
K
N P
A M
G K
C J
H
G

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27 - Driveline
24 - Differential
00 - General
(For: Front, Limited Slip Differential (LSD))
Figure 825.
E
F
H
J
K
N P
A M
G K
C J
H
G

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27 - Driveline
24 - Differential
00 - General
Check (Condition)
1. For JCB axles only: measure and note the
thickness of the friction plates, the result must not
be less than the specified dimension.
Dimension: 1.25 mm
2. Check the condition of the friction material, which
should be even over both surfaces. If in doubt,
discard the set (friction and counter plates).
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27 - Driveline
24 - Differential
00 - General
For: Front, Limited Slip Differential (LSD) 2. Remove the crownwheel.

................................................. Page 27-327
For: Front, Max-Trac ............... Page 27-330 3. Put marks on the two halves of the differential
housing before disassembly to make sure of
For: 55 Series (1 Piece Axle), 55 Series (3 correct assembly.
Piece Axle), Front, Limited Slip Differential
(LSD) ....................................... Page 27-331 4. Remove the capscrews.
................................................. Page 27-334 5. Disengage the two halves of the differential and
remove the following components:
(For: Front, Limited Slip Differential (LSD)) 5.1. Trunnion pins.
The numerical sequence shown on the illustration is 5.2. Side gears.
intended as a guide for disassembly.
5.3. Bevel gears.
The number of friction and counter plates shown in 5.4. Spherical washers.
the illustration is typical only. The actual number of
plates is determined by the axle variant. 5.5. Pressure plates.
5.6. Counter plates.
Important: The crownwheel and pinion are matched
and should be replaced as a pair if either one is 5.7. Friction plates.
damaged or excessively worn. The two halves of 5.8. Shims.
the differential housing are also matched as are the
differential side gears and bevel gears, do not use 6. Make a note of the relative positions of the
unmatched halves or gears. friction plates, counter plates and spacers before
disassembly, they must be installed in the same
Disassemble positions.
1. Use a heavy duty socket to remove the verbus-

ripp bolts. Discard the bolts.
27 - 327 9823/1700-1 27 - 327

27 - Driveline
24 - Differential
00 - General
E
F
H
J
K
N P
A M
G K
C J
H
G

Assemble 1.6. Thrust washers.
1. Install the following components into the 2. Do not install the shims at this stage.
crownwheel half of the differential assembly:
3. Align the two halves of the differential assembly
1.1. Trunnion pins. with the bolts. Make sure that the marks made
during disassembly are aligned.
1.2. Side gears with pressure plates.
4. Use a DTI (Dial Test Indicator) (or feeler gauges),
with two screwdrivers or suitable levers, gently
1.4. Friction plates. apply pressure to prise the side gear away from
the trunnion pins.
1.5. Bevel gears.
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27 - Driveline
24 - Differential
00 - General
Figure 827.
5. Measure and record the end float of the side assembled differential as this is only an
gear. initial setting figure which allows for bedding
in.
6. Turn the differential assembly over and repeat
steps 4 and 5 for the second side gear. 8.2. Select the minimum number of shims to
give the correct thickness.
7. Disassemble the differential assembly.
9. Do the steps 4 to 6 again.
8. Add shims to give an end float between the
specified range. 10. If the end float is correct, tighten the bolts to the
11. Install the crownwheel with new verbus-ripp
8.1. Shimming must be carried out whenever bolts.
the differential is dismantled, however, the
end float 0.1 and 0.2 mm (0.004 and 12. Tighten the verbus-ripp bolts to the correct torque
0.008 in) can be exceeded on previously value.

Item Nm
A
(1)
94
A
(2)
200
C 56
(1) The torque value is applicable for the 40 Series drivehead.
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00 - General
(For: Front, Max-Trac) Figure 828.

Consumables
JCB Threadlocker 4101/0250 0.01 L A
Strength)
The crownwheel and pinion are matched and should

F
be replaced as a pair if either one is damaged or
excessively worn.
The two halves of the differential housing are also

matched as are the differential side gears and bevel
gears. Do not use unmatched halves or gears. C
E
If it is necessary to install a new crownwheel to the B
differential unit, then install it and torque tighten the
crownwheel retaining bolts to the specified torque D
value. 94 N·m
Disassembly
1. Before you disassemble match-mark the two
halves of the differential housing for the correct
assembly.
A Capscrews
2. Remove the capscrews. B Side gears
C Thrust washers
3. Disengage the two halves of the differential D Bevel gears
housing. E Spherical washers
F Differential bearing cones
4. Remove the side gears, thrust washers, bevel
gears and spherical washers.
Assembly
5. Remove the differential bearing cones.
1. Assemble the side gears, thrust washers,
bevel gears and spherical washers into the
crownwheel half of the differential housing.
2. Position the top half housing onto the differential.
2.1. Make sure that they are aligned with
the match mark made at the time of
disassembly.
2.2. Apply sealant to the threads of capscrews
and install them.
(Medium Strength)
2.3. Tighten the capscrews to the correct torque
value.
3. Check the gears for free rotation.
4. Install the differential bearing cones.

Item Description Nm
A Capscrews 46
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24 - Differential
00 - General
(For: 55 Series (1 Piece Axle), 55 Series (3 3. Put marks on the two halves of the differential
Piece Axle), Front, Limited Slip Differential housing before disassembly to make sure of
correct assembly.
(LSD))
4. Remove the capscrews.
The numerical sequence shown on the illustration is
intended as a guide for disassembly. 5. Disengage the two halves of the differential and
remove the following components:
The number of friction and counter plates shown in
the illustration is typical only. The actual number of 5.1. Trunnion pins.
plates is determined by the axle variant. 5.2. Side gears.
Important: The crownwheel and pinion are matched 5.3. Bevel gears.
and should be renewed as a pair if either one is
5.4. Spherical washers.
damaged or excessively worn. The two halves of
the differential housing are also matched as are the 5.5. Pressure plates.
differential side gears and bevel gears, do not use
unmatched halves or gears. 5.6. Counter plates.
5.7. Friction plates.
Disassemble 5.8. Shims.
1. Use a heavy duty socket to remove the verbus- 6. Make a note of the relative positions of the
ripp bolts. Discard the bolts. friction plates, counter plates and spacers before
disassembly, they must be installed in the same
2. Remove the crownwheel.
positions.
E
F
H
J
K
N P
A M
G K
C J
H
G

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Assembly 1.6. Thrust washers.
1. Install the following components into the 2. Do not install the shims at this stage.
crownwheel half of the differential assembly:
3. Align the two halves of the differential assembly
1.1. Trunnion pins. with the bolts. Make sure that the marks made
during disassembly are aligned.
4. Use a DTI (or feeler gauges), with two
screwdrivers or suitable levers, gently apply
1.4. Friction plates. pressure to prise the side gear away from the
trunnion pins.
1.5. Bevel gears.
Figure 830.
5. Measure and record the end float of the side assembled differential as this is only an
gear. initial setting figure which allows for bedding
in.
6. Turn the differential assembly over and repeat
steps 4 and 5 for the second side gear. 8.2. Select the minimum number of shims to
give the correct thickness.
specified range. 10. If the end float is correct, tighten bolts to the
8.1. Shimming must be carried out whenever bolts.
the differential is dismantled, however, the
end float 0.1 and 0.2 mm (0.004 and 12. Tighten the verbus-ripp bolts to the correct torque
0.008 in) can be exceeded on previously value.
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00 - General

Item Nm
1
(1)
94
1
(2)
200
3 56
(For: Front, Limited Slip Differential (LSD)) 8. Remove the roll pins and then remove the
castellated nuts.
Special Tools
Description Part No. Qty. 9. Remove and discard the bearing cups.
Bearing Press 892/00179 1
10. Remove the bearing cones. Discard the
Drive Coupling 892/00812 1 bearings.
Spanner
Adaptor 992/07608 1 11. Remove the differential assembly from the
Bearing Adaptor 992/07609 1 drivehead when the bearings have been
removed from both sides.
Consumables 12. Use the service tool to remove the drive flange.
13. Remove the pinion and the collapsible spacer.
As the drivehead cannot be disassembled while
installed on the machine, we recommend that the 14. Remove the oil seal and pinion tail bearing.
complete axle is removed.
15. Remove the pinion head bearing cone from the
WARNING! A raised and badly supported machine pinion.
surface before raising one end. Ensure the other 16. Remove the pinion head bearing cap along with
end is securely chocked. Do not rely solely on the its shims 2.
machine hydraulics or jacks to support the machine 17. Use a heavy duty socket to remove the verbus-
when working under it. Disconnect the battery, to ripp bolts. Discard the bolts.
beneath it. 18. Remove the bolt 2.
Disassemble 19. Put marks on the two halves of the differential

housing before disassembly to make sure of
1. Drain the oil from the axle hubs. correct assembly.
2. Remove the following components from both the 20. Remove the capscrews.
hubs:
21. Disengage the two halves of the differential and
2.1. Planet gear carrier. remove the following components:
2.2. Brake pressure plate. 21.1. Trunnion pins.
2.3. Brake friction plates. 21.2. Side gears.
2.4. Brake counter plates. 21.3. Planet gears.
3. Remove the driveshaft. 21.4. Thrust washers.
4. Remove the propshaft. 21.5. Pressure plates.

5. Drain the oil from the differential casing.
6. Remove the bolts 1.
21.8. Shims.
7. Lift the drivehead carrier from the casing.
22. Inspect the condition and security of the bushes.
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22.1. Note: Later type differential assemblies the differential case halves are machined
are not installed with the bushes, instead, so that they support the driveshafts.
Figure 831.
AA
R M
N
L
H
T
G1 Q S
S Q
T
K
G2
J X
AE
AB
C
AD
AC
D1
F C
E
Y
Z
W
F
U
AA A B D2
A Bolt 1 B Drivehead carrier

C Roll pin D1 Castellated nut 1
D2 Castellated nut 2 E Bearing cup
F Bearing cone G1 Differential case half
G2 Differential case half H Verbus-ripp bolt
J Crownwheel K Bolt 2
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00 - General
L Trunnion pin M Planet gear

N Thrust washer P Side gear
Q Shim 1 R Counter plate
S Friction plate T Pressure plate
U Stake nut V Washer
W Drive flange X Pinion
Y Collapsible spacer Z Oil seal
AA Pinion tail bearing AB Pinion head bearing cone
AC Pinion head bearing cap AD Shim 2
AE Bush
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Assemble 4. Attach the two halves of the differential assembly

with the bolts 2. Make sure the marks made
Make sure all bearings are lightly oiled before during disassembly are aligned.
installation and setting. Make sure that the bearings
are rotated when they are being set. 5. Use a DTI (or feeler gauges), with two
screwdrivers or suitable levers, gently apply
1. Install the following components into the pressure to prise the side gear away from the
crownwheel half of the differential assembly: trunnion pins.
1.1. Trunnion pins. Figure 833.

1.5. Planet gears.
1.6. Thrust washers.
2. The counter plates and friction plates should be
installed alternatively, as shown. However, some
axles which incorporate differential assemblies
containing 9-friction faces require a unique
configuration. Before assembling these parts,
identify the correct configuration for your
machine.
Figure 832.
S R
6. Measure and record the end float of the side

gear.
S 7. Turn the differential assembly over and do the
steps 5 and 6 for the second side gear.
specified range.
9.1. For new plates.
T R Dimension: 0.1 –0.2 mm
9.2. For old plates.
S
11. If the end float is correct, tighten the bolts to the
bolts.
T R
13. Tighten the verbus-ripp bolts to the correct torque
R Counter plate value.
S Friction plate
T Pressure plate 14. Measure the pinion depth setting.
3. Do not install the shims 1 at this stage.
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15. Install a new pinion head bearing cone into the 30. Adjust castellated nut 2 until there is no end-float
pinion with suitable press and adaptors. and no pre-load. Make sure that the bearings are
bedded in by rotating in each direction.
Special Tool: Bearing Press (Qty.: 1)
Special Tool: Adaptor (Qty.: 1) 31. Tighten castellated nut 2 by a further 4
Special Tool: Bearing Adaptor (Qty.: 1) castellations to set pre-load. Make sure that the
correct backlash is maintained.
16. Install the new collapsible spacer onto the pinion.
32. Install the roll pins.
17. Apply oil on the pinion head bearing and install
the pinion in the housing. 33. Apply sealant to the mating surfaces of the drive
head carrier and the axle casing.
17.1. Before you install the pinion, make sure
that the pinion matches the crownwheel. Consumable: JCB Multi-Gasket
18. Apply oil on the pinion tail bearing. 34. Install the drivehead carrier to the axle casing
with the crownwheel towards the long driveshaft.
19. Use a suitable drift and tap the tail bearing into
its position in the housing. 35. Install the bolts 1.
20. Put a new oil seal into the housing. 36. Tighten the bolts 1 to the correct torque value.
20.1. Lubricate the seal lips. 37. Assemble the driveshafts and hub assemblies.
21. Install the drive flange with a new stake nut and 38. Fill the hubs and the differential with the correct
washer. grade of oil.
22. Tighten the stake nut into the collapsible spacer 39. Install the propshaft.
until the end float is almost zero, and then
measure the seal drag torque. 40. Fill the hubs and the differential with the correct
grade of oil.
22.1. The seal drag torque should be within the
specified range. Table 335. Torque Values
Torque: 0.4 –0.75 N·m Item Description Nm
A Bolt 1 56
23. Continue to tighten the stake nut to collapse the
spacer to get a rolling torque of the specified K Bolt 2 56
range. H Verbus-ripp bolt 94
23.1. Rotate the flange in each direction to bed
in the bearings before measuring.
23.2. Note: If the specified rolling torque is
exceeded, the collapsible spacer will be
distorted. Replace the spacer and start
again.
24. Stake the nut when the pre-load is correct.
25. Install the differential assembly (without the
bearings) into the drivehead.
26. Install the bearing cones onto the spigots.
27. Apply oil on the bearings and install the bearing
cups and the castellated nuts.
28. Do not install the roll pins at this stage.
29. Adjust castellated nut 1 on the crownwheel side
until you get a backlash value within the specified
range.
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27 - Hub
Contents Page No.
27-27-00 General ......................................................................................................................... 27-341

27-27-60 Swivel ........................................................................................................................... 27-353
27-27-66 Wheel Stud ................................................................................................................... 27-354
27 - 339 9823/1700-1 27 - 339

Notes:
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00 - General
Introduction .................................................. 27-341 The hub is the part of the axle where the wheel
Technical Data ............................................. 27-342 is mounted and where the axle shaft (if installed)
Component Identification ............................. 27-343 passes through.
Calibrate ...................................................... 27-345
Some hubs are not driven and rotate due to motion
Disassemble and Assemble ........................ 27-346 of the machine and some driven hubs may also have
reduction gearing installed.
The hub may also be designed to allow steering of

the wheels and/or incorporate brakes.
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00 - General
Technical Data
Technical data may differ between axle variants and

installations. For full data relating to specific axles
refer to the applicable machine Service Manual.
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Unit Identification Main Component Identification

The axle serial number is stamped on the unit Figure 836.
identification plate as shown. When you make an
order for parts replacement, always give the details
G H
of gear replacements, always check the part number
Figure 834. A
A J
K
D
Figure 835. L
E
F M
Table 336.
Item no Description
A Annulus ring
B Planet gear assembly
(x3)
C Thrust pad
D Sun gear
A Identification plate E Planet gear carrier
F Wheel stud (x5)
G Bearing carrier
H Hub swivel
J Driveshaft
K Oil seal
L Wheel bearing (inner)
M Wheel bearing (outer)
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00 - General
Sectional Drawing
Figure 837.
13 10 7 11 5 3 4 57 1
12
14
8 18
16
15
17
20
19
23
26 9 22 24 25
Item no Description
Table 337. 17 Thrust pad
Item no Description 18 Driveshaft
1 Swivel hub 19 Sun gear
3 Bearing (taper roller) 20 Circlip (external)
4 Oil seal 22 O-ring
5 Bearing carrier 23 Drain plug
7 Annulus carrier 24 Bearing
8 Dowels 25 Oil seal
9 Bolt Verbus-ripp 26 Spacer (55 Series hub
only)
10 Annulus ring
57 Cover plate
11 Circlip (internal)
12 Planet gear
13 Planetary hub carrier
14 Bearing
15 Circlip (L-shaped)
16 Circlip (external)
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00 - General
Calibrate
Refer to the relevant Disassemble and Assemble

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00 - General

Description Part No. Qty. F
Heavy Duty Socket 892/00333 1
19mm A/F x 3/4 in D
Drive G
Wheel Hub Service Kit 892/01092 1 B
Reaction Plate M14 998/M1374 4
Studs
Reaction Plate 998/M1375 1
Disassemble
WARNING A raised and badly supported
machine can fall on you. Position the machine
on a firm, level surface before raising one end.
Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks B Planet gear carrier
to support the machine when working under it. D Planet gear
Disconnect the battery, to prevent the machine G Driveshaft thrust pad
being started while you are beneath it. F External circlip 1
5.1. Remove the external circlip 1.
The illustrations in this procedure show the axle
removed from the machine but the hubs can be 5.2. Remove the planet gear.
disassembled without removing the axle. Refer to 5.3. The driveshaft thrust pad is drilled and
Figure 844. tapped for removal purposes. Use a
suitable M6 screw to extract the thrust pad
1. Drain the oil from the hub. from inside the planet gear carrier.
2. Remove the screws. 6. Remove the external circlip 2.
3. Remove the planet gear carrier from the bearing 7. Remove the sun gear from the driveshaft.
carrier.
8. To remove the verbus-ripp bolts it is necessary
4. Remove and discard the O-ring. to remove the spacer (if installed). Rotate the
spacer with a suitable drift to align the holes in
5. Remove the planet gears only if they are the spacer with the space between the bolts.
damaged. Note: Planet gears can only be
replaced as an assembly which contains the 9. Use two dowels and two heel bars to remove the
gear, bearing, and two L-shaped circlips. Refer spacer as shown. Refer to Figure 839.
to Figure 838. and Refer to Figure 843.
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Figure 839. 11.2. Install the four M14 studs and nuts on
the annulus carrier. Some annulus carriers
J have two tapped holes for use with jacking
K screws. Use two high grade M14 bolts
as jacking screws to remove the annulus
carrier.
Special Tool: Reaction Plate (Qty.: 1)
Special Tool: Reaction Plate M14 Studs
(Qty.: 4)
11.3. Engage the reaction plate.
AF 11.4. Adjust the studs to maintain a clearance
between the reaction plate and the
H driveshaft.
11.5. Install a three leg puller. Engage the puller
legs through the holes in the annulus
carrier.
H External circlip 2 11.6. Use the puller to remove the annulus

J Spacer carrier along with the annulus ring from the
K Verbus-ripp bolt axle stub shaft.
AF Sun gear 11.7. Make sure that the dowels remain either
in the annulus carrier or in the stub shaft.
10. Remove the verbus-ripp bolts with a heavy duty Note: It is normal for fretting to occur on
socket. the mating surfaces between the axle stub
Special Tool: Heavy Duty Socket 19mm A/F x 3/4 shaft and annulus carrier. Do not attempt
in Drive (Qty.: 1) to repair it.
10.1. Note: the verbus-ripp bolts are very tight 12. Remove the internal circlip to separate the
and care must be taken not to distort the annulus ring from the annulus carrier.
bolt heads. Use an extension bar as short
as possible. Discard the verbus-ripp bolts 13. Remove the outer wheel bearing and the bearing
after removal. carrier as follows:
11. Remove the annulus carrier along with the 13.1. Attach the legs of the bearing puller
annulus ring as follows: Refer to Figure 840. onto two diametrically opposite wheel
studs and put the reaction tube over the
Figure 840. driveshaft. Refer to Figure 841.
Special Tool: Wheel Hub Service Kit (Qty.:
1)
AG 13.2. The reaction tube must be used otherwise
damage to the driveshaft and driveshaft
bearings will occur.
AJ
13.3. On five wheel stud axles, the modified
wheel studs from the Wheel Hub Service
Kit must be used. Bolt to two diametrically
opposite holes provided on the bearing
carrier.
13.4. Slowly turn the screw until the bearing
AH carrier and the outer wheel bearing are
released from the axle stub shaft.
AG M14 studs and nuts 13.5. If the wheel hub starts to rotate use a
AH Reaction plate suitable bar to prevent further rotation.
AJ 3 Leg puller
13.6. If the screw becomes hard to turn, tap the
11.1. Put marks on the stub shaft and annulus back of the bearing carrier with a soft faced
carrier to identify their relative angular mallet to help release the bearing.
position during installation.
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00 - General
Figure 841. 15. Remove the inner wheel bearing as follows:

W Y
Figure 843.
X
Q
Q Bearing carrier W
W Reaction tube
X Screw
Y Bar
W Reaction tube
14. Remove and discard the outer part of the X Screw
combination oil seal by cutting the outer seal with
a sharp chisel. Take care not to damage the seal 15.1. Clamp the plates around the inner wheel
seat on the axle stub shaft. Refer to Figure 842. bearing.
Figure 842. 15.2. Attach the puller rods and put the reaction
tube over the driveshaft.
15.3. The reaction tube must be used otherwise
damage to the driveshaft and driveshaft
bearings will occur.
Z
15.4. Slowly turn the screw until the inner wheel
bearing is released from the axle stub
shaft.
15.5. Remove and discard the inner part of the
combination oil seal.
16. If installed do not remove the dirt shield.
T Combination oil seal

Z Chisel
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27 - Hub
00 - General
Figure 844.
F
D
V
E P
V
C N
L
B
J K
AF
G T
R U
S
A
A Screw B Planet gear carrier

C O-ring D Planer gear
E Bearing F External circlip 1
G Driveshaft thrust pad H External circlip 2
J Spacer K Verbus-ripp bolt
L Annulus carrier M Annulus ring
N Internal circlip P Dowel
Q Bearing carrier R Outer wheel bearing
S Inner wheel bearing T Combination oil seal
U Dirt shield (If installed) V L-shaped circlip
AF Sun gear
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Assemble Figure 847.
1. Install the outer wheel bearing cup into the AA

bearing carrier.
2. Install the inner wheel bearing cup and cone into
the bearing carrier.
3. Use the seal dolly 892/00891 from the Wheel
Hub Service Kit to install a new combination oil
seal. The seal dolly has two sides 'A' and 'B' B
marked for identification. Do not lubricate the
seal before installation. Refer to Figure 845.
Figure 845. Q
AA
A
Q Bearing carrier
AA Seal dolly
5. Install the seal on the dolly.
B
6. Use a soft-faced mallet to drive the seal squarely
AA Seal dolly into the bearing carrier until the dolly flange is up
against the carrier. Refer to Figure 848.
4. Make sure you use the correct side of the seal
dolly as follows: Figure 848.
4.1. For axles with a steel dirt shield use side 'A'
of the seal dolly. Refer to Figure 846.
Figure 846. AA
AA U
A
Q Bearing carrier
AA Seal dolly
7. Attach the bearing press extension shaft onto the
Q
end of the axle stub with four verbus-ripp bolts.
Figure 849.
Q Bearing carrier
U Dirt shield
AA Seal dolly
4.2. For axles without a steel dirt shield use side
'B' of the seal dolly. Refer to Figure 847.
K Verbus-ripp bolts
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8. Lightly apply oil on the inner wheel bearing cone. 22. Install the new verbus-ripp bolts.
9. Position the bearing carrier (complete with inner 23. Do not tighten the verbus-ripp bolts at this stage.
bearing) onto the axle stub over the extension
shaft. 24. Measure the seal drag rolling force:
10. Assemble the bearing press as shown. Refer to Figure 851.

Figure 850.
Figure 850.
BB
R AC BA
AD
AB BA Cord
BB Spring balance
R Outer wheel bearing 24.1. Install the planet gear carrier.

AB Handle 24.2. Do not install the sun gear.
AC Thrust washers (x2)
AD Reaction tube 24.3. Wrap a cord around the planet gear carrier
flange and attach a spring balance to it as
11. Slide the reaction tube over the extension shaft shown. Refer to Figure 851.
(the wide opening towards the bearing).
24.4. Pull the spring balance so that the hub
12. Make sure that the bearing and bearing carrier rotates, do this several times to let the seal
are properly positioned against the axle stub. bed in and record the reading.
24.5. Remove the planet gear carrier.
13. Attach the handle and make sure that the
thrust bearing is installed between the two thrust 25. Tighten the verbus-ripp bolts to the correct torque
washers. value.
14. Slowly turn the handle to press the inner wheel 26. Measure the rolling force:
bearing correctly into position, then remove the
handle and reaction tube. 26.1. Install the planet gear carrier.
15. Install the outer wheel bearing cone into the 26.2. Do not install the sun gear.
bearing carrier. 26.3. Wrap a cord around the planet gear carrier
flange and attach a spring balance to it as
16. Assemble the reaction tube and handle onto the
shown.
extension shaft.
26.4. Pull the spring balance so that the hub
17. Slowly turn the handle to press the outer bearing rotates and record the reading.
correctly into position until the free play is
removed. 26.5. To calculate the rolling force, subtract
the seal drag force (24.4) from the value
18. Remove the handle and reaction tube. obtained in the step 26.4.
19. Assemble the annulus ring onto the annulus 26.6. The rolling force should be within the
carrier and then install the internal clip. specified range.
Torque: 2 –22 N·m
20. Make sure that the dowels are correctly installed.
26.7. If the values are outside the limits specified
21. Attach the annulus assembly to the axle stub then check if the seal is installed correctly,
shaft in the same angular position based on the
marks made during installation.
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27 - Driveline
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and/or replace the wheel bearings if 30.1. Note: The sun gear must be installed with
necessary. the 1.5mm x 45° chamfer inboard.
26.8. Remove the planet gear carrier. 31. Install a new O-ring, and then install the planet
gear carrier onto the bearing carrier. Make sure
27. Press the driveshaft thrust pad (chamfered side
that the two tapped holes are in line with those
faces downwards) into the recess in the planet
on the bearing carrier.
gear carrier.
32. Do not strike the centre of the planet gear
28. Install the new planet gears in the position of any
carrier during installation as this may dislodge the
that were removed during disassembly. Refer to
driveshaft thrust pad.
Figure 851.
33. Apply sealant to the threads of the screws. Refer
28.1. Important: Make sure that you install the
to Figure 854.
planet gears in the correct orientation.
Install the large radius end of the bearing Figure 854.
over the pin first. Refer to Figure 852.
Q
Figure 852.
AE
A
A Screw
AE Large radius end 34. Install the screw to attach the planet gear carrier.
28.2. Secure the planet gears with external 35. Tighten the screws to the correct torque value.
circlip 1.
36. Fill the hub with the correct grade oil.
Figure 853.
F Table 338. Torque Values
Item Nm
D
G A 56
B K 320
B Planet gear carrier

D Planet gear
G Driveshaft thrust pad
F External circlip 1
29. Install the spacer (If installed).
30. Install the sun gear onto the driveshaft and
secure with the external circlip 2.
27 - 352 9823/1700-1 27 - 352

27 - Driveline
27 - Hub
60 - Swivel
60 - Swivel 7. Measure the gap at the top trunnion and subtract

1 mm (0.040 in) to give the shim thickness
(bearing pre-load). Refer to Figure 856.
Remove and Install
Figure 856. Measuring the top trunnion gap
(For: 55-Series)
Consumables
Strength)
Calibrate
Previous axles had a shim installed under the top
trunnion. The shim controls the bearing pre-load.
When you assemble, select the correct thickness

shim and check the bearing pre-load as follows:
1. Locate the hub swivel and install the bottom

trunnion. 8. Remove the top trunnion and install the correct
shim.
2. Apply JCB Threadlocker to the bottom trunnion
bolts. 9. Install the top trunnion.
Consumable: JCB Threadlocker and Sealer 10. Apply JCB Threadlocker to the top trunnion bolts.
(Medium Strength)
3. Tighten the bolts to the specified torque value. (Medium Strength)
Torque: 98 N·m 11. Tighten the bolts to the specified torque value.
4. Install the top trunnion and finger tighten the top Torque: 98 N·m
trunnion bolts.
12. Check that the spring balance reading which
5. Attach a spring balance to the track rod swivel should be 4.5 kgf (10lbf) more than the reading
and note the reading. Refer to Figure 855. mentioned in the step 5.
Figure 855. Measuring the swivel turning force Table 339. Example of
shim thickness calculation
Gap 1.55 mm
Subtract 1 mm
Shim Thickness 0.55 mm
6. Tighten the top trunnion bolts to stop end float

but not the bearing pre-load, so that there is no
increase in the spring balance reading.
27 - 353 9823/1700-1 27 - 353

27 - Driveline
27 - Hub
66 - Wheel Stud
66 - Wheel Stud Figure 858.

B
Remove and Install
This remove and install procedure is the same for all

wheel studs.
WARNING! If, for whatever reason, a wheel stud

is renewed, all the studs for that wheel must be
changed as a set, since the remaining studs may A
have been damaged.
Remove
C
A Wheel stud
2. Follow the general health and safety procedures. B Wheel stud hole
Refer to (PIL 01-03). C Hub carrier
3. Remove the wheel from the hub. Refer to (PIL 2. Use a nut and washer to pull the stud into the hub
27-29). carrier.
4. Push out the wheel stud. 3. Check the stud and make sure that it is installed
correctly.
Figure 857.
A 4. If the stud is loose replace the whole hub carrier
assembly.
A
A Wheel stud
5. Remove and discard all the wheel studs.
Check the condition of the wheel stud holes in the

hub carrier. If the holes are defective do not use the
hub carrier. Replace the hub carrier with a new one.
Install
1. Install the stud into the hub carrier hole.
27 - 354 9823/1700-1 27 - 354

27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ......................................................................................................................... 27-357

27-29-15 Wheel Nuts ................................................................................................................... 27-361
27 - 355 9823/1700-1 27 - 355

Notes:
27 - 356 9823/1700-1 27 - 356

27 - Driveline
29 - Wheel
00 - General
Introduction .................................................. 27-357 On new machines, and whenever a wheel has been
Health and Safety ........................................ 27-358 removed, check the wheel nut torques every two
Remove and Install ..................................... 27-358 hours until they stay correct. Every day, before
starting work, check that the wheel nuts are tight.
Tighten the wheel nuts (in a diagonal sequence) to
the correct torque value, refer to Technical Data.
27 - 357 9823/1700-1 27 - 357

27 - Driveline
29 - Wheel
00 - General
Health and Safety Remove and Install

WARNING If, for whatever reason, a wheel stud For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42
is renewed, all the studs for that wheel must be [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3],
changed as a set, since the remaining studs may Front ........................................ Page 27-358
have been damaged. For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42
WARNING Wheels and tyres are heavy. Take [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3],
care when lifting or moving them. Store with care Rear ........................................ Page 27-359
to ensure that they cannot fall and cause injury.
Use suitable lifting equipment if necessary. (For: 506-36 [T2/T3], 507-42 [T2/T3],
WARNING An exploding tyre can kill. Inflated 509-42 [T2/T3], 510-56 [T2/T3], 512-56
tyres can explode if over-heated or over-inflated. [T2/T3], Front)
Follow the instructions given when inflating the WARNING Whenever a wheel has been
tyres. Do not cut or weld the rims. Use a tyre/ changed, check the nut torques every two hours.
wheel specialist for all repair work. When the nuts stay tight for 8 h, the interval for
WARNING Deflate the tyre you wish to change checking can revert to the period stated in the
before removing the wheel from the machine. servicing schedule.
Air pressure in the tyres can cause the tyre and WARNING Run flat inserts are installed in the
rim sections to explode causing serious injury or rear wheels. These must remain installed to the
death. Never loosen the nuts that hold the inner rear wheels to ensure machine stability is not
and outer wheel halves together when there is air compromised in the event of a deflated tyre.
pressure in the tyre. Always wear safety glasses.
WARNING Wheels installed with semi-solid tyres
are heavy. Removing and installing them requires Remove (One Wheel)
special equipment and training. Have the work
carried out by your JCB dealer or a tyre specialist.
WARNING Do not install pneumatic tyres on a
wheel made for a solid tyre. Do not install a solid 2. Put chocks 1 under the rear wheels.
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for 3. Loosen the wheel nuts (x5) by half a turn.
your machine, contact your local JCB dealer or a
trained specialist. 4. Put a jack under the axle arm. Use the correct
jack.
DANGER Run flat inserts may be installed in the
rear wheels. These must remain installed to the 5. Use the jack to lift the machine until the front
rear wheels to ensure machine stability is not wheel is off the ground.
compromised in the event of a deflated tyre.
6. Put chocks 2 under the axle arm.
Make sure that all tyres are inflated to the correct
pressure and have run flat inserts as required. 7. Hold the wheel and remove the wheel nuts.
Where run flat inserts have been specified for use,
8. Remove the wheel.
ensure that replacement wheels also have run flat
inserts to ensure the machine stability.
27 - 358 9823/1700-1 27 - 358

27 - Driveline
29 - Wheel
00 - General
Figure 859. WARNING Run flat inserts are installed in the

rear wheels. These must remain installed to the
rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre.
Remove (One wheel)

2. Put chocks 1 under the rear wheels.
3. Loosen the wheel nuts (x5) by half a turn.
A
4. Put a jack under the axle arm. Use the correct
jack.
E 5. Use the jack to lift the machine until the front
C wheel is off the ground.
D 6. Put chocks 2 under the axle arm.
7. Hold the wheel and remove the wheel nuts.
B 8. Remove the wheel.

A Chocks 1 Figure 860.
B Wheel nuts
C Jack
D Front wheel E
E Chocks 2
E
Install
steps.
C
2. Make sure that the mating surfaces of the wheel
and axle hub are clean. D
3. Tighten the wheel nuts to the correct torque

value.

A
Item Torque value
B
(1)
650 N·m B
680 N·m A Chocks 1
B
(2)
B Wheel nuts
(1) 550-80 machines C Jack
(2) Other machines D Front wheel
E Chocks 2
(For: 506-36 [T2/T3], 507-42 [T2/T3],
509-42 [T2/T3], 510-56 [T2/T3], 512-56 Install
[T2/T3], Rear) 1. The installation procedure is the opposite of the
WARNING Whenever a wheel has been removal procedure. Additionally do the following
changed, check the nut torques every two hours. steps.
When the nuts stay tight for 8 h, the interval for
checking can revert to the period stated in the 2. Make sure that the mating surfaces of the wheel
servicing schedule. and axle hub are clean.
27 - 359 9823/1700-1 27 - 359

27 - Driveline
29 - Wheel
00 - General
3. Tighten the wheel nuts to the correct torque

value.

Item Nm
B 680
27 - 360 9823/1700-1 27 - 360

27 - Driveline
29 - Wheel
15 - Wheel Nuts
15 - Wheel Nuts
27 - 361 9823/1700-1 27 - 361

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-363
27 - 362 9823/1700-1 27 - 362

27 - Driveline
33 - Tyre
00 - General
Introduction .................................................. 27-363 Tyres provide a flexible cushion that absorb shocks,
Health and Safety ........................................ 27-364 while keeping the wheel in close contact with the
Check (Condition) ........................................ 27-364 ground.
Tyre materials are usually synthetic rubber, natural

rubber, fabric and wire, along with other compound
chemicals. They consist of a tread and a body.
The tread provides traction while the body ensures
support.
Make sure that the tyres are kept in good condition.
27 - 363 9823/1700-1 27 - 363

27 - Driveline
33 - Tyre
00 - General

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

make sure it is correctly installed on the machine
or installed in a tyre inflation cage.
27 - 364 9823/1700-1 27 - 364

27 - Driveline
33 - Tyre
00 - General
Figure 861.
2. Prepare the equipment.

2.1. Use only an air supply system which
includes a pressure regulator. Set the
regulator no higher than 1.38 bar (20 psi)
above the recommended tyre pressure.
2.2. Use an air hose fitted with a self-locking air
chuck and remote shut-off valve.
3. Add the air.
3.1. Make sure that the air hose is correctly
connected to the tyre valve. Clear other
people from the area. Stand behind the
tread of the tyre while adding the air.
3.2. Inflate the tyre to the recommended
pressure. Do not over-inflate.
27 - 365 9823/1700-1 27 - 365

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-367
27 - 366 9823/1700-1 27 - 366

27 - Driveline
47 - Propshaft
00 - General
00 - General Lubricate
Lubricate ...................................................... 27-367 There are 4 grease points for lubrication of the
Remove and Install ..................................... 27-368 propshaft. Refer to Figure 862.
Figure 862.
1 3 4
2
27 - 367 9823/1700-1 27 - 367

27 - Driveline
47 - Propshaft
00 - General
Remove and Install

Strength)
Special MPL-EP 4003/1501 0.4 kg
Grease 4003/1506 12.5 kg
4003/1510 50 kg
WARNING Before disconnecting any propshaft,

make sure you block both sides of all wheels B
to prevent machine movement. The park brake
will become ineffective or may only operate on 2
wheels (depending on machine specification). C
Remove
1. Make the machine safe with the lift arm
raised. Refer to (PIL 01-03). Install the lift arm
maintenance strut, refer to (PIL 06-69). A
2. Remove the central access panels. refer to (PIL A Bolts 1
06-06). B Bolts 2
C Strap
3. Put marks on both propshaft companion flanges
and the sliding joints before removal to help 4.2. Remove the nuts and the bolts 1 to
during the replacement procedure. disconnect the propshaft coupling from the
transmission.
4. Machines without RAS (Rear Axle Stabilization):
4.3. Remove the bolts 2 and straps to
4.1. Support the propshaft. disconnect the propshaft form the axles.
5. Machines with RAS:
5.1. Support the auxiliary speed sensor plate.
5.2. Support the propshaft.
5.3. Remove the bolts 1 to disconnect the
propshaft coupling from the transmission.
5.4. Remove the auxiliary speed sensor plates
from behind the park brake disc.
5.5. Remove the bolts 2 and straps to
disconnect the propshaft coupling from the
axle.
Consumable: Special MPL-EP Grease
27 - 368 9823/1700-1 27 - 368

27 - Driveline
47 - Propshaft
00 - General
Figure 864.
F D E
A
A Bolts 1 D Park brake disc

E Propshaft F Auxiliary speed sensor plate
Install 3. Straps must always be replaced with new ones.
Installation is the opposite of the removal procedure. 4. The propshaft must have both ends exactly on
At the time of installation follow the steps below. the same plane as shown below. Refer to Refer
to Figure 865.
1. Lubricate the sliding joints with the specified
4.1. The yokes must not be at right angles or
grease only, then align the shafts against
at an intermediate angle. Refer to Refer to
identification marks previously made or, in
Figure 865.
the case of a shaft being replaced use the
manufacturer's alignment markings.
Consumable: Special MPL-EP Grease
2. Apply sealant to the threads of all the flange
bolts.
(Medium Strength)
27 - 369 9823/1700-1 27 - 369

27 - Driveline
47 - Propshaft
00 - General
Figure 865.
X Same plane (correct)

Y Right angle (not correct)
Z Intermediate angle (not correct)
5. Tighten the bolts 1 and bolts 2 to the correct
torque value.

Item Description Nm
A Bolts 1 137
B Bolts 2 70
27 - 370 9823/1700-1 27 - 370

27 - Driveline
51 - Driveshaft
51 - Driveshaft
Contents Page No.
27-51-00 General ......................................................................................................................... 27-373

27-51-15 Shaft Hub Side ............................................................................................................. 27-376
27 - 371 9823/1700-1 27 - 371

Notes:
27 - 372 9823/1700-1 27 - 372

27 - Driveline
51 - Driveshaft
00 - General
Introduction .................................................. 27-373 The driveshaft is a mechanical component for
Component Identification ............................. 27-374 transmitting torque and rotation, usually used to
connect other components of the driveline that
cannot be connected directly because of distance
or the need to allow for relative movement between
them.
27 - 373 9823/1700-1 27 - 373

27 - Driveline
51 - Driveshaft
00 - General
Figure 866.
1 2 3 4
Item Description
4 Axle arm
Table 343.
5 Driveshaft
Item Description
1 Hub swivel
7 Trunnion (lower)
2 Trunnion (upper)
27 - 374 9823/1700-1 27 - 374

27 - Driveline
51 - Driveshaft
00 - General
Sectional Drawing
Figure 867.
1 2 3 4 5 6 7 8
5 9
Table 344.
Item Description
1 Bearing (needle roller)
2 Circlip (internal)
3 Oil seal
4 Spacer
5 Grease nipple
6 Seal
7 Trunnion
9 Retaining bolt
27 - 375 9823/1700-1 27 - 375

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
15 - Shaft Hub Side
Special Tools 3. Mark the position of the top and bottom trunnions.
Description Part No. Qty. Remove the bolts and remove the trunnions.
Impulse Extractor 892/00224 1 4. Remove the hub swivel.
Bearing Removal Tool 892/00225 1
Adaptor 993/59500 1 5. To easily remove the trunnions, pump grease
through the grease nipple.
Consumables Consumable: Special HP Grease
JCB Threadlocker 4101/0250 0.01 L 6. If it is necessary to replace, remove the top and
and Sealer (Medium bottom trunnion oil seals and bearings.
4101/0251 0.05 L
Strength) 7. Use an adaptor with a slide hammer tool to
Special HP Grease 4003/2020 0.5 kg remove the driveshaft oil seal1 and the needle
4003/2017 0.4 kg roller bearing from the hub swivel.
4003/2006 12.5 kg Special Tool: Impulse Extractor (Qty.: 1)
4003/2005 50 kg Special Tool: Adaptor (Qty.: 1)
8. Remove the driveshaft from the axle.
Disassembly
9. Prise out the driveshaft oil seal 2 from the axle
The hub assembly must be removed before you ram.
attempt to remove the hub swivel and driveshaft.
Refer to the applicable axle hub removal procedure. 10. Use a tool (892/00225) to remove the drive shaft
inner bearing.
1. Disconnect the track rod and steering cylinder
Special Tool: Bearing Removal Tool (Qty.: 1)
from the axle steer knuckles.
11. If there has been a component failure, remove
2. The top and bottom trunnions are the same.
all traces of debris from the axle and clean the
magnetic drain plug.
27 - 376 9823/1700-1 27 - 376

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
Figure 868.
20 Trunnions 21 Trunnion bolts

23 Hub swivel 24 Trunnions seals
25 Bearing 26 Driveshaft
27 Drive shaft seal 28 Needle roller bearing
30 Driveshaft inner oil seal 31 Circlip
32 Driveshaft inner bearing
27 - 377 9823/1700-1 27 - 377

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
Assembly 19. Connect the track rod and steering cylinder to the
axle steer knuckles.
1. Tap the driveshaft inner bearing into the position
in the axle case. Table 345. Torque Values
2. Install a new driveshaft oil seal 2. Apply grease Item Description Nm

between the lips of the seal. 21 Trunnion bolts 98
3. Tap the driveshaft needle roller bearing into the
position in the hub swivel driveshaft bore.
4. Install new driveshaft oil seal 1. Apply grease
between the lips of the seal.
5. Instal the spacer.
6. Install the driveshaft. Carefully locate the end into
the splines of the differential gears.
7. Push the new trunnion oil seals into the position
followed by the bearings.
8. Apply grease on the bearing and the oil seal
before you install them to the axle.
9. In the following step, take care not to damage the
trunnion oil seals when you tighten the trunnion
bolts.
10. Previous axles have a shim installed under the
top trunnion. Where a shim is installed follow the
calibration procedure.
11. Locate the hub swivel and install the top and
bottom trunnions.
12. Apply JCB Threadlocker to threads of trunnion
bolts.
(Medium Strength)
13. First finger tighten all of the bolts then
sequentially tighten them to bring the two
trunnions together.
15. Make sure that the swivel rotates smoothly on its
trunnions.
16. Stiff movement may result if seals have become
displaced and damaged during assembly.
17. Make sure that the grease nipple is clear and not
damaged, replace as necessary.
18. Tighten the nipple to the specified torque value.
Torque: 56 N·m
27 - 378 9823/1700-1 27 - 378

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-03 Smooth Ride System (SRS) .......................................................................................... 30-18
30-00-09 Levelling System ............................................................................................................ 30-19
30-00-12 Load Sense System ....................................................................................................... 30-27
30-00-15 Parallel Open Centre System ........................................................................................ 30-34
30-00-30 Rear Axle Stabilization (RAS) System ........................................................................... 30-38
30-00-36 Interlock System ............................................................................................................. 30-61
30-00-49 Schematic Symbols ........................................................................................................ 30-71
30-00-50 Schematic Circuit ........................................................................................................... 30-75
30-03 Tank
30-03-00 General ......................................................................................................................... 30-101
30-04 Filter
30-04-00 General ......................................................................................................................... 30-105
30-04-03 Main .............................................................................................................................. 30-106
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-108
30-11 Gear Pump
30-11-00 General ......................................................................................................................... 30-111
30-15 Cylinder / Ram
30-15-00 General ......................................................................................................................... 30-121
30-15-06 Lift Arm ......................................................................................................................... 30-130
30-15-07 Lift Extension ................................................................................................................ 30-131
30-15-08 Lift Compensating ........................................................................................................ 30-134
30-15-11 Lift Arm Crowd ............................................................................................................. 30-135
30-15-24 Stabiliser ....................................................................................................................... 30-136
30-15-34 Steering ........................................................................................................................ 30-139
30-15-63 Sway ............................................................................................................................. 30-142
30-15-66 Rear Axle Stabilization (RAS) ...................................................................................... 30-147
30-15-69 Axle Lock ..................................................................................................................... 30-152
30-15-99 Seal Kit ......................................................................................................................... 30-159
30-18 Accumulator
30-18-00 General ......................................................................................................................... 30-163
30-51 Lift Arm Control Valve Block
30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-169
30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-170
30-51-21 Load Sense Relief Valve .............................................................................................. 30-173
30-51-24 Flow Regulator ............................................................................................................. 30-175
30-53 Servo System Control Valve Block
30-53-00 General ......................................................................................................................... 30-179
9823/1700-1
2018-06-28
30-53-27 Pressure Compensator Valve ...................................................................................... 30-197
30-53-36 Load Hold Check Valve ............................................................................................... 30-203
30-54 Parallel Circuit Control Valve Block
30-54-00 General ......................................................................................................................... 30-205
30-60 Directional Control Valve
30-60-00 General ......................................................................................................................... 30-227
30-60-15 Joystick ......................................................................................................................... 30-229
30-60-27 Auxiliary Circuit ............................................................................................................ 30-237
30-60-90 Flow Regulator ............................................................................................................. 30-240
30-61 Counterbalance Valve
30-61-00 General ......................................................................................................................... 30-243
30-61-06 Lift Arm ......................................................................................................................... 30-248
30-63 Hose Burst Check Valve
30-63-00 General ......................................................................................................................... 30-255
30-70 Pilot Pressure Supply Valve
30-70-00 General ......................................................................................................................... 30-259
30-93 Hose
30-93-00 General ......................................................................................................................... 30-265
30-93-03 Lift Arm ......................................................................................................................... 30-268
30-96 Pipe
30-96-03 Lift Arm ......................................................................................................................... 30-279
30-97 Connectors
30-97-03 Quick Release Coupling .............................................................................................. 30-281
30-97-09 Adaptor ......................................................................................................................... 30-283
30-97-24 Push Lock Fitting ......................................................................................................... 30-285
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-286
9823/1700-1
2018-06-28
Acronyms Glossary
ARV Auxiliary Relief Valve

HBCV Hose Burst Check Valve
LED Light Emitting Diode
LHCV Load Hold Check Valve
LMI Load Moment Indicator
LS Load Sense
LSRV Load Sense Relief Valve
MRV Main Relief Valve
QRC Quick Release Coupling
SRS Smooth Ride System
9823/1700-1
2018-06-28
Notes:
9823/1700-1
2018-06-28
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-03 Smooth Ride System (SRS) .......................................................................................... 30-18
30-00-09 Levelling System ............................................................................................................ 30-19
30-00-12 Load Sense System ....................................................................................................... 30-27
30-00-15 Parallel Open Centre System ........................................................................................ 30-34
30-00-30 Rear Axle Stabilization (RAS) System ........................................................................... 30-38
30-00-36 Interlock System ............................................................................................................. 30-61
30-00-49 Schematic Symbols ........................................................................................................ 30-71
30-00-50 Schematic Circuit ........................................................................................................... 30-75
30 - 1 9823/1700-1 30 - 1
Notes:
30 - 2 9823/1700-1 30 - 2
00 - General
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Introduction ...................................................... 30-3 The hydraulic system is a power transmission system
Health and Safety ........................................... 30-4 that uses the force of flowing liquids to transmit power
Technical Data ................................................. 30-5 to specific components in a machine.
Component Identification ................................. 30-7
To help you trace specific hydraulic problems to a
Diagram ........................................................... 30-9 faulty unit (valve, actuator, ram etc.), refer to Fault
Fault-Finding .................................................. 30-10 finding. Refer to: PIL 30-00-00.
Discharge and Pressurise ............................. 30-12
Clean ............................................................. 30-13 Once you have traced the faulty unit, refer to
the relevant section for removal, disassembly and
Check (Level) ................................................ 30-14 checking instructions.
Check (Pressure) .......................................... 30-15
Adjust ............................................................ 30-17 To help identify circuits, valves, rams etc. mentioned
in the fault finding procedures. Refer to the hydraulic
schematic diagrams. Refer to: PIL 30-00-50.
• Before you begin fault finding, read the Health

and Safety Information. Refer to: PIL 30-00-00.
• Make simple checks before you remove or
disassemble a major component.
• Make sure that the hydraulic fluid is at the
correct working temperature 50 °C ( 121.9 °F).
• Whatever the fault, check the condition of the
hydraulic fluid. Drain and replace if necessary.
Refer to Hydraulic fluid quality in this procedure
and Hydraulic System - Clean. Refer to: PIL
30-00-00.
• Make sure you remove ALL contamination and
if possible identify its origin. It may be part of a
component from elsewhere in the circuit.
Hydraulic Fluid Quality

This machine uses a large volume of fluid in the
hydraulic system for power transmission, equipment
lubrication, rust prevention and sealing. According
to a survey conducted by a pump manufacturer,
seventy per cent of the causes of problems in
hydraulic equipment were attributable to inadequate
maintenance of the quality of the hydraulic fluid.
Therefore, it is obvious that control of the quality of
the hydraulic fluid helps prevent hydraulic equipment
problems and greatly improves safety and reliability.
Furthermore from an economic angle it extends the
life of the hydraulic fluid if quality is maintained.
Hydraulic Contamination
Once inside the system, hydraulic circuit
contaminants greatly affect the performance and life
of hydraulic equipment. For example, contaminants
in a hydraulic pump develop internal wear to cause
internal leakage and hence lower discharges. Wear
particles generated will circulate with the hydraulic
fluid to cause further deterioration in the performance
of this and other equipment. Contaminants also
enter principal sliding sections of the equipment
causing temporary malfunction, scuffing, sticking
30 - 3 9823/1700-1 30 - 3
00 - General
00 - General
and leakage and can lead to major problems. The Health and Safety
main contaminants can be classified as follows:
1. Solid Particles - Sand, fibres, metallic particles, Hydraulic Pressure

welding scale, sealing materials and wear Hydraulic fluid at system pressure can injure you.
particles etc. Before connecting or removing any hydraulic hose,
2. Liquid - Usually water and incompatible oils and hose line must be vented. Make sure the hose
greases. service line has been vented before connecting or
removing hoses. Make sure the machine cannot be
3. Gases - Air, sulphur dioxide etc. which can create
started while the hoses are open.
corrosive compounds if dissolved in the fluid.
WARNING! Fine jets of fluid at high pressure can
These contaminants can appear during penetrate the skin. Keep face and hands well clear of
manufacture, assembly and operation. pressurised fluid and wear protective glasses. If fluid
penetrates your skin, get medical help immediately.
WARNING! Take care when disconnecting hydraulic
hoses and fittings as the oil will be hot.
WARNING! Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not use
the machine if a hose or hose fixture is damaged.
Notice: Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component
has been disconnected, always install protective
caps and plugs to prevent dirt ingress. Failure to
follow these instructions will lead to dirt entering the
system. Dirt in the system will seriously damage
the systems components and could be expensive to
repair.
CAUTION! The temperature of the hydraulic oil will
be high soon after stopping the machine. Wait until it
cools before beginning maintenance.
30 - 4 9823/1700-1 30 - 4
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Technical Data Figure 869.
For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42

[T2/T3], 510-56 [T2/T3], 512-56 [T2/T3],
Flowshare System ....................... Page 30-5
For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42
[T2/T3], 510-56 [T2/T3], 512-56 [T2/T3],
Parallel System ........................... Page 30-6
(For: 506-36 [T2/T3], 507-42 [T2/T3],

509-42 [T2/T3], 510-56 [T2/T3], 512-56
[T2/T3], Flowshare System) A
Gear pump D
B
Table 346.
Description Data
Type Gear pump
Mounting Gearbox C
Direction of Rotation Anticlockwise A Boom extend ram head side
Main services pump 29 cc B Carriage tilt ram rod side
(mounting flange end) C LSRV (Load Sense Relief Valve)
Steering pump 19 cc D Carriage tilt ram head side
Cooling fan pump 16 cc
Main services pump 57.4 L/min Table 347. Flowshare Control Valve Block
(mounting flange end) Type 3 spool, LS (Load Sense) pres-
flowrate at 2200 RPM sure compensated, double acting
(Revolutions Per Minute) spools
Steering pump flowrate 37.6 L/min Spool 1 Carriage tilt ser- Pilot operated
at 2200 RPM vice
Cooling fan pump 31.7 L/min Spool 2 Boom extend Pilot operated
flowrate at 2200 RPM and retract ser-
Maximum pressure at 265 ( 3,840.6 ) vice
port EF Spool 3 Lift and lower Pilot operated
Maximum pressure at 200 ( 2,898.5 ) service
port P 260 bar
LSRV
(1)
Maximum Speed 3000 RPM ( 3,768.1 psi)

Minimum Speed 500 RPM (1) Before testing the LSRV pressure, allow the
Weight 33.3 kg hydraulic system to warm upto 50 °C ( 121.9 °F) to
ensure an accurate reading.
Flowshare control valve block
Table 348. ARV Pressures
The details of the flowshare valve block are given
in servo control valve block section. Refer to: PIL Boom extend ram head 200 bar ( 2,898.5 psi) (2)
30-53-00. side
Carriage tilt ram head 240 bar ( 3,478.2 psi)
side
Carriage tilt ram rod side 275 bar ( 3,985.5 psi)
(2) Machines from serial number 1402062 will be set
to 215 bar ( 3,115.9 psi).
Table 349. Pilot Pressure Range

All machines 10 –30 bar ( 144.9 –
434.8 psi)
30 - 5 9823/1700-1 30 - 5
00 - General
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(For: 506-36 [T2/T3], 507-42 [T2/T3], Table 351. Relief Valve Pressures
509-42 [T2/T3], 510-56 [T2/T3], 512-56 LSRV (Mounted within 260 ( 3,768.1 )
[T2/T3], Parallel System) flowshare valve block)
Auxiliary service ARV 140 ( 2,029.0 )
Gear pump (Auxiliary Relief Valve)
Sway service ARV 140 ( 2,029.0 )
Table 350.
5 Section Valves
Description Data
Type Gear pump Figure 871. 5 Section Parallel Valve
Control Block (5 Section, 4 Spool, Par-
Mounting Gearbox
allel Service, Double Acting Spools)
Direction of Rotation Anticlockwise
A
Main services pump 29 cc
(mounting flange end)
Steering pump 19 cc
Cooling fan pump 16 cc
Main services pump 57.4 L/min
flowrate at 2200 RPM
Steering pump flowrate 37.6 L/min
at 2200 RPM
Cooling fan pump 31.7 L/min
flowrate at 2200 RPM
Maximum pressure at 265 ( 3,840.6 )
port EF
B
Maximum pressure at 200 ( 2,898.5 )
port P 1 Spool 1, Auxiliary service, (manually operated)
2 Spool 2, Sway service manually operated
Maximum Speed 3000 RPM
3 Spool 3, Stabiliser, manually operated
Minimum Speed 500 RPM 4 Spool 4, Stabiliser, manually operated
Weight 33.3 kg 5 Section 5, Isolation valve (spools 2, 3 and 4)
Electrical solenoid operation
2 Section Valves
Table 352. Relief Valve Pressures
Figure 870. 2 Section Parallel Valve LSRV (Mounted within 260 ( 3,768.1 )
Control Block (2 Spool, Parallel flowshare valve block)
Service, Double Acting Spools)
Auxiliary service ARV 140 ( 2,029.0 )
A
Sway service ARV 140 ( 2,029.0 )
B
1 Spool 1- Auxiliary service (manually operated)
2 Spool 2- Sway service (manually operated)
30 - 6 9823/1700-1 30 - 6
00 - General
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Figure 872.
B
F
G
H
E
D
C1 C3 C2 A
L P
M Q
N R
Item Description
Table 353. Components C Pump assembly Three section gear
Item Description pump C1, C2, C3
A Control valve block Flowshare valve with C1 Pump1
servo spools C2 Pump 2
B Control valve block Parallel valve with C3 Pump 3
manual spools
30 - 7 9823/1700-1 30 - 7
00 - General
00 - General
Item Description
D Pilot pressure supply Supplies oil at pilot
valve pressure to the servo
control valves
E Hydraulic oil filter Positioned in the ser-
vo pilot valve feed
line
F Servo control valve Two axis control
lever
G Servo control valve Single axis control
lever
H Fan motor Driven by pump sec-
tion C2
J Hydraulic oil filter Positioned in the re-
turn line to tank
K Hydraulic tank
Table 354. Hydraulic Connections Colour Code

Item Description
L Oil from pump section C1
M Oil at pilot pressure
N Oil suction line from the tank to the pump
sections
P Return to tank
Q Oil from pump section C3
R Oil from pump section C2
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00 - General
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Diagram
Hydraulic State Colour Codes

Some diagrams in this section use colours to
represent the different hydraulic system states. Refer
to Figure 873.
Figure 873.
1 2 3 4 5 6 7
1 Lock up
2 Cavitation
3 Exhaust
4 Neutral
5 Servo
6 Pressure
7 Maximum pressure
30 - 9 9823/1700-1 30 - 9
00 - General
00 - General
Fault-Finding
Fault
One service fails, or is slow to operate. Table 355. Page 30-10
The engine tends to stall when hydraulics are under load. Table 356. Page 30-10
Forks creep down Table 357. Page 30-11
Parallel lift faulty Table 358. Page 30-11
Ram creep Table 359. Page 30-11
Table 355. One service fails, or is slow to operate.

Cause Remedy
LLMC (Longitudinal Load Moment Control) Active. Ensure operator fully understand the characteristics
of the LLMC system.
Boom and stabiliser interlocks engaged. Educate the operator. Make sure operator fully
(Construction machines) understands the characteristics of the interlock
system.
Related service pipework or hoses leaking, Check the pipework and hoses. Replace as
damaged, trapped or kinked. necessary.
ARV (Auxiliary Relief Valve) out of adjustment or Check and adjust as necessary.
defective.
Related ram leaking. Carry out ram leakage checks. Renew seals as
necessary.
Related service spool not operating correctly. Manual Spools: Check that the control lever
and related linkage is operating the spool to full
displacement, rectify as necessary.
Servo Operated Spools: Check the condition of
the related harness wiring and the connectors for
damage. Check the solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Renew
the solenoid coil
Servo Operated Spools: Check the condition of
the related harness wiring and the connectors
for damage. Renew the electronic control lever
assembly.
Pressure compensator piston sticking due to Disassemble and inspect the related pressure
contamination. compensator piston.
Service spool or related load hold check valves Disassemble and inspect the related service spool or
damaged or sticking due to contamination. load hold check valves.
Electronic fault Use Servicemaster to find the problem. Refer to
servicemaster, refer to (PIL 33-57).
Counterbalance valve not working correctly. Check operation of the related counterbalance valve.
Counterbalance pressure sensor (lift ram) not Check operation of the lift ram pressure sensor.
working correctly
Table 356. The engine tends to stall when hydraulics are under load.
Cause Remedy
MRV (Main Relief Valve) or LSRV (Load Sense Check and adjust as necessary.
Relief Valve)not adjustable or defective.
Poor engine performance. Check engine performance.
Check engine high and low idle speeds.
Check MRV/LSRV setting and adjust as necessary.
Check ARV setting and adjust as necessary.
Machines with Variflow Pump: Variflow pump fault.
30 - 10 9823/1700-1 30 - 10
00 - General
00 - General
Table 357. Forks creep down

Cause Remedy
Circuit routed incorrectly. Check if any work has been Check the circuit. Re-route the hoses if necessary.
done on the machine recently.
Tilt ram HBCV (Hose Burst Check Valve) leaking, Check for leakage in the tilt ram circuit.
tilt ram seals leaking, control valve spool leaking or
valve block section leaking internally.
Table 358. Parallel lift faulty

Cause Remedy
Displacement/lift link valve broken or leaking. Examine the valve. Check for damages on the ball.
Fit blank to isolate valve from circuit.
Fit latest type valve.
Check pipes, tilt spool, HBCV for missing ball.
Tilt section ARVs set incorrectly, causing oil to leak Check tilt ARV setting. Adjust if necessary.
from tilt/compensating ram circuit.
Tilt section ARVs could be sticking open due to Clean or install new as necessary.
contamination.
Leaking seals in tilt ram or compensation ram. Check tilt/compensation rams for leakage (use hand
pump if available). Install new seals as necessary.
working correctly.
Table 359. Ram creep

Cause Remedy
Associated ram or pipe lines from ram leaking. Check and rectify as necessary.
Check valve. Check operation and rectify as necessary.
working correctly
30 - 11 9823/1700-1 30 - 11
00 - General
00 - General
Discharge and Pressurise side mounted barrel lock and is operated by the
ignition key.
WARNING Depending on your machines
specification, other hydraulic systems will require 7. Make sure that the seal is in good condition and
additional venting. These may include (but not installed correctly in the cap. Replace the seal if
limited to) SRS, refer to (PIL 30-18-00) and power necessary.
brakes, refer to (PIL 24-03-00).
Figure 874. Hydraulic tank filler cap
Refer to (PIL 01-03). A
2. Operate the controls to remove the hydraulic

pressure from the service hose lines.
B
2.1. For manually operated services, operate
the controls several times of the service to
be disconnected.
2.2. For electrical and servo operated services,
make sure the battery is connected and
the battery isolator is set to on. Turn the
ignition key to the on position and operate
the controls several times of the service to
be disconnected.
2.3. For machines installed with a vent switch,
make sure the battery is connected and
the battery isolator is set to on. Turn the
ignition key to the on position and push and
hold the vent switch while you operate the
controls of the service to be vented. Make
sure you operate the controls several times A Filler cap
while the vent switch is set to on. While the B Ignition key
vent switch is on, a buzzer will sound and
the venting symbol will be displayed on the
dash. Refer to Figure 875.
2.4. For machines installed with an auxiliary
hydraulic venting knob- Pull and hold
the knob for the specified time. Some
attachments may require longer. Release
the knob to stop the venting function. (If
installed, auxiliary II will require selection in
order to vent. Make sure all auxiliary circuits
are vented. The specified duration is
Duration: 2 –3 s
3. Make sure that the pressure is vented correctly.
Electrical and pilot services have a limited
amount of accumulated pressure available for
venting.
4. Depending on your machines specification, other
systems will require additional venting such
as SRS (Smooth Ride System), refer to (PIL
30-18-00).
5. Clean the top of the tank around the filler cap.
6. Slowly remove filler cap to allow the system
to vent fully and to prevent the oil from being
forced out of the filler neck. The filler cap has a
30 - 12 9823/1700-1 30 - 12
00 - General
00 - General
Figure 875. Vent switch (If installed) Clean

Special Tools
Hydraulic Flushing Rig 892/01255 1
Cleaning Operation
The purpose of cleaning oil is to remove
contaminants of all types and sludge by filtering
hydraulic fluid through a cleaning unit. Follow the
instructions in the Hydraulic flushing rig instruction
manual.
Procedure
1. Connect the Hydraulic flushing rig in place of the
hydraulic filter.
Special Tool: Hydraulic Flushing Rig (Qty.: 1)
2. Run the system for sufficient time to pump all the
hydraulic fluid through the unit.
3. Disconnect the cleaning unit and reconnect the
filter.
4. Top up the system with clean hydraulic fluid as
required.
1 Position 1- Off
2 Position 2- Vent position, hold switch down Figure 877.
for on position (battery connected, isolator on,
ignition switch set to on, engine off)
Figure 876. Auxiliary Vent Valve (If installed)
A Auxiliary Vent Valve
A Hydraulic flushing rig
Contaminant Standards
Dirt that damages your system is in many cases
too small to be seen with the eye. The particle
size is measured in microns (1 micron = 0.001 mm
(0.0000394 in).
Listed below are a few typical comparisons:
30 - 13 9823/1700-1 30 - 13
00 - General
00 - General
• Red Blood Cell = 8 microns (0.008 mm, Check (Level)

0.000315 in)
• Human Hair = 70 microns (0.07 mm, 0.00275
in) 1. Make the machine safe.
• Grain of Salt = 100 microns (0.1 mm, 0.00394 Refer to: PIL 01-03.
in)
2. Machines may be installed with a sight tube or a
The smallest particle visible to the naked eye is dipstick for hydraulic fluid level display.
40 microns (0.00157) approximately. Standards will
often be quoted to ISO (International Standards Machines with a Sight Tube
Organisation) for which literature can be obtained.
1. Look at the hydraulic fluid in the sight tube. If
the hydraulic fluid is cloudy, water or air is in the
system. Water or air in the system can damage
the hydraulic pump. Refer to Hydraulic System
Clean and Fault Finding.
2. The level of hydraulic fluid should be between the
two marks on the sight tube.
3. If necessary, add the recommended hydraulic
fluid:
3.1. Discharge the pressure from the hydraulic
tank. Refer to (PIL 30-00).
3.2. Get safe access to the hydraulic filler port.
3.3. Use a suitable container to add the
hydraulic fluid through the filler port.
3.4. Check the level of hydraulic fluid.
Machines with a Dipstick

1. Open the rear cover if installed. Refer to (PIL
06-06-14).
2. Discharge the pressure from the hydraulic tank.
3. Get access to the hydraulic dipstick / breather.
Remove the dipstick from the hydraulic tank.
4. If the hydraulic fluid is cloudy, water or air is in the
system. Water or air in the system can damage
the hydraulic pump. Refer to Hydraulic System
Clean and Fault Finding.
5. Check the hydraulic oil level. The level of
hydraulic fluid should be between the two marks
on the dipstick
6. If necessary, add the recommended hydraulic
fluid:
6.1. Get safe access to the hydraulic filler port.
6.2. Use a suitable container to add the
hydraulic fluid through the filler port.
6.3. Check the level of hydraulic fluid.
30 - 14 9823/1700-1 30 - 14
00 - General
00 - General
Check (Pressure) Figure 879.
Checking Pump Flow

B
Check the pump flow. Refer to Hydraulic System-
Gear Pump, refer to (PIL 30-11).
Load Sense Relief Valve (LSRV)

The maximum pressure that the main hydraulic
system can get is set by the LSRV (Load Sense
Relief Valve) at the control valve block inlet section.
Make sure that the temperature of the hydraulic fluid

is 50 °C ( 121.9 °F).
To check the LSRV setting, do the procedure that

follows:
Figure 878.
A
B Main system pressure test point
2. Operate the engine at 1500 RPM (Revolutions
Per Minute).
3. Lower the boom and hold the boom ram in the
fully closed position and check the LSRV setting.
4. Note the maximum reading on the pressure
gauge. Make sure that the maximum pressure
is as per the specified value. Refer to Hydraulic
System- Load Sense System, refer to (PIL
30-00).
5. If the pressure is incorrect, adjust the LSRV.
Refer to Hydraulic system- General- Adjust, refer
to (PIL 30-00).
Auxiliary Relief Valve (ARV's)

1. Do not run the engine at maximum speed. There
will be large increase in the pressure recorded.
A LSRV 2. Make the machine safe with the lift arm lowered.
1. Connect a pressure gauge of the specified value
to the main system pressure point located behind 3. Release the hydraulic pressure. Refer to (PIL
the cab. 30-00).
Pressure: 0 –400 bar ( 0.0 –5,797.1 psi) 4. Follow the general safety precautions for the
hydraulic system. Refer to (PIL 30-00).
5. Connect a pressure gauge of the specified value
to the test point.
Pressure: 0 –400 bar ( 0.0 –5,797.1 psi)
30 - 15 9823/1700-1 30 - 15
00 - General
00 - General
6. Start the engine and bring the hydraulic system Figure 880. 506-36, 507-42,
up to the working temperature of specified value. 509-42 and 510-42 Machines
7. Set the engine to idle RPM.
8. Operate the applicable service to full travel and
hold in position.
9. Check the gauge reading. Make sure that the B
reading is as per the specified value. Refer to
(PIL 30-00).
10. If the pressure is incorrect, adjust the ARV
(Auxiliary Relief Valve). Refer to Hydraulic
system- General- Adjust, refer to (PIL 30-00).
Pilot Pressure
A
Make sure that the temperature of the hydraulic fluid A Pressure test point
is 50 °C ( 121.9 °F). B Regulating valve
1. Connect a pressure gauge of the specified value Figure 881. 510-56, 512-56 and 514-56 Machines
to the pilot pressure test point at the pilot
pressure supply valve.
A
Pressure: 0 –70 bar ( 0.0 –1,014.5 psi) B
2. Operate the engine at 2370 RPM.
3. Make sure that the pilot pressure reading on the
pressure gauge is as specified.
Pressure: 30 bar ( 434.8 psi)
The pilot pressure regulating valve is factory set and

sealed with a plastic tamper proof cap. Servicing is
allowed only for the repair of the solenoid coil. It is
not recommended to dismantle the valve further.
If you think that the valve is faulty, replace with a

new assembly. The pilot circuit accumulator is a A Pressure test point
non serviceable part and is sealed for life. It is not B Regulating valve
possible to recharge the accumulator with nitrogen.
30 - 16 9823/1700-1 30 - 16
00 - General
00 - General
Adjust
Relief Valve
1. If the pressure reading is incorrect when you
check the relief valve, adjust as follows:
1.1. Make the machine safe with the lift arm
lowered. Refer to (PIL 01-03).
1.2. Release the hydraulic pressure. Refer to
Hydraulic System- General- Discharge and
Pressurise, refer to (PIL 30-00).
1.3. Follow the general safety precautions for
the hydraulic system. Refer to (PIL 30-00).
1.4. Remove the plastic cap from the relief
valve.
1.5. Loosen the locknut and turn the adjuster
screw clockwise to increase the pressure
and counter clockwise to decrease the
pressure.
1.6. When the pressure is correct, tighten the
locknut and check the pressure again.
Adjust as required.
30 - 17 9823/1700-1 30 - 17
00 - General
03 - Smooth Ride System (SRS)
03 - Smooth Ride System (SRS)
Discharge and Pressurise
Refer to Hydraulic System, Accumulator, Smooth

Ride System (SRS), (PIL 30-18-06).
30 - 18 9823/1700-1 30 - 18
00 - General
09 - Levelling System
Operation
Table 360. Parallel Lift- Typical Systems

Parallel Lift- System 1 Example of a system with single displacement ram at
the rear of the lift arm pivot
Parallel Lift- System 2 Example of a system with single and twin displace-
ment rams forward of the lift arm pivot
Parallel lift (S1) When the lift arm ram extends or lowers the lift arm,
the displacement ram extends or retracts. The ram
Ram operation displaces oil, then oil flows to the tilt ram which will
extends or retracts and will keep the forks parallel
The following describes a typical system: with the ground.
The parallel lift system operates when the lift arm

extends or lowers.
Figure 882. Single displacement ram at the rear of the lift arm pivot
N P
P
N
N Displacement ram P lift arm ram

Q Tilt ram R Forks
30 - 19 9823/1700-1 30 - 19
00 - General
Lift Arm Raise Cycle This allows oil to feed back to the rod side of the
displacement ram.
When lift spool is selected, the neutral circuit is
blocked and oil feeds to the lift ram hose-burst check- Displacement/ lift link valve is installed between the
valve. Oil flows through free flow direction of HBCV lift spool and the tilt spool. The function of this valve
(Hose Burst Check Valve) and raises the lift arm. is to allow a restricted flow of oil into the tilt circuit to
increase the lift force.
Oil is forced out of the head side of displacement ram
as the lift arm extends. The oil cannot pass the tilt The ARV (Auxiliary Relief Valve) opens to protect
spool, as the spool is not selected. Instead, it flows the tilt ram from over pressurisation. The anti-
to the head side of tilt ram. Oil displaced from the rod cavitation feature of valve makes sure that the tilt and
side of the tilt ram increases pilot pressure in HBCV. displacement rams will not cavitate.
Figure 883.
A
D
B
T
E F
A
C
B
J
L
K
P
M
G
H
C Lift spool D Tilt spool

E ARV 1 F ARV 2
G Lift ram H HBCV 1
J Displacement ram K Tilt ram
L HBCV 2 M Lift link valve
30 - 20 9823/1700-1 30 - 20
00 - General
Lift Arm Lower Cycle spool, as the spool is not selected. Instead, it flows
through free flow direction of HBCV to the rod side
When the lift spool is selected, the neutral circuit is of the tilt ram.
blocked and oil feeds to the rod side of the lift ram. Oil
displaced from the head side of the lift ram increases Displaced oil from the displacement ram closes the
pilot pressure in HBCV and allows oil out of the lift check valve in displacement/ lift link valve.
ram back to tank, thus lower the lift arm.
The ARV opens to protect the tilt ram from over
As the lift arm lowers, oil is forced from the rod side pressurisation. The anti-cavitation feature of valve
of the displacement ram. The oil cannot flow past tilt makes sure that the tilt and displacement rams will
not cavitate.
Figure 884.
A
D
B
T
E F
A
C
B
J
L
K
P
M

E ARV 1 F ARV 2
G Lift ram H HBCV 1
Parallel lift (S2) When the lift arm ram extends or lowers the lift arm,
the displacement ram extends or retracts. The ram
Ram operation displaces oil, then the oil flows to the tilt ram which
will extend or retract and will keep the forks parallel
The following describes a typical system: with the ground.
The parallel lift system operates when the lift arm Machines have a single or twin displacement rams,
extends or lowers. dependent on the machine variant.
30 - 21 9823/1700-1 30 - 21
00 - General
Figure 885. Displacement ram forward of the lift arm pivot
N P
Q
N P
N Lift arm displacement ram P Lift arm ram

Q Tilt ram R Forks
S Lift arm pivot
30 - 22 9823/1700-1 30 - 22
00 - General
Lift arm raise cycle This allows oil to feed back to the rod side of the
displacement ram.
When the lift spool is selected, the neutral circuit is
blocked and oil feeds to the lift ram HBCV. Oil flows A displacement/ lift link valve is installed between the
through free flow direction of HBCV and lifts the lift lift spool and the tilt spool. The function of this valve
arm. is to allow a restricted flow of oil into the tilt circuit to
increase the lift force.
Oil is forced out of the rod side of displacement ram
as the lift arm extends. The oil cannot flow past the tilt The ARV opens to protect the tilt ram from over
spool, as the spool is not selected. Instead, it flows to pressurisation. The anti-cavitation feature of the
the rod side of tilt ram. Oil displaced from the rod side valve makes sure that the tilt and displacement rams
of the tilt ram increases pilot pressure in the HBCV. will not cavitate.
Figure 886. Lift arm raise cycle (machines with single displacement ram)
A
D
B
T
E F
A L
C
B
J
K
P
M
G
H

E ARV 1 F ARV 2
G Lift ram H HBCV 1
30 - 23 9823/1700-1 30 - 23
00 - General
Figure 887. Lift arm raise cycle (machines with two displacement rams)
A
D
B
T
E F
A
C
B
K
J
P
J
L
G
H

E ARV 1 F ARV 2
G Lift ram H HBCV 1
30 - 24 9823/1700-1 30 - 24
00 - General
Lift arm lower cycle flows through the free flow direction of the HBCV to
the head side of the tilt ram. Oil displaced from the
When the lift spool is selected, the neutral circuit is rod side of the tilt ram feeds back to the rod side of
blocked and oil feeds to the rod side of the lift ram. Oil the displacement ram.
displaced from the head side of the lift ram increases
pilot pressure in HBCV and allows oil out of the lift Displaced oil from the displacement ram closes the
ram back to tank, lowering the lift arm. check valve in displacement/lift link valve.
As the lift arm lowers, oil is forced from the head side The ARV opens to protect the tilt ram from over
of the displacement ram. The oil flow cannot pass pressurisation. The anti-cavitation feature of the
the tilt spool, as the spool is not selected. Instead, it valve makes sure that the tilt and displacement rams
will not cavitate.
Figure 888. Lift arm lower cycle (machines with single displacement ram)
A
D
B
T
E F
A L
C
B
J
K
P
M
G
H

E ARV 1 F ARV 2
G Lift ram H HBCV 1
30 - 25 9823/1700-1 30 - 25
00 - General
Figure 889. Lift arm lower cycle (machines with two displacement rams)
A
D
B
T
E F
A
C
B K
J
P
J
L
G
H

E ARV 1 F ARV 2
G Lift ram H HBCV 1
30 - 26 9823/1700-1 30 - 26
00 - General
12 - Load Sense System
12 - Load Sense System Introduction

Introduction .................................................... 30-27
(For: 506-36 [T2/T3], 507-42 [T2/T3],
509-42 [T2/T3], 510-56 [T2/T3], 512-56
Operation ....................................................... 30-30
[T2/T3], Flowshare System)
Diagram ......................................................... 30-31
The JCB Flowshare hydraulic system differs in many
important aspects to that of the normal hydraulic
system. Before you do maintenance or fault find the
system, make sure that you read and understand all
the descriptions in this section.
The flowshare system operates the boom lift/

lower, tilt/ crowd and extend/retract services. The
other services such as the auxiliary hydraulics are
operated by a parallel type hydraulic system. Both
systems are supplied with oil flow from the same
hydraulic pump.
When you use multiple services on a parallel system

one or more services may suffer from an unequal
flow, that causes services to slow down or lose
power. A flowshare system makes sure that all
services receive sufficient flow to continue operation.
30 - 27 9823/1700-1 30 - 27
00 - General
(For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42 [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3],
Flowshare System)
Figure 890.
E
H
D F
A1
A4
A2 A3
30 - 28 9823/1700-1 30 - 28
00 - General
Table 361. Component Key

Item Description
A Pump assembly Three section gearpump
A1 Fan section Gearpump- cooling fan motor and pilot valve supply
A2 Steering section Gearpump
A3 Main hydraulic supply section Gearpump
A4 Priority valve Steering
B Servo control valve (Two axis) Servo control lever (Lift and extend services)
C Servo control valve (Single ax- Servo control lever (Tilt service)
is)
D Control valve block Flowshare valve with pilot spools
E LSRV (Load Sense Relief LSRV
Valve)
F Pilot pressure supply valve Supplied hydraulic oil at reduced pressure to operate the
control valve spools
G Hydraulic oil filter Positioned in the pilot valve feed line
H Hydraulic oil filter Positioned in the return line to tank
J Hydraulic tank
Figure 891.
B
C
A
H E F
A Hydraulic tank B Parallel control valve

C Filter D Servo valve
E Fan supply pump F Main hydraulic supply pump
G Fan return pipework H Flow share control valve
J Steer circuit return
30 - 29 9823/1700-1 30 - 29
00 - General
Operation of one service can be affected by the operating

pressure of another service. This is not the case with
flowshare.
(For: 506-36 [T2/T3], 507-42 [T2/T3],
The pressure compensator valves for each service
509-42 [T2/T3], 510-56 [T2/T3], 512-56 react to the differing load pressures. For example,
[T2/T3], Flowshare System) when a pressure compensator valve is subjected to
a higher load sense pressure from another service,
The schematic diagrams show a typical system. For it reacts to reduce the flow to its service, ensuring
machine specific schematics, refer to the schematics that the associated ram operates at a constant
circuits. speed, regardless of the increase in the main system
pressure.
Neutral
Main system pressure relief
Oil from the primary pump flows to the inlet-outlet
section of the control valve. When the main system The maximum main system pressure is controlled by
pressure reaches a preset limit, the spring tension limiting the maximum load sense pressure.
in the flushing valve is overcome and oil is returned
back to the tank. When a service ram reaches the end of its stroke, or
the service meets resistance and generates pressure
The secondary pump supplies oil to the steer circuit above a preset value in the load sense line, the
and to the main hydraulic system, via the steer load sense relief valve opens and load sense oil
priority valve. When the steering is operated, the is dumped to tank, preventing further pressure rise.
priority valve spool moves to divert all the oil flow from The flushing valve operates as normal.
the secondary pump to the steering circuit.
For figure, refer to Load sense system, Diagram (PIL
Oil from the pump flows to the pilot pressure supply 30-00-12).
valve and the fan motor. The valve supplies pilot
pressure oil to the servo control lever.

30-00-12).
One service operated

When a service is operated such as boom extend,
the movement of the control lever allows pilot
pressure oil to actuate the service spool. Oil passes
across the service spool to the applicable pressure
compensator valve. The valve opens and diverts
oil to the load sense gallery and to the load hold
check valve. Pressure in the load sense gallery
increases and the flushing valve begins to close.
Main system pressure continues to increase until the
load hold check valve opens and the boom extend
ram operates.
The main system pressure will now be equal to the

load sense pressure (load from the boom lift ram)
plus the force of the flushing valve spring.
Oil from the other side of the ram flows across the
service spool and back to tank in the normal way.

30-00-12).
Multiple Service Operation

In the normal hydraulic system the services are
connected in parallel, this means that when multiple
services are operated simultaneously, the speed
30 - 30 9823/1700-1 30 - 30
00 - General
Diagram
Figure 892. Neutral Circuit
AA AD
AB AE
AC
1A Primary pump 1B Pump

1C Secondary pump 1D Priority valve
2 Fan motor 3 Control valve
3A Flushing valve 3B Spring
4 Pilot pressure supply valve
Colour code Description

AC Exhaust
Table 362. Colour codes
for oil flow and pressure AD Servo
AE Load sense line
AA Full Pressure
AB Neutral
30 - 31 9823/1700-1 30 - 31
00 - General
Figure 893. One service operated
AA AD
AB AE
AC
3A Flushing valve 3B Spring

3D Pilot pressure supply valve 3E Service spool
3F Pressure compensator valve 5 Boom extend ram

AC Exhaust
AE Load sense line
AA Full Pressure
AB Neutral
30 - 32 9823/1700-1 30 - 32
00 - General
Figure 894. Main system pressure relief
AA AD
AB AE
AC
3A Flushing valve 3C LSRV (Load Sense Relief Valve)

for oil flow and pressure
AA Full Pressure
AB Neutral
AC Exhaust
AD Servo
AE Load sense line
30 - 33 9823/1700-1 30 - 33
00 - General
15 - Parallel Open Centre System
15 - Parallel Open Centre System Diagram

Diagram ......................................................... 30-34
Check (Pressure) .......................................... 30-37
Neutral
Figure 895.
D
E
G
F F
C K
H J
B L
AA
M AB
AC
AD
AE
A
A Tank B Primary pump

D Control valve E Valve spool
H Isolation proportional solenoid J Variable orifice pilot valve

AC Exhaust
AE Load sense line
AA Full Pressure
AB Neutral
30 - 34 9823/1700-1 30 - 34
00 - General
One service operated
Figure 896.
D
E
G
F F
C
K
H J
B L
AA
M
AB
AC
AD
AE
A
A Tank E Valve spool

G Ram

AC Exhaust
AE Load sense line
AA Full Pressure
AB Neutral
30 - 35 9823/1700-1 30 - 35
00 - General
Main system pressure relief
Figure 897.
D
E
G
F F
C K
H J
B L
M AA
AB
AC
AD
A AE
K Main relief valve

for oil flow and pressure
AA Full Pressure
AB Neutral
AC Exhaust
AD Servo
AE Load sense line
30 - 36 9823/1700-1 30 - 36
00 - General
Check (Pressure)
Please refer to (PIL 30-00) and (PIL 30-11).
30 - 37 9823/1700-1 30 - 37
00 - General
30 - Rear Axle Stabilization (RAS) System
30 - Rear Axle Stabilization (RAS) Component Identification

System
Operation ....................................................... 30-42
Diagram ......................................................... 30-45
Fault-Finding .................................................. 30-52
Discharge and Pressurise ............................. 30-55
Check (Leaks) ............................................... 30-55
Bleed ............................................................. 30-58
30 - 38 9823/1700-1 30 - 38
00 - General
Rear Axle Stabilisation System
Figure 898.
H
F
B
B
C
C
D
D
30 - 39 9823/1700-1 30 - 39
00 - General
Table 368.
Item Description
A RAS (Rear Axle Stabilization) ECU (Electronic Con-
trol Unit)
B RAS Rams
C RAS Ram control valve
D Proportional solenoid control valve
E Dual output transmission speed sensor
(1)
F Sway spool switch

G
(2)
Left stabiliser spool switch
H
(2)
Right stabiliser spool switch
J
(2)
Stabiliser pressure transducers (left and right)
(1) Machines built before April 2010 have an external auxiliary speed sensor and a single output transmission
speed sensor. Later machines with a PS750 Mk IV gearbox have a gearbox mounted dual output speed sensor.
(2) 510-56, 512-56, 514-56 and 516-42 machines.
Electrical Connectors Use the table and the relevant electrical schematic
to identify the pins in the harness connectors.
The table shows the harness connectors that Continuity checks on the harness wires can be
connect to the electrical devices. The connectors carried out using a multi-meter. Do not touch ECU
are shown looking at the mating face when connector pins. Do not use a multi-meter on ECU
disconnected. Remember that the drawings show connector pins.
the harness connectors NOT the device connectors.
Table 369.
Device Description Location Harness Connector
1013 Column Switch LH A cable and connector con-
nects to the panel harness
at the steering column below
the steering wheel.
1057 Park-brake Switch Located on the parkbrake

lever.
1058 Sway spool switch Parallel valve block
1062A Right stabiliser pressure Located on the stabiliser

switch cylinder body.
1062B Left stabiliser pressure switch Located on the stabiliser

cylinder body.
1063 Left stabiliser spool switch Parallel valve block
1064 Right stabiliser spool switch Parallel valve block
30 - 40 9823/1700-1 30 - 40
00 - General
Device Description Location Harness Connector

2000 Relays Refer to electrical system-
fuse and relay, refer to (PIL
33-09).
3051 RAS left cylinder control Located on the left RAS hy-
valve solenoid draulic ram.
3052 RAS right cylinder control Located on the right RAS hy-
valve solenoid draulic ram.
4013 LMS display connector J2 The ECU connectors are lo- 10 1

cated behind the LMS display
unit. Be sure to identify the 20 11
correct connector. Connector

J2 is coloured Black.
4018A RAS interface 1 (black) The ECU is fitted below the
operators seat. The panel
harness connector connects 12 1
directly to the ECU.

23 13
35 24
4018B RAS interface 2 (white) The ECU is fitted below the

operators seat. The panel
harness connector connects 12 1
directly to the ECU.

23 13
35 24
5018 Dual output speed sensor Located on the gearbox cas-

ing
8000 Harness interconnections Refer to electrical system-

harness, refer to (PIL 33-12).
9000 Fuses Refer to electrical system-
fuse and relay, refer to (PIL
33-09).
30 - 41 9823/1700-1 30 - 41
00 - General
Operation
Operation Overview 3. Mode 3 Unlocked- The rear axle is free to

oscillate on its chassis pivot.
Some machines are fitted with the JCB RAS
(Rear Axle Stabilization) system. The system is The RAS ECU (Electronic Control Unit) is the central
fully automatic and controls the oscillation of the of the system. The ECU controls the system. There
machine's rear axle. Two hydraulic actuators lock or are no operator controls.
unlock axle oscillation as required.
The system is designed to change the mode of rear
The system has a lock mode, an unlock mode and a axle oscillation in relation to the machine status. For
cushioned mode for controlled oscillation of the rear example when the machine is stationary the rear axle
axle. The cushioned mode allows the rear axle to is locked.
adjust slowly to changes in terrain as the machine
moves. It also allows the rear axle to adjust if the The sway and stabiliser functions are also monitored
lateral angle of the machine is changed when the by the RAS system. When the sway or stabilisers
sway and stabiliser functions operate. operate, the ECU sets the correct cushioned rate.
There are several modes of RAS operation: The switch and the sensor inputs enable the ECU to
calculate the machine status. The outputs control the
1. Mode 1 Locked- The RAS rams prevent rear axle RAS hydraulic rams via proportional solenoid control
oscillation on its chassis pivot. valves.
2. Mode 2 Cushioned- The rear axle is free to

oscillate at a preset rates on its chassis pivot.
Table 370.
Machine Status RAS Mode
Engine stopped, ignition OFF 1- Locked
Stationary, engine running 1- Locked
Engine running, ground speed more than zero but 2- Cushioned (rate changes in relation to ground
less than 4 ( 2.5 )
(1)
speed)
Engine running, ground speed more than 4 ( 2.5 )
(1)
3- Unlocked
Sway ram operation 2- Cushioned (preset rate)
Stabiliser operation
(2)
2- Cushioned (preset rate)
(1) Example value, actual value can be different.
(2) 510-56, 512-56, 514-56 and 516-52 machines.
The instrument cluster includes RAS indicator LED system. There is no indicator LED illuminated when
(Light Emitting Diode)s to show the status of the RAS the system is unlocked (mode 3).
Table 371.
RAS mode LED indicator
1- Locked (green LED comes ON)
2- Cushioned (green LED flashes)
RAS fault
30 - 42 9823/1700-1 30 - 42
00 - General
Hydraulic operation of the machine changes, the RAS ECU changes the
PWM signal. This causes the control valves to open
Refer to: PIL 30-00-30. or close gradually. When sway or stabilisers operate,
the ECU opens the control valves to a pre-set value.
Operation- Mode 1- Locked
This allows the rear axle to adjust, as the lateral angle
When the RAS ECU operates the system in mode 1, of the machine changes.
the rear axle is not free to oscillate.
The control valves control the oil flow only in one
The solenoids of proportional control valves are de- direction, as it flows from the head side of the rams.
energised and oil is trapped in the rams and locks Oil flows to the head side of the rams via the check
them in position. valves.
In hot environments, the trapped oil expands. The oil from the pilot pressure supply valve maintains
System relief valves open at a preset pressure to the system pressure.
prevent damage. The oil is vented to the hydraulic
Operation- Mode 3- Unlocked
tank until the pressure reduces.
When the RAS ECU operates the system in mode 3,
Operation- Mode 2- Cushioned
the rear axle is free to oscillate.
When the RAS ECU operates the system in mode 2,
The solenoids of the proportional control valves are
the rear axle will oscillate at a controlled rate.
fully energised and the oil flows between the rams
The solenoids of the proportional control valves via the valves as the axle oscillates.
are energised by means of a PWM (Pulse Width
The control valves allow oil flow only in one direction,
Modulation) signal. Because of this, the control
as it flows from the head side of the rams. Oil flows
valves do not open fully and restricts the oil flow
to the head side of the rams via the check valves.
between the rams. The speed of the rams is
controlled together with the oscillation rate of the The oil from the pilot pressure supply valve maintains
axle. the system pressure.
RAS ECU changes the PWM signal in relation to the
machine status. For example, if the ground speed
Electrical operation
Control devices
Table 372.
The RAS ECU 4018 uses input from control devices to determine the following machine parameters:
Ground speed The system checks for a valid speed sensor input:
Machines from April 2010:The ECU uses the signals
from transmission speed sensor 5018 to determine
the machine ground speed. One signal is transmitted
to the RAS ECU. The other signal is transmitted on
the CAN (Controller Area Network) bus to the LMS
display ECU. The ECU compares the two speed sen-
sor signals.
Machines before April 2010: (not shown) The ECU
uses the input from the transmission mounted sin-
gle output speed sensor. The ECU compares the
transmission speed sensor signal to a signal from the
transmission auxiliary speed sensor. The signal from
the auxiliary sensor is transmitted on the CAN bus by
the LMS display ECU.
If the speed sensor input is not valid the system the
ECU compares the speed sensor signals to a speed
value calculated from the current gear ratio and en-
gine speed. The engine speed value is transmitted
on the CAN bus.
30 - 43 9823/1700-1 30 - 43
00 - General
The RAS ECU 4018 uses input from control devices to determine the following machine parameters:
Transmission set to neutral The ECU uses inputs from the drive select column
switch 1013 and the park brake switch 1057 to deter-
mine when the transmission is set to neutral.
Sway service operation The ECU uses an input from sway valve spool switch
1058 to detect sway ram operation.
Stabiliser status The ECU uses an input from stabiliser valve spool
switches 1063 and 1064 to detect stabiliser ram op-
eration. Inputs from pressure transducers 1062A and
1062B detect if the stabiliser is retracted or deployed.
CAN bus The CAN messages are received from the LMS dis-
play ECU 4020. This enables the RAS ECU to vali-
date the inputs and monitor other aspects of the ma-
chine status. These include:
Transmission speed sensor value
Engine speed
Transmission switch position (FNR)
Transmission gear select switch position (1,2,3,4)
Engine running
Actuated devices
Table 373.
The RAS ECU 4018 actuates the following devices:
RAS proportional solenoid control valves The ECU controls the RAS left and right control valve
solenoids 3051 and 3052 with a PWM signal.
RAS diagnostic LED The ECU sends a signal to the LMS display ECU
4013 in the right hand instrument cluster to activate
the RAS diagnostic LED if there is a fault with the
system.
RAS mode LEDs The ECU sends a signal to the LMS display ECU
4013 in the right hand instrument cluster to activate
the RAS mode LEDs via the CAN bus.
Table 374.
The LMS display ECU 4013 actuates the following devices:
Left and right RAS isolation relays If there is a critical RAS system fault, the ECU en-
ergises the left and right isolation relays 2051 and
2052. The solenoids 3051 and 3052 are de-ener-
gised and the RAS system is set to mode 1 (locked).
30 - 44 9823/1700-1 30 - 44
00 - General
Diagram
Hydraulic Schematics
Figure 899.
PILOT VALVE B
E
D
ACC
TP2
P4
T3 R
T2
30
BAR
L
0.5
BAR
T1
A P1
P
P1
T TP1 P3
P2
PILOT
FILTER
C
B
RASLH RASRH
MANIFOLDBLOCK P1 P2 P1 MANIFOLDBLOCK P3
B1 B2 B3 C1 C2 C3
P3 P2 P4
B
G
QR1 QR2
C
RASLH RASRH
CYLINDER L R
CYLINDER
D
E
A Pilot pressure supply valve B Left RAS (Rear Axle Stabilization) control
valve block
B1 Check valve 1 B2 Proportional solenoid control valve 1
B3 System relief valve 1 C Right RAS control valve block
C1 Check valve 2 C2 Proportional control valve 2
C3 System relief valve 2 D Right RAS hydraulic cylinder
E Left RAS hydraulic cylinder F Rear axle
G Hydraulic tank
30 - 45 9823/1700-1 30 - 45
00 - General
Electrical Schematics
Control devices
Figure 900. Electrical Schematic 507-42, 509-42 and 510-42 Control Devices
FUSE 4 8020 11A

15A 8020
16A
-003
4 17A
10
9001 22B
2A
3A
8020
22A
FUSE 6 8019 -003
4A
5
5A
8 32A 1
9004 6A 3
20A 2
FUSE 6 1057
8020 24B
10A
9003 11 B
F 4 21A 8022 A N
1A
N 6 13 C
R 10 9A 1
13B
1 12
12
27B
1058
3
2 1 8A
9
16B ECU
2
2
3 5 28B
4 13 14
17B
1013 3
34A CAN H
FUSE 18 8004 8016 8034

33A CAN L
38 12 C
9001
8034 8016 8004 8021 14A

1 2
B 11 68 2
3 33B
A 13 32 1 4018A/B
4 8035 8004 19
5
A 69
6 13
ECU
5018 C 62
8035 8004
B 63
4020
FUSE 16
SP9
9001
+VE -VE
30 - 46 9823/1700-1 30 - 46
00 - General
Figure 901. Electrical Schematic 510-56, 512-56, 514-56 and 516-42 Control Devices
FUSE 6 11A
9001 2A
3A
FUSE 6
4A
5A
9004 6A
10A
FUSE 6 15A
F 4 21A 16A
-003
N 6 17A
9003
R 10 9A 22B
1 12 27B
2 9 20A
16B 2
3
3 5 28B 32A 1
4 13
17B 1057
24B
1013
FUSE 18 8004 8016 8034

38 12 C
9001
B
8027 A N
8034 8016 8004 8021 24A
2 14A ECU C
1
1
B 11 68 2 3B
3 33B 1064
3
A 13 32 1 26B
2
4 8035 8004
5
A SC14 27 B
8004 A N
6 13A
5018 C
C 63 59
22B
8035 8004 1063
49
B 64 CAN H 34A 25B
FUSE 16 CAN L 33A 56
SP9 B
9001 29B 8004 A N
1A
18B C
65
13B
22A 1058
13 66
8A
30B
ECU 19 4018A/B 67
4020 8026
2 2
19
8004 8023 2
ECU 3
45 3 4 1
4
4013
52 5 3
1062A
27 6 8025 2
FUSE 8
32 1 2
9001 3
44 2 4 1
4
51 4 3
1062B
+VE -VE
30 - 47 9823/1700-1 30 - 47
00 - General
Table 375.
Key Device RAS ECU (Electronic Control Unit) Connector Pins
1013 Column Switch L/H 9A, 10A, 21A 16B, 17B, 27B, 28B
1057 Park brake Switch 20A, 32A 24B
1058 Sway spool switch 1A, 6A 13B
1062A
(1)
Right stabiliser pressure 22A 30B
transducer
1062B
(1)
Left stabiliser pressure 29B, 18B
transducer
1063
(1)
Left stabiliser spool switch 13A 22B, 25B
1064
(1)
Right stabiliser spool switch 24A 26B, 3B
4013 LMS Display ECU Connec- - -
tor J2 (Black)
4018A RAS ECU connector 1 - -
(black)
4018B RAS ECU connector 2 - -
(white)
4020 LMS ECU connector 2 - -
5018 Dual Output Transmission 14A 33B
speed sensor
8000 Harness interconnections - -
9001 Secondary fuse box A 11A
9003 Secondary fuse box C - -
9004 Secondary fuse box D 2A, 3A, 4A, 5A, 6A
-003 Earth point, cab harness 15A, 16A, 17A 22B
(1) 510-56, 512-56, 514-56 and 516-42 machines.
30 - 48 9823/1700-1 30 - 48
00 - General
Actuated devices
Figure 902. Electrical Schematic 507-42, 509-42 and 510-56 Actuated Devices
8020
15A 8020
FUSE 4 11A 16A
-003
17A
4 10
9001 22B
2A
8020
3A 22A
-003
FUSE 6 8019
4A 5
5A
8
9004 6A
27A 8019 17 15
ECU
7
ECU 4013
5 3
8019
8019 1
35A 4
10 9
2051
8022 1 2 8022
23B
11 13
3051
10 8
7 8021
8021 6
12A 9
4 3
CAN H 34A 2052
8022 2 8022
CAN L 33A 12B 1
10 12
4018A/B 3052
+VE
-VE
30 - 49 9823/1700-1 30 - 49
00 - General
Figure 903. Electrical Schematic 510-56, 512-56, 514-56 and 516-42 Actuated Devices
15A
FUSE 6 11A 16A
-003
17A
9001 22B
2A
3A
FUSE 6
4A
5A
9004 6A
27A 17 15
ECU
E CU 4013
5 3
1
35A 4
2051
8004 1 2 8004
23B
61 62
3051
10 8
7 6
12A 9
2052
CAN H 34A
8004 2 8004
12B 1
CAN L 33A
54 55
4018A/B 3052
+VE
-VE
Table 376.
Key Device RAS ECU Connector Pins
2051 RAS isolation relay- Left 35A
cylinder
2052 RAS isolation relay- Right 12A
cylinder
3051 RAS Left cylinder control 23B
valve solenoid
3052 RAS Right cylinder con- 12B
trol valve solenoid
4018A RAS ECU connector 1 - -
(black)
30 - 50 9823/1700-1 30 - 50
00 - General
Key Device RAS ECU Connector Pins

4018B RAS ECU connector 2 - -
(white)
4013 LMS Display ECU con-
nector J2 (Black)
8000 Harness interconnections - -
9001 Secondary fuse box A 11A
9003 Secondary fuse box C 2A, 3A, 4A, 5A, 6A
-003 Earth point, cab harness 15A, 16A, 17A 22B
30 - 51 9823/1700-1 30 - 51
00 - General
Fault-Finding
Fault
Diagnostic Blink Codes (Long Flash-Short Flash) Table 377. Page 30-52
Table 377. Diagnostic Blink Codes (Long Flash-Short Flash)

Cause Remedy
1-1 (Long Flash - Short Flash) = FNR column switch- Check related wires and connectors between the
open circuit RAS (Rear Axle Stabilization) ECU (Electronic
Control Unit) input and the switch
1-2 = FNR column switch- short circuit Check related wires and connectors between the
RAS ECU input and the switch
1-4 = Park brake switch fault- open circuit Check related wires and connectors between the
RAS ECU and the normally closed and normally
open switch contacts
1-3 = Park brake switch fault- short circuit Check related wires and connectors between the
1-5 = Sway spool switch fault- open circuit Check related wires and connectors between the
1-6 = Sway spool switch fault- short circuit Check related wires and connectors between the
1-7 = Left stabiliser spool switch fault- open circuit Check related wires and connectors between the
1-8 = Left stabiliser spool switch fault- short circuit Check related wires and connectors between the
2-1 = Right stabiliser spool switch fault- open circuit Check related wires and connectors between the
2-2 = Right stabiliser spool switch fault- short circuit Check related wires and connectors between the
2-5 = Transmission speed sensor fault Check related wires and connectors between the
RAS ECU output and the sensor. Check sensor
installation at the gearbox. Replace the sensor with a
new one.
2-8 = Foot brake relay coil fault- shorted to battery Replace the relay with a new one. Check related
voltage wires and connectors between the RAS ECU and the
relay coil.
2-7 = Foot brake relay coil fault- shorted to ground Replace the relay with a new one. Check related
wires and connectors between the RAS ECU and the
relay coil.
2-6 = Foot brake relay coil fault- open circuit Replace the relay with a new one. Check related
relay coil.
3-3 = RAS Valve fault- ECU output short to battery Check related wires and connectors between the
voltage- RAS can continue to operate when ground RAS ECU and the RAS proportional valve coils.
speed is less than the pre-set value Replace the valve coil with a new one
3-2 = RAS Valve fault- ECU output short to ground. Check related wires and connectors between the
RAS can continue to operate when ground speed is RAS ECU and the RAS proportional valve coils.
less than the pre-set value Replace the valve coil with a new one
30 - 52 9823/1700-1 30 - 52
00 - General
Cause Remedy
3-1 = RAS Valve fault- ECU output open circuit. RAS Check related wires and connectors between the
can continue to operate when ground speed is less RAS ECU and the RAS proportional valve coils.
than the pre-set value Replace the valve coil with a new one
3-6 = RAS Valve fault- ECU output short to battery Check related wires and connectors between the
voltage. RAS switches to mode 1- locked when RAS ECU and the RAS proportional valve coils.
ground speed is more than the pre-set value Replace the valve coil with a new one
3-5 = RAS Valve fault- ECU output short to ground. Check related wires and connectors between the
RAS switches to mode 1- locked when ground speed RAS ECU and the RAS proportional valve coils.
is more than the pre-set value Replace the valve coil with a new one
3-4 = RAS Valve fault- ECU output open circuit. RAS Check related wires and connectors between the
switches to mode 1- locked when ground speed is RAS ECU and the RAS proportional valve coils.
more than the pre-set value Replace the valve coil with a new one
4-1 = Sway spool switch fault- switch power output Check related wires and connectors between the
from ECU shorted to battery voltage RAS ECU output and the switch common contact
from ECU shorted to ground RAS ECU output and the switch common contact
from ECU open circuit RAS ECU output and the switch common contact
4-4 = Left stabiliser spool switch fault- switch power Check related wires and connectors between the
output from ECU shorted to battery voltage RAS ECU and the normally closed and normally
output from ECU shorted to ground RAS ECU and the normally closed and normally
output from ECU open circuit RAS ECU and the normally closed and normally
4-7 = Right stabiliser spool switch fault- switch power Check related wires and connectors between the
output from ECU shorted to battery voltage RAS ECU output and the switch common contact
output from ECU shorted to ground RAS ECU output and the switch common contact
output from ECU is open circuit RAS ECU output and the switch common contact
5-5 = RAS diagnostic LED (Light Emitting Diode) Check related wires and connectors between the
circuit fault- output from ECU shorted to battery RAS ECU and the LMS (Loadall Monitoring System)
voltage ECU.
5-4 = RAS diagnostic LED circuit fault- output from Check related wires and connectors between the
ECU shorted to ground RAS ECU and the LMS ECU.
5-3 = RAS diagnostic LED circuit fault- output from Check related wires and connectors between the
ECU is open circuit RAS ECU and the LMS ECU.
5-6 = Foot brake switch fault- open circuit Check related wires and connectors between the
5-7 = Foot brake switch fault- short circuit Check related wires and connectors between the
6-2 = Foot brake switch fault- switch power output Check related wires and connectors between the
from ECU shorted to ground RAS ECU output and the switch common contact
from ECU is open circuit RAS ECU output and the switch common contact
8-8 = RAS isolation relay fault- LMS display ECU Check related wires and connectors between the
output shorted to ground LMS ECU and the RAS isolation relays
30 - 53 9823/1700-1 30 - 53
00 - General
Cause Remedy
8-7 = RAS isolation relay fault- LMS display ECU Check related wires and connectors between the
output is open circuit LMS ECU and the RAS isolation relays
9-7 = RAS isolation relay fault- RAS ECU ground Check related wires and connectors between the
output shorted to battery voltage RAS ECU and the RAS isolation relays
output shorted to ground RAS ECU and the RAS isolation relays
output is open circuit RAS ECU and the RAS isolation relays
9-8 = Gear position column switch fault- open circuit Check related wires and connectors between the
10-1 = Gear position column switch fault- short circuit Check related wires and connectors between the
10-3 = Park brake relay coil fault- shorted to battery Replace the relay with a new one. Check related
voltage wires and connectors between the RAS ECU and the
relay coil.
10-2 = Park brake relay coil fault- open circuit Replace the relay with a new one. Check related
relay coil.
10-5 = Park brake switch fault- switch power output Check related wires and connectors between the
10-4 = Park brake switch fault- switch power output Check related wires and connectors between the
from ECU open circuit RAS ECU output and the switch common contact
10-6 = CAN (Controller Area Network) fault Check related CAN bus wires and connectors
10-7 = CAN fault- RAS switches to mode 1 - locked Check related CAN bus wires and connectors
10-8 = RAS ECU memory fault- ECU operating with Use JCB Servicemaster to load the correct data onto
default data the ECU
30 - 54 9823/1700-1 30 - 54
00 - General
Discharge and Pressurise Check (Leaks)
To release the hydraulic pressure, refer to remove The RAS (Rear Axle Stabilization) ECU (Electronic
and install, (PIL 30-15-66). Control Unit) continuously tests for valid inputs from
the system electrical devices. If there is a fault, the
ECU alerts the operator with a blink code. The RAS
ECU is not able to detect hydraulic system leakage.
If there are external or internal leaks the system will
not function correctly. Do the following test procedure
to test the RAS system for hydraulic leakage.
Leak Test Procedure (With Use of

Servicemaster Diagnostics)
The test procedure that follows requires use of
JCB Servicemaster. You must have the correct
software installed on a laptop computer. If the
JCB Servicemaster tool is not available, follow
the alternative (without the use of servicemaster)
procedure.
1. Make sure that there is no air trapped in the

2. Connect Servicemaster to the machine and start
the RAS diagnostics service tool software. Refer
to electrical system- electronic diagnostic, refer
to (PIL 33-57).
5. Put a block of the specified thickness in front of
the right side front wheel.
6. Start the engine. Drive the machine slowly onto
the block.
7. Set the drive control to N. Set the park brake to
ON.
8. Use the sway control to level the machine to the
specified angle.
Angle: 0 °
9. Use a laptop computer with servicemaster
loaded. Go to the diagnostics tool. Click on the
'TEST HOLD' button.
10. Select 2nd gear. Set the drive control to F and
drive the machine slowly off the block. If the RAS
system is working correctly, the right side front
wheel will stay clear of the ground.
11. Stop the machine. Set the drive control to N. Set
the park brake to ON.
30 - 55 9823/1700-1 30 - 55
00 - General
12. Use your servicemaster lap top computer. Click 4. Put a block of the specified thickness in front of
on the 'TEST HOLD' button. This de-activates the the right side front wheel.
software. Length/Dimension/Distance: 150 mm
13. Use the sway control to slowly sway the chassis 5. Start the engine. Drive the machine slowly onto
to the left. RAS will enter a cushion mode and the the block.
right side front wheel will return to the ground.
6. Set the drive control to N. Set the park brake to
14. With all four wheels on the ground, use the ON.
sway control to level the machine to the specified
angle. 7. Use the sway control to level the machine to the
Angle: 0 ° specified angle. Stop the engine and remove the
starter key.
15. Make the machine safe. Refer to (PIL 01-03). Angle: 0 °
8. Remove the valve covers and disconnect the
electrical connectors at the proportional control
17. Put a block of the specified thickness in front of valves on the left and right side RAS rams.
the left side front wheel. Repeat the steps 6 to 16. 9. Start the engine. Make sure that the RAS
Length/Dimension/Distance: 150 mm diagnostic LED (Light Emitting Diode) is ON.
If the left or right side wheel does not remain clear of 10. Select 2nd gear. Set the drive control to F and
the ground (step 10), there is hydraulic leakage. drive the machine slowly off the block. If the RAS
system is working correctly the right side front
Find and correct the cause of hydraulic leakage. If wheel will stay clear of the ground.
the left side wheel failed the test, check the right side
RAS ram components and circuit. If the right side 11. Stop the machine. Set the drive control to N.
wheel failed the test, check the left side RAS ram Set the park brake to ON. Stop the engine and
components and circuit. remove the starter key.
• Inspect the RAS system hose and pipework for 12. Connect the electrical connectors at the
external leaks. Correct the defective hose and proportional control valves on the left and right
pipework. side RAS rams.
• Remove the RAS ram. Disassemble the ram 13. Start the engine. Make sure that the RAS
and seal it again. Refer to hydraulic system- diagnostic LED is OFF.
• Install new RAS ram check valve. Refer to 14. Use the sway control to slowly sway the chassis
hydraulic system- general, refer to (PIL 30-00). to the left. RAS will enter a cushion mode and the
• Install new RAS ram relief valve. Refer to right side front wheel will return to the ground.
hydraulic system- general, refer to (PIL 30-00).
• Install new RAS ram proportional solenoid 15. With all four wheels on the ground, use the
valve. Refer to hydraulic system- general, refer sway control to level the machine to the specified
to (PIL 30-00). angle.
Angle: 0 °
During disconnection of RAS system hydraulic
components, air can enter the system. After you 16. Make the machine safe. Refer to (PIL 01-03).
connect the components, bleed the system to
remove the air. Refer to hydraulic system- general, 17. Follow the general health and safety procedures.
bleed. Refer to (PIL 30-00). Refer to (PIL 01-03).
18. Put a block of the specified thickness in front of
Leak Test Procedure (Without Use of the left side front wheel. Repeat the steps 5 to 17.
Servicemaster Diagnostics)
1. Make sure that there is no air in the system. Refer
to (PIL 30-30). If the left or right side wheel does not remain clear of
the ground (step 10), there is hydraulic leakage.
Find and correct the cause of hydraulic leakage. If
3. Follow the general health and safety procedures. the left side wheel failed the test, check the right side
Refer to (PIL 01-03). RAS ram components and circuit. If the right side
30 - 56 9823/1700-1 30 - 56
00 - General
wheel failed the test, check the left side RAS ram
components and circuit.
• Inspect the RAS system hose and pipework for

external leaks. Correct the defective hose and
pipework.
• Remove the RAS ram. Disassemble the ram
and seal it again. Refer to (PIL 30-00).
• Install new RAS ram check valve. Refer to (PIL
30-00).
• Install new RAS ram relief valve. Refer to (PIL
30-00).
• Install new RAS ram proportional solenoid
valve. Refer to (PIL 30-00).
During disconnection of RAS system hydraulic

components, air can enter the system. After the
you connect the components, bleed the system to
remove the air. Refer to (PIL 30-00).
Figure 904.
A Electrical connectors
Figure 905.
B
B LED
30 - 57 9823/1700-1 30 - 57
00 - General
Bleed
Special Tools 2. Follow the general safety precautions for the

Description Part No. Qty. hydraulic system. Refer to (PIL 30-00).
Bleeding Cap 332/D1039 1 3. Install the bleed hoses at the RAS ram bleed
points and the hydraulic tank filler tube.
Bleed procedure
4. Start the engine. Use the sway control to sway
During the disconnection of RAS (Rear Axle the machine fully from left to right three times.
Stabilization) system hydraulic components, air
can enter the system. After the reconnection of 5. Put block in front of the right front wheel.
components bleed, the system to remove the air. 6. Drive the machine slowly onto the block and set
the park brake to ON. Set the drive selector to N.
Make sure to get the following before you do the
procedure: 7. Use the sway control to sway the machine fully
to the left. Refer to Figure 906. .
1. Two hydraulic bleed hoses with the correct quick
release couplings for use with the RAS bleed 8. Do not stop the engine. Disconnect the bleed
points. hose from the left ram bleed point1.
2. A block of the specified thickness. 9. Use the sway control to level machine. Keep the
Length/Dimension/Distance: 100 mm wheels straight and slowly drive off the block.
3. A system of connecting the bleed hoses to the 10. Remove the block in front of the right front wheel
hydraulic tank. Use special tank cap. and put it in front of the left front wheel.
Special Tool: Bleeding Cap (Qty.: 1) 11. Drive the machine slowly onto the block and set
the park brake to ON. Set the drive selector to N.
We recommend you to use the special tank cap. If
the cap is not available, the ends of the bleed hoses 12. Use the sway control to sway the machine fully
can be put through the hydraulic tank filler neck and to the right. Refer to Figure 906. .
into the oil. Make sure that the hoses cannot come
out of the tank filler neck. 13. Do not stop the engine. Disconnect the bleed
hose from the left ram bleed point2.
Oil will flow from the bleed hoses at a pressure of 30
14. Slowly drive off the block, set the park brake to
bar ( 434.8 psi). Make sure that the bleed hoses are
ON and stop the engine.
correctly retained inside the hydraulic tank filler neck.
When possible always use the special tank cap. 15. Disconnect the bleed hoses at the hydraulic tank.
During the procedure that follows, all the machine 16. Replace the dust covers on the bleed point
wheels must touch the ground or the block at all couplings.
times.
17. Check the hydraulic oil level. Refer to hydraulic
1. Park the machine and make it safe with the lift system- general, refer to (PIL 30-00).
arm lowered. Refer to (PIL 01-03).
30 - 58 9823/1700-1 30 - 58
00 - General
Figure 906.
A B
L
A Ram bleed point 1 B Ram bleed point 2

C Tank cap D Bleed hoses
E Block L Left
R Right
30 - 59 9823/1700-1 30 - 59
00 - General
Remove and Install
Refer to electrical system, control module, rear axle

stabilisation (PIL 33-45-39).
30 - 60 9823/1700-1 30 - 60
00 - General
36 - Interlock System
36 - Interlock System Introduction

Introduction .................................................... 30-61
(For: 507-42 [T2/T3], 509-42 [T2/T3],
510-56 [T2/T3], 512-56 [T2/T3])
Operation ....................................................... 30-64
Diagram ......................................................... 30-70 510-56, 512-56 and 514-56 machines use a system
Fault-Finding .................................................. 30-70 of interlocks to prevent the operation of the
machine (beyond pre-set limits) unless the boom and
stabilizer legs are moved to the correct position. The
interlock logic is shown in the table and on a decal
found in the cab.
The interlock system prevents the operation of the

sway and stabilizer functions at the same time.
Figure 907.
Table 378.
Interlock Machine Status Active Interlock To Deactivate Interlock
A Boom angle more than Stabilizer isolation. Lower the boom to less
60 ° than 60 °
B Stabilizers retracted. Boom angle limited to a Lower the stabilizers. The
maximum 60 ° stabilizer indicator lights
must come ON).
C Boom angle more than Sway isolation. Retract the boom to less
60 ° and extended more than 6.5 m or lower the
than 6.5 m boom to less than 60 °.
30 - 61 9823/1700-1 30 - 61
00 - General
(For: 507-42 [T2/T3], 509-42 [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3])
Figure 908.
F
E
M L
B
A
C
H
K
J
30 - 62 9823/1700-1 30 - 62
00 - General
Table 379.
Item Description
A Stabiliser pressure
transducers (left and
right)
B Left stabiliser spool
switch
C Right stabiliser spool
switch
D Stabiliser deployed indi-
cator lights
E Boom angle proximity
switch- 60 ° (stabiliser
isolation)
F Boom angle proximity
switch- 60 °
G Boom extend proximity
switch
H Sway spool switch
J Sway / stabiliser isola-
tion valve
K Boom lift pilot pressure
supply isolation valve
L ECU (Electronic Control
Unit) 4018
M Stabiliser isolation
switch
30 - 63 9823/1700-1 30 - 63
00 - General
Operation
(For: 507-42 [T2/T3], 509-42 [T2/T3], spool. The lift spool operates when the operator
510-56 [T2/T3], 512-56 [T2/T3]) moves the servo control lever.
When the lift pilot pressure supply solenoid valve is

Hydraulic operation de-energised, the valve isolates pilot pressure supply
to the lift valve spool. The lift spool remains in the
Lift pilot pressure supply isolation valve neutral position when the operator moves the servo
control lever.
When the lift pilot pressure supply solenoid valve is
energised, pilot pressure is available at the lift valve
Figure 909. Lift pilot pressure supply valve open

A B
C D
H
F J
E G K
Figure 910. Lift pilot pressure supply valve closed

A B
C D
E H
G J
K
Item Description
Table 380. H Flowshare control valve
Item Description J Lift valve spool
A Pilot pressure pump K Lift ram
supply
B Pilot pressure supply ECU (Electronic Control Unit) 4018 controls the
valve operation of the solenoid.
C Pilot pressure reducing
valve
Sway/stabiliser isolation valve
D Pilot pressure enable When the sway/stabiliser isolation valve solenoid
solenoid energised oil from the main pump flows to the sway
E Tank return and stabiliser valve spools so that the sway and
F Lift pilot pressure supply stabiliser services can operate.
isolation valve
G Servo control lever
30 - 64 9823/1700-1 30 - 64
00 - General
When the sway/stabiliser isolation valve solenoid operator moves the control levers, lockout valves in
is de-energised, oil from the main pump cannot the hydraulic circuit prevent the rams moving due to
flow to the sway and stabiliser valve spools. If the loads from the machine mass.
Figure 911. Sway/stabiliser isolation valve energised
D E F
Figure 912. Sway/stabiliser isolation valve not energised

A
D E F
Electrical operation
Table 381. ECU 4018 controls the boom safety interlock system.
Item Description The ECU receives inputs from control devices.
A Parallel control valve The ECU uses a program stored in its memory
block to determine outputs. The ECU outputs energise
hydraulic solenoid isolation valves when interlocks
B Pump supply to parallel are applicable. The operator can isolate the stabiliser
valve block services by means of a switch in the cab. The input
C Sway/stabiliser isolation from this switch is connected to ECU 4018.
valve
D Sway valve spool Control devices
E Right stabiliser valve
spool The ECU 4018 uses input from control devices to
measures the following machine parameters.
F Left stabiliser valve
spool Table 382.
ECU 4018 control the operation of the sway/stabiliser Boom angle more than Inputs from chassis
isolation valve solenoid. or less than 60 °. mounted proximity
switches are used to de-
Some machine functions require sway operation tect if the boom angle is
at the same time as stabiliser isolation. For sway more than or less than
operation oil must also flow to the left and right 60 °.
stabiliser valve spools from the main pump. If the Boom extended more Input from a boom
operator moves a stabiliser lever from its neutral than or less than 6.5 m. mounted proximity
position inputs from the stabiliser spool switches switch is used to detect
cause ECU 4018 to de-energise the valve solenoid. if the boom is extended
Sway service is only resumed when the stabiliser more than or less than
levers are returned to the neutral position. 6.5 m.
30 - 65 9823/1700-1 30 - 65
00 - General
Sway service operation Input from sway valve Stabiliser service opera- Input from stabiliser
spool switch 1058 de- tion valve spool switches
tects sway ram opera- 1063 and 1064 detect
tion. When the service stabiliser ram operation.
spool is moved from When the service spool
its neutral position the is moved from its neu-
switch (1058) contacts tral position the switch
change state. (1063 or 1064) contacts
Stabiliser status Inputs from pressure change state.
transducers 1062A and Cab stabiliser isolation Input from switch 1042A
1062B detect if the sta- switch status is used to detect if the
biliser is retracted or de- operator has set the sta-
ployed. The transduc- biliser operation to on
ers have digital and ana- or off. When the input is
log outputs. The ECU high the ECU allows op-
compares the outputs to eration. When the input
check for valid signals. is low the ECU isolates
If the transducer sig- stabiliser operation.
nals are not as expected
the ECU sends an error
message. The analog
signals are used by the
LMS (Loadall Monitoring
System) display ECU to
control the stabiliser de-
ployed LED (Light Emit-
ting Diode).
30 - 66 9823/1700-1 30 - 66
00 - General
Figure 913. Control devices
15A
FUSE 6 11A 16A
-003
17A
9001 2A 22B
3A
FUSE 6
4A
5A
9004 6A
1 21B
FUSE 14 2
8004
9004 8B 1 4
1042A
2 NC
15B 2
B
8027
27A 8
A N 14B 3 NO
C 1
3B 9
E CU 1065
1064 3
26B 8004
7B 1
4
8004
2
-003
3 NC
19B 2 1
B
8004
13A 16
A N 31B NO
3
C 59
22B 15
1066
1063 49
25B 8004 8028
56
6B 1 4
8028
4 1 NC
B
8004 32B 2 4
8A
A N 42 2
67 20B 3 NO
C
13B
43 3
1067
1058 66
1A
65
29B
18B
9 22A
12 30B 4018A/B
E CU 8026
19
2 2
8004 8023 2
3
4013
45 3 4 1
4
52 5 3
1062A
27 6 8025 2
FUSE 8
32 1 2
9001 3
44 2 4 1
4
51 4 3
1062B
+VE -VE
Item Description
Table 383.
4013 LMS display connector
Item Description J2
1042A Stabiliser isolation 4018A ECU connector 1 (black)
switch 4018B ECU connector 2 (white)
1058 Sway spool switch 8000 Harness interconnec-
1062A Right stabiliser pressure tions
transducer 9000 Fuses
1062B Left stabiliser pressure
transducer Actuated devices
1063 Left stabiliser switch
1064 Right stabiliser switch The ECU 4018 activates the devices as follows:
1065 Boom angle proximity
switch- 60 ° (stabiliser
isolation)
1066 Boom angle proximity
switch- 60 °
1067 Boom extend proximity
switch
30 - 67 9823/1700-1 30 - 67
00 - General
Table 384.
Sway/stabiliser isolation When the sway/stabilis-
valve er isolation solenoid
valve 3054 is energised
the stabiliser and sway
services are active. The
ECU energises relay
2054 to energise sole-
noid valve 3054.
Some machine functions
need sway operation at
the same time as sta-
biliser isolation. The iso-
lation valve 3054 can
only allow or isolate both
services at the same
time. The ECU allows
sway operation only by
energising the valve
when the sway spool is
moved away from neu-
tral. If a stabiliser spool
moves away from neu-
tral at the same time the
ECU de-energises valve
3054. Sway service is
only resumed when the
stabiliser levers are re-
turned to the neutral po-
sition.
Boom raise pilot isola- When the boom lift pilot
tion valve isolation solenoid valve
3055 is energised the
boom lift service is ac-
tive. The ECU energises
relay 2053 to energise
solenoid valve 3055.
30 - 68 9823/1700-1 30 - 68
00 - General
Figure 914. Actuated devices
FUSE 6 11A
9001 2A
3A
4
8004 8004
FUSE 6 1 2
4A
5A ECU 6 36
9004 6A
3054
8004 8004
5 1 2
10 5
3055
26
2053
1 4
25 2
3 5
4018A/B
8 10
7
6
9
2054
-VE
+VE
Table 385.
Item Description
2053 Boom lift isolation relay
2054 Sway / Stabiliser isola-
tion relay
3054 Sway/ Stabiliser isola-
tion valve solenoid
3055 Lift pilot pressure supply
isolation valve solenoid
4018A ECU connector 1 (black)
4018B ECU connector 2 (white)
8000 Harness interconnec-
tions
9000 Fuses
30 - 69 9823/1700-1 30 - 69
00 - General
Diagram
(For: 507-42 [T2/T3], 509-42 [T2/T3],

510-56 [T2/T3], 512-56 [T2/T3])
Refer to operation (PIL 30-00-36).
Fault-Finding
(For: 507-42 [T2/T3], 509-42 [T2/T3],

510-56 [T2/T3], 512-56 [T2/T3])
The ECU 4018 controls the boom and stabiliser
interlocks. For system faults, please refer to
RAS (Rear Axle Stabilization) system topics (PIL
30-00-30).
The hydraulic system fault finding procedures are
covered in (PIL 30-51).
30 - 70 9823/1700-1 30 - 70
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-71 Complex hydraulic components and circuits can
Diagram ......................................................... 30-72 be described to the engineer by using graphical
symbols. The tables illustrate and give a brief
description for some of the more common symbols
used.
There are many symbols in use and it would

be impossible to include them all here. However
it should be noted that most are only variations
or refinements on the basic principles explained
here. If more detailed information is required you
are recommended to obtain a copy of BS2917 or
IS01219.
Once familiar with the symbols, the engineer can use

hydraulic circuit diagrams as an aid to fault finding. It
will be possible to see the complete hydraulic circuit
and decipher the relationship between hydraulic
components.
30 - 71 9823/1700-1 30 - 71
00 - General
Diagram Table 389. Directional control valves

Symbol Description
Used to enclose sever-
Table 386. General al valves indicating they
are supplied as one unit
Symbol Description
Spring
Flow restriction affected 3-Position, 4-port spring
by viscosity centered pilot operated
valve
Direction of flow 3-position, 6-port spring
centered manually oper-
Indication of rotation ated valve
3-Position, 4-port spring
Indication of direction centered solenoid & pilot
and paths of flow pressure operated valve
3-Position, 4-port spring
Variable control centered detent hand
operated valve
Non-return valve
Table 387. Cylinder Rams

Non-return valve with
Symbol Description back pressure spring
Single acting Pilot operated non-re-
turn valve
Double acting
One way restrictor

Double ended
High pressure selector

Double acting with
(shuttle valve)
damping at rod area end
Throttling orifice - nor-

mally closed
Table 388. Pumps and Motors
Symbol Description
Variable capacity pump Throttling orifice - nor-
two directions of flow mally open
Fixed capacity motor

one direction of flow Relief valve
Fixed capacity motor

two directions of flow
Variable restrictor
Variable capacity motor
one direction of flow
Variable capacity motor

two directions of flow
30 - 72 9823/1700-1 30 - 72
00 - General
Table 390. Energy Symbol Description

Transmissions and Conditioning Filter or strainer
Symbol Description
Working line, return or
feed Water trap
Pilot control
Drain lines
Flexible pipe Cooler - with no indica-
tion of coolant flow
Line junction Cooler - indicating direc-

tion of coolant flow
Heater
Crossing lines
Table 391. Control Mechanisms
Symbol Description
Rotating shaft - one di-
rection
Rotating shaft - two di-
rections
Detent
Air bleed Locking device
Line plugged, also pres-

sure test point Over centre device
Line plugged with take-
off line Simple linkage
QRC (Quick Release
Coupling) - connected General control
QRC - disconnected
Push button operated
Tank - return line above
fluid level Lever operated
Tank - return line below

Pedal operated
fluid level
Stem operated
Header tank
Spring operated
Pressure sealed tank Roller operated
Accumulator Roller trip operated (one

directional)
Solenoid one winding
Solenoid two windings
30 - 73 9823/1700-1 30 - 73
00 - General
Symbol Description
Electric motor operated
M
Internal pressure pilot

operated
External pressure pilot

operated
Pressure operated
spring release
Pilot operated by sole-
noid pilot valve
Pilot operated by a so-
lenoid or separate pilot
valve
Pressure gauge
Pressure switch
30 - 74 9823/1700-1 30 - 74
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-75 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-76 representation of the machines hydraulic circuit. It
shows the components of the circuit as simplified
hydraulic symbols, and the connections between
the different components. The schematic diagram
is used to troubleshoot problems and to make
sure that all the connections have been made and
that everything is present. Detailed schematics for
individual systems are given in the relevant PIL
section.
30 - 75 9823/1700-1 30 - 75
00 - General
Diagram
For: 506-36 [T2/T3] ................... Page 30-76

For: 507-42 [T2/T3], 509-42 [T2/T3]
................................................... Page 30-81
For: 510-56 [T2/T3] ................... Page 30-88
For: 512-56 [T2/T3] ................... Page 30-93
(For: 506-36 [T2/T3])

Figure 915. 332/C5224 Issue 13............................................................................................ Page 30-77
30 - 76 9823/1700-1 30 - 76
00 - General
Page 30-78 Figure 915. 332/C5224 Issue 13 Page 30-79
12 13 2A
14
2 8A
2M
2B 7
8
17
13 2L
12 17D
17F 2G
2F
17B 9A
17A 2H 2N 9C
15 9
4 2L 9B
17C 2J
3 2E
17E
3A
2K 2N
4A
6B
2L
3D 2D
3C
2N
6A 6
1E
6A
1 6
1D
1B 5
16
1C 1A
5B
10
F
B 11B
F1
T S 5A 11A 11A
11
332/C5224-13
30 - 77 9823/1700-1 30 - 77
00 - General
Page Page
30-78 30-79
Figure 915. (Part 1 of 2)
12 13
14
17
12 13 17D
17F
17B
17A
15
4 17C
3
17E
3A
4A
3D
3C
1E
Page 30-79
1
1D
1B
16
1C 1A
F
B
F1
T S
30 - 78 9823/1700-1 30 - 78
00 - General
Page Page
30-78 30-79
2A
2 8A
2M
2B 7
8
2L
2G
2F
9A
2H 2N 9C
9
2L 9B
2J
2E
2K 2N
6B
2L
2D
2N
6A 6
6A
Page 30-78
5B
10
11B
5A 11A 11A
11
332/C5224-13
30 - 79 9823/1700-1 30 - 79
00 - General
S.No Part Name

4A Relief valve
Table 392.
5 Parallel valve block
S.No Part Name
5A Sway spool
B Pressure breather cap
5B Auxiliary spool
F Return line filter
6 Lift ram
F1 Filter bypass
6A Counterbalance valve
S Pump suction strainer
6B Regenerative valve (if installed)
T Tank
7 Displacement ram
1 Pump assembly
8 Tilt ram
1A Main pump
1B Fan pump
9 Extension ram
1C Steer pump
1D Priority valve
9B Regenerative valve
1E Test points
9C Check valve
2 Flowshare valve block
10 Auxiliary 1 boom quick release couplings
2A Flushing valve
11 Sway ram
2B LSRV (Load Sense Relief Valve)
11A One way restrictors
2D Lift spool
11B Pilot operated check valve
2E Extension spool
12 Front steer rams
2F Tilt spool
13 Rear steer rams
2G Tilt ARV (Auxiliary Relief Valve)
14 Steer mode valve
2H Tilt ARV
15 Servo control lever - Twin axis
2J Extend ARV
16 Servo control lever - Single axis
2K Extend ARV
2L LHCV (Load Hold Check Valve)
17A Accumulator
2M LSRV pressure test point
17B Relief valve
2N Pressure compensator valve
17C Pilot filter
3 Steer unit assembly
17D Pilot pressure test point
3A Steer valve
17E Fan supply pressure test point
3B Shock valves (if installed)
17F Isolation valve - Servo control levers
3C Relief valve
3D Non return valve
4 Cooling fan motor
30 - 80 9823/1700-1 30 - 80
00 - General
(For: 507-42 [T2/T3], 509-42 [T2/T3])

Figure 916. 332/D0698 Issue 14............................................................................................ Page 30-83
30 - 81 9823/1700-1 30 - 81
Notes:
30 - 82 9823/1700-1 30 - 82
00 - General
Page 30-84 Figure 916. 332/D0698 Issue 14 Page 30-85
12 14 13 2 2A
2M
7 8A
2C
8
12 13 17D 17 15 2L
17F 2G
2F
17B 9A
17A 2N
2H
9C 9
2L
4 17E
9B
2J
3 17C 2E
2K 2N
3A
4A
6A
2L
3D 2D
3C 2N
1E 6A 6
1
1D 6
1B
24 16
1C 1A
5
F 18 21
5B
F1 10
B
11B
S 20
T 23
19 22 11A 11A
5A
11
332/ D0698- 14
30 - 83 9823/1700-1 30 - 83
00 - General
Page Page
30-84 30-85
12 14 13
12 13 17D 17 15
17F
17B
17A
4 17E
3 17C
3A
4A
3D
3C
1E
Page 30-85
1D
1B
24 16
1C 1A
F 18 21
F1
S 20
T
19 22
30 - 84 9823/1700-1 30 - 84
00 - General
Page Page
30-84 30-85
2 2A
2M
7 8A
2C
8
2L
2G
2F
9A
2H 2N
9C 9
2L 9B
2J
2E
2K 2N
6A
2L
2D
2N
6A 6
Page 30-84
21
5B
10
11B
23
11A 11A
5A
11
332/ D0698- 14
30 - 85 9823/1700-1 30 - 85
00 - General
Table 393.
S.No Part Name
F1 Filter bypass
T Tank
1 Pump assembly
1A Main pump
1B Fan pump
1C Steer pump
1D Priority valve
1E Test point(s)
2A Flushing valve
2C LSRV
2D Lift spool
2E Extension spool
2F Tilt spool
2G Tilt ARV
2H Tilt ARV
2J Extend ARV
2K Extend ARV
2L LHCV
3A Steer valve
3C Relief valve
3D Non return valve
4 Cooling fan motor
4A Relief valve
5A Sway spool
5B Auxiliary spool
6 Lift ram
7 Displacement ram
8 Tilt ram
9 Extension ram
9C Check valve
10 Auxiliary 1 boom QRC (Quick Re-
lease Coupling)
11 Sway Ram
30 - 86 9823/1700-1 30 - 86
00 - General
S.No Part Name

12 Front steer rams
13 Rear steer rams
14 Steer mode valve
17A Accumulator
17B Relief valve
17C Pilot filter
17F Isolation valve - servo control levers
18 Left side RAS (Rear Axle Stabiliza-
tion) manifold block
19 Left side RAS ram
20 Left side RAS QRC
21 Right side RAS manifold block
22 Right side RAS ram
23 Right side RAS QRC
24 RAS Check Valve
30 - 87 9823/1700-1 30 - 87
00 - General
(For: 510-56 [T2/T3])

Figure 917. 332/D0983 Issue 17............................................................................................ Page 30-89
30 - 88 9823/1700-1 30 - 88
00 - General
Page 30-90 Figure 917. 332/D0983 Issue 17 Page 30-91
12 14 13 2 2A
8A
2M
8
17 2C 7 31
17G
15 2F 2L
12 13 17D 17F
2G 9A
17B 17A 2N
9C
2H 9
4 2E 2L 9B
17E
3 2J
17C
2N
3A 2K
4A
6A
2D 2L
4
3C
2N 6A
3D
1E 6
1 6A
1D
6
1B 16 24A
1C 1A 26
27 5 24B 25
F 5D
24A
18 21
B F1 5C
76 76
11A 11B 24B 24
20 23
T
22 5A
19 11A
S
11
5E
5B 10
332/ D0983- 17
30 - 89 9823/1700-1 30 - 89
00 - General
Page Page
30-90 30-91
12 14 13
17
17G
13 15
12 17D 17F
17B 17A
4
17E
3
17C
3A
4A
4
3C
3D
1E
Page 30-91
1D
1B 16
1C 1A 26
27
F
18 21
B F1
76 76
20 23
T
19 22
S
30 - 90 9823/1700-1 30 - 90
00 - General
Page Page
30-90 30-91
2 2A
8A
2M
8
2C 7 31
2F 2L
2G 9A
2N
9C
2H 9
2E 2L 9B
2J
2N
2K
6A
2D 2L
2N 6A
6
6A
Page 30-90
6
24A
5 24B 25
5D
24A
21
5C
76
11A 11B 24B 24
23
5A
11A
11
5E
5B 10
332/ D0983- 17
30 - 91 9823/1700-1 30 - 91
00 - General
S.No Part Name

Table 394.
S.No Part Name
7 Displacement ram
8 Tilt ram
F1 Filter by pass
9 Extension ram
T Tank
1 Pump assembly
9C Check valve
1A Main pump
10 Auxiliary 1 boom quick release couplings
1B Fan pump
11 Sway ram
1C Steer pump
1D Priority valve
1E Test points
12 Front steer rams
13 Rear steer rams
2A Flushing valve
14 Steer mode valve
2C LSRV
2D Lift spool
2E Extension spool
2F Tilt spool
17A Accumulator
2G Tilt ARV
17B Relief valve
2H Tilt ARV
17C Pilot filter
2K Extend ARV
2L LHCV
17G Isolation valve - Lift spool pilot pressure
18 Left side RAS manifold block
3A Steer valve
19 Left side RAS ram
20 Left side RAS QRC
3C Relief valve
21 Right side RAS manifold block
3D Non return valve
22 Right side RAS ram
4 Cooling fan motor
23 Right side RAS QRC
4A Relief valve
24 Right stabiliser ram
24A Stabiliser lock cut out valve
5A Sway spool
24B Stabiliser pressure switch
5B Auxiliary spool
25 Left stabiliser ram
5C Right stabiliser spool
26 RAS check valve
5D Left stabiliser spool
27 Bi directional steer return check valve
5E Stabiliser and sway isolation valve
6 Lift ram
30 - 92 9823/1700-1 30 - 92
00 - General
(For: 512-56 [T2/T3])

Figure 918. 333/C7984 Issue 1.............................................................................................. Page 30-95
30 - 93 9823/1700-1 30 - 93
Notes:
30 - 94 9823/1700-1 30 - 94
00 - General
Page 30-96 Figure 918. 333/C7984 Issue 1 Page 30-97
12 13 2 2A
14
2C 7
8
17 8A
17G 2L
12 13 17D
17F
2F
17B 15 2G 9A
17A 2N 9C
2H 9
4 2L 9B
17E
3 17C
2E
2N
3A 2K
4A
6A
2L
2D
3C
3D 2N 6A
1E 6
16
1 6A
1D 6
1B 26
1C 1A 24A
5
27 6
5D
18 21 24A
B
20 5C
76
11A 11B 24B 24
T 20 23
19 22 5A 11A
S
11
5E
5B 10
333/ C7984- 1
30 - 95 9823/1700-1 30 - 95
00 - General
Page Page
30-96 30-97
12 13
14
17
17G
12 13 17D
17F
17B 17A 15
4
17E
3 17C
3A
4A
3C
3D
1E
16
1
1D
Page 30-97
1B 26
1C 1A
27
18 21
B
20 76
T 20
19 22
S
30 - 96 9823/1700-1 30 - 96
00 - General
Page Page
30-96 30-97
2 2A
2C 7
8
8A
2L
2F
2G 9A
2N 9C
2H 9
2L 9B
2E
2N
2K
6A
2L
2D
2N 6A
6
6A
6
Page 30-96
24A
5
6
5D
21 24A
5C
76
11A 11B 24B 24
23
22 5A 11A
11
5E
5B 10
333/ C7984- 1
30 - 97 9823/1700-1 30 - 97
00 - General
S.No Part Nme

Table 395.
11 Sway ram
S.No Part Nme
B Pressure cap breather
12 Front steer rams
F1 Filter bypass
13 Rear steer rams
14 Steer mode valve
T Tank
1 Pump assembly
1A Main pump
1B Fan pump
17A Accumulator
1C Steer pump
17B Relief valve
1D Priority valve
17C Pilot filter
1E Test points
2A Flushing valve
2C LSRV
17 Isolation valve - Lift spool pilot pres-
2D Lift spool sure
2E Extension spool 18 Left side RAS manifold block
2F Tilt spool 19 Left side RAS ram
2G Tilt ARV 20 Left side RAS QRC
2H Tilt ARV 21 Right side RAS manifold block
2K Extend ARV 22 Right side RAS ram
2L LHCV 23 Right side RAS QRC
2M LSRV pressure test point 24 Right stabiliser ram
2N Pressure compensator valve 24A Stabiliser lock cut out valve
3 Steer unit assembly 24B Stabiliser pressure switch
3A Steer valve 25 Left stabiliser ram
3B Shock valves (if installed) 26 RAS check valve
3C Relief valve 27 Bi directional steer return check
3D Non return valve valve
4 Cooling fan motor
4A Relief valve
5A Sway spool
5B Auxiliary spool
5C Right stabiliser spool
5D Left stabiliser spool
5E Stabiliser and sway isolation valve
6 Lift ram
7 Displacement ram
8 Tilt ram
9 Extension ram
9C Check valve
10 Auxiliary 1 boom quick release cou-
plings
30 - 98 9823/1700-1 30 - 98
03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ......................................................................................................................... 30-101

30 - 99 9823/1700-1 30 - 99
Notes:
30 - 100 9823/1700-1 30 - 100

03 - Tank
00 - General
00 - General
Introduction
The hydraulic tank holds excess hydraulic oil to

accommodate volume changes due to the following.
• Cylinder ram extension and contraction.

• Temperature driven expansion and contraction.
• Hydraulic oil leaks.
The tank is also designed to aid in the separation

of air from the fluid and it also acts as a heat
accumulator to cover losses in the system when peak
power is used.
The tank also houses filters or strainers that help to

separate dirt and other particulates from the oil.
The cleanliness of this component is critical. Refer

to: PIL 30-00-00.
30 - 101 9823/1700-1 30 - 101

03 - Tank
Introduction
The suction strainer is a component used for trapping

large and coarse particles, preventing them entering
the hydraulic system. The strainer is usually located
inside the hydraulic tank, at the hydraulic pump
suction port.
30 - 102 9823/1700-1 30 - 102

04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ......................................................................................................................... 30-105

30-04-03 Main .............................................................................................................................. 30-106
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-108
30 - 103 9823/1700-1 30 - 103

Notes:
30 - 104 9823/1700-1 30 - 104

04 - Filter
00 - General
00 - General
Introduction
Hydraulic filters are an important part of the

machines hydraulic system. Metal particles are
continually produced by mechanical components
and need to be removed along with other
contaminants.
The hydraulic filter assemblies are designed to filter

all the contamination that is generated through use
to the required level of cleanliness.
Filters are positioned in many different locations.

Refer to the relevant hydraulic filter for the location
and removal procedure.
The filters must be serviced to the requirements

of the machine maintenance schedules. To ensure
optimum performance and reliability it is important
that the machine's hydraulic system is serviced
periodically in accordance with the manufacturers
requirements.
30 - 105 9823/1700-1 30 - 105

04 - Filter
03 - Main
03 - Main Figure 919.
Remove and Install

CAUTION When the strainer is removed, oil will
gush out. Keep to one side when you remove the
strainer.
Canister Type Filter
Remove
The canister filter is installed under the chassis,
located to the rear of the front axle.
1. Make the machine safe with the lift arm lowered,

2. Discharge the hydraulic system pressure. Refer
to (PIL 30-00).
A Canister filter
3. Clean the area around the filter body. C Seal
4. Place a container of suitable size beneath the 4.1. Run the engine for a few minutes.
machine to catch the oil.
4.2. Make the machine safe.
5. From under the machine, unscrew and remove 4.3. Check for leaks at the filter.
the element. The element will contain hydraulic
fluid; keep your face clear of spilling fluid.
Oil Filter (Hydraulic Oil Tank, Top
Install Mounting)
1. Install the new element. Remove

1.1. Clean the mating faces on the new element 1. Make the machine safe with the lift arm raised,
and filter holder. refer to (PIL 01-03).
1.2. Smear the seal with clean new hydraulic 2. Open rear cover. Refer to (PIL 06-06).
fluid.
1.3. Screw the new element in place, hand-tight 3. Discharge the hydraulic system pressure. Refer
only. to (PIL 30-00).
2. Check oil level and replenish as required through 4. Clean the top of the tank around the filter.
filler. Refer to (PIL 30-00). 5. Either disconnect the hose or undo clip to enable
3. Install the filler cap. cover plate removal.
4. Check for leaks: 6. Remove the element assembly:

6.1. Remove the screws. Remove the cover
plate and gasket, discard the gasket.
6.2. Remove the spring.
6.3. Hold the handle and pull the element
assembly from the hydraulic tank.
7. Remove the element from its canister:
7.1. Hold the canister.
7.2. Hold the handle and rotate the element 90°
counter-clockwise.
30 - 106 9823/1700-1 30 - 106

04 - Filter
03 - Main
7.3. Pull on handle, the element should separate H Seal 1

from its canister. Discard the old element. J Seal 2
K Hose
7.4. Remove and discard the seal.
7.5. Clean the inside of canister.
Install
1. Install the new element.
1.1. Install a new seal 1.
1.2. Make sure that seal 2 is installed in the new
element.
1.3. Push the element into its canister and rotate
the element 90° to lock it into position.
Check that the element has locked into
position by pulling on the handle.
1.4. Install the element assembly in the
hydraulic tank.
1.5. Install the spring and gasket.
1.6. Install the cover plate and tighten the
screws.
2. Check oil level and replenish as required through
filler.
3. Install the filler cap.
4. Close the rear cover.
Figure 920.
A Screws
B Cover plate
C Gasket
D Spring
E Handle
F Canister
G Element
30 - 107 9823/1700-1 30 - 107

04 - Filter
60 - Pilot Pressure Supply Main
60 - Pilot Pressure Supply Main Figure 921.
Remove and Install

WARNING You could be killed or injured if the
boom drops while you are working under it. Install
the boom maintenance strut as instructed before
doing any maintenance work with the boom
raised. Keep people away from the machine while
you install or remove the boom maintenance strut. A
CAUTION You must climb on the machine to
install or remove the central access panels. Take
care, especially if the machine is wet. Remove B
mud and oil before you climb on the machine. Do
not put your body weight on the central access
panels.
Remove
2. Turn the ignition switch on. Do not start the C
engine.
3. Operate the auxiliary switch to discharge the
residual pressure.
4. Turn the ignition switch to off.
A Central access panel 1
6. Remove the central access panel 1. B Central access panel 2
C Cap
7. Remove the central access panel 2.
Install
8. Get access to the chassis access hole.
9. Make a note that the pilot filter is located at the
front of the chassis access hole.
steps.
10. Remove the end cap.
2. Tighten the cap to the correct torque value.
11. Remove the filter element with associated seals.
3. Run the engine and check for hydraulic leaks.
12. Discard the filter element and seals.
Item Nm
C 25
30 - 108 9823/1700-1 30 - 108

11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ......................................................................................................................... 30-111
30 - 109 9823/1700-1 30 - 109

Notes:
30 - 110 9823/1700-1 30 - 110

11 - Gear Pump
00 - General
Operation ..................................................... 30-111 The pump is a gear type and driven by the engine.
Diagram ....................................................... 30-113 The separate sections of the gear pump assembly
Check (Pressure) ........................................ 30-114 supply hydraulic oil to the main hydraulic circuits, to
Remove and Install ..................................... 30-117 the steering circuit and to the hydraulic cooling fan
circuit.
The separate sections of the gear pump operate

individually as described below.
The working principle of a gear pump depends on the

meshing of two spur gears. Oil is picked up on the
suction side of the pump by the gears and carried
round between the gear teeth and the pump body. As
the gears come into mesh the oil is forced through the
outlet port, or through an internal port into the integral
priority valve depending on the type of pump.
Some oil is allowed to circulate behind the bushes to

hold them in balance against the gears and minimise
oil leakage.
Lubrication is provided by the hydraulic oil,which is

directed around the unit via oil ways, by the motion
of the meshing gears.
For the priority valve operation, refer to (PIL 25-03).
Figure 922.
A Spur gear 1 B Spur gear 2

C Bushes 1 D Bushes 2
30 - 111 9823/1700-1 30 - 111

11 - Gear Pump
00 - General
Table 397. Colour coding

Color Coding Description
Green Pump oil inlet (suction
side)
Amber Pump oil outlet (at pump
pressure)
30 - 112 9823/1700-1 30 - 112

11 - Gear Pump
00 - General
Diagram
A typical triple pump layout is shown. For double

pump schematics and machine specific details refer
to the hydraulic systems and schematics (PIL 30-00).
Figure 923.
LS P EF F G
C A
B
Item Description
Table 398. Main components EF Control valve block sec-
Item Description ondary feed
A Main pump section LS Steering load sense port
B Steering pump section
C Fan and pilot pump sec-
tion
D Priority steer valve
E Hydraulic tank
Table 399. Port details

Item Description
F Fan and pilot valve feed
G Test point
P Pump main output
30 - 113 9823/1700-1 30 - 113

11 - Gear Pump
00 - General
Check (Pressure) Figure 925.
Special Tools
Flowmeter 892/00229 1 D
Load Valve 892/00270 1
Digital Hydraulic 998/11051 1
Pressure Test Kit
Double pump
The gear pump assembly has isolated sections that
supply hydraulic oil to the main services circuits, to
the steering circuit and to the hydraulic cooling fan
circuit. To find if the pump, steer circuit or services
circuit has a problem, measure the output flow at
system pressure from each pump outlet port.

2. Make sure that you follow the hydraulic health D Hose 1
and safety information. Refer to (PIL 30-00).
5. Connect the flow meter, digital pressure test kit
3. Discharge the hydraulic pressure. Refer to (PIL and a load valve into the discharge line from the
30-00). cooling fan pump as follows:
Figure 924. 5.1. Disconnect the hose 2 from the pump.

B 5.2. Install the flowmeter and the load valve
between the hose 2 and the pump 2.
Figure 926.
C A
A Flowmeter
B Pressure gauge
C Load valve
4. Connect the flowmeter, digital pressure test kit E
and a load valve into the discharge line from the
main service pump as follows:
Special Tool: Load Valve (Qty.: 1)
Special Tool: Flowmeter (Qty.: 1)
Special Tool: Digital Hydraulic Pressure Test Kit
(Qty.: 1) E Hose 2
4.1. Disconnect the hose 1 from the pump. 6. Make sure that the load valve and the flowmeter
4.2. Install the flow meter and the load valve is installed in the correct way with the direction
between the hose 1 and the pump 1. arrow pointing away from the pump.
7. Make sure the load valve is in the open position,
(the adjusting knob screwed fully out), before
starting the following pressure test. Failure to do
so could damage the pump.
30 - 114 9823/1700-1 30 - 114

11 - Gear Pump
00 - General
8. Start the engine and put the hydraulic system up 4.1. Install the flow meter and load valve in the
to working temperature. discharge line1 at an applicable place in the
hose and pipework. Make sure that there
are no other hydraulic connections between
9. Put the steering and control valve block spools to the pump and the load valve.
the neutral position. 4.2. Disconnect the valve from the steer priority
valve port.
10. Set the engine speed to 2200 RPM (Revolutions
Per Minute). 4.3. Install cap in the open hose.
11. Carefully adjust the load valve to make the gauge 4.4. Connect a slave hose to the hydraulic tank.
reading to the specified value. 4.5. Slowly remove the hydraulic tank filler cap
Pressure: 240 bar ( 3,478.2 psi) and place the end of the slave hose inside
the filler tube.
12. Check the flow reading.
Figure 928.
13. If the flow reading is low, you will not get the
required pressure. Refer to (PIL 30-00).
14. Switch off the engine and allow to cool after the H
test.
15. Disconnect the test equipment and connect the
hydraulic hoses again. G
Triple pump F
The gear pump assembly has isolated sections that

supply hydraulic oil to the main services circuits, to
the steering circuit and to the hydraulic cooling fan
circuit. To find if the pump, steer circuit or services
circuit has a problem, measure the output flow at
system pressure from each pump outlet port.

2. Make sure that you follow the hydraulic health
3. Discharge the hydraulic pressure. Refer to (PIL F Discharge line 1
30-00). G Priority valve port
H Slave hose
Figure 927.
5. Connect the flowmeter, digital pressure test kit
B
and a load valve into the discharge line 2 from
the steering pump as follows:
5.1. Install the flowmeter and load valve in the
discharge line 2 at an applicable place in the
the pump and the load valve.
C A
A Flow meter
B Pressure gauge
C Load valve
the main service pump as follows:
30 - 115 9823/1700-1 30 - 115

11 - Gear Pump
00 - General
Figure 929. 10. Put the steering and control valve block spools to
the neutral position.
11. Set the engine speed to 2200 RPM.
12. Carefully adjust the load valve to make the gauge
reading to the specified value.
Pressure: 240 bar ( 3,478.2 psi)
J
13. Check the flow reading.
14. If the flow reading is low, you will not get the
required pressure. Refer to (PIL 30-00).
15. Test the priority valve. Refer to (PIL 25-03).
Figure 931.
J Discharge line 2
the cooling fan pump as follows:
6.1. Install the flowmeter and load valve in the
discharge line 3 at an applicable place in the
the pump and the load valve.
Figure 930.
16. Switch off the engine and allow to cool after the
test.
17. Disconnect the test equipment and connect the
hydraulic hoses again.
K Discharge line 3
7. Make sure that the load valve and the flowmeter
are installed in the correct way with the direction
arrow pointing away from the pump.
8. Make sure the load valve is in the open position,
(the adjusting knob screwed fully out), before
starting the following pressure test. Failure to do
so could damage the pump.
9. Start the engine and bring the hydraulic system
up to working temperature.
30 - 116 9823/1700-1 30 - 116

11 - Gear Pump
00 - General
Remove and Install 5. Plug all the open ports and hoses to prevent
contamination.
be removed or handled using a suitable lifting 6. Disconnect the feed hoses.
method and device.
contamination.
Before Removal
8. For triple pump, remove the socket head screws.
1. Make the machine safe. Refer to PIL (01-03).
8.1. Disconnect the outlet pipe from the pump
2. Make sure that you follow the hydraulic health body.
Figure 933. Typical triple pump
3. Before you remove and disassemble the pump, A
check the flow and pressure. If either of these
are low and cannot be corrected at the relief
valve, replace the appropriate pump section
completely.
D
4. If you replace the pump component such as
gears, bearings and the housing will not effect a
permanent cure.
5. If the pump output is satisfactory but there is
external leakage, the pump should be removed B C
and disassembled for re-sealing only.
6. Before you remove or disassemble the pump,
make sure the exterior of the pump and working
area is thoroughly cleaned and free of possible A Flange bolts (x4)
sources of contamination. B Socket head screws
C Outlet pipe
Remove D Mounting bolts
1. Discharge the hydraulic pressure. Refer to (PIL 8.2. Plug all the open ports and hoses to prevent
30-00). contamination.
2. Drain the hydraulic fluid from the hydraulic tank 9. Use a sling to secure the pump body.
into a suitable clean container. 10. With the pump suitably supported, remove the
3. Put a label on the hoses to help installation. mounting bolts.
4. Remove the flange bolts and then disconnect the 11. Carefully remove the pump from the gearbox.
suction hose flange from the pump body. 12. Keep the drive coupling.
Figure 932. Typical double pump
Install
A
steps.
1.1. Before assembly, make sure the pump
flange and gearbox mating faces are clean
and free from oil and grease.
1.2. Install new O-ring seals.
1.3. Install the drive coupling and then engage
the pump drive into the coupling.
D
1.4. Support the pump and secure the pump to
the gearbox with the mounting bolts.
A Flange bolts (x4)
D Mounting bolts
30 - 117 9823/1700-1 30 - 117

11 - Gear Pump
00 - General
1.5. Tighten the mounting bolts to the correct

torque value.
1.6. Make sure that the mounting bolts are 10.9
grade M12 Tuf-Lok.
1.7. Make sure that correct bolts are installed.
1.8. Make sure that the hoses are correctly
installed, and phased in the same position
as removal to prevent chafing.
1.10. After you install a new or serviced pump
and before you start the engine, screw out
the MRV (Main Relief Valve) four full turns.
1.11. Adjust the MRV.
1.12. Check the fan motor speed. Refer to (PIL
21-03).
1.13. Check the hydraulic pressure. Refer to
Technical Data (PIL 30-00).

Item Description Nm
A Flange bolts 46
B Socket head screws 46
D Mounting bolts 96
30 - 118 9823/1700-1 30 - 118

15 - Cylinder / Ram
15 - Cylinder / Ram
Contents Page No.
30-15-00 General ......................................................................................................................... 30-121

30-15-06 Lift Arm ......................................................................................................................... 30-130
30-15-07 Lift Extension ................................................................................................................ 30-131
30-15-08 Lift Compensating ........................................................................................................ 30-134
30-15-11 Lift Arm Crowd ............................................................................................................. 30-135
30-15-24 Stabiliser ....................................................................................................................... 30-136
30-15-34 Steering ........................................................................................................................ 30-139
30-15-63 Sway ............................................................................................................................. 30-142
30-15-69 Axle Lock ..................................................................................................................... 30-152
30-15-99 Seal Kit ......................................................................................................................... 30-159
30 - 119 9823/1700-1 30 - 119

Notes:
30 - 120 9823/1700-1 30 - 120

15 - Cylinder / Ram
00 - General
Introduction .................................................. 30-121 A hydraulic cylinder ram is a mechanical actuator
Health and Safety ........................................ 30-122 that is used to give a single directional force
Component Identification ............................. 30-124 through a single action stroke. It is used in many
Check (Condition) ........................................ 30-125 applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
Disassemble and Assemble ........................ 30-126 consists of a cylinder barrel, in which a piston
connected to a piston rod moves back and forth.
The barrel is closed on one end by the cylinder

cap and the other end by the cylinder head where
the piston rod comes out of the cylinder. The piston
has sliding rings and seals. The piston divides the
inside of the cylinder into two chambers, the bottom
chamber (cap end) and the piston rod side chamber
(rod end / head end).
30 - 121 9823/1700-1 30 - 121

15 - Cylinder / Ram
00 - General
Health and Safety Caution During Use

1. Use only under designated conditions.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 1.1. If hydraulic oil other than the designated oil
Before connecting or removing any hydraulic hose, is used, the seals quickly degenerate and
residual hydraulic pressure trapped in the service become damaged. If the relief valve is set at
hose line must be vented. Make sure the hose a value higher than specified, it may cause
service line has been vented before connecting or ram damage and is dangerous.
removing hoses. Make sure the engine cannot be 1.2. In high temperature environments (approx.
started while the hoses are open. 90°C and above) or low temperature
Lifting Equipment environments (below -20°C), seals quickly
become damaged. Special seal materials
You can be injured if you use incorrect or faulty lifting are necessary so check to see if the ram
equipment. You must identify the weight of the item to that you are using is suitable or not.
enough and suitable for the job. Make sure that lifting 1.3. The number one cause of ram oil leakage is
equipment is in good condition and complies with all rod damage. Be careful not to damage the
local regulations. rod.
WARNING! A raised and badly supported machine 2. Warm up sufficiently before beginning work.
surface before raising one end. Ensure the other 2.1. In cold conditions the rod seals may
end is securely chocked. Do not rely solely on the be frozen, so if the ram is operated at
machine hydraulics or jacks to support the machine maximum pressure and maximum speed,
when working under it. Disconnect the battery, to the seals will be damaged.
2.2. There is a large amount of air in a new
beneath it.
ram or one which has been left for a long
time, so the ram will not operate smoothly.
Precautions for Installation Also, if pressure is applied suddenly without
bleeding the air, high temperatures will be
1. Precautions when installing the ram on the
generated due to adiabatic compression
machine.
and the seals may burn.
1.1. When installing and removing from the 2.3. Before beginning work, always move the
machine, suspend the ram safely. ram at full stroke with no load and expel air
1.2. Suspending the ram by the piping is not only from the cylinder.
dangerous, but can also cause damage to
3. When stopping or storing, do it at a safe and fixed
the cylinder.
position.
1.3. Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. 3.1. The installed ram cannot maintain the same
Also, the rod can be damaged and become position for a long period of time, because
unusable. the oil inside the ram may leak and the
hydraulic oil volume decreases as it cools.
2. Welding after installing the ram may result in Stop or store the machine in a safe and
damage. fixed position.
2.1. If electric welding is done even at a point Maintenance, Inspection Points

away from the ram, there may be sparking
inside the ram and it will become necessary 1. Carry out daily maintenance and inspection.
to replace the ram with a new one.
1.1. The key point for correct long-term
3. When painting the machine, mask the ram. If ram function is daily maintenance and
paint adheres to the rod surface or to the wiper inspection. Carry out maintenance and
ring and the ram is operated, the wiper ring will inspection so that the ram functions fully at
not function properly and foreign matter and paint all times. Always remove any mud, water,
can easily enter the ram. This will cause damage dust or oil film adhering to the rod and
to the seals, drastically shortening the life of the keep it in normal condition. However, when
ram. cleaning the wiper ring and seals, do not get
them wet with water but wipe clean with a
4. Install the ram only when it is clean.
rag. To prevent rust forming during storage,
the amount of exposed ram piston rod
30 - 122 9823/1700-1 30 - 122

15 - Cylinder / Ram
00 - General
should be kept to a minimum. If leaving for

more than one week, apply a light coating
of suitable grease or petroleum jelly to the
exposed part of the ram piston rod.
2. Use genuine JCB parts when replacing parts.
2.1. If parts other than genuine JCB parts
are used, the desired results may not be
obtained. Use only genuine JCB parts.
3. Caution during dismantling and reassembly.
3.1. Dismantling the ram while it is still installed
on the machine can be dangerous as
unexpected movements of the machine can
occur. Remove the ram from the machine
and then dismantle.
3.2. If reassembled with dirty hands, foreign
matter can enter the ram causing a shorter
life span and also the other hydraulic
equipment may be damaged. Reassemble
in a clean state.
3.3. Follow the instructions in the diagrams
regarding torque tightening for screwed
parts. If the torque is too high or too low, it
can cause damage.
30 - 123 9823/1700-1 30 - 123

15 - Cylinder / Ram
00 - General
Figure 934.
A Tilt ram B Extension ram

C Lift ram D Displacement ram
30 - 124 9823/1700-1 30 - 124

15 - Cylinder / Ram
00 - General
Check (Condition)
Check the primary components for scoring, damage,

wear, distortion, uneven surface (i.e. polished or
pitted areas) and scratches. Replace all damaged
parts.
Check the components for burrs. Give special

attention to the traversing diameters, locking pin
holes and mounting chamfers. If minor burrs are
seen, remove them by polishing with a fine grade
abrasive paper.
Check pivot bushes for signs of wear or damage.

Replace if necessary.
If a cylinder is damaged it must be replaced. New

piston seals will fail after only a short period of time
if the cylinder is worn or damaged.
30 - 125 9823/1700-1 30 - 125

15 - Cylinder / Ram
00 - General

Cleaner/Degreaser 4104/1557 0.4 L
- General purpose
solvent based parts
cleaner
JCB Activator 4104/0251 0.2 L
4104/0253 1L
JCB Threadlocker 4101/0250 0.01 L 2. Use the correct size spanner to remove the end
and Sealer (Medium 4101/0251 0.05 L cap and then remove the piston rod assembly
Strength) from the cylinder.
Lifting Equipment 3. Place the piston rod assembly on the bench in
You can be injured if you use incorrect or faulty lifting place of the ram cylinder.
equipment. You must identify the weight of the item to 4. Remove and discard the seal 1,seal 2 and the
be lifted then choose lifting equipment that is strong wear ring 1, wear ring 2 from the piston head.
equipment is in good condition and complies with all 5. Put appropriate sized screw threaded into the
local regulations. extractor hole to remove dowel from the piston
head.
Single piston rams
6. Use the correct size spanner to remove the
piston head from the rod and then discard the O-
Disassembly ring 1.
CAUTION If air or hydraulic pressure is used to
force out the piston assembly, ensure that the end 7. For extension ram, after removal of then piston,
cap is securely installed. Severe injury can be slide and remove the spacer from the piston rod.
caused by a suddenly released piston rod. 8. Remove the gland bearing and the end cap from
the piston rod.
The disassembly and assembly procedures for many
jcb hydraulic rams are same. 9. Remove the O-ring 2, wiper seal and the rod seal.
The ram must be removed from the machine before 10. Check the end cap bearing for damage, scores or
you disassemble it. nicks. If damaged, the bearing must be replaced
as part of the end cap assembly.
The ram shown in the illustration is not installed with
11. Make sure that the metal components are free
HBCV (Hose Burst Check Valve). If HBCV is installed
from scoring, nicks and burrs. A damaged piston
also with the ram, the disassembly and assembly
rod will reduce the life of gland seals.
procedure will remain unchanged and can be carried
out without the removal of the check valve. 12. Check the bore of the ram cylinder for damage.
1. Place the ram assembly on a locally
manufactured strip or on a rebuild bench.
30 - 126 9823/1700-1 30 - 126

15 - Cylinder / Ram
00 - General
Figure 936.
T S
R
U
F
A
G
J
H
E
K
L
C B
D
Q
P
N
Table 401.
Item Description
A Wear ring 1
B Seal 1
C seal 2
D Wear ring 2
E Dowel
F Piston head
G O-ring 1
H Gland bearing and end cap
J O-ring 2
K Rod seal
L Wiper seal
M Piston rod
N Seal 3
30 - 127 9823/1700-1 30 - 127

15 - Cylinder / Ram
00 - General
Item Description
P
Q Seal 4
R Seal 5
S
T Seal 6
U Cylinder
Assembly Cold weather operation, When operating in

conditions which are consistently below freezing, it is
1. Use a wire brush to the clean the threads of the recommended that the rams are operated slowly to
piston rod, end cap and cylinder. their full extent before commencing normal working.
2. Use cleaner and degreaser to make sure that all
threads are free from grease, hydraulic oil and
Piston head retention
old sealing or retaining compounds. Install the locking dowel to piston as follows:
purpose solvent based parts cleaner Existing piston head and rod
3. Make sure the degreaser is fully dried. Align holes so that dowel can be installed with the
Duration: 15 min tapped extractor hole, as shown.
4. Apply the sealant. New piston head and rod

(Medium Strength) Drill and ream piston head and rod to the diameter
and depth indicated, refer to the Refer to Table
5. Make sure that the O-rings or the seals do not 402.. Remove all swarf and contamination and install
come into the contact with the JCB activator or dowel with tapped extractor hole as shown.
anaerobic sealing and retaining compounds.
Make sure that the top of the dowel is below the level
6. Install new seals, O-rings and wear rings. of the bearing ring groove and use an undersized
pilot drill before you drill to final size.
7. Make sure that lubricants used during assembly
do not come into contact with de-greased Existing piston head and new rod
components or sealing or retaining compounds.
Drill through existing hole in piston head to the
8. Install the locking dowel to the piston. diameter and depth indicated, refer to the Refer to
9. Put the cylinder on the bench and then install the Table 402.. Remove all swarf and contamination and
piston rod assembly into the cylinder. insert dowel with tapped extractor hole as shown.
10. Apply JCB activator to threads of end cap and Make sure that the top of the dowel is below the level
cylinder. Allow JCB activator to dry for the of the bearing ring groove and use an undersized
specified time before bringing into contact with pilot drill before you drill to final size.
JCB threadlocker.
New piston head and existing rod
Duration: 15 min
Consumable: JCB Activator Same as existing piston head and new rod but at 90
° to existing hole in rod.
11. Apply sealant to the threads of the cylinder and
tighten the end cap to the correct torque value.
(Medium Strength)
If hydraulic oil make contacts with locking fluid it will

weaken the bond. Cure times vary according to the
ambient temperature. The approximate cure time for
JCB threadlocker & sealer (high strength) or JCB
threadlocker with JCB activator is 1 h, applies at 20
°C ( 68.0 °F) and is the minimum period between
assembly and filling the ram with oil.
30 - 128 9823/1700-1 30 - 128

15 - Cylinder / Ram
00 - General
Figure 937.
AH
AJ
AH Diameter
AJ Depth
Table 402. Drilling dimensions

Ram size Diameter (AH) Depth (AJ)
50 x 25 6.02 –6.1 mm 23 mm
90 x 50 8.02 –8.1 mm 28 mm
100 x 60 12.02 –12.1 33 mm
mm
110 x 60 12.02 –12.1 33 mm
mm
120 x 60 12.02 –12.1 38 mm
mm
130 x 70 12.02 –12.1 38 mm
mm
130 x 75 12.02 –12.1 38 mm
mm
140 x 75 12.02 –12.1 48 mm
mm
160 x 80 12.02 –12.1 48 mm
mm

Item Description Nm
F Piston head 405
H Gland bearing and end cap 678
30 - 129 9823/1700-1 30 - 129

15 - Cylinder / Ram
06 - Lift Arm
06 - Lift Arm Figure 939.
Remove and Install
Follow the general safety precautions for rams during

removal and installation. Refer to (PIL 30-15).
Remove
1. Raise the lift arm to get access to the lower pivot
of the lift ram. Retract the lift arm fully. Support
the front end of the lift arm.
safe.
C C
Refer to (PIL 01-03). C Feed pipes
4. Remove the bolt 1 and take out the upper pivot Figure 940.
pin.
5. Select the lift arm lower operation and bring down
the ram until it is just closed.
30-00).
7. Disconnect the hydraulic feed pipes and install D
plugs on the hydraulic pipes.
8. Remove the wheel to access the drive out lower E
pivot pin.
9. Support the ram. D Bolt 2
10. Remove the bolt 2 and take out the lower pivot E Lower pivot pin
pin.
Install
11. Remove the ram from the machine.
Figure 938. removal procedure. Additionally do the following
steps.
B 1.1. Grease the ram pivot pins. Refer to (PIL
06-30).
1.2. Check the hydraulic oil level. Refer to (PIL
30-00).
1.3. Tighten fastenings to the correct torque
value. Refer to (PIL 72-00).
A Bolt 1
B Upper pivot pin
30 - 130 9823/1700-1 30 - 130

15 - Cylinder / Ram
07 - Lift Extension
07 - Lift Extension Lubricate

Lubricate ...................................................... 30-131 There are 2 grease points for lubrication of the lift arm
Remove and Install ..................................... 30-132 extension cylinder ram. Refer to Figure 941.
Figure 941.
30 - 131 9823/1700-1 30 - 131

15 - Cylinder / Ram
07 - Lift Extension
CAUTION This component is heavy. It must only B

be removed or handled using a suitable lifting D
method and device.
C
Remove
1. Raise the lift arm to the horizontal position and
retract the lift arm fully. Support the front end of
the lift arm.
A
4. Discharge the hydraulic pressure. Follow the
health and safety precautions. Refer (PIL 30-00).
5. Disconnect and install a plug on the hydraulic
feed pipes to the ram.
6. Support the ram.
A Feed pipes
7. Loosen and remove the nut and bolt 1. B Nut
C Bolt 1
8. Take out the pivot pin1 from the rear pivot. D Pivot pin 1
9. Remove the bolt 2 and take out the pivot pin 2 Figure 943.
from the front pivot.
E
10. Slowly drive the machine forward until the ram is
out of the bracket.
E Bolt 2
F Pivot pin 2
G Bracket
Install
removal procedure. Additionally do the followings
steps.
30 - 132 9823/1700-1 30 - 132

15 - Cylinder / Ram
07 - Lift Extension
1.1. Install the ram correctly on the machine. 1.3. Grease the ram pivot pins. Refer to (PIL
Position the regenerative valve ports as 06-30).
shown in the figures. Refer to Figure 944.
and Refer to Figure 945.
Figure 944. 506-36, 507-42,
509-42 and 510-42 machines
H Regenerative valve ports

Figure 945. 510-56, 512-56 and 514-56 machines
H Regenerative valve ports

1.2. Check the chain adjustment. Refer to (PIL
06-12-66).
30 - 133 9823/1700-1 30 - 133

15 - Cylinder / Ram
08 - Lift Compensating
08 - Lift Compensating Figure 947.
C C
Remove and Install
Remove
Follow the general safety precautions for rams during E
removal and installation. Refer to health and safety, D
(PIL 30-15-00).
1. Raise the lift arm and access the lower pivot of

the displacement ram. Retract the lift arm fully.
Support the front end of the lift arm.
2. Make the machine safe. Follow the safety
precautions. Refer (PIL 30-00).
3. Remove the bolt 1 and take out the upper pivot
pin. C Feed pipes
D Bolt 2
4. Select tilt back until the displacement ram closes. E Lower pivot pin
30-00). Install
6. Disconnect the hydraulic feed pipes to the ram 1. The installation procedure is the opposite of the
and install plugs on the hydraulic pipes. removal procedure. Additionally do the following
steps.
7. Disconnect the remote greasing connection.
1.1. Grease the ram pivot pins. Refer to (PIL
8. Support the ram. 06-30).
9. Remove the bolt 2 and take out the lower pivot 1.2. Check the hydraulic oil level and top up as
pin. required. Refer to (PIL 30-00).

Figure 946.
B A
A Bolt 1
B Upper pivot pin
30 - 134 9823/1700-1 30 - 134

15 - Cylinder / Ram
11 - Lift Arm Crowd
11 - Lift Arm Crowd Figure 949.
Remove and Install C

E
Remove
Follow the general safety precautions for rams during
removal and installation. Refer to (PIL 30-15).
D
1. Put the lift arm in such a position that, the lift arm
does not touch the floor.
3. Follow the hydraulic system, health and safety
procedures. Refer (PIL 30-00).
4. Remove the bolt 1 and take out the outer pivot
pin.
5. Select tilt back and close the ram.
30-00).
7. Disconnect and install plug on the hydraulic feed
pipes to the ram.
8. Support the ram.
9. Remove the bolt 2 and take out the inner pivot
pin.
10. Remove the ram from the machine. C Bolt 2
D Inner pivot pin
Figure 948. E Ram
B Install
A removal procedure. Additionally do the following
steps.
06-30).
1.2. Check the hydraulic fluid level and top up as
A Bolt 1
B Outer pivot pin
30 - 135 9823/1700-1 30 - 135

15 - Cylinder / Ram
24 - Stabiliser
24 - Stabiliser
Remove and Install
(For: 510-56 [T2/T3], 512-56 [T2/T3]) 4. Support the stabiliser leg.

Special Tools 5. Put a label on each hydraulic hose to help
Description Part No. Qty. installation.
6. Disconnect the stabiliser ram hydraulic hoses.
CAUTION This component is heavy. It must only 7. Plug all the open ports and hoses to prevent
be removed or handled using a suitable lifting contamination.
method and device.
8. Remove the screws that secure the pressure
switch cover.
Remove
9. Remove the pressure switch cover to access the
The illustration and procedure is for the removal of pressure switch harness connector.
one stabilizer ram. The same procedure is applicable
for the second ram also. 10. Remove the nut and bolt 1.
The stabilizer ram can be removed without removing 11. Remove the ram pivot pin 1 with the slide
the stabilizer leg. hammer kit. Refer to (PIL 06-30).
12. Remove the nut and the bolt 2.
30-00). 13. Remove the ram pivot pin 2 with the slide
hammer kit. Refer to (PIL 06-30).
for rams during removal and installation. Refer to 14. Lift the stabiliser ram and release it from the
(PIL 30-15). stabiliser leg.
30 - 136 9823/1700-1 30 - 136

15 - Cylinder / Ram
24 - Stabiliser
Figure 950.
A F
A
G
H
J
B K
D
C
A Hydraulic hoses B Pressure switch cover securing screws

C Pressure switch harness connector D Pressure switch cover
E Bolt 1 F Ram pivot pin 1
G Stabiliser ram H Stabiliser leg
J Bolt 2 K Ram pivot pin 2
30 - 137 9823/1700-1 30 - 137

15 - Cylinder / Ram
24 - Stabiliser
Install
steps.
06-30).
1.2. Check the hydraulic fuel level. Refer to (PIL
30-00).
30 - 138 9823/1700-1 30 - 138

15 - Cylinder / Ram
34 - Steering
34 - Steering Remove and Install

Remove and Install ..................................... 30-139 Working Under the Machine
Disassemble and Assemble ........................ 30-141 Make the machine safe before getting beneath it.
movement.
Remove
Before you remove the steer rams clean the area
around the axle and steer rams.
The following procedure applies to each of the

steering rams on the front and rear axles:

4. Disconnect all the three hoses.
5. Plug all the open ram ports and hoses to prevent
contamination.
6. Remove the screws and the pins from each end
of the ram.
7. Lift the ram from the axles.
Figure 951.
B
C
A
A Hoses B Screws
C Pins
30 - 139 9823/1700-1 30 - 139

15 - Cylinder / Ram
34 - Steering
Install
steps.
1.1. Tighten the screws to the correct torque
value.
steering system. Refer to (PIL 25-00).

Item Description Nm
B Screws 56
30 - 140 9823/1700-1 30 - 140

15 - Cylinder / Ram
34 - Steering
Refer to Hydraulic system, cylinder ram, general (PIL

30-15-00).
30 - 141 9823/1700-1 30 - 141

15 - Cylinder / Ram
63 - Sway
63 - Sway Bleed
Bleed ........................................................... 30-142 Communications
Remove and Install ..................................... 30-144 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.
Sway Ram Bleed Procedure

The sway ram has an integral bleed valve which can
be used to bleed the sway ram circuit.
Make sure that the lift arm is in lowered position when

the sway ram circuit is bled.
Two persons are required to do this procedure. One

person to operate the sway controls and another to
tighten the bleed screw when all air is removed. If this
procedure is done by one person, air may enter the
cylinder due to delay in dismounting from the cab to
attend the sway cylinder.

30-00).
4. Make sure that the sway ram bleed valve is
closed, because, if opened the machine may
sway unexpectedly.
4.1. Make sure to open the bleed valve only after
the machine is swayed fully to the left or
right.
4.2. Do not stand between the chassis and
the wheel because you can be trapped or
crushed when the sway is operated.
4.3. The bleed valve should only be completely
removed from the valve body to allow
cleaning of the integral orifice. The orifice
diameter is
Dimension: 1.2 mm
5. Start the engine.
6. Operate the sway lever to sway the machine fully
to the operator's left side (sway ram extended).
7. Stop the engine and discharge the hydraulic
pressure. Refer to (PIL 30-00).
30 - 142 9823/1700-1 30 - 142

15 - Cylinder / Ram
63 - Sway
8. Tell the assistant to carefully loosen the bleed

valve and expect hydraulic fluid to escape. Make
sure the bleed valve is not unscrewed more than
Length: 6.5 mm
10. Operate the sway lever to sway the machine fully
to the operator's left side.
11. Hold the lever in this position.
12. Make sure that the air is removed completely
through the bleed valve.
13. Return the control lever to the neutral position.
14. Tighten the bleed valve immediately to prevent
air entering the circuit.
Figure 952.
A Bleed valve
15. Operate the sway ram fully in both directions 10
times.
16. Repeat steps 7 to 17.
17. Stop the engine and remove the ignition key.
18. Check the hydraulic fluid level and top up as
30 - 143 9823/1700-1 30 - 143

15 - Cylinder / Ram
63 - Sway
Remove and Install
CAUTION This component is heavy. It must only 5. Put a label on each hose to help installation.
method and device. 6. Disconnect the sway ram hydraulic hoses.
Follow the general safety precautions for rams during 8. Support the sway ram.
removal and installation. Refer to (PIL 30-15). 9. Remove the nut 1 and bolt 1 and then take out
the pivot pin 1 from the cylinder end.
10. Attach the correct lifting equipment to the cylinder
2. Follow the general hydraulic safety procedures.
end of the ram. Support the ram.
11. Remove the nut 2 and the bolt 2 and then take
out the pivot pin 2 from the rod end.
30-00).
4. Support the chassis on both the sides of the
machine.
30 - 144 9823/1700-1 30 - 144

15 - Cylinder / Ram
63 - Sway
Figure 953.
F C
A
B
A Sway ram hydraulic hoses B Sway ram

C Bolt 1 D Pivot pin 1
E Bolt 2 F Pivot pin 2
30 - 145 9823/1700-1 30 - 145

15 - Cylinder / Ram
63 - Sway
Install
steps.
06-30).
1.3. Bleed the sway ram. Refer to (PIL
30-15-63).
30 - 146 9823/1700-1 30 - 146

15 - Cylinder / Ram
66 - Rear Axle Stabilization (RAS)
66 - Rear Axle Stabilization (RAS) Remove and Install

(For: 507-42 [T2/T3], 509-42 [T2/T3],
510-56 [T2/T3], 512-56 [T2/T3])
WARNING The RAS rams control the rear axle
oscillation. Removal of the RAS ram or RAS
system components can make the machine
unstable. Make sure the left and right sides of the
chassis are correctly supported before removal of
RAS system components.
WARNING The normal hydraulic pressure
venting procedure will not vent the pressure from
the RAS ram circuit.
WARNING When venting the RAS circuit, oil
will discharge at very high pressure. Make sure
the vent hose is correctly retained and that
appropriate safety precautions are observed.
Make sure that both the left and right side rams
are vented even if only one ram is to be removed.
method and device.
Remove
30-00).
4. Make sure you support the chassis on both sides
of the machine.
5. Release the hydraulic pressure from the left hand
and right hand side RAS (Rear Axle Stabilization)
rams.
5.1. Attach one end of the vent hose to the
pressure test adaptor and hold the other
end in the suitable container. Refer to
Figure 954.
5.2. Hydraulic pressure of the RAS ram will
release immediately as the vent hose is
connected to the ram.
5.3. Do the above steps again to release
pressure for the other side RAS ram.
30 - 147 9823/1700-1 30 - 147

15 - Cylinder / Ram
Figure 954. 6. Oil will flow through the vent hose at a pressure of
30 bar. Make sure that the vent hose is attached
correctly.
7. Discharge the hydraulic pressure from both the
left hand and right hand side RAS rams, even if
only one ram is to be removed.
B
8. Remove the screws to remove the valve cover.
solenoid valve. Refer to Figure 955.
A
A Right hand RAS ram

B Pressure test adaptor
Figure 955.
D
E
C Valve cover D Solenoid valve

E Electrical connector
10. Put labels on the hoses to help installation. 12. Plug all the open ports and hoses to prevent
contamination.
11. Disconnect the hydraulic hoses from inside the
chassis. Refer to Figure 956.
30 - 148 9823/1700-1 30 - 148

15 - Cylinder / Ram

L
F K
F Hydraulic hoses
13. Disconnect the hydraulic hose that connects to H
the solenoid valve. Refer to Figure 957.
contamination. J
Figure 957. H Nut and bolt
J Rod end pivot pin
K Nut
L Bolt
M Cylinder end pivot pin
G 19. Remove the ram from the machine.

20. Do steps 8 thru 19 to remove the LH side RAS
ram.
Install
D 1. The installation procedure is the opposite of the
steps.
D Solenoid valve 1.1. Apply the grease to the ram pivot pins.
G Hydraulic hose
1.2. Bleed and do the operational test of the
15. Support the RAS ram. RAS system. Refer to (PIL- 30-15-66).
16. Remove the nut and bolt to remove the pivot pin
from the rod end. Refer to Figure 958.
17. Use suitable lifting equipment to support the
cylinder end of the ram.
18. Remove the nut and bolt to remove the pivot pin
from the cylinder end. Refer to Figure 958.
30 - 149 9823/1700-1 30 - 149

15 - Cylinder / Ram
(For: 507-42 [T2/T3], 509-42 [T2/T3], 5. Support the chassis on both sides of the
510-56 [T2/T3], 512-56 [T2/T3]) machine.
6. Discharge the hydraulic pressure from the left
If necessary, remove the following components from
and right side RAS rams.
the rams:
7. Install a vent hose to coupling and at the same
• Solenoid valve time hold the other end of the hose inside a
• Thermal relief valve suitable container. Pressure will vent as soon as
the hose is connected at the ram.
• Check valve
WARNING! The RAS rams control the rear axle 8. Repeat the procedure for the ram on the other
oscillation. Removal of the RAS ram or RAS system side of the machine.
components can make the machine unstable. Make 9. Make sure you release the trapped hydraulic
sure the left and right sides of the chassis are pressure from both the left and right side rams,
correctly supported before removal of RAS system even if components from only one ram are to be
components. removed.
WARNING! The normal hydraulic pressure venting
procedure will not vent the pressure from the RAS Disassemble
ram circuit.
WARNING! When venting the RAS circuit, oil will Solenoid valve
discharge at very high pressure. Make sure the vent
hose is correctly retained and that appropriate safety 1. Remove the cover. Remove dirt and debris from
precautions are observed. Make sure that both the the valve block.
left and right side rams are vented even if only one 2. Disconnect the electrical connector at the
ram is to be removed. solenoid valve.
The valve block is part of the ram. If the valve block 3. Remove the nut and take out the solenoid coil.
is defective, make sure you install a new ram.
4. Remove the valve cartridge from the valve block.
If one or more of these components are to be
removed, with the RAS (Rear Axle Stabilization) ram Thermal relief valve
still installed on the machine, first do the procedure
that follows: 1. Remove the cover. Remove dirt and debris from
the valve block.
Support the left and right sides of the chassis before
you remove the RAS ram components. 2. Remove the plug.
1. Make the machine safe. Refer to (PIL 01-03). 3. Remove the valve cartridge from the valve block.
2. Discharge the hydraulic pressure. Refer to (PIL Check valve

30-00).
1. Remove the cover. Remove dirt and debris from
3. Follow the general safety precautions for the the valve block.
rams during removal and installation. Refer to
(PIL 30-15). 2. Remove the valve cartridge from the valve block.
4. The normal hydraulic pressure release

procedure will not release the pressure from the
RAS ram circuit.
30 - 150 9823/1700-1 30 - 150

15 - Cylinder / Ram
Figure 959.
H J
C
A D
G
F
E
A Coupling B Cover
C Valve block D Electrical connector
E Nut F Solenoid coil
G Valve cartridge 1 H Plug
J Valve cartridge 2 K Valve cartridge 3
Assemble
following steps.
1.1. If the O-ring seals are worn or defective,
install new O-ring seals.
1.2. Tighten the valves and plugs to the correct
torque value.
1.3. Bleed and test the RAS system. Follow the
correct procedures

Item Nm
E 6.1
G 47.5
J 6.1
K 40.6
30 - 151 9823/1700-1 30 - 151

15 - Cylinder / Ram
69 - Axle Lock
69 - Axle Lock Introduction

Introduction .................................................. 30-152 The rear axle lock system uses a hydraulic ram to
Component Identification ............................. 30-153 prevent movement of the rear axle when using the
Operation ..................................................... 30-154 work platform.
Bleed ........................................................... 30-157
30 - 152 9823/1700-1 30 - 152

15 - Cylinder / Ram
69 - Axle Lock
Figure 960.
B B
A D F G H
E
C
A End cap 90 x 50 S-E assembly B Piston seal

C Wear ring D End cap 90 x 50 S-E assembly
E Piston rod head assembly F Nut
G Eye end H Grease nipple
30 - 153 9823/1700-1 30 - 153

15 - Cylinder / Ram
69 - Axle Lock
Operation
Controls provided. The pump allows the platform to be safely

lowered to the ground from the platform or the cab.
Control of the lift arm is via a servo control lever in the
cab or a remote control unit from the JCB platform. Pressing the machine isolation push button stops
Both control systems operate the same servo control the engine and hydraulic system in an emergency.
valve. The Platform also has an emergency stop (isolation)
button.
A safety key system prevents operation of the lift arm
by the cab control lever and remote control unit at Longitudinal Load Moment Control
the same time. When the machine is operated from (LLMC) (If installed)
the cab it is in Cabin Mode. When the machine is
operated from the remote control unit it is in Remote The LLMC (Longitudinal Load Moment Control)
Mode. system is active with the lift arm retracted
on machines with Work Platforms. On standard
All the control signals are processed by the JCB ECU machines the LLMC system is not active when the
(Electronic Control Unit) located under the operator’s lift arm is fully retracted.
seat.
LLMC is always active when the JCB work platform
Remote Servo Control is operated by the remote control unit.
The JCB work platform system enables remote The LLMC system automatically reduces the speed
control of the lift arm lift, lower, extend, retract, tilt and of the lift arm hydraulic services. When the machine
engine speed functions by an operator located in the is nearing its maximum working limit (when it could tip
platform. The control of these functions is achieved forward) an intermittent audible alarm sounds. When
through a remote control unit radio transmitter the machine is at its maximum working limit forward
and radio receiver. Before remote operation is reach of the platform is prevented. A continuous
enabled, there are safety interlocks which require the audible alarm sounds.
machine’s park brake to be on and the stabiliser legs
to be down. Switches and sensors indicate the status For information about the LLMC system refer to the
of the park brake and stabilisers. machine Operator Manual or Service Manual.
The stabiliser and sway systems are isolated when System Operation
the machine is in remote mode.
An overload switch is installed to the platform. If
The LMI (Load Moment Indicator) transducer the platform exceeds the specified weight the switch
measures the load exerted on the rear axle and informs the ECU. The ECU isolates all platform
sends a signal to the JCB ECU. When the machine operations. This is indicated by a Yellow light
is near its maximum working limit (when it could tip illuminating on the remote control unit.
forward), the JCB ECU prevents forward reach of the
platform (extending and lowering). The remote control unit must be correctly “Docked” in
the platform. If the remote control unit is not correctly
When the system is operated in remote mode a “Docked” it will not operate.
safety system monitors operation of the remote
control unit. If the unit is not operated during the When docking the remote control unit on the platform
specified time period the engine automatically stops. make sure not to depress the remote control unit
If necessary the engine can be re-started by use of emergency stop button. The remote control unit will
the remote control unit. The specified time period is not operate if this emergency stop is depressed.
10 min.
Interlocks are installed to ensure correct operation of
Emergency Operation cabin mode and remote mode. The table explains the
operating logic.
In case of emergency, (engine failure for example)
an independent electrically driven hydraulic pump is
Table 406. Operating Logic
Function Cabin Mode Remote Mode
Engine start Yes Yes
(1)
Stabilisers Yes (2)
30 - 154 9823/1700-1 30 - 154

15 - Cylinder / Ram
69 - Axle Lock
Function Cabin Mode Remote Mode

Sway Yes (3)
Lift arm raise Yes Yes

Lift arm lower Yes Yes
Lift arm extend Yes Yes
Lift arm retract Yes Yes
Tilt Yes Yes
(4)
Auxiliary hydraulics Yes

Platform slew (If installed) Yes Yes
LLMC Yes Yes
(5)
Engine speed control Yes Yes

Automatic engine speed control Yes
Engine stop Yes Yes
(6)
Engine stop (After safety time peri- Yes

(7)
od)
Emergency stop (Cab isolation but- Yes
ton)
Emergency stop (Platform isolation Yes
button)
Emergency lift arm operation Yes
(8)
Yes
(8)
(1) Stabilisers must be down and the park brake must be on before engine will start.
(2) Stabiliser service is isolated. Control must be switched back to cabin mode to re-activate stabiliser service.
(3) Sway service is isolated. Control must be switched back to cabin mode to re-activate sway service.
(4) Only when lift arm angle is below 10 °.
(5) LLMC operates at all times when in Remote Mode, even with the lift arm fully retracted.
(6) If the engine is running when remote mode is selected, the engine will stop. The engine must be re-started
by use of the remote control unit.
(7) If the remote control unit is not operated during a 10 min period the engine automatically stops. If necessary
the engine can be re-started by use of the remote control unit.
(8) Enables the emergency electric hydraulic pump. Only lift arm lower and retract services operate. The system
will not enable lift arm operation in the event of control valve failure.
Table 407. Light and Alarm Logic

Condition Red LED (Light Yellow LED 2 LED 3 Remote Alarm Alarm active
Emitting Diode)
1
Platform over- On Flashing Slow flashing Off On
load green
LLMC cut out On Off Slow flashing Off On
green
Emergency stop On Flashing Slow flashing Off On
- platform green
Emergency stop Off Off Off 1 beep Off
- remote
Emergency stop Off Off Red 1 beep Off
- remote active -
wake up
Emergency stop On Flashing Slow flashing Off On
- cab green
Park brake off Off Off Off Off Off
Direction selec- Off Off Off Off Off
tion - column
switch
30 - 155 9823/1700-1 30 - 155

15 - Cylinder / Ram
69 - Axle Lock
Condition Red LED (Light Yellow LED 2 LED 3 Remote Alarm Alarm active
Emitting Diode)
1
Lowering below On Off Slow flashing Off On
2m green
Activating the On Off Slow flashing Off Off
horn green
Remote - single Off Off Red 1 beep Off
button press
Remote - button Off Off Orange Off Off
press and hold
Pairing cycle 2 s on 2 s on Quick flashing Off Off
green
Paired Off Off Slow flashing Off Off
green
Starting machine On Off Slow flashing Off On
green
Emergency low- Off Off Off Off Off
er platform sig-
nal
Platform locking On Flashing Slow flashing Off On
pins green
30 - 156 9823/1700-1 30 - 156

15 - Cylinder / Ram
69 - Axle Lock
Bleed Remove and Install
The rear axle locking ram is self bleeding. Refer to Remove

check operation (PIL 30-15-69).
method and device.
CAUTION This component must not be lifted by
the pipes. Make sure you use the correct lifting
procedure.

2. Lower the lift arm and the carriage to the ground.
3. Release the hydraulic pressure. Refer to
hydraulic system- general (PIL 30-00).
4. Support the chassis on both sides of the
machine.
5. Remove the blanking bolt and install the correct
lifting eye in to the top of the ram rod and connect
a suitable lifting device.
6. Remove the lower mount bolt and locknut.
7. Remove the pivot pin.
8. Disconnect the hydraulic hoses from the valve
block.
30 - 157 9823/1700-1 30 - 157

15 - Cylinder / Ram
69 - Axle Lock
Figure 961. Real Axle Lock Ram Lower Mounting

G
F Remove
1. Remove the rear axle lock ram.
F
2. Remove the bolts, nuts and washers and
spreader plate.
D
B
D 3. Remove the lower mounting casting.
A
Install
1. Position the casting with the pivot pin retaining
E
bolt towards the rear of the machine.
C 2. Install the two bolts, washers and nuts and
tighten to the correct torque.
Figure 962. Lower Mounting
K
L H
J
H
A Hydraulic hose
B Hydraulic hose
C Lower mount bolt and locknut
D Upper mount bolts (x4) and spacers
E Pivot pin
F Threaded backplates (Chassis not shown for
clarity)
G Blanking bolt and sealing washer (Lifting eye H Lower mounting casting bolts / nuts / washers
installation point) J Pivot pin retaining bolt location
K Lower mounting casting
8.1. Put a label on the hoses to help installation. L Rear axle
contamination. Table 408. Torque Values
Item Nm
9. Remove the upper mount bolts and lift the
assembly from the machine. Make sure you D 562
retain the threaded backplates. H 621
Install
steps.
1.1. Make sure the threaded backplates
and spacers are located correctly when
installing the lower mount bolts.
1.2. Tighten all fastenings to the correct torque.
Refer to (PIL 72).
1.3. Remove the lifting eye and install the
blanking bolt and sealing washer.
1.4. Grease the pivots.
1.5. Bleed the lock ram. Refer to (PIL 30-15-69).
30 - 158 9823/1700-1 30 - 158

15 - Cylinder / Ram
99 - Seal Kit
99 - Seal Kit Figure 963.
Remove and Install

Special Tools
Ram Protection Sleeve 892/00167 1
(90mm rod diameter)
Ram Seal Installation 892/00334 1 A Ram seal installation tool
Tool B Pins
Ram Protection Sleeve 892/01016 1 1.2. Open the seal installation tool and insert
(25mm rod diameter) the new rod seal. Install the seal behind the
Ram Protection Sleeve 892/01017 1 two front pins but in front of the rear pin as
(30mm rod diameter) shown.
Ram Protection Sleeve 892/01018 1 Figure 964.
(40mm rod diameter)
(50mm rod diameter)
- Slew (50mm rod
diameter)
(60mm rod diameter)
- Slew (60mm rod
diameter)
A Rod seal
(65mm rod diameter) 1.3. Later ram end caps and piston heads
Ram Protection Sleeve 892/01024 1 have metric threads. The seals are also
(70mm rod diameter) different, make sure that the correct seals
Ram Protection Sleeve 892/01025 1 are installed. On metric threaded rams,
(75mm rod diameter) make sure that the seals are installed the
correct way around, as shown.
(80mm rod diameter) Figure 965.
Ram Seal Assembly 892/01027 1
Tool
Remove
1. Remove and discard the old seals.
Install
1. Install new rod seals:
A Inner seal
1.1. Use the ram seal installation tool to install B Outer seal
rod seals, the size (diameter) and position
of pins is determined by the diameter and 1.4. Close the tool. The seal must form a
radial width of the rod seal being installed. reniform (kidney shape).
The pins are screwed into threaded holes
in the tool body, the spacing of the holes is
designed to suit small or large diameter rod
seals.
Special Tool: Ram Seal Installation Tool
(Qty.: 1)
30 - 159 9823/1700-1 30 - 159

15 - Cylinder / Ram
99 - Seal Kit
Figure 966. Special Tool: Ram Protection Sleeve - Slew

(60mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
1.5. Before you install the rod seals, check that (80mm rod diameter) (Qty.: 1)
the seal grooves are free of contamination Special Tool: Ram Protection Sleeve
and sharp edges. (90mm rod diameter) (Qty.: 1)
1.6. Locate the seal in the end cap groove. Figure 968.
When the seal is in position, open the tool
to release the seal. Make sure the seal is
correctly installed in its grooved and remove
the tool.
Figure 967.
A Protection Sleeve (various sizes)

2. Install new head piston seals.
2.1. Use the Piston seal assembly tool to lever
the inner seal into the piston head seal
groove. Do not let the seal twist. There are
identification marks on the outer diameter
1.7. Install the rod wiper seal into the seal of the seal, make sure that the marks are
groove. Make sure that the seal is correctly visible and the seal is free to rotate, if not
installed as shown. Note: Some rod wipers, remove the seal and retry.
i.e. power track rod, may use a metal
encased seal which is pressed into the Special Tool: Ram Seal Assembly Tool
housing. Care must be taken to make sure (Qty.: 1)
that the seal is square before it is pressed Figure 969.
in.
1.8. A special sleeve must be used to protect
the rod seals from damage, when installing
the end cap on to the piston rod. There are
various sizes of sleeve, make sure you use
the correct size sleeve and also make sure
that the hexagon on the end cap is towards
the eye end of the rod.
Special Tool: Ram Protection Sleeve - Slew A Piston seal assembly tool
(50mm rod diameter) (Qty.: 1) B Inner seal
Special Tool: Ram Protection Sleeve C Outer seal
30 - 160 9823/1700-1 30 - 160

15 - Cylinder / Ram
99 - Seal Kit
2.2. Use the same procedure to install the outer

seal as stated for the inner seal. Check that
the external grooves are visible.
2.3. Make sure that the O-ring is installed into
the internal seal groove on the piston head.
Screw the piston head on to the thread of
the piston rod and tighten to the correct
torque value.
2.4. Install the piston head retaining dowel.
2.5. Install wear rings, rotate the wear rings so
that the piston retention dowel is covered by
the wear ring, not as shown at C.
Figure 970.
A Outer wear ring

B Inner wear ring
C Incorrect installation
3. Install the piston rod and head assembly into the
cylinder.
3.1. Insert the piston/rod assembly into the
cylinder ram. Align the rod and head
assembly until parallel with the cylinder ram
then push the assembly into the cylinder.
3.2. Install the end cap and assemble the ram
assembly.
30 - 161 9823/1700-1 30 - 161

18 - Accumulator
18 - Accumulator
Contents Page No.
30-18-00 General ......................................................................................................................... 30-163
30 - 162 9823/1700-1 30 - 162

18 - Accumulator
00 - General
Introduction .................................................. 30-163 A hydraulic accumulator is a pressure storage
Health and Safety ........................................ 30-164 reservoir used to store hydraulic fluid, the non-
Component Identification ............................. 30-164 compressible hydraulic fluid is held under pressure
Discharge and Pressurise ........................... 30-165 by a compressed nitrogen gas. It is designed to
increase or relieve pressure in the hydraulic system.
Accumulators enable a hydraulic system to cope with

extremes of demand using a less powerful pump, to
respond more quickly to a temporary demand, and
to smooth out pulsations.
It is not possible to disassemble the accumulators.

The extent of permissible servicing is limited to
checking the nitrogen gas pre-charge pressure. If an
accumulator is suspected as being faulty it must be
renewed as a complete assembly.
Make sure you have read and understood the Health

and Safety implications. Refer to: PIL 30-18-00.
There are three different types of accumulator

installed on JCB machines:
• Diaphragm (sealed for life) - Non

Rechargeable.
• Diaphragm (with gas valve) - Rechargeable.
• Piston Bladder - Rechargeable.
Although some accumulators are identical in

appearance, the accumulators are charged to
different pressures. When renewing an accumulator
make sure you know the correct charge pressure,
refer to the applicable Technical Data.
Upon installation of a new accumulator the correct

label stating the charge pressure must be attached.
The original label which states a zero charge must
be removed.
30 - 163 9823/1700-1 30 - 163

18 - Accumulator
00 - General
Health and Safety Component Identification

DANGER Use only nitrogen gas to charge
accumulators. The use of any other gas can Figure 971.
cause the accumulators to explode. Remember
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your
workplace. Do not allow excessive quantities of
nitrogen to be discharged into the atmosphere.
CAUTION To reduce pressure use the
recommended charging tool or the charge valve
could be damaged which may result in rapid C
discharge of the accumulator.
WARNING You must vent all the hydraulic
pressure from the accumulators before A
disconnecting them from the hydraulic system.
Replacement accumulators will only be supplied in B

an uncharged, non pressurised condition to meet
Health and Safety, and Air freight hazardous goods
requirements.
A Diaphragm (non rechargeable sealed for life)

B Diaphragm (rechargeable with gas valve)
C Piston bladder (rechargeable)
30 - 164 9823/1700-1 30 - 164

18 - Accumulator
00 - General
Discharge and Pressurise Figure 972.
Special Tools
Accumulator Charging 892/01042 1 B
Kit (Diaphragm)
Accumulator Charging 892/01043 1 A
J
Adaptor
WARNING You must vent all the hydraulic

pressure from the accumulators before
C
disconnecting them from the hydraulic system.
DANGER Use only nitrogen gas to charge F
accumulators. The use of any other gas can H G
cause the accumulators to explode. Remember
that although nitrogen is not poisonous you can
be killed by suffocation if it displaces the air in your D
workplace. Do not allow excessive quantities of
nitrogen to be discharged into the atmosphere.
E
Before removing accumulators make sure hydraulic
pressure is released.
Even when the hydraulic pressure is released the A Adaptor

accumulator still contains pressurised nitrogen gas. B Filler plug
Do not attempt to discharge the gas pressure. C Gas bottle valve
D Pressure regulator
Do not transport accumulators charged with E Charging hose
pressurised gas by air freight. F Discharge plug
G Charging unit
Charging H Charging unit knob
J Pressure gauge
Important: The following charging procedure is only 1. Hold the accumulator vertical and remove the
applicable to accumulators supplied in a discharged plastic cap from the top of the accumulator.
state.
2. Note: Some accumulators are supplied with a
Operating charge pressures: Accumulators are measured quantity of oil inside the gas chamber.
charged to different operating pressures depending Take care to prevent oil loss.
on the application. Refer to: PIL 30-18. for the
correct charge pressure. 3. With a suitable allen key, slowly remove the filler
plug.
Charge the replacement accumulator with nitrogen
as follows: 3.1. Remove the sealing washer and plug.
3.2. Lightly oil the sealing washer.
3.3. Install the new plug.
3.4. Loosen the plug by 1/8 of a turn.
4. Connect the accumulator adaptor to the
accumulator.
Special Tool: Accumulator Charging Adaptor
(Qty.: 1)
5. Connect the charging unit to the accumulator
adaptor.
Special Tool: Accumulator Charging Kit
(Diaphragm) (Qty.: 1)
30 - 165 9823/1700-1 30 - 165

18 - Accumulator
00 - General
6. Connect the charging hose to the pressure Figure 973.

regulator on the nitrogen gas bottle with the
correct adaptor.
7. Set the pressure regulator on the gas bottle to
the minimum pressure.
8. Turn the charging tool knob to open the filler plug
by three turns.
9. Open the discharge valve on the charging unit.
10. Carefully open the nitrogen gas bottle valve and
A
make sure that the nitrogen gas flows freely
through the discharge valve.
C
11. Close the gas bottle valve and the discharge
valve. B
12. Carefully open the gas bottle valve.

13. Slowly increase the pressure using the gas bottle
pressure regulator and watching the gauge on
the charging unit, allow nitrogen to flow until
the pressure reading reaches the specified value A Label position
above the operating charge pressure. B Discharged state label
Pressure: 4 bar ( 58.0 psi) C Pressurised warning label
14. Important: Do not exceed the maximum working 25. Install the accumulator and make sure the
pressure of the accumulator. The maximum pressurised warning label is clearly visible.
working pressure is marked on the accumulator
body.
15. Close the gas bottle valve.
16. Wait for the specified duration to dissipate the
heat generated during charging.
Duration: 10 min
17. Carefully open and close the discharge valve to
reduce the pressure in the accumulator to the
specified operating charge pressure.
18. Turn the charging tool knob to close the filler plug
and tighten to the correct torque value.
Torque: 20 N·m
19. Open the discharge valve to release the pressure
from the charging hose.
20. Disconnect the charging unit and adaptor from
the accumulator.
21. Pour oil around the filler plug to make sure that
it is gas tight.
22. Replace the plastic cap.
23. Remove the discharged state label.
24. Attach the pressurised warning label on the
accumulator at the position shown.
30 - 166 9823/1700-1 30 - 166

51 - Lift Arm Control Valve Block
Contents Page No.

30-51-21 Load Sense Relief Valve .............................................................................................. 30-173
30-51-24 Flow Regulator ............................................................................................................. 30-175
30 - 167 9823/1700-1 30 - 167

Notes:
30 - 168 9823/1700-1 30 - 168

03 - Main Relief Valve (MRV)
03 - Main Relief Valve (MRV) Figure 975.

D
N
Operation
The relief valve is located in the control valve, which EX

connects either the neutral and exhaust galleries
(Parallel Control Valves) or the load sense and A
exhaust galleries (Flowshare Control Valves). It is B
designed to prevent the circuitry from damage that
could be caused by excessive pressures.
Valve at rest
The services are in neutral and pressure in the
neutral gallery is not sufficient to operate the relief
valve which is held closed by its spring.
Figure 974.
N A Control valve block
B Relief valve
D Hollow poppet
N Neutral gallery
EX
EX Exhaust gallery
A
B
A Control valve block

B Relief valve
C Spring
N Neutral gallery
EX Exhaust gallery
Poppet opens
A service has been selected and the pressure
generated exceeds the setting of the relief valve.
Pressure acts on the periphery of the hollow poppet
which is forced downwards against the spring
releasing the pressure into the exhaust gallery.
30 - 169 9823/1700-1 30 - 169

06 - Auxiliary Relief Valve (ARV)
06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................. 30-170 The auxiliary relief valves are not serviceable. The
Operation ..................................................... 30-171 complete valve must be replaced if it is defective.
Do not remove or damage the tamper proof cap as
this may invalidate a warranty claim.
30 - 170 9823/1700-1 30 - 170

Operation Figure 977. Poppet opens
The ARV (Auxiliary Relief Valve) are located in the

control valve to limit potentially damaging pressures
within specified services due to external loadings.
ARV may also be used to limit the maximum pressure

in a specified service to less than the LSRV (Load
Sense Relief Valve) setting.
Valve at rest EX
A service is selected but pressure in the service

gallery has not reached the setting of the ARV which
is held closed by its spring. S
S Service gallery
Figure 976. Valve at rest
EX Exhaust gallery
Anti-cavitation mode
When a service is operated in such a way that low
pressure, or cavitation, exists in the service line, the
relatively high pressure oil in the exhaust gallery acts
on the lower poppet and flows into the service gallery
to make up the deficiency.
Figure 978. Anti-cavitation mode

EX
S Service gallery
EX Exhaust gallery
Poppet opens
The setting of the ARV is exceeded by the service EX
pressure which causes the poppet to rise against
spring force allowing the pressure to be released into
the exhaust gallery. S
S Service gallery
EX Exhaust gallery
30 - 171 9823/1700-1 30 - 171

Consumables
A
JCB Hydraulic Fluid OP 4002/2001 5L
46 4002/2005 20 L
4002/2003 200 L
The ARV (Auxiliary Relief Valve)'s are not B

serviceable. The complete valve must be replaced if C
it is not operational.
D
Do not remove or damage the tamper proof cap as
this may void the warranty claim.
Remove
1. Remove the valve assembly from the valve
block. E
2. Remove the O-ring 1 and O-ring 2 then remove

the thrust ring.
3. Use a rounded tool to remove the O-rings, that F
will not cause any damage to the seal grooves.
4. Discard all O-rings and back-up rings. Do not use A Load hold check valve assembly
worn or damaged items. B O-ring 1
C Thrust ring
5. If necessary, remove the load hold check valve D O-ring 2
assembly. Refer to (PIL 30-54-39). E Valve assembly
F Tamperproof cap
Install
steps.
1.1. Make sure the tamperproof cap supplied
with the valve, is installed.
1.2. Replace all O-rings and back-up rings.
1.3. Before you assemble the parts, apply
lubricants on them.
Consumable: JCB Hydraulic Fluid OP 46
1.4. If necessary, adjust the ARV pressure
setting. Refer to (PIL 30-00).

Item Description Nm
E Valve assembly 70
30 - 172 9823/1700-1 30 - 172

21 - Load Sense Relief Valve
21 - Load Sense Relief Valve Remove and Install

Remove
Do not remove or damage the tamperproof cap as
this may invalidate a warranty claim.
1. Follow all the hydraulic safety procedures. Refer

to (PIL 30-00).
2. Remove the valve assembly from the valve
block.
3. Remove the O-rings and the thrust ring. Make
sure you use a rounded tool that will not cause
any damage to the seal grooves. Discard all O-
rings and back-up rings. Do not use worn or
damaged items.
Figure 980.
1 O-ring
2 Thrust ring
3 O-ring
4 Valve assembly
5 Tamperproof cap
Install
steps.
1.1. Make sure the tamperproof cap supplied
with the valve is installed.
1.2. Replace all O-rings and back-up rings.
1.3. Lubricate the parts with the correct clean
hydraulic fluid before installation.
1.4. Adjust the LSRV (Load Sense Relief Valve)
pressure setting as required.
30 - 173 9823/1700-1 30 - 173

21 - Load Sense Relief Valve
Table 410. Torque Data Disassemble and Assemble

Item Torque
4 45 N·m The load sense relief valve is not serviceable.
Replace the complete valve with the correct valve if
it is defective.
30 - 174 9823/1700-1 30 - 174

24 - Flow Regulator
24 - Flow Regulator Check (Condition)

Check (Condition) ........................................ 30-175
Inspection
1. Examine the valve components for scratches,
pitting, corrosion or any other damage.
2. Clean the filter gauze installed in the end of the
valve body.
3. If any part other than the O-rings are damaged,
replace the entire valve.
Figure 981.
A Filler gauze
30 - 175 9823/1700-1 30 - 175

24 - Flow Regulator
Disassemble and Assemble 2.2. Lubricate the parts with JCB hydraulic fluid
before you assemble them. Make sure that
all the parts move freely.
Disassemble 2.3. Install new O-rings and back-up rings.
1. Loosen and remove the top plug. 2.4. Make sure to install the filter gauze in the
2. Carefully remove the shims, the spring and the
piston. Table 411. Torque Values
3. Remove the O-rings and the seals with the Item Description Nm
correct round tool. Make sure that no damage is F Valve body 20
caused to the seal grooves.
4. Discard all the O-rings and the back-up rings.
5. Do not use worn or damaged items.
Figure 982.
A Top plug
B Shims
C Spring
D Piston
E Filter gauze
F Valve body
Assemble
1. The assembly procedure is the opposite of the
disassembly procedure.
2. When assembling do the following steps also:
2.1. Clean the valve components in the correct
solvent.
30 - 176 9823/1700-1 30 - 176

53 - Servo System Control Valve Block
Contents Page No.
30-53-00 General ......................................................................................................................... 30-179

30-53-27 Pressure Compensator Valve ...................................................................................... 30-197
30 - 177 9823/1700-1 30 - 177

Notes:
30 - 178 9823/1700-1 30 - 178

00 - General
Introduction .................................................. 30-179
(For: 506-36 [T2/T3], 507-42 [T2/T3],
509-42 [T2/T3], 510-56 [T2/T3], 512-56
Operation ..................................................... 30-181
Diagram ....................................................... 30-183
Fault-Finding ................................................ 30-186 The JCB flowshare hydraulic system differs in many
Remove and Install ..................................... 30-188 important aspects to that of the normal hydraulic
Disassemble and Assemble ........................ 30-190 system. Before attempting to service or fault find on
the system, ensure that you read and understand all
the descriptions in this section.
The flowshare system operates the boom lift/lower,

tilt/crowd and extend/retract services. The other
services such as the auxiliary hydraulics are operate
by a parallel type hydraulic system. Both systems are
supplied with oil flow from the same hydraulic pump.
When using multiple services on a parallel system,

one or more services may suffer from an unequal
flow causing them to slow down or loose power.
A flowshare system makes sure that all services
receive sufficient flow to continue operation.
30 - 179 9823/1700-1 30 - 179

00 - General
(For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42 [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3],
Flowshare System)
Figure 983.
L A B C J
M
M D D K
A A A
Q T1
H
E E E
T2
P P P
LS
N F
P2 P
E E E G
M B B B T M
A Lift arm lift/lower spool B Lift arm extend/retract spool

C Carriage tilt/crowd spool D Auxiliary relief valve
E Service ports F Inlet port
G Tank port H Load sense port
J Load sense relief valve K L.S. relief valve drain port
L Flow regulator valve M Flushing valve housing
N Inlet port P Pressure compensating valves
Q Tank port
30 - 180 9823/1700-1 30 - 180

00 - General
Operation Figure 984.
(For: 506-36 [T2/T3], 507-42 [T2/T3], D

509-42 [T2/T3], 510-56 [T2/T3], 512-56
Individual valve slice

The control valve has pilot operated spools. The
service spools are of a closed-center design.
They have pressure compensating valves for each
service.
F
E
A
LS
A Pressure compensating valve

B Inlet gallery
C Service spool
D Centering spring
E Load hold check valve
F Tank port
LS Load sense relief valve
The inlet gallery is supplied with oil from the main

hydraulic pump. When you select the required
service spool, it moves against the force of the
centering spring. This allows the oil to move the
required service. When you de-select the service
spool, the centering spring returns the spool to the
neutral position.
30 - 181 9823/1700-1 30 - 181

00 - General
When you select one or more services, the pressure

compensator valves will detect the service that
requires the highest pressure. This allows the pump
to supply oil at sufficient pressure to move the load.
The load hold check valves prevent the load from
falling back if the load pressure is more than the
pump pressure.
The closed center design ensures consistent service

operation regardless of the load.
Figure 985.
LS
C
A
A Pressure compensating valve

B Inlet gallery
C Service spool
D Centering spring
E Load hold check valve
LS Load sense relief valve
30 - 182 9823/1700-1 30 - 182

00 - General
Diagram
30 - 183 9823/1700-1 30 - 183

00 - General
(For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42 [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3],
Flowshare System)
Figure 986.
T LS P
1A
T2 P2
1B
260
BAR
1C
T1
1D
1G
A B
1E B1
1H A1
1F
1D
A B
1J B2
1L A2
1F
1D
A B
1M B3
A3
1F
1A Flushing valve 1B Flushing valve spring
30 - 184 9823/1700-1 30 - 184

00 - General
1C LSRV (Load Sense Relief Valve) 1D Load hold check valve

1E Tilt spool 1F Pressure compensation valve
1G Tilt head side auxiliary relief valve 1H Tilt rod side auxiliary relief valve
1J Extend spool 1L Extend head side auxiliary relief valve
1M Lift spool
30 - 185 9823/1700-1 30 - 185

00 - General
Fault-Finding
(For: 506-36 [T2/T3], 507-42 [T2/T3],

509-42 [T2/T3], 510-56 [T2/T3], 512-56
Fault
Lack of power at all hydraulic functions Table 412. Page 30-186
All services slow to operate Table 413. Page 30-186
One service fails or is too slow to operate Table 414. Page 30-186
Table 412. Lack of power at all hydraulic functions

Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up as required.
Hydraulic leaks in system. Check hoses, renew as required.
Flushing valve piston within the control valve block Dismantle and inspect the flushing valve piston.
inlet section sticking open due to contamination. Refer to hydraulic system- flow control valve, refer to
(PIL 30-60).
Engine performance. Check engine performance.
MRV (Main Relief Valve) setting incorrect. Check and adjust as required.
Low pump flow. Check pump flow.
Check for external leaks, use new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install new pump.
Table 413. All services slow to operate

Cause Remedy
Hydraulic fluid level not sufficient Check for leaks and top up as required.
Neutral circuit or low pressure lines leaking, Check pipe lines and install new as required.
damaged, trapped or kinked.
Flushing valve piston within the control valve block Disassemble and inspect the flushing valve piston.
inlet section sticking open due to contamination. Refer to (PIL 30-51)
MRV setting incorrect. Check and adjust as required. Refer to (PIL 30-51)
Low pump flow. Check pump flow. Refer to (PIL 30-11)
Check for external leaks, use new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install new pump.
Table 414. One service fails or is too slow to operate

Cause Remedy
Lift arm and stabiliser interlocks engaged. (For Educate the operator. Make sure that the operator
machines 510-56, 512-56 and 514-56) fully understands the characteristics of the interlock
system. Refer to body and framework- lift arm, refer
to (PIL 06-12).
Associated service pipework or hoses leaking, Check pipework and hoses, replace as required.
ARV (Auxiliary Relief Valve) out of adjustment or Check and adjust as required. Refer to (PIL 51-06).
defective.
Associated ram leaking. Carry out ram leakage checks, use new seals as
required.
Associated service spool not operating correctly. Check the servo control lever for correct operation.
30 - 186 9823/1700-1 30 - 186

00 - General
Cause Remedy
Pressure compensator piston sticking due to Disassemble and inspect the associated service
contamination. spool or load hold check valves.
Service spool or associated load hold check valves Dismantle and inspect the associated service spool
damaged or sticking due to contamination. or load hold check valves.
Counterbalance valve not working correctly. Check operation of the applicable counterbalance
valve.
working correctly.
30 - 187 9823/1700-1 30 - 187

00 - General
Remove and Install
(For: 506-36 [T2/T3], 507-42 [T2/T3], 4. Gain access to the control valve. Refer to (PIL
509-42 [T2/T3], 510-56 [T2/T3], 512-56 06-06-09).
[T2/T3], Flowshare System) 5. Disconnect any hoses or pipes which may
CAUTION This component is heavy. It must only interfere with the removal of the valve assembly.
be removed or handled using a suitable lifting 6. Disconnect the pilot control hoses from the valve
method and device. spools.
1. Make the machine safe with the lift arm raised. 8. Make sure you properly support the valve block,
Refer to (PIL 01-03). otherwise the valve can be damaged.
2. Install the lift arm safety strut. Refer to (PIL 9. Remove the valve mounting bolts.
06-69).
10. Carefully lift the valve block clear of the mounting
3. Discharge the hydraulic pressure from the bracket.
system. Refer to health and safety (PIL 30-00).
Figure 987.
D
C
A Mounting bolts B Valve spools

C Valve block D Mounting bracket
30 - 188 9823/1700-1 30 - 188

00 - General
Install 1.3. For the hose connectors with no specified

torque setting, use the JCB standard torque
1. The installation procedure is the opposite of the setting. Refer to (PIL 72-00).
steps.
30-00).
1.1. Operate the machines hydraulic system. 1.5. After installation, check the pressure of the
Check for correct operation and leaks. LSRV (Load Sense Relief Valve) and the
1.2. Tighten the hoses to the correct torque ARV (Auxiliary Relief Valve).
value. Refer to Table 415.
Figure 988.
E
E Hose 1 F Hose 2
G Hose 3 H Hose 4
J Hose 5

Item Description Value
E Hose 1 24 –27 N·m
F Hose 2 115 –126 N·m
G Hose 3 84 –92 N·m
H Hose 4 84 –92 N·m
J Hose 5 122 N·m
30 - 189 9823/1700-1 30 - 189

00 - General
(For: 506-36 [T2/T3], 507-42 [T2/T3], sure you note the location of all components
509-42 [T2/T3], 510-56 [T2/T3], 512-56 when you disassemble. Although some components
may appear to be identical but they are not
[T2/T3], Flowshare System) interchangeable. Make sure that components are
Consumables assembled in their original positions.
Be careful when you disassemble and assemble the
JCB Hydraulic Fluid HP 4002/0801 5L valve block to avoid the following, as they can affect
46 4002/0805 20 L the pump operation.
4002/0803 200 L
JCB Threadlocker 4101/0250 0.01 L • Contamination
and Sealer (Medium • Damage to spools
4101/0251 0.05 L • Damage to seal grooves
Strength)
Working Under the Machine Disassemble

Make the machine safe before getting beneath it. 1. Remove the valve block from the machine.
correctly attached. Engage the park brake, remove 2. Remove the tie rod nuts.
has wheels use blocks to prevent unintentional 3. Carefully separate and remove the end plate
movement. then the remaining service sections.
4. If the inlet section is to be replaced, remove and
Valve block section keep the tie rods.
The valve block is a sectional type, which is

made up of a number of separate sections. Make
30 - 190 9823/1700-1 30 - 190

00 - General
Figure 989.
F
A
G
E
B
H
C
L
D
M
N
Assemble
Table 416. 1. The assembly procedure is the opposite of
Item Description the disassembly procedure. Additionally do the
following steps.
A Tie rod nuts (x3)
B End plate 1.1. Clean the valve components in an
C Service sections appropriate solvent. Make sure that the
mating faces of the valve sections are
D Inlet- outlet section thoroughly clean before assembly.
E Tie rods
1.2. Replace the O-rings located between the
F Load hold check valves
valve sections. Make sure the O-ring seals
G Pressure compensator are not trapped or damaged.
valves
H Service spool- pilot op- 1.3. Check the load hold check valve O-rings
erated and replace if necessary.
J Flushing valve 1.4. Apply hydraulic fluid to all the parts before
K LSRV (Load Sense Re- assembly. Make sure that all the parts move
lief Valve) freely.
L Flow regulator valve Consumable: JCB Hydraulic Fluid HP 46
M ARV (Auxiliary Relief 1.5. If the tie rods are removed from the inlet
Valve) section then apply sealant to the threads
N Blanking plug before you install them.
30 - 191 9823/1700-1 30 - 191

00 - General
Consumable: JCB Threadlocker and Sealer 1. Make the machine safe. Refer to (PIL 01-03).
(Medium Strength)
1.6. Apply sealant to the threads of tie rod nuts. Refer to (PIL 01-03).
(Medium Strength) 3. Discharge the hydraulic pressure. Refer to (PIL
30-00).
Valve spool 4. Disconnect and put caps on any hoses or pipes
CAUTION When removing 'O' rings and seals, which may interfere with the removal of the spool.
use an appropriately rounded tool that will not
5. Disconnect and put caps on the pilot hoses
cause any damage to the seal grooves. Discard
connected to the end caps at each end of the
all used 'O' rings and back up rings (where used).
spool.
Make sure you do not use worn or damaged
items. 6. Remove the screws and carefully lift off the end
cap.
It is possible to remove a spool without removing the
valve block from the machine. 7. Take out the spring and spring retainer, then
remove the spool from the valve body.
Disassemble
8. Use an appropriately rounded tool to remove the
Before you start the work make sure that the O-rings and seals, so that seal grooves will not
exterior of the valve block and the working area are be damaged.
thoroughly cleaned and free of possible sources of 9. Discard all the O-rings and seals.
contamination.
30 - 192 9823/1700-1 30 - 192

00 - General
Figure 990.
V
U
Assemble
Table 417. 1. The assembly procedure is the opposite of the

Item Description
steps.
P Screws
Q End cap 1.1. Clean the valve components in an
R O-rings appropriate solvent.
S Spring 1.2. Apply hydraulic fluid to all the parts before
T Spring retainer assembly. Make sure that all the parts move
freely.
U Spool
V Ring Consumable: JCB Hydraulic Fluid HP 46
1.3. Replace O-rings with new ones.
Before assembly
1.4. The spool may have a ring machined into it,
1. Check the valve components for scratches, which must be positioned downwards.
pitting, corrosion or any other type of damage.
Replace as necessary.
30 - 193 9823/1700-1 30 - 193

00 - General

Item Description Nm
A Tie rod nuts 35
P Screws 10
30 - 194 9823/1700-1 30 - 194

Introduction
30 - 195 9823/1700-1 30 - 195

Introduction
30 - 196 9823/1700-1 30 - 196

27 - Pressure Compensator Valve
27 - Pressure Compensator Valve Operation

Operation ..................................................... 30-197
Operation (Hydraulic) .................................. 30-199
Pressure Compensation (Flowshare)
Each service spool incorporates a pressure
compensator valve. When services are operated
simultaneously the system ensures consistent
operating speed for all services, even when the limit
of the hydraulic pump performance is approached.
The oil from the main hydraulic pump arrives at

the inlet gallery. When the relevant service spool
is selected, the spool moves against the force of
the centring spring. This allows the oil flow to move
the required service. When the service spool is de-
selected, the centring spring returns the spool to the
neutral position.
When one or more services are selected, the

pressure compensator valve detects the service
generating the highest pressure and allows the pump
to deliver oil at sufficient pressure to move the load.
The load hold check valve prevents the load falling
back if the load pressure is greater than the pump
pressure.
The closed centre design ensures consistent service

operation regardless of load.
For information about service spool and pressure

compensator valve operation, refer to hydraulic
system- lift arm control valve block, refer to (PIL
30-51).
30 - 197 9823/1700-1 30 - 197

Figure 991.
B A
F B
E C D F
A Service spool B Centering spring

C Pressure compensator valve D Load hold check valve
E Inlet gallery F Drain port
30 - 198 9823/1700-1 30 - 198

Operation (Hydraulic)
(For: 506-36 [T2/T3], 507-42 [T2/T3], dead ended. This generates sufficient pressure of
509-42 [T2/T3], 510-56 [T2/T3], 512-56 about 15 bar ( 217.4 psi) to overcome the spring. The
oil flows across the flushing valve spool assembly to
[T2/T3], Flowshare System) the tank. Any load acting on the service ram is held
by the service spool.
A typical layout is shown. For machine specific
information, refer to hydraulic system- general, refer Oil in the load sense gallery is vented to the tank
to (PIL 30-00). across the flow regulator valve. This allows the load
sense pressure to decay when no service is selected.
No Service Selected (All Spools in If the flow regulator valve is blocked, a reduced flow
Neutral) rate will be evident.
When the spools are in the neutral position, the oil The pressure compensator valve and load hold
from the pump flows to each service spool and is check valves are closed.
Figure 992.
F
P
CV
E
E1
LS
S PC
A Service gallery CV Load hold check valve

E Flushing valve spool E1 Spring
F Flow regulator valve LS Load sense gallery
P Pump PC Pressure compensator valve
R Service ram S Service spool
T Tank
30 - 199 9823/1700-1 30 - 199

Operating a Service bar ( 217.4 psi)), the load hold check valve moves off
its seat and allows oil to flow into the service gallery.
When the service spool is moved, the oil from the This initiates the movement of the service ram. The
pump is connected to the gallery. The pressure in exhaust oil from the other side of the service ram is
this chamber opens the pressure compensator valve directed by the service spool to tank.
and allows the oil into the load sense gallery. The oil
pressure builds in the gallery and the flushing valve The maximum load sense pressure and hence the
spool begins to close under the combined action of pump pressure is set by the LSRV (Load Sense
the oil pressure and spring force, causing the pump Relief Valve).
pressure to rise as follows:
Pump pressure = Pressure in the load gallery +
When the pump pressure has risen sufficiently, i.e. to Pressure from the spring
a pressure equal to the load + spring pressure ( 15
Figure 993.
F
P
E A B CV
E1
LS
S
PC
A Service gallery CV Load hold check valve

E Flushing valve spool E1 Spring
F Flow regulator valve LS Load sense gallery
P Pump PC Pressure compensator valve
R Service ram S Service spool
T Tank
30 - 200 9823/1700-1 30 - 200

Operating an Individual Service pressure acting on either side of the particular

service spool. The pressure compensator valve will
It must be noted that the load sense gallery is move in response to the pressure drop (pressure
connected to all the pressure compensator valves differential) created across the spool.
PC (one for each service) as shown. Refer to Figure
994. The pressure in the load sense gallery will When one service only is operated, the pressure
always be equal to the highest load from any of the compensator valve is fully opened. It connects the
services. gallery 1 to the gallery 2 and to the ram service port
without any pressure drop.
The pressure compensator valves are fitted between
each service spool and service ram. It senses the
Figure 994.
LS
PC
P1 P2
LS Load sense gallery P1 Gallery 1

P2 Gallery 2 PC Pressure compensator valve
30 - 201 9823/1700-1 30 - 201

Operating Multiple Services speed remains constant (as controlled by the lift arm
service spool) and is not affected by the greater
Normal condition operating pressure in the tilt service.
When another service with a higher load is operated With Insufficient Flow from Pump
simultaneously, a typical example is the lifting of
the lift arm and simultaneous operation of the tilt as If the oil flow demanded by the sum of the combined
shown. Refer to Figure 995. services operating exceeds that of the pump, all
the pressure compensator valves will partially close
The higher load pressure in the tilt service causes accordingly, effectively dividing the available flow
the pressure compensator valve in the lift arm between all the services proportionally.
service to partially close. It reduces the size of the
opening through which the oil must flow, and in this In this condition, the service ram with the highest load
way maintains a pressure drop across the pressure will not stop, because the speed of the other service
compensator equal to the pressure drop across the rams operating will have been reduced proportionally
lift arm service spool. by the action of the pressure compensator valves to
compensate.
In this example, because of the action of the pressure
compensator valve the lift arm service is always kept When one of the service spools is returned to neutral,
independent of the other services, the lift arm ram the speed of the other service rams still operating will
all increase proportionally.
Figure 995.
PC
LS
X Y
LS Load sense gallery PC Pressure compensator valve

X Lift arm Y Tilt
30 - 202 9823/1700-1 30 - 202

36 - Load Hold Check Valve
36 - Load Hold Check Valve 1. The installation procedure is the opposite of the
steps.
1.1. Clean the valve components in an
Consumables applicable solvent.
Cleaner/Degreaser 4104/1557 0.4 L purpose solvent based parts cleaner
- General purpose
solvent based parts 1.2. Lubricate the parts with hydraulic fluid
cleaner before assembly.
JCB Hydraulic Fluid HP 4002/0801 5L Consumable: JCB Hydraulic Fluid HP 46
46 4002/0805 20 L 1.3. Make sure that all the parts move freely.
4002/0803 200 L
Remove Item Description Nm
D Load hold check valve plug 15
3. Remove the valve block from the machine.
4. Remove the ARV (Auxiliary Relief Valve)
assembly.
5. Remove the LHCV (Load Hold Check Valve)
from the valve block section.
6. Remove the spring and the poppet.
Figure 996.
B
D
A Valve block section

B Poppet
C Spring
D LHCV plug
Install
Examine the valve components for scratches, pitting,
corrosion or damage. Make sure the seating faces on
the poppets, and the mating faces in the valve block
are in good condition. Replace as necessary.
30 - 203 9823/1700-1 30 - 203

54 - Parallel Circuit Control Valve Block
Contents Page No.
30-54-00 General ......................................................................................................................... 30-205

30 - 204 9823/1700-1 30 - 204

00 - General
Introduction .................................................. 30-205
Technical Data ............................................. 30-206
Parallel valve block- 2 section
Component Identification ............................. 30-207 The 2 section control valve operates the auxiliary and
Diagram ....................................................... 30-211 sway hydraulic services.
Fault-Finding ................................................ 30-214
The valve spools are operated by mechanical
Remove and Install ..................................... 30-215 linkages attached to control levers.
For diagram, refer to the lift arm control valve block-
2 section, Diagram (PIL 30-51-00).
Parallel valve block- 5 section

The 5 section control valve operates the auxiliary,
sway and stabiliser hydraulic services.
The valve spools are operated by mechanical

linkages attached to control levers.
Section 3 of the valve block isolates sway spool

sections, stabiliser service spool 1 and stabiliser
service spool 2 from oil at pump pressure when its
unloader valve solenoid coil is energised.
Electrical switches, spool neutral switch 1, spool

neutral switch 2 and spool neutral switch 3 close
when the applicable spool is not in the neutral
position. The switches are part of the rear axle
stability system.
For diagram, refer to the lift arm control valve block-

5 section, Diagram (PIL 30-51-00).
30 - 205 9823/1700-1 30 - 205

00 - General
Technical Data Table 421. Relief Valve Pressures

LSRV (Mounted within 260 ( 3,768.1 )
flowshare valve block)
2 Section Valves ARV C 140 ( 2,029.0 )
Figure 997. 2 Section Parallel Valve ARV D 140 ( 2,029.0 )
Control Block (2 Spool, Parallel
Service, Double Acting Spools) Hydraulic Pump (110 L/Min)
C
Table 422.
Type Gear pump
Mounting Gearbox
P B B Direction of rotation Counter clockwise
1 2 Maximum speed 3000 RPM
T Minimum speed 500 RPM
A A
Weight 33.3 kg
Table 423. Theoretical Displacement

D Description Value
1 Spool 1- Auxiliary service (manually operated) Main services pump 29 cc/rev
2 Spool 2- Sway service (manually operated) (mounting flange end)
Steering pump 19 cc/rev
Table 420. Relief Valve Pressures Cooling fan pump 16 cc/rev
LSRV (Load Sense Re- 260 ( 3,768.1 ) Table 424. Flow
lief Valve) (Mounted
within flowshare valve Description Value
block) Main services pump 57.4 L/min
(1)
ARV (Auxiliary Relief 140 ( 2,029.0 )
Valve) C Steering pump 37.6 L/min
ARV D 140 ( 2,029.0 ) Cooling fan pump 31.7 L/min
5 Section Valves (1) Flow at 2200 RPM and system pressure (90%
min. displacement).
Figure 998. 5 Section Parallel Valve
Control Block (5 Section, 4 Spool, Par- Table 425. Maximum Pressure
allel Service, Double Acting Spools) Description Value
C Port EF 265 bar ( 3,840.6 psi)
Port P 200 bar ( 2,898.5 psi)
P B B B B
1 5 2 3 4
T A A A A
D
1 Spool 1, Auxiliary service, (manually operated)
2 Spool 2, Sway service manually operated
5 Section 5, Isolation valve (spools 2, 3 and 4)
Electrical solenoid operation
30 - 206 9823/1700-1 30 - 206

00 - General
Figure 999.
B
C
H E F
A Hydraulic tank B Parallel control valve

C Filter D Servo valve
E Fan supply pump F Main hydraulic supply pump
G Fan return pipework H Flowshare control valve
J Steer circuit return
30 - 207 9823/1700-1 30 - 207

00 - General
Figure 1000.
R S
L K
N M
Item Description -
P Control lever Control lever
Table 426.
(Single axis)
Item Description - Q Control valve Parallel valve
K Main hydraulic Gear pump block with manual
supply section spools
L Priority valve Steering R 2 Section paral- -
M Steering section Gear pump lel control valve
N Fan section Gear pump block
30 - 208 9823/1700-1 30 - 208

00 - General
Item Description - Figure 1001. Parallel valve block- 2 section

S 5 Section paral- -
lel control valve
block
T Flowshare The system is LS
valve inlet/outlet connected to
section the load sense
components in
the inlet/outlet
section of the
flowshare valve. 2
U Hydraulic oil fil- Positioned in
ter the return line
to tank
V Hydraulic tank - 1A
1B 1
P T
1 Auxiliary service spool
1A ARV (Auxiliary Relief Valve) 1
1B ARV 2
LS Load sense port
P Pressure port- Oil from pump
T Tank port
30 - 209 9823/1700-1 30 - 209

00 - General
Figure 1002. Parallel valve block- 5 section
1 Auxiliary service spool 1A ARV 1

1B ARV 2 2 Sway service spool
2A Spool neutral switch 1 3 Unloader valve (stabiliser isolation)
3A Unloader valve solenoid coil 4 Stabiliser service spool 1
4A Spool neutral switch 2 5 Stabiliser service spool 2
5A Spool neutral switch 3 LS Load sense port
P Pressure port- Oil from pump T Tank port
30 - 210 9823/1700-1 30 - 210

00 - General
Diagram
1 Auxiliary service spool 1A ARV (Auxiliary Relief Valve) 1

1B ARV 2 1C Load sense check valve 1
1D Load hold check valve 1 2 Sway service spool
2C Load sense check valve 2 2D Load hold check valve 2
P Pressure Port- Oil from pump T Tank port
LS Load sense port
30 - 211 9823/1700-1 30 - 211

00 - General
1 Auxiliary service spool 1A ARV 1

1B ARV 2 1C Load sense check valve 1
1D Load hold check valve 1 2 Sway service spool
2A Spool neutral switch 1 2B Load sense check valve 2
2C Load hold check valve 2 3 Unloader valve (Stabiliser isolation)
3A Unloader valve solenoid coil 4 Stabiliser service spool 1
4C Load hold check valve 3 5 Stabiliser service spool 2
30 - 212 9823/1700-1 30 - 212

00 - General

5C Load hold check valve 4 P Pressure Port- Oil from pump
T Tank port LS Load sense port
30 - 213 9823/1700-1 30 - 213

00 - General
Fault-Finding
Fault
Lack of power at all hydraulic functions Table 427. Page 30-214
All mechanically operated hydraulic services slow to operate Table 428. Page 30-214
All solenoid/servo operated hydraulic services slow to operate Table 429. Page 30-214
Is the machine experiencing boom extend or retract problems? Table 430. Page 30-214
Bleed air from the hydraulic cylinders - is it OK now? Table 431. Page 30-214
Table 427. Lack of power at all hydraulic functions

Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up as necessary.
Hydraulic leaks in system. Check hoses, If necessary replace with new one.
Engine performance. Check engine performance.
MRV (Main Relief Valve) setting not correct. Check and adjust as necessary.
Check for external leaks, replace seals.
Priority valve sticking. Refer to (PIL 25-03).
Replace pump.
Table 428. All mechanically operated hydraulic services slow to operate

Cause Remedy
Neutral circuit or low pressure lines leaking, Check pipe lines and if necessary replace.
MRV setting not correct. Check and adjust as necessary.
Check for external leaks, replace seals.
Priority valve sticking. Refer to (PIL 25-03).
Replace pump.
Table 429. All solenoid/servo operated hydraulic services slow to operate

Cause Remedy
Refer to Table 2 -
Low pilot pressure Check that the pressure maintenance valve is not
sticking open.
Check the pressure reducing valve.
Solenoid power supply not present. Check fuse 2.
Table 430. Is the machine experiencing boom extend or retract problems?

Cause Remedy
YES = Go to Table 5, NO = done
Table 431. Bleed air from the hydraulic cylinders - is it OK now?

Cause Remedy
YES = Done, NO = Go to Table 6
30 - 214 9823/1700-1 30 - 214

00 - General
Remove and Install
Parallel control valve- 2 section Install

CAUTION This component is heavy. It must only 1. The installation procedure is the opposite of the
be removed or handled using a suitable lifting removal procedure. Additionally do the following
method and device. steps.
Figure 1006.
Remove
1. Make the machine safe. Refer to (PIL 01-03). F E
D
2. Follow the hydraulic safety procedures. Refer to
(PIL 30-00).
30-00).
5. Remove the central access panel and access the
valve. Refer to (PIL 06-06). B
6. Put a label on each hose to help installation.

7. Disconnect the hoses.
contamination.
9. Disconnect the control rod linkages from the
valve spools.
B
10. If installed, disconnect the electrical connector at
the valve block switch.
11. Support the valve block, remove the mounting
screws.
12. Carefully lift and remove the valve block from the B Control rod linkages
machine. D Control rod
E Locknut
Figure 1005.
F Clevis
A A
C
B
A Mounting screws
B Control rod linkages (shown not connected)
C Valve block switch
30 - 215 9823/1700-1 30 - 215

00 - General
Figure 1007. Parallel control valve- 5 section

G CAUTION This component is heavy. It must only
method and device.
Remove
2. Follow the hydraulic safety procedures. Refer to
(PIL 30-00).
30-00).
H 5. Remove the central access panel and access the

J valve. Refer to (PIL 06-06).
G Connector 1
H Connector 2 6. Put labels on each hose to help installation.
J Connector 3 7. Disconnect the hoses.
1.1. After installation, check the operation of the 8. Plug all the open ports and hoses to prevent
mechanical control linkages. contamination.
1.2. Make sure that the control levers in the cab
are vertical when in neutral. If the lever is 9. Remove the stabiliser control lever knobs and
not vertical, loosen the locknuts at each end gaiters from inside the cab.
of the control rod. Turn the control rod to 10. Remove the clevis pin and disconnect the control
increase or decrease the length of the rod rod linkages from the valve spool rod.
as required. Tighten the locknuts.
1.3. To make adjustment for machines with 11. Put labels on the connectors to help installation.
cranked control rods, disconnect the clevis
12. Disconnect the electrical connectors connected
and turn it as required. Make sure that the
to the valve block switches and the isolation
control rod is phased correctly before you
solenoid.
tighten the locknut.
1.4. Tighten the hose connector 1, the hose 13. Support the valve block, remove the mounting
connector 2 and the hose connector 3 to screws.
the specified torque value. For the hose
14. Carefully lift and remove the valve block from the
connectors with no specified torque setting,
machine.
refer to JCB standard torque settings. Refer
to (PIL 72-00).
Install
1.5. Operate the hydraulic system. Check for
correct operation and make sure that there 1. The installation procedure is the opposite of the
are no leaks. removal procedure. Additionally do the following
steps.
30-00). 1.1. After installation, check the operation of the
mechanical control linkages.
Table 432. Torque Values 1.2. Make sure that the control levers in the cab
are vertical when in neutral. If the lever is
Item Nm not vertical, loosen the locknuts at the end
G 25 of the control rod. Turn the control rod to
H 88 increase or decrease the length of the rod
J 61 as required. Tighten the locknuts.
1.3. To adjust some machines with cranked
control rods, disconnect the clevis and turn
it as required. Make sure that the control rod
30 - 216 9823/1700-1 30 - 216

00 - General
is phased correctly before you tighten the refer to JCB standard torque settings. Refer
locknut. to (PIL 72-00).
1.4. Tighten the hose connector 1, the hose 1.5. Operate the hydraulic system. Check for
connector 2 and the hose connector 3 to correct operation and make sure that there
the specified torque value. For the hose are no leaks.
connectors with no specified torque setting,
30-00).
30 - 217 9823/1700-1 30 - 217

00 - General
Figure 1008.
K K
P L
T
L
B L
C
K
E
F
G H
A Hose connector 1 B Hose connector 2

C Hose connector 3 D Spool rod
E Clevis pin F Rod linkages
30 - 218 9823/1700-1 30 - 218

00 - General
G Locknut H Control rod

J Gaiters K Mounting screw
L Electrical connectors

Item Nm
A 25
B 61
C 88
30 - 219 9823/1700-1 30 - 219

00 - General
For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42 Figure 1009.

[T2/T3], Parallel Control Valve 2 Section
................................................. Page 30-220
For: 510-56 [T2/T3], 512-56 [T2/T3], Parallel
Control Valve 5 Section ........... Page 30-221 B C C C G
(For: 506-36 [T2/T3], 507-42 [T2/T3],

509-42 [T2/T3], Parallel Control Valve 2
Section)
Consumables
46 4002/2005 20 L
4002/2003 200 L
JCB Threadlocker 4101/0250 0.01 L A D E F
and Sealer (Medium 4101/0251 0.05 L A Tie rods
Strength) B Inlet section
C Section O-rings
2 Section Valve Block D Auxiliary section
E Sway section
The valve block is made up of a number of separate F Outlet section
sections. The illustration is intended as a guide to G Tie rod nuts
identify the components.
Assemble
Note the location of all the components when
you disassemble. Although some components may 1. The assembly procedure is the opposite of
appear to be identical they are not interchangeable. the disassembly procedure. Additionally do the
Make sure that you assemble the components in following steps.
their original positions.
Take great care when you disassemble and appropriate solvent. Make sure that the
assemble the valve. Avoid the following: mating faces of the valve sections are
thoroughly clean before assembly.
• Contamination.
1.2. Install new O-rings located between the
• Damage to the spools.
• Damage to the seal grooves.
are not trapped or damaged.
Any of the above may result in possible problems 1.3. Lubricate the parts with hydraulic fluid
with the operation of the valve. before you assemble them. Make sure that
Disassemble Consumable: JCB Hydraulic Fluid OP 46
1. Remove the valve block from the machine. 1.4. If the tie rods were removed, apply sealant
to the threads before you install it again.
2. Remove the three tie rod nuts. Torque tighten to the specified value.
3. Carefully separate and remove the outlet section Consumable: JCB Threadlocker and Sealer
followed by the sway section and the auxiliary (Medium Strength)
section. If the inlet section is to be replaced,
remove and keep the tie rods safe. Table 434. Torque Values
Item Description Nm
G Tie rod nuts 43
30 - 220 9823/1700-1 30 - 220

00 - General
(For: 510-56 [T2/T3], 512-56 [T2/T3], Make sure that you assemble the components in
Parallel Control Valve 5 Section) their original positions.
Consumables Take great care when you disassemble and

Description Part No. Size assemble the valve. Avoid the following:
• Contamination.
46 4002/2005 20 L • Damage to the spools.
4002/2003 200 L • Damage to the seal grooves.
and Sealer (Medium Any of the above may result in possible problems
4101/0251 0.05 L
Strength) with the operation of the valve.
Disassemble
5 Section Valve Block
1. Remove the valve block from the machine.
The valve block is made up of a number of separate
sections. The illustration is intended as a guide to 2. Remove the tie rod nuts (x3).
identify the components.
3. Carefully separate and remove the outlet section
Note the location of all the components when followed by the auxiliary section, the isolation
you disassemble. Although some components may section, the sway section, the stabiliser section
appear to be identical they are not interchangeable. 1 and the stabiliser section 2. If the inlet section
is to be replaced, remove and keep the tie rods
safe.
Figure 1010.
B C C C C C C K
A D E F G H J
A Tie rods B Inlet section

C Section O-rings D Auxiliary section
E Isolation section F Sway section
G Stabiliser section 1 H Stabiliser section 2
J Outlet section K Tie rod nuts
30 - 221 9823/1700-1 30 - 221

00 - General
Assemble
following steps.
appropriate solvent. Make sure that the
mating faces of the valve sections are
thoroughly clean before assembly.
1.2. Install new O-rings located between the
are not trapped or damaged.
1.3. Lubricate the parts with hydraulic fluid
before you assemble them. Make sure that
Consumable: JCB Hydraulic Fluid OP 46
1.4. If the tie rods were removed, apply sealant
to the threads before you install it again.
Tighten to the specified torque value.
(Medium Strength)

Item Description Nm
K Tie rod nuts 43
30 - 222 9823/1700-1 30 - 222

Introduction
30 - 223 9823/1700-1 30 - 223

Introduction
30 - 224 9823/1700-1 30 - 224

39 - Load Hold Check Valve
39 - Load Hold Check Valve Figure 1011.
B
Remove and Install
Consumables
and Sealer (Medium 4101/0251 0.05 L C
Strength)
Remove
working on it. Park the machine on level ground A
1. Remove the valve block securing nuts and pull

the valve blocks away from the chassis.
A Middle tie rod hole
2. Remove the middle tie rod from the hole to get B Compensator plug
access to the pressure compensator valves. The C Compensator valve
valve block sections are held together with the
remaining two tie rods. Install
3. Remove the compensator plug with an Allen key The installation procedure is the opposite of the
of specified value. removal procedure.
1. When installing do the following steps also:
4. Remove the compensator valve from the bore
with a magnet. 1.1. Clean the valve components with the
correct solvent.
5. Check the valve components for scratches,
pitting, corrosion or any other kind of damage. 1.2. Lubricate the parts with JCB hydraulic fluid
Replace if necessary. before you assemble them. Make sure that
1.3. Install new O-rings and back-up rings.
1.4. Apply the specified sealant to the threads
of the tie rod and the tie rod nut before
installation.
(Medium Strength)

Item Description Nm
B Compensator plug 60
30 - 225 9823/1700-1 30 - 225

60 - Directional Control Valve
Contents Page No.
30-60-00 General ......................................................................................................................... 30-227

30-60-15 Joystick ......................................................................................................................... 30-229
30-60-27 Auxiliary Circuit ............................................................................................................ 30-237
30-60-90 Flow Regulator ............................................................................................................. 30-240
30 - 226 9823/1700-1 30 - 226

00 - General
00 - General
Introduction
Flow Control Valves Figure 1015.
Control valves are usually represented by one or

more square boxes.
The number of boxes indicates the number of

possible valve operating positions, (3 boxes, 3
positions etc).
Figure 1012.
1 Position 1 (P1 - P2, P3 - P4)

3 Position 3 (P1 - P4, P2 - P3)
In circuit diagrams the pipework is usually shown It must be noted that not all spools are of the
connected to the box which represents the same type. Their operating designs can be seen
unoperated condition. (Hydraulic circuit diagrams are by following the path the flow arrows take in their
usually shown in the unoperated condition). respective operating squares.
Figure 1013. Three typical JCB style spools are known as 'D'
spools, 'F' spools and 'N' spools.
The 'D' spools generally control rams because when

in the neutral position the outlet ports are blocked,
preventing ram movement.
'F' spools are often shown as four position spools

A valve described as a 3-position, 4-port control with the three normal positions for neutral and
valve. Port describes the openings to and from the service control; and the forth position, which has a
valve by which the hydraulic fluid enters or leaves. In detent, connects both sides of the ram together to
an unoperated condition all ports are blocked. allow the service to 'float'.
2 Position 2 (all 4 ports blocked)

'N' spools are sometimes used to control hydraulic
If the valve spool was moved to Position 1, motors, and it can be seen from the flow arrows, that
movement of the spool would connect Port P1 to Port in neutral position both service ports are connected
P2, and Port P3 to Port P4. to the exhaust oil port
If the valve spool was moved to Position 3, Figure 1017.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 227 9823/1700-1 30 - 227

00 - General
Figure 1018. Simple Schematic Circuit Example
A
B
C G
D E
A Hydraulic tank B Strainer

C Fixed displacement pump D Relief valve
E Spool F One way valve
G Double acting hydraulic ram
Some of the symbols described on the preceding

pages have been arranged into a simple schematic
circuit.
The hydraulic tank is a pressurised tank with an

internally mounted strainer on the suction line to the
fixed displacement pump. System pressure is limited
to the setting of relief valve.
The valve spool is an open-centre spool that is in

neutral position; flow from the pump passes through
the spool and returns to the hydraulic tank.
If the lever operated spool is moved away from

neutral position hydraulic fluid is directed to either
head side or rod side of hydraulic ram. Notice that
the fluid must first open one way valve before flowing
to the ram.
30 - 228 9823/1700-1 30 - 228

15 - Joystick
15 - Joystick Introduction
Introduction .................................................. 30-229 The lift arm and other hydraulic services are
Operation ..................................................... 30-231 controlled by levers.
Fault-Finding ................................................ 30-232
Remove and Install ..................................... 30-233 There are different types of control lever depending
on the machine model and variant.
Dual Lever Controls (Manual Controls)
These machines use mechanical levers and rods to
transmit the movement of the control lever to the
applicable control valve section.
Figure 1019.
Single Lever Controls (Electro

Proportional Control Hydraulics)
With single lever controls a joystick with thumb wheel
switches is used to control the hydraulic services.
Additional services can be controlled using manual

or electronic levers.
For details of operation refer to (PIL 30-60-12).
30 - 229 9823/1700-1 30 - 229

15 - Joystick
Figure 1020.
1
2
3
1 Hydraulic control lever

2 Transmission dump switch
3 Drive direction selection switch
Servo Lever Controls

The servo lever controls are installed on 540-170,
550-170 and 550-140 machines.
The main control lever is a pilot valve which directs

pilot flow to the applicable services.
Also other manual control levers are used to control

auxiliary and stabiliser operations.
Figure 1021.
3
1
3
1 Transmission dump switch

2 Stabiliser control levers
3 Hydraulic control lever
Electro Hydraulic Stabiliser Control

Some machines have electronic switches to control
the stabiliser operation.
For details refer to (PIL 09-27-21).
30 - 230 9823/1700-1 30 - 230

15 - Joystick
Operation
(For: Manual Controls)
Figure 1022.
A
B
A Hydraulic control valve B Manual stabiliser control lever

C Manual control lever (Joystick) D Connecting rod
The levers are mechanically connected to the

applicable spool on the hydraulic control valve.
The manual control lever - joystick - is connected

using rods.
The stabiliser control levers are a direct connection

to the valve spool.
Movement of the lever moves the applicable valve

spool in the required direction enabling the hydraulic
service to operate.
30 - 231 9823/1700-1 30 - 231

15 - Joystick
Fault-Finding
For related fault finding information refer to (PIL
30-00).
Machines with an electronic instruments system will
log some system faults as a fault code. These fault
codes can be accessed with the correct diagnostics
software tool, using a laptop computer connected to
the machine CAN system. Refer to (PIL 33-57).
30 - 232 9823/1700-1 30 - 232

15 - Joystick
Remove and Install
(For: Manual Controls) 5. Remove the cab side cover (if installed) to access
the valve block. Refer to (PIL 06-06).
Remove 6. Remove the stabiliser control lever knobs and the
gaiters from inside the cab.
Refer to (PIL 01-03). 7. Remove the securing clip and the pin.
2. Install the safety strut. Refer to (PIL 06-69). 8. Disconnect the control lever rod from the spool
end.
Refer to (PIL 01-03). 9. Repeat the step 7 and the step 8 again for the
other control linkages.
30-00).
30 - 233 9823/1700-1 30 - 233

15 - Joystick
Figure 1023.
A B
H
D
E
F
G
A
L
M
N
K
N
A
N J
A Mounting screws B Control lever knobs

C Control rod 1 D Securing clip
E Pin F Locknut 1
G Spool end H Electrical connectors
J Valve block K Bracket
L Locknut 2 M Control rod 2
N Control rod 3
30 - 234 9823/1700-1 30 - 234

15 - Joystick
Install
steps.
1.1. After you install, check the operation of the
mechanical control rod 1 and control rod
3. Operate the control levers. Make sure
that the lever travel is the same in both
directions. To adjust the levers loosen the
locknut 1 or locknut 2 at each end of the
control rod 1 or control rod 2. Turn the
rod to increase or decrease the length as
necessary. Tighten the locknuts.
1.2. Check the lever and spool adjustment -
refer to Adjustment PIL (30-54-00)
1.3. Operate the hydraulic system. Check for
correct operation and leaks.
30 - 235 9823/1700-1 30 - 235

15 - Joystick
Do not attempt to dismantle the joystick. If the joystick

is defective, a new unit must be installed.
Externally facing seals, port adaptors, gaiters and

joystick handles may be replaced if the correct parts
are available and the correct cleanliness procedures
are followed.
30 - 236 9823/1700-1 30 - 236

27 - Auxiliary Circuit
27 - Auxiliary Circuit Component Identification

Diagram ....................................................... 30-238
(For: 509-42 [T2/T3], 510-56 [T2/T3],
512-56 [T2/T3])
Discharge and Pressurise ........................... 30-239
Figure 1024. Auxiliary Vent Valve
C
D
A Auxiliary vent valve

B Pilot control valve
C Valve block
D Shuttle valve
30 - 237 9823/1700-1 30 - 237

Diagram
(For: 509-42 [T2/T3], 510-56 [T2/T3], 512-56 [T2/T3])
Figure 1025. Auxiliary Venting Valve
A
D
F
E
A Shuttle valve B Valve block

C Auxiliary hoses D Auxiliary vent valve
E Line to tank F Pilot control valve
30 - 238 9823/1700-1 30 - 238

Discharge and Pressurise
Refer to discharge and pressurise, (PIL 30-00).
30 - 239 9823/1700-1 30 - 239

90 - Flow Regulator
90 - Flow Regulator
Introduction
30 - 240 9823/1700-1 30 - 240

61 - Counterbalance Valve
Contents Page No.
30-61-00 General ......................................................................................................................... 30-243

30-61-06 Lift Arm ......................................................................................................................... 30-248
30 - 241 9823/1700-1 30 - 241

Notes:
30 - 242 9823/1700-1 30 - 242

00 - General
Introduction .................................................. 30-243
Operation ..................................................... 30-244
Operation overview
The lift, extend and tilt ram circuits include a
counterbalance valve.
When there is a load on the carriage, the weight of

the load could cause the lift arm to lower or dump.
This would be dangerous as the load could lower
suddenly or fall off the carriage.
To prevent this, counterbalance valves are installed

to make sure that only the pressure of flow from
the control valve spool will move the lift arm or the
carriage and the weight will not affect it. Therefore
when the lift/lower or crowd/dump services are not
operated, the valve is closed effectively locking the
ram in position regardless of the load.
30 - 243 9823/1700-1 30 - 243

00 - General
Operation
The extend and tilt ram circuits have a To prevent this, counterbalance valves are installed
counterbalance valve. to make sure that, only the pressure of flow from the
control valve spool will move the lift arm or carriage
When there is a load on the carriage, the weight of and the weight will not affect it. Therefore when the
the load could cause the lift arm to lower or dump. lift/lower or crowd/dump services are not operated,
This would be dangerous as the load may lower the valve is closed effectively locking the ram in
suddenly or fall off the carriage. position regardless of load.
Component Location
Figure 1026.
A Extend ram counterbalance valve B Tilt ram counterbalance valve
30 - 244 9823/1700-1 30 - 244

00 - General
Hydraulic Operation and Schematics to hydraulic system- general, schematic circuit, refer
to (PIL 30-00-50).
Valve schematic
The schematic diagrams show a typical system. For
information about machine specific schematics, refer
Figure 1027. Typical Valve Schematics
A B
A Extend counterbalance valve B Tilt counterbalance valve
30 - 245 9823/1700-1 30 - 245

00 - General
System schematic ram. The counterbalance valve housing contains two

valves to prevent the compression of the ram due to
The schematic diagrams show a typical system. For the pressure in the ram returning to tank. The check
information about machine specific schematics, refer valve only allows flow when the piston end service
to hydraulic system- general, schematic circuit, refer is operated. The pressure valve will only open and
to (PIL 30-00-50). allow a return to tank when there is pressure in the
+ line feeding the piston side of the ram. If there is
The figure shows no hydraulic service operated. no pressure in this line the pressure valve will remain
Refer to Figure 1028. There is a load on the carriage closed and the ram is locked in position.
and the weight of this load is tries to compress the
Figure 1028.
D
A
B
_
C
In this figure, the rod side service spool in the control pressure valve opens and allows the pressure from
valve is operated. Refer to Figure 1029. Pressure is the piston side of the ram to return to tank. The check
supplied to retract the ram. When the pressure in the valve remains closed.
+ line is greater than the pressure from the spring, the
Figure 1029.
D
A
C1 B
_
In this figure, the piston side service spool in the valve opens to supply the ram. The pressure valve
control valve is operated. Refer to Figure 1030. remains closed.
Pressure is supplied to extend the ram. The check
30 - 246 9823/1700-1 30 - 246

00 - General
Figure 1030.
D
A
B
+
C
Electrical Operation
There are no electrical devices used in this system.
30 - 247 9823/1700-1 30 - 247

06 - Lift Arm
06 - Lift Arm Operation

Operation ..................................................... 30-248 The counter balance valve is used to hold the lift
Diagram ....................................................... 30-251 arm in position and for it not to lower under its own
weight. Refer to hydraulic system- counterbalance
valve, refer to (PIL 30-61).
When you operate the crowd and lift arm raise

hydraulic services, there are rare occasions when
the flow may divert through the displacement ram
circuit and cause the lift arm to raise under the power
of the displacement ram.
Pressure monitoring of the lift ram full bore (rod

end) maintains a minimum pressure ensuring correct
operation of the lift arm service. A pressure
transducer is installed in the full bore (rod end) side
of the lift arm circuit.
If the pressure in the circuit is less than 10 bar

( 144.9 psi) and the crowd and lift service operate at
the same time, the hydraulic ECU (Electronic Control
Unit) deselects the crowd service. This allows the
pressure to increase in the lift ram circuit.
When the pressure in the circuit raises to more than

20 bar ( 289.9 psi) the hydraulic ECU responds by
restoring normal operation of the crowd service.
On machines with SRS (Smooth Ride System), the

SRS pressure transducer is used. For information
about the SRS system, refer to hydraulic system-
On machines without the SRS, a pressure transducer

is installed.
30 - 248 9823/1700-1 30 - 248

06 - Lift Arm
Component Location
Figure 1031.
A Pressure transducer B Lift ram
30 - 249 9823/1700-1 30 - 249

06 - Lift Arm
Electrical Operation For machines with SD, SE and SF engines, refer to

hydraulic system- cylinder ram, refer to (PIL 30-15).
On machines with SRS, the SRS pressure
transducer is used. For information about the SRS For machines with SH, SL and DH engines, refer to
system, refer to hydraulic system- general, refer to hydraulic system- cylinder ram, refer to (PIL 30-15).
(PIL 30-00).
Figure 1032.
1 4 4 1
2 3 3 2
30 - 250 9823/1700-1 30 - 250

06 - Lift Arm
Diagram
Lift Pressure Balance System (S2)

Machines with SD,SE and SF engines
Figure 1033.
J1-14
J1-28 2 3
ECU
1
A 4
J2-29 J2-21
V5
V 12 D
C
4.5
0.7
0.5
0 X
0
X 0 20 25
0 20 25
A Hydraulic ECU (Electronic Control Unit) B SRS (Smooth Ride System) pressure
transducer
C Pin 3 switch output signal D Pin 4 variable output signal
V Output (volts) X Pressure (bar)
Table 437.
Harness connector SR02
Connectors Pins Details
SR02 1 2 3 4
i001 7 1 4 5 Chassis harness to lift arm harness con-
nector
C023 29 21 Hydraulic control ECU connector J2
C018 14 28 Hydraulic control ECU connector J1
30 - 251 9823/1700-1 30 - 251

06 - Lift Arm
Machines with SH, SL and DH engines
Figure 1034.
J5-7
J5-14 2 3
ECU
1
A 4
J5-16 J2-17
V5
V C D
12 4.5
0.7
0.5
0 0 X
X 0 20 25
0 20 25
A Hydraulic ECU B SRS pressure transducer

C Pin 3 switch output signal D Pin 4 variable output signal
V Output (volts) X Pressure (bar)
Table 438.
Harness connector SR02
Connectors Pins Details
SR02 1 2 4 4
i001 7 1 3 5 Chassis harness to lift arm harness con-
nector
C049 7 14 16 Hydraulic control ECU connector J5
C046 17 Hydraulic control ECU connector J2
30 - 252 9823/1700-1 30 - 252

63 - Hose Burst Check Valve
Contents Page No.
30-63-00 General ......................................................................................................................... 30-255
30 - 253 9823/1700-1 30 - 253

Notes:
30 - 254 9823/1700-1 30 - 254

00 - General
Introduction .................................................. 30-255 The HBCV (Hose Burst Check Valve) prevents the
Check (Operation) ....................................... 30-256 uncontrolled movement of the cylinder ram pistons.
The HBCV will lock if the hydraulic pressure is
unsatisfactory or if a hose bursts.
30 - 255 9823/1700-1 30 - 255

00 - General
Check (Operation) 5.2. If the lift arm moves after the engine stops,
then the lift arm HBCV is faulty. Do not use
DANGER Before lowering the attachments to the the machine until you correct the fault.
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or Carriage tilt cylinder
close to the machine could fall and be crushed by
the attachments, or get caught in the linkages. 1. Pick up a load on the forks.
WARNING Maintenance must be done only by 2. Tilt the carriage fully back.
suitably qualified and competent persons.
Before doing any maintenance make sure the 3. Make sure to engage the park brake and put the
machine is safe, it must be correctly parked on transmission to neutral.
solid, level ground. 4. Raise the lift arm and put it in a position that, the
To prevent anyone starting the engine, remove carriage can be tilted forward fully.
the ignition key. Disconnect the battery (by means
of the battery isolator if installed) when you are 5. Run the engine at mid speed and operate the
not using electrical power. If you do not take these control lever to tilt the carriage forward. While the
precautions you could be killed or injured. carriage is moving, switch off the engine.
5.1. The carriage movement must slow as the
Check each movement in turn. engine slows. The carriage movement must
stop when the engine stops.
Lift arm lift cylinders 5.2. If the carriage moves after the engine stops,
1. Start the engine. then the HBCV is faulty. Do not use the
machine until you correct the fault.
2. Make sure to engage the park brake and put the
transmission to neutral. Stabiliser cylinder (if installed)
3. Raise the lift arm to the specified angle. 1. Start the engine.
Angle: 45 ° 2. Make sure to engage the park brake and put the
4. Run the engine at mid speed and operate the transmission to neutral.
control lever to lower the lift arm. While the lift 3. Lower the stabilisers.
arm is moving, switch off the engine.
4. Make sure that the stabiliser legs are in the down
4.1. The lift arm movement must slow as the position and supports the machine weight. Make
engine slows. The lift arm movement must sure that the front wheels are lifted from the
stop when the engine stops. ground.
4.2. If the lift arm moves after the engine stops,
then both the lift arm HBCV (Hose Burst 5. Stop the machine.
Check Valve) are faulty. Do not use the
6. Operate the stabiliser controls.
machine until you correct the fault.
7. Make sure that the front wheels of the machine
Lift arm extension cylinder do not lower to the ground.
1. Start the engine. 7.1. If the machine moves when the stabiliser
controls are operated after the engine is
2. Make sure to engage the park brake and put the stopped, the HBCV are faulty. Do not use
transmission to neutral. the machine until you correct the fault.
3. Raise the lift arm fully.
4. Extend the lift arm fully.
5. Run the engine at mid speed and operate the
control lever to retract the lift arm. While the lift
arm is retracting, switch off the engine.
5.1. The lift arm movement must slow as the
engine slows. The lift arm movement must
stop when the engine stops.
30 - 256 9823/1700-1 30 - 256

00 - General
Figure 1035.
X Gap between the wheel and the ground
Sway cylinder (if installed)

2. Make sure to engage the park brake and put the
transmission to neutral.
3. Sway the machine body approximately halfway
to the left and release the sway control.
4. Stop the engine.
5. Operate the sway control to the left. Check that
the machine does not sway.
6. Do steps 1 to 5 again for right sway.
7. If the body moves when the sway control is
moved with the engine stopped, the hose burst
protection valves are faulty.
8. Do not use the machine until you correct the fault.
30 - 257 9823/1700-1 30 - 257

70 - Pilot Pressure Supply Valve
Contents Page No.
30-70-00 General ......................................................................................................................... 30-259
30 - 258 9823/1700-1 30 - 258

00 - General
Operation ..................................................... 30-259
Operation Overview
The pilot pressure supply valve is supplied from a
single line tapped into the gear pump feed line to the
cooling fan hydraulic motor.
The pressure regulating valve maintains pilot

pressure by regulating the incoming supply pressure.
Oil at pilot pressure is supplied to the flowshare
control valve spools.
The pressure supply valve incorporates the

accumulator. The accumulator traps and stores pilot
pressure to enable the service spools to be operated
for a limited period with a stopped engine. This allows
for attachments to be lowered safely to the ground if
the engine stops.
Supply of pilot oil can be isolated from the main

control valve by de-energising the solenoid. When
the valve is de-energised, the trapped pilot oil in the
main control valve is diverted to tank. The service
spools are `locked' and services cannot be operated
with or without the engine running.
The oil stored in the accumulator is isolated from the

pilot system when the solenoid is de-energised.
Figure 1036. Pilot Pressure Supply Valve
C A B
A Pressure supply valve

B Solenoid
C Accumulator
510-56, 512-56 and 514-56 machines

An additional solenoid isolates the pilot pressure
supply to the lift valve spool. This solenoid operates
as a part of the stabiliser system.
30 - 259 9823/1700-1 30 - 259

00 - General
Figure 1037. 510-56, 512-56 and Service operation

514-56 Pilot Pressure Supply Valve
The flow from the cooling fan section of the main
pump flows to the pilot filter. The flow from the pilot
filter enters the pilot pressure supply valve. The pilot
pressure relief valve decreases the pressure of the
fluid.
The pilot pressure enable solenoid valve isolates

the pilot pressure supply. When the solenoid coil
is de-energised, the service spools are locked and
services cannot be operated. The pump supply flows
back to tank. When the solenoid coil is energised, the
pilot pressure supply flows through the solenoid to
the servo control valves.
The valve has two test points. Pump supply pressure

can be tested at the pump supply pressure test point.
A The pilot supply pressure can be tested at the pilot
A Solenoid pressure test point.
The accumulator stores fluid at pilot pressure to

Hydraulic Operation and Schematics allow a small number of operations of the hydraulic
services when the engine is not running.
Hydraulic circuit operation
The schematic diagrams show an overview of the
system. For machine specific schematics, refer to
hydraulic system- general, refer to (PIL 30-00).
Figure 1038.
C B
E TP2
J
T3
F
T2
P
0.5
BAR
T
T1
P
A T TP1
G H
B K
A Hydraulic tank return line B Supply from hydraulic pump

C Pilot pressure supply valve D Pilot pressure enable solenoid
E Pilot pressure test point F Pilot pressure relief valve
G Pump supply pressure test point H Pilot filter
J Pilot pressure accumulator K Servo control lever
30 - 260 9823/1700-1 30 - 260

00 - General
510-56, 512-56 and 514-56 machines of the solenoid is controlled by the ECU (Electronic
Control Unit) and the stabiliser system interlocks.
Lift pilot pressure supply isolation valve
The lift pilot pressure supply valve isolates the pilot

pressure supply to the lift valve spool. The operation
Figure 1039. Lift Pilot Pressure Supply Valve Open
A B
C D
H
F J
E G K
A Pilot pressure pump supply B Pilot pressure supply valve

C Pilot pressure reducing valve D Pilot pressure enable solenoid
E Tank return F Lift pilot pressure supply valve
G Servo control lever H Flowshare control valve
J Lift valve spool K Lift ram
Figure 1040. Lift Pilot Pressure Supply Valve Closed
A B
C D
F
H
E G J
K
A Pilot pressure pump supply B Pilot pressure supply valve

C Pilot pressure reducing valve D Pilot pressure enable solenoid
E Tank return F Lift pilot pressure supply valve
G Servo control lever H Flowshare control valve
J Lift valve spool K Lift ram
30 - 261 9823/1700-1 30 - 261

00 - General
Electrical Operation and Schematics For harness connector pin numbers refer to electrical
system- general, refer to (PIL 33-00). For harness
The schematic diagrams show a typical system. connector details refer to electrical system- harness,
For machine specific schematics refer to electrical refer to (PIL 33-12)
system- general, refer to (PIL 33-00).
When the switch is set to the ON position, the

solenoid coil is energised and the pilot oil pressure is
supplied to the servo control valves.
Figure 1041.
A B C
A Fuse B Switch
C Solenoid coil
510-56, 512-56 and 514-56 machines For harness connector pin numbers refer to electrical
system- general, refer to (PIL 33-00). For harness
The ECU supplies a feed to the lift pilot pressure connector details refer to electrical system- harness,
supply isolation valve solenoid. The lift arm raise refer to (PIL 33-12).
return relay provides the earth for the isolation valve
solenoid.
Figure 1042.
B C
A Relay B ECU
C Solenoid
30 - 262 9823/1700-1 30 - 262

00 - General
Remove and Install 2. The installation procedure is the opposite of the

steps.
Remove 2.1. Make sure that the hoses are connected
1. Make the machine safe. Refer to (PIL 01-03). back to the correct ports.
2. Install the safety strut. refer to (PIL 06-69). required. Refer to (PIL 30-00).
3. Follow the hydraulic care and safety procedures. 2.3. After installation, check the pilot pressure.
Refer to (PIL 30-00). Refer to (PIL 30-70).
4. Discharge the hydraulic pressure. Refer to (PIL The extent of permissible servicing is the
30-00). replacement of the solenoid coil and accumulator.
Further dismantling of the valve is not recommended.
5. Disconnect the electrical harness at the solenoid
If the valve is suspected as being faulty it must be
electrical connector.
replace as a complete assembly.
6. Put labels on the hoses to help installation.
contamination.
9. Support the pilot valve block. Loosen and remove
the 4 screws and lift out the valve.
Figure 1043.
E
C B
A Pilot valve block
B Solenoid electrical connector
C Hoses
D Screws
E Solenoid coil
Install
1. If you install a new accumulator, it may require
charging. Make sure that you charge it if needed.
30 - 263 9823/1700-1 30 - 263

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-265

30-93-03 Lift Arm ......................................................................................................................... 30-268
30 - 264 9823/1700-1 30 - 264

93 - Hose
00 - General
Introduction .................................................. 30-265 Hydraulic hoses are used to connect different
Disconnect and Connect ............................. 30-266 components in the hydraulic circuit. The hoses
Check (Condition) ........................................ 30-267 are graded by pressure, temperature, and fluid
compatibility. Hoses are built up with rubber and steel
layers. A rubber interior is surrounded by multiple
layers of woven wire and rubber. The exterior is
designed for abrasion resistance. The bend radius
of a hydraulic hose is carefully designed into the
machine, since hose failures can be deadly, and
violating the hose's minimum bend radius will cause
failure. Hydraulic hoses generally have steel fittings
swaged on the ends.
30 - 265 9823/1700-1 30 - 265

93 - Hose
00 - General
Disconnect and Connect Figure 1046.
Some attachments are hydraulically powered. The

following procedures show how to connect and
disconnect the hydraulic hoses safely.
Connecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Check the hoses and adaptors for damage. 5. Check for leaks:
4. Connect the hoses: 5.1. Start the machine.
4.1. Make sure that the hose is not twisted. 5.2. Operate the related controls to increase the
Pressure applied to a twisted hose can pressure in the hydraulic system.
cause the hose to fail or the connections to 5.3. Stop the machine then remove the key.
loosen.
5.4. Check for indications of leakage at the hose
Figure 1044. connections. Correct, as necessary.
Disconnecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
4.2. Make sure that the hose does not touch 4. Check the hoses and adaptors for damage.
hot parts. High ambient temperatures can
cause the hose to fail. 5. If necessary, install the blanking caps.
4.3. Make sure that the hose does not touch 6. Check for leaks:
parts which can rub or cause abrasion.
6.1. Start the machine.
4.4. Use the hose clamps (where possible) to
support long hose runs and keep the hoses 6.2. Operate the related controls to increase the
away from moving parts, etc. pressure in the hydraulic system.
Figure 1045. 6.3. Stop the machine then remove the key.
6.4. Check for indications of leakage at the hose
connections. Correct, as necessary.
4.5. To allow for length changes when the hose

is pressurised, do not clamp at the bend.
The curve absorbs the change.
30 - 266 9823/1700-1 30 - 266

93 - Hose
00 - General
Check (Condition)
Hydraulic Hoses
WARNING Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not
use the machine if a hose or hose fixture is
damaged.
clear of fluid under pressure and wear personal
protective equipment. Hold a piece of cardboard
close to suspected leaks and then examine the
cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
Examine the hoses for:
• Damaged hose ends

• Worn outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Exposed armouring in the outer covers
• Displaced hose end fittings.
• Worn cover sheathing or hose burst protection
covering
Replace a damaged hose before you use the

machine again.
The replacement hoses must be of the same size,

standard and pressure rating. If necessary, for more
information contact your JCB dealer.
30 - 267 9823/1700-1 30 - 267

93 - Hose
03 - Lift Arm
03 - Lift Arm Technical Data

Technical Data ............................................. 30-268 Refer to hydraulic system, hose, lift arm, component
Remove and Install ..................................... 30-269 identification (PIL 30-93-03).
30 - 268 9823/1700-1 30 - 268

93 - Hose
03 - Lift Arm
Remove and Install
Lift Arm Hose (3 Stage Lift Arm) 12.1. Attach the male to male adaptors to
the tilt service hose end connectors and
Remove the auxiliary service hydraulic hose end
connectors.
1. Remove the attachments from the lift arm. 12.2. Attach the new hoses to the tilt service
2. Raise the lift arm to the horizontal position and hose connectors and the auxiliary service
fully retract the lift arm. Support the lift arm. hydraulic hose connectors. This will
enable the new hoses to be pulled
3. Make the machine safe. Refer to (PIL 01-03). through the lift arm when the old hoses
are removed. This will also prevent
4. Follow the general health and safety procedures. contamination.
13. If you use the old hoses again, do as follows.
5. Remove lift arm rear cover. Refer to (PIL 06-06).
13.1. Tie some string to the end of each hose.
6. If you are reinstalling the same hoses, put label It is used for pulling the hoses back inside
on the hoses to help installation. the lift arm during installation.
7. Disconnect the two tilt service hose connectors 14. Remove the two bolts 1 and the hose retaining
and two auxiliary service hydraulic hose plate.
connectors at the lift arm nose.
15. Remove the bolt 4 and the guide pin from the
8. Remove the bolts 2 that clamp the outer pipes to roller bracket.
the lift arm.
16. Working under the lift arm, carefully pull the
9. Remove the bolts 3 that secure the clamps. hoses from inside the outer lift arm.
10. The hoses and pipes are clamped to the lift arm 17. Feed the hoses past the guide roller at the rear
sections. Make sure to remove all the clamps and of the lift arm.
the clamping bolts.
18. For new hoses, disconnect the old hoses from
11. Disconnect the four hydraulic hoses from the the new hoses and remove the adaptor.
pipes at connections.
19. For old hoses, take out the string and remove the
12. If you use new hoses, do as follows. hoses.
30 - 269 9823/1700-1 30 - 269

93 - Hose
03 - Lift Arm
Figure 1047.
A
E
B D
F H
A Bolt 1 B Hose retaining plate

C Hydraulic hoses D Connections
E Pipes F Tilt service hose connectors
G Auxiliary service hydraulic hose connectors H Bolts 2
30 - 270 9823/1700-1 30 - 270

93 - Hose
03 - Lift Arm
Figure 1048.
P M
J Hose K White mark

L Bolt 3 M Clamp
N Bolt 4 P Guide pin
Q Roller bracket R Guide roller
30 - 271 9823/1700-1 30 - 271

93 - Hose
03 - Lift Arm
Install 7. Disconnect the two tilt service hoses and the two
auxiliary service hydraulic hoses at the bulkhead
1. The installation procedure is the opposite of the plate 1 and the bulkhead plate 2 located at rear
removal procedure. Additionally do the following of the lift arm.
steps.
8. Remove the six hose clamps 1 and the two hose
1.1. Make sure that the hoses are routed clamps 3 from the underside of the lift arm and
correctly. Do not cross the hoses over. release the hydraulic hoses.
1.2. Make sure to tension the hoses. Pull them 9. Disconnect the four hydraulic hoses at the pipe
tight inside the lift arm until the white marks matrix.
on the hoses align with the clamps. This
prevents the hoses becoming damaged 10. If you use new hoses, do as follows.
when moving inside the lift arm.
10.1. Attach the male to male adaptors to the
2. For new hoses to the following step. hose end connectors.
2.1. Use the old hoses connected to the new 10.2. Attach the new hoses to the hose
hoses to pull the new hoses through the lift adapters at the hose end connectors.
arm. This will enable the new hoses to be
pulled through the lift arm when the old
3. For old hoses do the following step. hoses are removed. This will also prevent
contamination.
3.1. Use the string to pull the hoses inside the
lift arm. 11. If you use the old hoses again, do as follows.
Lift Arm Hose (4 Stage Lift Arm) 11.1. Tie some string to the end of each hose.
It is used for pulling the hoses back inside
the lift arm during installation.
Outer hoses
12. Remove the two hose clamps 2.
Remove
13. Remove the guide pin.
1. Remove the attachments from the lift arm.
14. Working under the lift arm, carefully pull the
2. Raise the lift arm to the horizontal position and hoses from inside the outer lift arm.
fully retract the lift arm. Support the lift arm.
15. Feed the hoses past the guide roller at the rear
3. Make the machine safe. Refer to (PIL 01-03). of the lift arm.
4. Follow the general health and safety procedures. 16. For new hoses, disconnect the old hoses from
Refer to (PIL 01-03). the new hoses and remove the adaptor.
5. Remove lift arm rear cover. Refer to (PIL 06-06). 17. For old hoses, take out the string and remove the
6. If you reinstall the same hoses, put label on the hoses.
hoses to help installation.
30 - 272 9823/1700-1 30 - 272

93 - Hose
03 - Lift Arm
Figure 1049.
B
A
A C
X
A
D
A
A A
E
J
A Hose clamp 1 B Bulkhead plate 1

C Hose clamp 2 D Bulkhead plate 2
E Pipe matrix F Hydraulic hose
G Guide pin H Guide roller
J Hose clamp X Hose end connectors
30 - 273 9823/1700-1 30 - 273

93 - Hose
03 - Lift Arm
Install 9.1. Attach the male to male adaptors to

the auxiliary service hydraulic hose end
1. The installation procedure is the opposite of the connector and the tilt service hydraulic hose
removal procedure. Additionally do the following connector.
steps.
9.2. Attach the new hoses to the hose adapters
1.1. For new hoses, use the old hoses at the auxiliary service hydraulic hose end
connected to the new hoses to pull the new connector and the tilt service hydraulic
hoses through the lift arm. connector. This will enable the new hoses to
be pulled through the lift arm when the old
1.2. For old hoses, use the string to pull the hoses are removed. This will also prevent
hoses inside the lift arm. contamination.
2. Make sure that the hoses are routed correctly. Do 10. If you use the old hoses again, do as follows.
not cross the hoses over.
10.1. Tie some string to the end of each hose.
Inner hoses It is used for pulling the hoses back inside
the lift arm during installation.
Remove
11. Disconnect the four hydraulic hoses at the pipe
1. Remove the attachments from the lift arm. matrix at the rear of the lift arm.
2. Remove the attachments from the lift arm. 12. Remove the nut and the bolt and release the
pipe matrix from the second intermediate lift arm
3. Raise the lift arm to the horizontal position and section.
fully retract the lift arm. Support the lift arm.
13. Pull out the pipe matrix together with the hoses
4. Park the machine and make it safe. Refer to (PIL from the rear of the lift arm. Make sure that the
01-03). string is routed through the lift arm and each end
5. Follow the general safety precautions. Refer to is accessible.
(PIL 01-03). 14. Disconnect the other end of the tilt and auxiliary
6. Remove lift arm rear cover. Refer to (PIL 06-06). service hydraulic hoses at position 1 and position
2 of the pipe matrix.
7. If you reinstall the same hoses, put label on the
hoses to help installation. 15. For new hoses, disconnect the old hoses from
the new hoses and remove the adaptor.
8. Disconnect the two tilt service hoses and the two
auxiliary service hydraulic hoses at the front of 16. For old hoses, take out the string and remove the
the lift arm. hoses.
9. If you use new hoses, do as follows.
30 - 274 9823/1700-1 30 - 274

93 - Hose
03 - Lift Arm
Figure 1050.
C
B
A
E
F
G F
A Position 1 B Position 2
C Pipe matrix D Bolt
E Hydraulic hose F Auxiliary service hydraulic hose
G Tilt service hydraulic hose
30 - 275 9823/1700-1 30 - 275

93 - Hose
03 - Lift Arm
Install
steps.
1.1. For new hoses, use the old hoses
connected to the new hoses to pull the new
hoses through the lift arm.
1.2. For old hoses, use the string to pull the
hoses inside the lift arm.
2. Make sure that the hoses are routed correctly. Do
not cross the hoses over.
30 - 276 9823/1700-1 30 - 276

96 - Pipe
96 - Pipe
Contents Page No.
30-96-03 Lift Arm ......................................................................................................................... 30-279
30 - 277 9823/1700-1 30 - 277

Notes:
30 - 278 9823/1700-1 30 - 278

96 - Pipe
03 - Lift Arm
03 - Lift Arm
Refer to component identification, (PIL 30-93-03).
30 - 279 9823/1700-1 30 - 279

97 - Connectors
97 - Connectors
Contents Page No.
30-97-03 Quick Release Coupling .............................................................................................. 30-281

30-97-09 Adaptor ......................................................................................................................... 30-283
30-97-24 Push Lock Fitting ......................................................................................................... 30-285
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-286
30 - 280 9823/1700-1 30 - 280

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-281 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-282 operator to remove and install attachments swiftly
and efficiently. Generally, your machine pipework will
have female couplings installed, and the optional
attachment hoses will have male couplings installed.
The quick release couplings will be trouble free and

relatively easy to connect and disconnect, if they are
kept clean and used correctly. The recommendations
listed below must always apply when using flat face
quick release couplings.
Read the correct connecting and releasing

procedures before you install or remove any optional
attachment connected with quick release couplings.
Figure 1051.
A B
A Female coupling
B Male coupling
Essential Do's
• Before connecting or removing any hydraulic
hose, the residual hydraulic pressure trapped
in the service hose line must be vented. Make
sure the hose service line has been vented
before connecting or removing the hoses.
• Always wipe the two mating faces clean before
connecting.
• Use caps and plugs when the couplings are
disconnected.
• Always align the external locking ball (if used)
with the notch in the locking sleeve and then pull
the locking sleeve back fully to disconnect.
• If a coupling sticks, first check that pressure
has been released. Make sure the locking ball
and notch in the locking sleeve are aligned,
pull back the sleeve and twist the couplings
apart. Sticking is normally caused by dirt in the
coupling or physical damage due to abuse.
• Connect and disconnect the new couplings
two or three times to work the PTFE seals.
Sometimes a new coupling will stick if the seal
has not been worked.
• When connecting the couplings, only apply the
spanner or grips to the hexagon and nowhere
else.
• Avoid damage to the coupling faces. Burrs
and scratches cause damage to the seals and
cause leaks. They can also impede connection
and disconnection of the couplings.
30 - 281 9823/1700-1 30 - 281

97 - Connectors
03 - Quick Release Coupling
• Periodically lubricate the internal locking balls Disconnect and Connect

on the female half of the coupling with silicone
grease.
Some attachments are hydraulically powered. The
Essential Don'ts following procedures show how to connect and
disconnect the hydraulic hoses safely.
• Never try to reconnect using a damaged half
coupling as this will destroy the seals in the
mating half and necessitate replacement of Connect
both halves. 1. Make the machine safe.
• Do not leave the coupling where it may be run
over by a machine or otherwise crushed, this Refer to: PIL 01-03.
will distort the sleeve and prevent connection
and disconnection. 2. Discharge the hydraulic pressure.
• Never try to turn the sleeve when the coupling is Refer to: PIL 30-00-00.
disconnected as this will cause the locking ball
to jam under the locking sleeve and damage the 3. Wipe the two faces of the male and female
coupling. couplings and make sure they are clean.
• Never try to strip the coupling down, there are
no user serviceable parts. If the coupling is 4. Make sure that the ball in the female coupling is
damaged it must be replaced with a new one. located in one of its slots.
• Never hit the centre poppet of the coupling to 5. Connect the male coupling into the female
try and release the locked in pressure. This can coupling.
cause irreparable damage to the coupling and
serious injury. 6. Where applicable, rotate the sleeve half a turn
• When connecting the couplings, never clamp and make sure that the locking ball does not align
on the sleeve of the female or nose of the male, with the slot.
this will cause distortion and/or damage.
• Never subject the couplings to external forces, Disconnect
especially side load. This can decrease the life
of the coupling or cause failure. 1. Make the machine safe.
• Never allow the torsional forces transmitted
from the hoses to unscrew/screw together the Refer to: PIL 01-03.
couplings.
2. Discharge the hydraulic pressure.
• Never use a coupling as a plug.
• Do not connect and disconnect with pressure in Refer to: PIL 30-00-00.
the line unless the coupling type is specifically
designed to do so. 3. Where applicable, align the slot with the ball.
4. Pull back the sleeve to release the coupling.
Figure 1052.
C D E
C Ball
D Slot
E Sleeve
30 - 282 9823/1700-1 30 - 282

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-283 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-284 may utilise Positional Type Hydraulic Adaptors.
When you install a Positional Type Hydraulic
Adaptor, it is important to adopt the Remove and
Install procedure. Refer to: PIL 30-97-09.
If this procedure is not followed correctly, damage to

the O-ring seal can occur which can result in oil leaks.
Figure 1053.
A O-ring seal
B Locknut
C Washer
30 - 283 9823/1700-1 30 - 283

97 - Connectors
09 - Adaptor
1. Make sure that the locknut is screwed back on to

the body of the adaptor as far as possible.
2. Check that the O-ring backing washer is a tight
fit on the adaptor. Note that the washer should
not move freely, if the washer is slack do not use
the adaptor.
3. Check that the O-ring seal is installed and
that it is free from damage or nicks. Before
you install the adaptor, smear the O-ring with
clean hydraulic fluid. The dimensions and shore
hardness of the O-ring seal is critical. Should it
become necessary to replace the O-ring seal,
make sure you use JCB Genuine Parts.
Figure 1054.
Z Adaptor thread
6. Tighten the locknut to the correct torque value.
A O-ring seal
B Locknut
C Backing washer
4. Screw the adaptor into the port of the hydraulic
component as far as possible, so that all the
threads engage and the O-ring seal is correctly
seated against the sealing face.
5. Set the angular position of the adaptor as
required, then secure by tightening the locknut.
When installed correctly no more than one thread
should be visible at Z as shown.
30 - 284 9823/1700-1 30 - 284

97 - Connectors
24 - Push Lock Fitting
24 - Push Lock Fitting
Remove and Install
The fitting is installed and removed without the need

for tools, it is removable and reusable.
1. To release the tube push the collet and release

the tube. All tubes have an assembly mark to
assist installation.
Figure 1056.
D A
C B
A Tube
B Collet
C O-ring
D Steel support tube
30 - 285 9823/1700-1 30 - 285

97 - Connectors
27 - Rapid Assembly Hose Fitting
27 - Rapid Assembly Hose Fitting
Remove and Install
The hose has a toolless installation. The hose is not

removable. The complete hose and fitting assembly
must be replaced.
1. To install the hose, push the tube into the fitting

body.
Figure 1057.
A B C
E D
A Snap ring
B O-ring and back-up ring
C Tube
D Fitting body
E Hose
30 - 286 9823/1700-1 30 - 286

Contents Page No.
33-00 Electrical System

33-00-00 General ............................................................................................................................. 33-3
33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ................................................................................................................... 33-140
33-03 Battery
33-03-00 General ......................................................................................................................... 33-145
33-03-03 Isolator Switch .............................................................................................................. 33-158
33-06 Battery Cable
33-06-00 General ......................................................................................................................... 33-161
33-09 Power Distribution
33-09-00 General ......................................................................................................................... 33-163
33-09-03 Fuse ............................................................................................................................. 33-165
33-09-06 Relay ............................................................................................................................ 33-168
33-12 Harness
33-12-00 General ......................................................................................................................... 33-171
33-12-04 Chassis ......................................................................................................................... 33-189
33-12-06 Lift Arm ......................................................................................................................... 33-206
33-12-09 Engine .......................................................................................................................... 33-211
33-12-12 Operator Station ........................................................................................................... 33-220
33-12-15 Front Console ............................................................................................................... 33-225
33-12-30 Gearbox ........................................................................................................................ 33-322
33-12-34 Trailer ........................................................................................................................... 33-343
33-12-36 Work Lights .................................................................................................................. 33-345
33-12-39 Road Lights .................................................................................................................. 33-346
33-12-53 Stabiliser ....................................................................................................................... 33-351
33-12-56 Extreme Cold Climate Heater ...................................................................................... 33-365
33-15 Alarm
33-15-03 Reverse Warning .......................................................................................................... 33-377
33-21 Immobiliser
33-21-00 General ......................................................................................................................... 33-379
33-24 Instruments
33-24-03 Instrument Panel .......................................................................................................... 33-389
33-24-10 Hourmeter .................................................................................................................... 33-393
33-27 Interior Switch
33-27-03 Multi-Purpose ............................................................................................................... 33-395
33-40 Bulb
33-40-00 General ......................................................................................................................... 33-399
33-45 Control Module
33-45-00 General ......................................................................................................................... 33-403
33-45-01 Instrument Panel .......................................................................................................... 33-406
33-45-18 Steer Mode ................................................................................................................... 33-432
9823/1700-1
2018-06-27
33-48 Entertainment
33-48-03 Radio ............................................................................................................................ 33-441
33-51 Beacon
33-51-00 General ......................................................................................................................... 33-445
33-51-03 Socket .......................................................................................................................... 33-446
33-54 Window Washer/Wipe
33-54-00 General ......................................................................................................................... 33-449
33-54-09 Front Motor ................................................................................................................... 33-450
33-54-10 Rear Motor ................................................................................................................... 33-453
33-54-11 Roof Motor .................................................................................................................... 33-454
33-57 Electronic Diagnostic
33-57-00 General ......................................................................................................................... 33-457
33-57-03 Servicemaster .............................................................................................................. 33-460
33-57-90 Fault Codes .................................................................................................................. 33-503
33-66 Load Motion Control System
33-66-00 General ......................................................................................................................... 33-573
33-66-03 Display Unit .................................................................................................................. 33-582
33-84 Sensor
33-84-09 Speed Sensor .............................................................................................................. 33-585
33-84-15 Transmission Oil Temperature ..................................................................................... 33-586
33-84-41 Lift Arm ......................................................................................................................... 33-587
33-84-72 Chassis ......................................................................................................................... 33-590
9823/1700-1
2018-06-27
Acronyms Glossary
2WD Two Wheel Drive

DEF Diesel Exhaust Fluid
DLA Data Link Adaptor
DTC Diagnostic Trouble Code
HVCS Hydraulic Variable Control Solenoid
Valve
LCD Liquid Crystal Display
LED Light Emitting Diode
LLMI Longitudinal Load Moment Indicator
MIL Malfunction Indicator Lamp
OEM Original Equipment Manufacturer
SCR Selective Catalytic Reduction
SRS Smooth Ride System
9823/1700-1
2018-06-27
Notes:
9823/1700-1
2018-06-27
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ................................................................................................................... 33-140
33 - 1 9823/1700-1 33 - 1
Notes:
33 - 2 9823/1700-1 33 - 2
00 - General
Introduction ...................................................... 33-3 It is important that the electrical system on the
Health and Safety ........................................... 33-4 machine is in a sound state of repair.
Technical Data ................................................. 33-4
Fault-Finding .................................................... 33-5 Make sure that all the health and safety warnings
in this section are followed. The machine must be
Check (Condition) ............................................ 33-7 safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.
33 - 3 9823/1700-1 33 - 3
00 - General

Arc Welding Table 439.
To prevent the possibility of damage to electronic
Description Data
components, disconnect the battery and the
alternator before arc-welding on the machine or Battery
attached implements. Cold Crank Amps for 30 s at 1.2 V 1000 CCA
per cell or higher at -18 °C ( -0.4 °F)
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control Alternator
units (ECUs), monitor displays, etc., then disconnect Type 12 V, 95 A
them before welding. Failure to disconnect the No load speed 1100 RPM
sensitive electrical equipment could result in (Revolu-
irreparable damage to these components. tions Per
Parts of the machine are made from cast iron, welds Minute)
on cast iron can weaken the structure and break. Do Maximum continuous speed 15000
not weld cast iron. Do not connect the welder cable RPM
or apply any weld to any part of the engine. Maximum intermittent speed 18000
Always connect the welder earth (ground) cable to RPM
the same component that is being welded to avoid Weight 5.7 kg
damage to pivot pins, bearings and bushes. Attach
the welder earth (ground) cable a distance from the
part being welded no more than 0.6 m.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION! Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
33 - 4 9823/1700-1 33 - 4
00 - General
Fault-Finding
Fault
Battery Fault Table 440. Page 33-5
General Relay Fault Table 441. Page 33-5
Electrical Network - CAN (Controller Area Network) Bus system Table 442. Page 33-6
ECM Faults Table 443. Page 33-6
Table 440. Battery Fault

Cause Remedy
Battery Voltage Switch on the ignition key and check the battery
voltage with a multimeter. If the terminal voltage of
the battery is below 9 Volt or above 16 Volt, charge
or replace the battery.
Battery Connection Fault Disconnect the electrical connection from the battery.
Check for signs of corrosion or contamination in the
battery terminals, clean the terminals. Repair as
necessary.
If no fault is found proceed to ECM (Engine Control
Module) Connection Faulty.
ECM Connection Faulty Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
If ECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing an ECM).
If harness is damaged, repair or replace as
necessary.
Check the resistance between the vehicle chassis
ground and ECM ground, if the resistance is high
repair the ECM ground.
If no fault is found proceed to 'Battery Charge Circuit
Fault'.
Battery Charge Circuit Fault Check the battery charge circuit, if the circuit is found
faulty repair as necessary.
If no fault is found raise a Techweb Helpdesk call.
Table 441. General Relay Fault

Cause Remedy
Relay Supply Voltage Fault Perform the relay test routine.
If relay supply voltage is found fault, proceed to
'Relay Connection Faulty'.
If relay supply voltage is OK, raise Techweb
Helpdesk Call.
Relay Connection Faulty Check the condition of relay to harness connection,
make sure the seals are in place, check for signs
of corrosion or contamination. Repair/replace as
necessary.
If no fault is found, proceed to ECM connection fault.
33 - 5 9823/1700-1 33 - 5
00 - General
Cause Remedy
ECM Connection Fault Disconnect the harness from engine ECM and
inspect. Check seals are in place, check for signs of
corrosion or contamination.
necessary.
Check the continuity and electrical insulation, repair
or replace as necessary.
If a relay fault is found, raise Techweb Helpdesk Call.
Table 442. Electrical Network - CAN (Controller Area Network) Bus system
Cause Remedy
necessary.
If no fault is found proceed to Wiring Fault.
Wiring Fault Check the harness continuity and electrical
insulation, repair or replace as necessary.
If no fault is found, proceed to 'Network and CAN
Resistors Faulty'.
Network and CAN Resistors Faulty Check the network and CAN resistors, repair as
necessary.
If no fault is found proceed to raise Techweb
Helpdesk call.
Table 443. ECM Faults

Cause Remedy
ECM Overheat Identify the root cause and repair as necessary: – Air
intake problem – Engine too hot – Cooling fan failure
– Extreme hot soak.
If no fault is found proceed to ECM temperature fault.
ECM Temperature Fault Check the ECM temperature is consistent with
physical ECM temperature, if found faulty raise
Techweb Helpdesk call.
ECM General Fault Visually check the ECM pins and connections on the
wiring harness. If ECM pins are damaged, replace
ECM and re-flash appropriate calibration (see Re-
flashing an ECM).
If no fault is found proceed to ECM connection fault.
Check the conformity of ground connection of vehicle
chassis. If harness is damaged, repair or replace as
necessary.
necessary.
If no fault is found raise Techweb Helpdesk call.
33 - 6 9823/1700-1 33 - 6
00 - General
Check (Condition)
Examine the electrical circuits regularly for:
• Damaged connectors.
• Loose connections.
• Chafing on the wiring harnesses.
• Corrosion.
• Missing insulation.
• Incorrect routing of the wiring harnesses.
Do not use the machine if one or more of these faults

are found. You must make sure that the electrical
circuit is repaired immediately.
33 - 7 9823/1700-1 33 - 7
50 - Schematic Circuit Introduction

Introduction ...................................................... 33-8 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 33-11 representation of the machines electrical circuit. It
shows the components of the circuit as simplified
electrical symbols, and the power and signal
connections between the devices. The wiring
diagram is used to troubleshoot problems and to
make sure that all the connections have been made
and that everything is present.
Use the schematics together with the correct

electrical harness drawings to reference the
connector pin details.
This section may contain more than one set of

electrical schematics for different machine variants.
Understanding Electrical Schematics

Use the applicable schematic set to trace wires
and connections between electrical devices. In most
cases it will be necessary to trace wires across more
than one schematic sheet.
The example identifies the information contained on

the diagrams. It also shows how to follow wires from
one diagram sheet to another.
The harness inter-connector codes and device

harness connector codes are the same as used on
the applicable harness drawings.
Splices are not normally accessible. Splices are

inside the harness sheath and not visible on the
outside. Wires are welded together at a splice, there
are no individual connector components.
33 - 8 9823/1700-1 33 - 8
Figure 1058.
/7.B4 TO
0.50 mm² 1009A -S012
TO SWITCH:MAIN WIPER C116 #1996
C 7
-SW5
A 701/E0089
7219/0013 SWITCH: MAIN WIPER
FROM SPLICE:BACKLIGHTING S012 #1996
-C116 8 7
0.50 mm² 1009A 8/10 7/10
/3.D1 FROM
0.50 mm² 8100J B

-S011 1 D
F F 2/10 2
L H 3 3/10
4 4/10
-IC08_M -IC08_M
0.75 mm² 8006 21/21 21/21 0.75 mm² 8006 5/10 5
/9.B5 TO
#1783 6 6/10
TO MOTOR:WIPER-UPPER C058
D GD
K J
E
7236/0002
MOTOR:WIPER UPPER 9
-C058
6/6 6/6 RED 5/6 5/6 1.00 mm² 8006 5/20 5/20 0.75 mm² 8006 FROM
/7.B4
BLACK #1783 FROM SWITCH:MAIN WIPERS C116
2/6 2/6 GREEN
YELLOW
-B8 3/6 3/6
1/6 1/6 BROWN
WHITE 4/6 4/6
A Wire size (area) and number B Device harness connector code

C Device description D Connector pin number (wire location / total)
E Device internal schematic F Harness inter-connector codes
G Harness inter-connector symbol H Splice code and symbol
J Destination reference number K Destination (harness connector code)
L Destination (diagram sheet and grid)
To help locate a wire destination from other diagram Due to space limitations, the grid is sometimes
sheets use the grid reference. This identifies the omitted.
applicable location zone on the sheet in a similar way
to a map reference.
33 - 9 9823/1700-1 33 - 9
Figure 1059. Grid reference example (D4)
1 2 3 4 5 6 7 8
F GROUND
RC012:6 /15.C5 FROM 1.00 mm² 601SP
F
GROUND 1.00 mm² 601AV
RC011:1 /13.A4 FROM
GROUND 1.00 mm² 601AX CAN SHLD

RC007:2 /13.B4 FROM
P006:5 /3.D2 FROM 0.75 mm² 601HB
GROUND 2.00 mm² 601AR 6.00 mm² 601RC1 CAN SHLD

RC009:1 /12.F6 FROM
P006:10 /3.D2 FROM 0.75 mm² 601EK

-SRC5
CAN SHLD 0.75 mm² 601HK
P007:10 /3.C2 FROM
GROUND 1.50 mm² 600WP CAN SHLD

RC18:2 /12.C6 FROM
P007:5 /3.C2 FROM 0.75 mm² 601HL
GROUND 2.00 mm² 601AW CAN SHLD

RC004:1 /12.E6 FROM
P008:10 /3.A2 FROM 0.75 mm² 601X
GROUND 2.00 mm² 601FK CAN SHLD

RC003:2 /14.F7 FROM
P008:5 /3.B2 FROM 0.75 mm² 601JJ
GROUND 2.00 mm² 601DG CAN SHLD -SP3

RC005:2 /13.C7 P101:10 1.00 mm² 601TS 3.00 mm² 601JC
E /8.D4
FROM
FROM
GROUND 2.00 mm² 601KG 6.00 mm² 601RC2 10.00 mm² 601RC CAN SHLD
E
RC008:2 /13.C7 FROM
P014:1 /13.F1 0.75 mm² 601LH

-RC06
FROM
-SRC6 -SRC7 M10
CAN SHLD 0.75 mm² 601SH

P014:5 /13.E1 FROM
HYD ECU SENSOR GND 0.75 mm² 699CE CAN SHLD

SP43 /30.E6 FROM
P058:4 /15.E2 FROM 1.00 mm² 601RD
HYD ECU SENSOR GND 1.00 mm² 699SK CAN SHLD CAN SHLD
SP44 /25.C5 FROM
P013:5 /8.C1 FROM 1.00 mm² 601LL P072:17 /9.C5 FROM 1.00 mm² 601DE
HYD ECU SENSOR GND 1.00 mm² 699CH CAN SHLD CAN SHLD
P095:3 /26.D1 FROM
P016:5 /11.E6 FROM 0.75 mm² 601SY P112:2 /14.C4 FROM 1.00 mm² 601HT
HYD ECU SENSOR GND 1.00 mm² 699SJ CAN SHLD CAN SHLD -SP11
P095:6 /26.D1 FROM
P016:10 /11.E6 FROM 0.75 mm² 601JB P020:7 /11.D3 FROM 0.75 mm² 601AD 3.00 mm² 601JE
HYD ECU SENSOR GND 0.75 mm² 699CB CAN SHLD CAN SHLD
P091:2 /29.E5 FROM
P010:5 /4.E2 FROM 0.75 mm² 601NS P063:7 /9.F7 FROM 1.00 mm² 601HP
HYD ECU SENSOR GND 0.75 mm² 699CC -SP42 1.50 mm² 699CA HYD ECU SENSOR GND CAN SHLD CAN SHLD
P092:2 /29.E5 FROM FROM
/22.B7 SC9 / P039:F7 P011:5 /10.F6 FROM 0.75 mm² 601BL P073:A /17.D1 FROM 1.00 mm² 601C
D
HYD ECU SENSOR GND 0.75 mm² 699CD CAN SHLD
P087:2 /21.B7 P036:7 /25.D2 1.00 mm² 601DZ
D
FROM
FROM
HYD ECU SENSOR GND 1.00 mm² 699CG

SP2 /27.E4 FROM
HYD ECU SENSOR GND 0.75 mm² 699CF

P111:2 /29.B6 FROM
CAN SHLD 1.00 mm² 601FV

P067:10 /14.D4 FROM
CAN SHLD 1.00 mm² 601KP -SP29 3.00 mm² 601JH -SP62 10.00 mm² 600 -P030 M10
P015:10 /14.D5 FROM
CAN SHLD 1.00 mm² 601V

P013:10 /10.B1 FROM
CAN SHLD 1.00 mm² 601AC

P015:5 /14.D3 FROM
CAN SHLD 2.00 mm² 601TR

P070:16 /21.C6 FROM
CAN SHLD
C CAN SHLD 1.50 mm² 606TR
P052:1 /14.E7 FROM 1.00 mm² 601DD
P070:15 /21.C6 FROM
C
CAN SHLD 1.00 mm² 601AC CAN SHLD 1.00 mm² 610ACF
CAN SHLD P017:7 /14.C5 FROM
P013:5 /14.E2 FROM
P055:1 /12.B6 FROM 2.00 mm² 600P 10.00 mm² 600

-SP61 -P035 M10 CAN SHLD
P062:7 /27.E4 FROM 1.00 mm² 601KK
CAN SHLD 2.00 mm² 601BU
P130:3 /13.D7 FROM
CAN SHLD 0.50 mm² 601P

CAN SHLD P40:10 /9.A3 FROM
P130:4 /13.D7 FROM 2.00 mm² 601AL

CAN SHLD 1.00 mm² Y
CAN SHLD P066:11 /8.B7 FROM
2.00 mm² SCR

SPMC12 /17.C3 FROM
CAN SHLD 0.75 mm² 601BF

CAN SHLD P024:7 /10.C1 FROM
2.00 mm² SCR

SVMC15 /17.D5 FROM
CAN SHLD 1.00 mm² 601DC -SP6 2.00 mm² 601JD

CAN SHLD P023:7 /10.F2 FROM
1.00 mm² 600H

P034:2 /7.C2 FROM
CAN SHLD 1.00 mm² 601AC

P026:7 /13.F3 FROM
CAN SHLD 1.00 mm² 601AY CAN SHLD 1.00 mm² 601BB
P028:7 /13.B2 FROM
P017:7 /25.E3 FROM
B P029:7 /13.E3
CAN SHLD 1.00 mm² 601KA P021:7 /12.F3
CAN SHLD 1.00 mm² 601BH
B
FROM FROM
CAN SHLD 1.00 mm² 601AL CAN SHLD 1.00 mm² 601DX 2.00 mm² 601JF
P061:7 /16.F2 FROM
P022:7 /12.E3 FROM
-SP28
CAN SHLD 1.00 mm² 601BL CAN SHLD 1.00 mm² 601KC
P052:7 /14.B5 FROM
P065:2 /15.B5 FROM
CAN SHLD 1.00 mm² 601N

P027:7 /21.B4 FROM
CAN SHLD 0.75 mm² 601AK

P042-A /28.E2 FROM
CAN SHLD 1.00 mm² 601EN

P018:7 /30.F2 FROM
A
A
1 2 3 4 5 6 7 8
33 - 10 9823/1700-1 33 - 10
Diagram
For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42

[T2/T3] ....................................... Page 33-11
For: 510-56 [T2/T3], 512-56 [T2/T3]
................................................... Page 33-76
(For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42 [T2/T3])

Figure 1060. Fusebox A P001, Ignition - 332/D5983 Issue 2 (Sheet 1 of 16)........................Page 33-13
Figure 1061. Fusebox B P002, Sensors - 332/D5983 Issue 2 (Sheet 2 of 16)...................... Page 33-17
Figure 1062. Fusebox C P003, ESOS - 332/D5983 Issue 2 (Sheet 3 of 16)......................... Page 33-21
Figure 1063. Fusebox D P004, Ignition - 332/D5983 Issue 2 (Sheet 4 of 16)........................Page 33-25
Figure 1064. Speed sensors, Immobiliser and Transmission control - 332/D5983 Issue 2 (Sheet 5 of
16)........................................................................................................................................... Page 33-29
Figure 1065. Right hand Cluster Connectors, P055 and P056 - 332/D5983 Issue 2 (Sheet 6 of
16)........................................................................................................................................... Page 33-33
Figure 1066. Instruments and warning lamps - 332/D5983 Issue 2 (Sheet 7 of 16).............. Page 33-37
Figure 1067. Road lamps, Reverse Alarm and Trailer Electrics - 332/D5983 Issue 2 (Sheet 8 of
16)........................................................................................................................................... Page 33-41
Figure 1068. Wiper and Motors - 332/D5983 Issue 2 (Sheet 9 of 16)................................... Page 33-45
Figure 1069. Worklight, Rotating Beacon, Heated Seat and Interior lamp - 332/D5983 Issue 2 (Sheet
10 of 16)..................................................................................................................................Page 33-49
Figure 1070. Air Con and Cold start - 332/D5983 Issue 2 (Sheet 11 of 16)...........................Page 33-53
Figure 1071. In-Cab Entertainment - 332/D5983 Issue 2 (Sheet 12 of 16)............................Page 33-57
Figure 1072. RAS Controller - 332/D5983 Issue 2 (Sheet 13 of 16)......................................Page 33-61
Figure 1073. RAS Interface - 332/D5983 Issue 2 (Sheet 14 of 16)....................................... Page 33-65
Figure 1074. RAS Chassis/Panel - 332/D5983 Issue 2 (Sheet 15 of 16)...............................Page 33-69
Figure 1075. Splices and Resistors - 332/D5983 Issue 2 (Sheet 16 of 16)........................... Page 33-73
33 - 11 9823/1700-1 33 - 11
Notes:
33 - 12 9823/1700-1 33 - 12
Page 33-14 Figure 1060. Fusebox A P001, Ignition

- 332/D5983 Issue 2 (Sheet 1 of 16) Page 33-15
1 2 3 4 5 6
SP1 P020 C007. 36

121 121C
D D
900
To P101 - 4
102
To P038 - B
Fuse 1
1 2
10.0 Am ps P006
I gnit ion Relay 1
3
Fuse 2 4
9
6
7 011
10.0 Am ps
8 10 601X SP3
Fuse 3
5 6
25.0 Am ps SP19
100A
Fuse 4
7 8
200S SP41
20.0 Am ps
Fuse 5
9 10
C 25.0 Am ps P009 C
To P010 - 7 Fuse 6 I gnit ion Relay 2
012 11 12
4
15.0 Am ps 1
2 010
Fuse 7
13 14
3 5 601EK
To SP3 - 4
10.0 Am ps
To SP19 - 3.
15
Fuse 8 16
100B
25.0 Am ps To SP41 - 2
Fuse 9 200T
17 18
7.5 Am ps
TO SP28 - 1 P010
Fuse 10
811A 19 20 I gnit ion Relay 3
4
10.0 Am ps
1
2 013
To Fusebox B - 1
3 5 601HL To SP3 - 6
100H
To SP19 - 7
204B To SP35 - 3
P010.
I gnit ion Relay 4
B 6
9
B
7
8 10
To Fusebox A - 11
012
601HK
To SP3 - 5
100G To SP19 - 6
204A To SP35 - 2
To P025 - 1
104
106 SP9 To P020 - 63

106D
109 SP66 To P097 - 1

109
807 To Chassis Connect or - 31
A A
332/D5983-2
1 2 3 4 5 6
33 - 13 9823/1700-1 33 - 13
Page Page
33-14 33-15
Figure 1060. (Part

1 1 of 2) 2 3
Fuse 1
1 2
10.0 Am ps P006
I gnit ion Relay 1
3
Fuse 2 4
9
6
7 011
10.0 Am ps
8 10
Fuse 3
5 6
25.0 Am ps
Fuse 4
7 8
20.0 Am ps
Fuse 5
9 10
C 25.0 Am ps P009
To P010 - 7 Fuse 6 I gnit ion Relay 2
012 11 12
4
15.0 Am ps 1
2 010
13
Fuse 7 14
3 5
10.0 Am ps
15
Fuse 8 16
25.0 Am ps
Fuse 9
17 18
7.5 Am ps
TO SP28 - 1 P010
Fuse 10
Page 33-15
4
10.0 Am ps
1
2
3 5
P010.
I gnit ion Relay 4
B 6
9
8 10
109
1 2 3
33 - 14 9823/1700-1 33 - 14
Page Page
33-14 33-15
Figure 1060. (Part4 2 of 2) 5 6
SP1 P020 C007. 36

121 121C
D
900
To P101 - 4
102
To P038 - B
601X SP3
SP19
100A
200S SP41
601EK
To SP3 - 4
To SP19 - 3.
100B
To SP41 - 2
200T
Page 33-14
013
To Fusebox B - 1
601HL To SP3 - 6
100H
To SP19 - 7
204B To SP35 - 3
To Fusebox A - 11
012
601HK
To SP3 - 5
100G To SP19 - 6
204A To SP35 - 2
To P025 - 1
104
106 SP9 To P020 - 63

106D
SP66 To P097 - 1
109
332/D5983-2
4 5 6
33 - 15 9823/1700-1 33 - 15
33 - 16 9823/1700-1 33 - 16
Page 33-18 Figure 1061. Fusebox B P002, Sensors

1 2 3 4 5 6
133
TO SP16 - 1
D D
110
TO SP38 - 1
To P028 - 2
905
834
To Chassis Connect or - 46
838 SP18
To P010 - 2 Fuse 1
013 1 2
EO
10.0 Am ps
COOLANT TEMP
EA C003. 4 C007. P020 17 To P055 - 4
To SP61 - 1 A 409 409 409
3
Fuse 2 4
C007. P020 60
2801
B C
To Splice SB - 3.
10.0 Am ps 109H
To SC02 - 3 602B
Fuse 3 C005 To Engine Connect or EA - 2

SP20 406
832B 5 6
Agglom erat or.
25.0 Am ps A
SC10
To P058 - 9 Fuse 4 2801 B C 601FL
C007. P020 58
To SP62 - 1
833 7 8 2800
20.0 Am ps
To P058 - 13 Fuse 5 109G
To SC02 - 2.
836 9 10
C 25.0 Am ps C011 C004 C

To SP21 - 4 Fuse 6 Low Coolant Level Sender.
942D 11 12 Vacuum Swit ch. To SC05 - 1
402 1 2 600CH 1
15.0 Am ps
To SC10 - 2
2 3 601FK
To SP21 - 5 Fuse 7 2800
942E 13 14
To Clust er J1 P055 - 8
C007. P020 19 SP58
10.0 Am ps 402 402B
To P060 - 6 ES
Fuse 8 Trans Tem p.
014 15 16
C003. EA 11
To SB - 7
25.0 Am ps 404E 1 2 602F
Fuse 9 To Clust er J1 P055 - 10
17 18 EA C003. 1 C007. P020 20
403 403 SP59 403B
7.5 Am ps 404B
Fuse 10 EL To P052 - 15
19 20
Engine Oil Pressure 40 4A
10.0 Am ps To SB - 2
403 1 2 602A To P056 - 10 P020 C007. 21 C014 T001. 14
404B 404 404 404A
C010 SP60 SC11

Fuel Level Sender To Clust er J1 P055 - 5
To SC10 - 5 C007. P020 18
600E 1 2 240 241
RED B+
412 W
Alt ernat or
407 D+
St art er Mot or Solenoid
To Bat t ery B+ .
RED B+
B S 2
B
To P005 - 2 C003. EA 7
EA C003. 3
407
C007. P020 41
407
SP14
407G
P100 1
P020 C007. 33
842 842 842
To P055 - 3
M EA C003. 5
412 C007. P020 25 412
St art er Mot or
829E To SP6 - 1
119 P077 1
AUXI LLI ARY
To P040 - 6 601AS
P077 2 SOCKET
180 P071 1
SPARE
To SP6 - 14 180
P071 2
A A
332/D5983-2
1 2 3 4 5 6
33 - 17 9823/1700-1 33 - 17
Page Page
33-18 33-19
Figure 1061. (Part

1 1 of 2) 2 3
To P010 - 2 Fuse 1
013 1 2
10.0 Am ps
To SP61 - 1
3
Fuse 2 4
C007. P020 60
2801
10.0 Am ps 109H
To SC02 - 3
Fuse 3 C005
SP20 832B 5 6
Agglom erat or.
25.0 Am ps A
SC10
To P058 - 9 Fuse 4 2801 B C 601FL
833 7 8
20.0 Am ps
To P058 - 13 Fuse 5
836 9 10
C To SP21 - 4
25.0 Am ps C011
Fuse 6 Vacuum Swit ch.
942D 11 12 To SC05 - 1
402 1 2 600CH
15.0 Am ps
To SP21 - 5 Fuse 7
942E 13 14
C007. P020 19 SP58
10.0 Am ps 402 402B
To P060 - 6
Fuse 8
014 15 16
25.0 Am ps
Fuse 9 To Clust er J1 P055 - 10
17 18 EA C003. 1 C007. P020 20
403 403 SP59 403B
7.5 Am ps
Fuse 10 EL
Page 33-19
19 20
Engine Oil Pressure
10.0 Am ps To SB - 2
403 1 2 602A
C010
Fuel Level Sender To Clust er J1 P055 - 5
To SC10 - 5 C007. P020 18
600E 1 2 240 241
St art er Mot or Solen

To Bat t ery B+ .
RED B+
B S
To P005 - 2 C003. EA 7
P020 C007. 33
842 842 842
M
St art er Mot or
1 2 3
33 - 18 9823/1700-1 33 - 18
Page Page
33-18 33-19
Figure 1061. (Part4 2 of 2) 5 6
133
TO SP16 - 1
D
110
TO SP38 - 1
To P028 - 2
905
834
To Chassis Connect or - 46
838 SP18
EO
COOLANT TEMP
EA C003. 4 C007. P020 17 To P055 - 4
To SP61 - 1 A 409 409 409
B C
To Splice SB - 3.
To SC02 - 3 602B
406
To Engine Connect or EA - 2
SC10
C007. P020 58
To SP62 - 1
2800
109G
To SC02 - 2.
C004 C
To SC05 - 1 Low Coolant Level Sender.
1
To SC10 - 2
2800 2 3 601FK
ES
Trans Tem p.
C003. EA 11
To SB - 7
404E 1 2 602F
404B
To P052 - 15
Page 33-18
404
A
To SB - 2
To P056 - 10 P020 C007. 21 C014 T001. 14
404B 404 404 404A
SP60 SC11
241
RED B+
412 W
Alt ernat or
407 D+
B+
S 2
B
EA C003. 3 C007. P020 41 SP14 P100 1
407 407 407G
To P055 - 3
M EA C003. 5
412 C007. P020 25 412
St art er Mot or
829E To SP6 - 1
119 P077 1
AUXI LLI ARY
To P040 - 6 601AS
P077 2 SOCKET
180 P071 1
SPARE
To SP6 - 14 180
P071 2
332/D5983-2
4 5 6
33 - 19 9823/1700-1 33 - 19
33 - 20 9823/1700-1 33 - 20
Page 33-22 Figure 1062. Fusebox C P003, ESOS

1 2 3 4 5 6
100
TO SP19 - 1
D D
To P093 - 3
105
SP23 P057 11
107 107AC
To P012 - 1
182
To P017 - 1
108
To P060 - 5 Fuse 1
001 1 2
10.0 Am ps To P029 - 2
307
3
Fuse 2 4
10.0 Am ps
Fuse 3
5 6
25.0 Am ps
Fuse 4
7 8
20.0 Am ps
Fuse 5
9 10
C TO Prim ary Fuse P062 - 2 25.0 Am ps

EJ 1
E.S.O.S. C
Fuse 6 105
1
200G 11 12
15.0 Am ps
To P093 - 4 105 P020 C007. 26 C003. EA 6 EJ 2 2
105 600
Fuse 7 EJ 3 3
502
13 14
C003. EA 8 Opt ional I m obilised ESOS.
502
10.0 Am ps
602C To Splice SB - 4.
Fuse 8
15 16
EM
25.0 Am ps 105A Cold St art Advance Swit ch.
Fuse 9 SA 105B 1 2
17 18
105
7.5 Am ps
19
Fuse 10 20
105C
10.0 Am ps
EH
Cold St art Advance Solenoid. To Splice SB - 5.
1 2 602D
To P101 - 5
To Spare P071 - 2 610
82 9A
R
SP6 P097 601GX

SP10 601GY P099 1
P078 1
Hydraulic I solat ion Swit ch.
AUX SOCKET I LLUMI NATI ON C018
829 AK 829AT 8 7
To SP66- 3 Hydraulic I solat ion To Splice SC06 - 4

1 2 2988 P020 C007. 70 1900 1 2 603C
109B
B B
304A
To P058 - 4 301J
P057 9
To P093 - 7
To P041 - 11 301N
304B
To P046 - B
301H
To P032 - 2
310
To P055 - 11
301E
SP32
301
To P082 - 2
301F
300
To P025 - 3 301L
P020 C007. 59
A 301P
P098 1
A
332/D5983-2
1 2 3 4 5 6
33 - 21 9823/1700-1 33 - 21
Page Page
33-22 33-23
Figure 1062. (Part

1 1 of 2) 2 3
To P060 - 5 Fuse 1
001 1 2
10.0 Am ps
3
Fuse 2 4
10.0 Am ps
Fuse 3
5 6
25.0 Am ps
Fuse 4
7 8
20.0 Am ps
Fuse 5
9 10
C TO Prim ary Fuse P062 - 2 25.0 Am ps

Fuse 6
200G 11 12
15.0 Am ps
To P093 - 4 105 P020 C007. 26 C003. EA 6
105
13
Fuse 7 14
C003. EA 8
10.0 Am ps
15
Fuse 8 16
25.0 Am ps
Fuse 9
17 18
7.5 Am ps
Fuse 10
Page 33-23
19 20
10.0 Am ps
To Spare P071 - 2
829
AR
P078 1
AUX SOCKET I LLUMI NATI ON K
82 9A
To SP66- 3
B
1 2 3
33 - 22 9823/1700-1 33 - 22
Page Page
33-22 33-23
Figure 1062. (Part4 2 of 2) 5 6
100
TO SP19 - 1
D
To P093 - 3
105
SP23 P057 11
107 107AC
To P012 - 1
182
To P017 - 1
108
To P029 - 2
307
EJ 1
E.S.O.S. C
1
105
EJ 2 2
C003. EA 6
600
EJ 3 3
502
502
602C To Splice SB - 4.
EM
105A Cold St art Advance Swit ch.
SA 105B 1 2
105
105C
Page 33-22
EH
Cold St art Advance Solenoid. To Splice SB - 5.
1 2 602D
To P101 - 5
610
829
AR
SP6 P097 601GX

SP10 601GY P099 1
82 9A
K
829AT 8 7 C018
To SP66- 3 Hydraulic I solat ion To Splice SC06 - 4
1 2 2988 P020 C007. 70 1900 1 2 603C
109B
B
304A
To P058 - 4 301J
P057 9
To P093 - 7
To P041 - 11 301N
304B
To P046 - B
301H
To P032 - 2
310
To P055 - 11
301E
SP32
301
To P082 - 2
301F
300
To P025 - 3 301L
P020 C007. 59
301P
P098 1
A
332/D5983-2
4 5 6
33 - 23 9823/1700-1 33 - 23
33 - 24 9823/1700-1 33 - 24
Page 33-26 Figure 1063. Fusebox D P004, Ignition

1 2 3 4 5 6
D D
125
TO Chassis Connect or - 34
To P017 - 6
306
Fuse 1 004
005 1 2
10.0 Am ps
Fuse 2 P005.
003 3 4
Neut ral St art Relay 1
10.0 Am ps 4
P062 1 To Chassis Connect or - 33
TO Fusebox C - 11 Prim ary Fuse Fuse 3 To P102 - 8 2 842
200G 200H 5 6 108A
25.0 Am ps 3 5
To SP3 - 1
601Z
Fuse 4 SP24 To P101 - 13

7 8
810G 810J
20.0 Am ps
C Fuse 5 C
I gnit ion Swit ch ( P059 - P060) 9 10 308
25.0 Am ps
3
Fuse 6
4
11 12 309 P005
To Fusebox C - 1 15.0 Am ps Neut ral St art Relay 2
5
001 9
1 6
014 13
Fuse 7 14
6 To FuseBox D - 13
015 7 015
2 7
To Fusebox B - 15 10.0 Am ps
8 8 10 To SP3 - 10
9 15
Fuse 8 16
601HB
10 25.0 Am ps 100J
To SP19 - 8
To P005 - 7 Fuse 9
17 18
203 To P064 - 1 Prim ary Fuse

7.5 Am ps
19
Fuse 10 20
200
10.0 Am ps
P011
Front Working Lam ps Relay
4
To SP41 - 3 Prim ary Fuse P061 1 To P030 - 2

200Z 1 2
2 943
150.0 Am ps
3 5 To SP3 - 7
601FG
To SP39 - 2
PO64 1851A
Prim ary Fuse To P005 - 6
B 203
B
60.0 Am ps P011.
20 3D Rear Working Lam ps Relay
Bat t ery P065
9
Prim ary Fuse To Splice SP35 - 1. 6 To P030 - 5
204C 204 7 944
ED
60.0 Am ps
8 10
To SP3 - 8
601FH
I solat or Swit ch
To SP39 - 3
1851B
To Rear Cab Harness P057 - 7

151
To Face Fan P067 - 1

151A
181
To P082 - 1
A A
332/D5983-2
1 2 3 4 5 6
33 - 25 9823/1700-1 33 - 25
Page Page
33-26 33-27
Figure 1063. (Part

1 1 of 2) 2 3
Fuse 1 004
005 1 2
10.0 Am ps
Fuse 2 P005.
003 3 4
10.0 Am ps
P062 1
TO Fusebox C - 11 Prim ary Fuse Fuse 3 To P102 - 8

200G 200H 5 6 108A
25.0 Am ps 3
Fuse 4
7 8
20.0 Am ps
C Fuse 5
I gnit ion Swit ch ( P059 - P060) 9 10 308
25.0 Am ps
3
Fuse 6
4
11 12 309 P005
To Fusebox C - 1 15.0 Am ps Neut ral St art Relay 2
5
001
1 6
014 13
Fuse 7 14
6
015
2 7
8 8
9 15
Fuse 8 16
10 25.0 Am ps
To P005 - 7 Fuse 9
17 18
Page 33-27
7.5 Am ps
19
Fuse 10 20
200
10.0 Am ps
P011
To SP41 - 3 Prim ary Fuse P061 1
200Z 1 2
150.0 Am ps
3
PO64
Prim ary Fuse To P005 - 6
B 203
60.0 Am ps P011.
D
203 Rear Working Lam ps Relay
Bat t ery P065
Prim ary Fuse To Splice SP35 - 1. 6
204C 204
ED
60.0 Am ps
8
I solat or Swit ch
1 2 3
33 - 26 9823/1700-1 33 - 26
Page Page
33-26 33-27
Figure 1063. (Part4 2 of 2) 5 6
125
TO Chassis Connect or - 34
To P017 - 6
306
P005.
4
2 842
3 5
To SP3 - 1
601Z
SP24 To P101 - 13
810G 810J
P005
9
6 To FuseBox D - 13
7 015
8 10 To SP3 - 10
601HB
100J
To SP19 - 8
To P064 - 1 Prim ary Fuse

Page 33-26
203
P011
4
1 To P030 - 2
2 943
3 5 To SP3 - 7
601FG
To SP39 - 2
1851A
B
P011.
Rear Working Lam ps Relay
9
6 To P030 - 5
7 944
8 10
To SP3 - 8
601FH
To SP39 - 3
1851B
To Rear Cab Harness P057 - 7

151
To Face Fan P067 - 1

151A
181
To P082 - 1
332/D5983-2
4 5 6
33 - 27 9823/1700-1 33 - 27
33 - 28 9823/1700-1 33 - 28
Figure 1064. Speed sensors, Immobiliser
Page 33-30 and Transmission control - 332/

D5983 Issue 2 (Sheet 5 of 16) Page 33-31
1 2 3 4 5 6
To 106 - 1
P093 480
P020 C007. 32
480 T010
I m obiliser. Speed Sensor
To SP23 - 2 To 106 - 2 P020 C007. 68 C014 T001. 11
604 604 604 A
D 107A 1 12 601KC
To SP33 - 6 D
To P003 - 4 107Z
2 11
To SC02 - 1 C014 T001. 12
109K 109K B
3 10
105 CAN LO
To SP56 - 4
To P020 - 26 105 4 9
CAN H C014 T001. 13
To SP55 - 4 480 C
5 8
100M
To SP19 - 9
6 7 301N To Fusebox A P001 - 19
To SP32 - 7 811A
SP28
P014 T003
Reverse Hi/ Low Relay Reverse Low Solenoid.
P020 C007. 29 T001. C014 4
4 1863 860 860 1 2 600AS
1
811E
2 P020 C007. 28
1 12 1862 1811
P094 C016 T002
LI NKED I F NO
2 11
Horn. 874D 3 5
Reverse High Solenoid
601CY T001. C014 3
811 1 2
600AC
I MOBI LI SER FI TTED 3 10
1
814
4 9 600F
2
5 8
To P101 - 3
874F
6 7
To Ground C008 - 4 T005

874E
Mainshaft Solenoid.
P013 T001. C014 6
858 1 2
600AQ
P041 872A Driveshaft Relay
L/ H COLUMN SWI TCH P042- 3 P042- 7
9
1865
P020 C007. 13
858
T004
Horn Swit ch P041 8 P020 C007. 57
872B 6
7
Layshaft Solenoid.
814 1866 P020 C007. 14 T001. C014 7
857 1 2
C Fusebox C - 14. P041 11 To P101 - 2

P042- 4 P042- 8 857 600AP
C
304B P041 13 872C 8 10
874 871B 601CZ
C003 12 To SB - 1
To P101 - 14 873
P041 5
Gear Select or Swit ch. SP27
602 385
4t h 871A
To SC05 - 4
To SP23 - 4 P041 14
3rd
P041 9
872 SP26 601A
107J
2nd
P006 P013 T001. C014 9
1st
P041 12
871 SP25 Forward Relay. Drive Relay 601DB 601DB
ST1
1
4
861B
4
1 890 C008 Eart h 600G
To SC10 - 6
852B SP30
Forward/ Reverse Swit ch P041 4 SP63
2 861 811D 2
M10 Ring Term inal
F 809A
600F
To Horn C016 - 2
P041 7 N
P041 6
810 To SP24 - 1 809 3 5 601T 811C 3 5
601EJ
R
600A
To SC06 - 5
P041 10 SP64
808
P009 P014. T006
Reverse Drive Relay Forward Hi/ Low Relay Forward Low Solenoid.
To SP23 - 5 SP29 9
P020 C007. 30 T001. C014 2 1 2
9 1861 859 859 600AR
6 861A 6
852A
P012 P018 7
811B
7 1860 P020 C007. 24 T001. C014 1
812 812 1 2
600AB
Transm ission Dum p Relay Parkbrake Relay
808 8 10 874C 8 10 601CX
Fusebox C - 8 182 1
4
1852
6
9
852 601AA T007
2 7 1854 Forward High Solenoid.
To SP23 - 3 P019
107H 3 5
107AB
8 10 815 Parkbrake/ 2WD Relay
4
856 1855A
1
2
T009
601KG
To C001 - 6 Two/ Four Wheel Drive Solenoid.
B 3 5
601KF
P020 C007. 5
818A
T001. C014 10
818 1 2 600M
B
C015 To C002 - 6 SP34
Transm ission Dum p Eart h
P020 C007. 48 SC06
856 1 2 600AN
To C018 - 2 T008
Transm ission Oil Pressure
P020 C007. 22 T001. C014 8
405 405 1 2
600J
To C008 - 7 To SP5 - 2 To SP10 - 8
601JD
601JH
601JE
P012
Parkbrake warning Lam p Relay SP33
To SP3 - 11 To P055 - 6
601JF 601JC 382
To Warning Lam ps P052 - 14. 1853
6
9
Eart h
401
7 P063- 1 P063- 3
To SP24 - 2 810H 8 10 601R To SP3 - 9 871C

C019
To P101 - 1 Speed Sensor 2
809C To P056 - 19
P039 Eart h 606
P020 C007. 69
606 A
To P056 - 4 M10 Ring Term inal

809B
To SP9 - 4 P020 C007. 63
106F 106F B
To P101 - 11 To P056 - 13 P020 C007. 62

808B 480A 480A C
To P101 - 12
808C
To P056 - 7
815
A To P101 - 8 A
332/D5983-2
1 2 3 4 5 6
33 - 29 9823/1700-1 33 - 29
Page Page
33-30 33-31
Figure 1064. (Part

1 1 of 2) 2 3
To 106 - 1
P093
To SP23 - 2 I m obiliser.
To 106 - 2
D 107A 1 12 601KC
To SP33 - 6
2 11
To P003 - 4 107Z
3 10
105 CAN LO
To SP56 - 4
To P020 - 26 105 4 9
CAN H
To SP55 - 4
5 8
100M
To SP19 - 9
6 7 301N To Fusebox A P001 - 19
To SP32 - 7 811A
SP28
1 12
P094 C016
LI NKED I F NO
2 11
Horn. 874D
1
814
4 9 600F
2
5 8
To P101 - 3
874F
6 7
To Ground C008 - 4
874E
P041 872A
872B
Horn Swit ch P041 8
814
P020 C007. 57
P042- 4 P042- 8
C Fusebox C - 14.
304B
P041 11 To P101 - 2
P041 13 872C
874
To P101 - 14 873
P041 5
4t h 871A
To SP23 - 4 P041 14
3rd
P041 9
872 SP26
107J
2nd
P006
1st
P041 12
871 SP25 Forward Relay.
4
1
852B SP30
2 861
F 809A
P041 7 N
P041 6
810 To SP24 - 1 809 3 5 601T
R
Page 33-31
P041 10 SP64
808
P009
Reverse Drive Relay
To SP23 - 5 SP29
9
6
852A
P012 P018 7
811B
808 8 10
Fusebox C - 8 182 1
4
1852
6
9
852 601AA
2 7 1854
To SP23 - 3 P019
107H 3 5
107AB
8 10 815 Parkbrake/ 2WD Relay
4
1
856 1855A
2
601KG
To C001 - 6
B 3 5
601KF
C015 To C002 - 6
Transm ission Dum p
P020 C007. 48 SC06
856 1 2 600AN
To C018 - 2
To C008 - 7 To SP5 - 2
601JD
P012
601JF
To Warning Lam ps P052 - 14. 1853
6
9
Eart h
401
7 P063- 1 P063- 3
To SP24 - 2 810H 8 10 601R To SP3 - 9 871C
To P101 - 1
809C
To P056 - 4
809B
To P101 - 11
808B
To P101 - 12
808C
To P056 - 7
815
To P101 - 8
A
1 2 3
33 - 30 9823/1700-1 33 - 30
Page Page
33-30 33-31
Figure 1064. (Part4 2 of 2) 5 6
To 106 - 1
480
P020 C007. 32
480 T010
Speed Sensor
To 106 - 2 P020 C007. 68 C014 T001. 11
604 604 604 A
D
To SC02 - 1 C014 T001. 12
109K 109K B
C014 T001. 13
480 C
SP28
P014 T003
P020 C007. 29 T001. C014 4
4 1863 860 860 1 2 600AS
1
811E
2 P020 C007. 28
1862 1811
T002
3 5
601CY T001. C014 3
811 1 2
600AC
T005
Mainshaft Solenoid.
P013 T001. C014 6
858 1 2
600AQ
Driveshaft Relay
P042- 7
9
1865
P020 C007. 13
858
T004
6
7
Layshaft Solenoid.
1866 P020 C007. 14 T001. C014 7
857 1 2
P042- 8 857 600AP
C
8 10
871B 601CZ
C003 12 385
To SB - 1
602
To SC05 - 4
601A
P013 T001. C014 9

Drive Relay 601DB 601DB
ST1
861B
4
1 890 C008 Eart h 600G
To SC10 - 6
SP30
811D 2
M10 Ring Term inal
600F
To Horn C016 - 2
3 5
811C 601EJ
600A
To SC06 - 5
Page 33-30
P014. T006
Forward Hi/ Low Relay Forward Low Solenoid.
9
P020 C007. 30 T001. C014 2 1 2
1861 859 859 600AR
861A 6
7 1860 P020 C007. 24 T001. C014 1
812 812 1 2
600AB
874C 8 10 601CX
T007
Forward High Solenoid.
T009
Two/ Four Wheel Drive Solenoid.
P020 C007. 5
818A
T001. C014 10
818 1 2 600M
B
SP34
Eart h
T008
Transm ission Oil Pressure
P020 C007. 22 T001. C014 8
405 405 1 2
600J
To SP10 - 8
601JD
601JH
601JE
To SP3 - 11 To P055 - 6
601JF 601JC 382
C019
Speed Sensor 2
To P056 - 19
P039 Eart h 606
P020 C007. 69
606 A
M10 Ring Term inal

To SP9 - 4 P020 C007. 63
106F 106F B
To P056 - 13 P020 C007. 62

480A 480A C
332/D5983-2
4 5 6
33 - 31 9823/1700-1 33 - 31
33 - 32 9823/1700-1 33 - 32
Figure 1065. Right hand Cluster
Page 33-34 Connectors, P055 and P056 - 332/

1 2 3 4 5 6
D D
CLUSTER J1 CLUSTER J2
Clust er J1 P055 Clust er J2 P056
C C
To SP14 - 2 To SP61 - 3
1 2 407B 2801B 1 2
To Chassis Connect or P020 - 25 To Chassis Connect or P020 - 17 To SP63 - 4

412 3 4 409 3 4 809C
To Chassis Connect or P020 - 18 To Chassis Connect or P020 - 22 To SP24 - 5

408 5 6 405 5 6 810M
To SP62 - 3 To SP58 - 3 To SP64 - 4

2800B 7 8 402B 808C 7 8
To RAS I nt erface 2 P102 - 5 To SP59 - 3 To SP60 - 3

1800 9 10 403B 9 10 404B
To SP32 - 4 To SP10 - 1
301E 11 12 601G 11 12
To Chassis Connect or P020 - 62

To SP52 - 3 To SP53 - 3 To P052 - 17
CAN HI 13 14 CAN LO 480A 13 14 405A
B To SP54 - 2 To SP65 - 1 To P052 - 16 B

SCREEN 15 16 1805 15 16 411
To P102 - 7 To P043 - 3
17 18 1802 17 18 2910
To SP9 - 2 To SP6 - 4 To Chassis Connect or P020 - 69

106B 19 20 829AA 606 19 20
A A
332/D5983-2
1 2 3 4 5 6
33 - 33 9823/1700-1 33 - 33
Page Page
33-34 33-35
Figure 1065. (Part

1 1 of 2) 2 3
CLUSTER J1
Clust er J1 P055
C
To SP14 - 2
1 2 407B
To Chassis Connect or P020 - 25 To Chassis Connect or P020 - 17

412 3 4 409
To Chassis Connect or P020 - 18 To Chassis Connect or P020 - 22

408 5 6 405
To SP62 - 3 To SP58 - 3
2800B 8 402B
Page 33-35
7
To RAS I nt erface 2 P102 - 5 To SP59 - 3

1800 9 10 403B
To SP32 - 4 To SP10 - 1
301E 11 12 601G
To Chassis Connect or P0
To SP52 - 3 To SP53 - 3
CAN HI 13 14 CAN LO
B To SP54 - 2 To SP65 - 1
SCREEN 15 16
17 18
To SP9 - 2 To SP6 - 4 To Chassis Connect or P02

106B 19 20 829AA
1 2 3
33 - 34 9823/1700-1 33 - 34
Page Page
33-34 33-35
Figure 1065. (Part4 2 of 2) 5 6
CLUSTER J2
Clust er J2 P056
C
To SP61 - 3
2801B 1 2
3 4
To SP63 - 4
809C
To SP24 - 5
5 6 810M
To SP64 - 4
808C 7 8
Page 33-34
To SP60 - 3
9 10 404B
11 12

To P052 - 17
480A 13 14 405A
To SP65 - 1 To P052 - 16 B
1805 15 16 411
To P102 - 7 To P043 - 3
1802 17 18 2910

606 19 20
332/D5983-2
4 5 6
33 - 35 9823/1700-1 33 - 35
33 - 36 9823/1700-1 33 - 36
Page 33-38 Figure 1066. Instruments and warning

lamps - 332/D5983 Issue 2 (Sheet 7 of 16) Page 33-39
1 2 3 4 5 6
D D
2801
L.I .M. Unit
Wat er in Fuel
To Clust er J2 P056 - 1 P052 19
2801B SP61 2801A
To SP58 - 2 Vacuum Swit ch

P052 6
402A
Engine Oil Pressure

To SP59 - 2 P052 7
403A
To Com bined Tem p. Sender Transm ission Oil Tem perat ure
To SP60 - 2 P052 15
and Swit ch EO - A To Clust er J1 P055 - 4
404A
EA C003. 4 C008. P020 17
409 409 315
To Clust er J2 P056 - 14 Transm ission Oil Pressure

P052 17
405A
To Com bined Tem p. Sender

and Swit ch EO - B Coolant Tem perat ure
406 EA C003. 2 406 C007. P020 23 P052 8
C
406
C
To SP14 - 3 Charge Warning

P052 9
407C
To P025 - 18
Main Beam
P036
To P058 - 10 SP7
I ndicat or Diode To SP18 - 2
805B P036 - 1 P036 - 3 807C P052 3
838A
To P020 - 40 I ndicat ors
SP13 P052 2
807B
To P042 - 5 Crab St eer
P036
To P058 - 11 SP8
I ndicat or Diode P052 11
806B P036 - 2 P036 - 4 807A
To P020 - 39 All Wheel St eer
P052 1
P052 12 2 Wheel St eer

P043
To SP6 - 5 I nfo Swit ch. To SP10 - 3
829AH 601HP
To Clust er J2 P056 - 16 P052 16
8 7
411
B 2 3 B
Park Brake
To SP10 - 2 To Clust er J2 - 18 To Park Brake Lam p Relay P012 - 6. P052 14
401
601JK 338
Low Coolant
To P055 - 7 SP62 P052 18
2800B 2800A
P018
Engine Running Relay. To P011 - 3 To SP9 - 3 P052 20
1851A 106C
4
To SP19 - 10 100N 1
2 SP39
1851
To P101 - 10 Cold St art
SP5
To SP14 - 4 3 5
To P011 - 8 610A 601P P052 10
407F 601KD 1851B

To SP34 - 11 2805
P052 4
P052 13
A A
332/D5983-2
1 2 3 4 5 6
33 - 37 9823/1700-1 33 - 37
Page Page
33-38 33-39
Figure 1066. (Part

1 1 of 2) 2 3
D
2801
2801B SP61
To SP58 - 2
To SP59 - 2
To Com bined Tem p. Sender To SP60 - 2

and Swit ch EO - A To Clust er J1 P055 - 4
EA C003. 4 C008. P020 17
409 409 315
To Com bined Tem p. Sender

and Swit ch EO - B C007. P020 23
406 EA C003. 2 406
C
To SP14 - 3
To P025 - 18
P036
To P058 - 10 SP7
I ndicat or Diode To SP18 - 2
805B P036 - 1 P036 - 3 807C
To P020 - 40
SP13
Page 33-39
To P042 - 5
P036
To P058 - 11 SP8
I ndicat or Diode
806B P036 - 2 P036 - 4 807A
To P020 - 39
P043
To SP6 - 5 I nfo Swit ch. To SP10 - 3
829AH 601HP
8 7
B 2 3
To SP10 - 2 To Clust er J2 - 18 To Park Brake Lam p Relay P012 - 6.

601JK 338
To P055 - 7 SP62
2800B
P018
Engine Running Relay. To P011 - 3 To SP9 - 3
1851A
4
To SP19 - 10 100N 1
2 SP39
1851
To P101 - 10 SP5
To SP14 - 4 3 5
To P011 - 8 610A
407F 601KD 1851B

To SP34 - 11
1 2 3
33 - 38 9823/1700-1 33 - 38
Page Page
33-38 33-39
Figure 1066. (Part4 2 of 2) 5 6
L.I .M. Unit

Wat er in Fuel
2801A P052 19
Vacuum Swit ch
P052 6
402A
Engine Oil Pressure

P052 7
403A
Transm ission Oil Tem perat ure

P052 15
404A
st er J2 P056 - 14 Transm ission Oil Pressure

P052 17
405A
Coolant Tem perat ure

P052 8
406
C
Charge Warning
P052 9
407C
Main Beam
P052 3
838A
I ndicat ors
P052 2
807B
Page 33-38
Crab St eer
P052 11
All Wheel St eer
P052 1
To Clust er J2 P056 - 16 P052 16

411
B
Park Brake
ke Lam p Relay P012 - 6. P052 14
401
Low Coolant
2800A P052 18
P052 20
106C
Cold St art
601P P052 10
Connect or P020 - 35 P052 4

2805
P052 13
332/D5983-2
4 5 6
33 - 39 9823/1700-1 33 - 39
33 - 40 9823/1700-1 33 - 40
Figure 1067. Road lamps, Reverse
Page 33-42 Alarm and Trailer Electrics - 332/

1 2 3 4 5 6
C017
To SP8 - 4 Reverse Alarm .
D 806C
C007. P020 39
415 SC12
D
807A P020 C007. 31 807C 807C 1
To Fusebox A - 20 601
SC01 806C 603
R/ H Headlam p - C001 To C008 - 6 2
SC10
GREEN 806D
C001 5
806D
To L/ H Headlam ps C002 - 3
R/ H I ndicat or. 838A
807E
BLUE 838A
C001 3
838B
SC07
838D
C007. P020 11
838B
To SP18 - 3
R/ H Main Beam . R/ H Rear Com binat ion Lam p.
C013 2 SRL4 RL003 5
C001 2 SC03 C007. P020 46 To P002 - 8 807E 807E
Reverse Lam p.
YELLOW 834A 834B 834B 834
R/ H Dip Beam . C013 6
806E RL003 3
To L/ H Headlam ps C002 - 2 603C
834A R/ H I ndicat or.
C001 4 SC04 C013 4
RED 830B 830B 830C 830C
R/ H Side Lam p.
RL003 2
C001 6 To SC06 - 1 C013 3
WHI TE 600Y 600Y R/ H Side Lam p.
SRL2 RL003 1
816 816B
R/ H Brake Lam p.
P028 RL003 4
Fog Lam p Swit ch. 941B
Fog Lam p.
8 7
To Fusebox B - 14 P020 C007. 50 RL003 6
To Fusebox B - 6 2 3
830E 830
905
C P020 C007. 7 816 C
To SP6 - 2 P020 C007. 47
829A 829E
To SP7 - 4 805D P020 C007. 40 805

C033
P020 C007. 53
941 Num ber Plat e Lam p.
C033 1
To SP6 - 7. 829AE
601DC
To SP5 - 3
C033 2
P017
Brake Lam ps Relay.
To Fusebox C - 12 P029 To P003 - 10 4 C030
Roadlight s Swit ch. 108B
1
2
Towing Link
816
C030 1
8 7
To P102 - 1 To SP34 - 8
817 3 5
601GZ C030 2
1
P017 307
2
3
To SP21 - 2
942B
Roadlight s Relay. P066
To SP20 - 1
To Fusebox D - 8. 9
Foot Brake Swit ch. C034
306 6 4
7 5 To P102 - 2 Num ber Plat e Lam p.
828A
6
To SP5 - 4 817A
A
To P102 - 3 C034 1
To SP19 - 4 100C
832
817B C013 5
8 10 To P102 - 4 817C B C
829B
SC09 C034 2
To SP34 - 9 To SP19 - 5 C013 7
601V 601BF 805D
SC08
100D C013 8
941 941
B To C008 - 5 603A
C013 1
603A
B
SRL1
L/ H Headlam p - C002
601A L/ H Rear Com binat ion Lam p.
RL002 6
To C012 - 2 SC05 603B
C002 6
To SC06 - 2 601DP
WHI TE 600Y 600AH
To C011 - 2 RL002 5
C002 4
To SC09 - 1 601CH 807A
Reverse Lam p.
RED 830B 829
L/ H Side Lam p.
P008
Flasher Unit .
C002 2
To SC03 - 2 To SP3 - 3 816A RL002 1
YELLOW 834A 834A 2 6 L/ H Brake Lam p.
L/ H Dip Beam . 803 601U
4 8
802
C002 3
To SC07 - 2 829B
RL002 2
BLUE 838A 838A
L/ H Main Beam . P025 L/ H Side Lam p.
Hazzard Swit ch.
To SP10 - 7
C002 5
To SC08 - 1 10 601AD RL002 3
GREEN 806D 805C 805D
L/ H I ndicat or. 1
104 To Fusebox A - 12 L/ H I ndicat or.
2
3
300
To Fusebox C - 20 941A RL002 4
Fog Lam p.
SRL3
5 To SP8 - 1
17
804A 806
To R/ H Colum n Swit ch P058- 14 P042- 1 P042- 5
803A
18
805 To SP7 - 1
8
A A
332/D5983-2
1 2 3 4 5 6
33 - 41 9823/1700-1 33 - 41
Page Page
33-42 33-43
Figure 1067. (Part

1 1 of 2) 2 3
D 806C
C007. P020 39
SC01 806C
R/ H Headlam p - C001
GREEN 806D
C001 5
806D
BLUE 838A
C001 3
838B
SC07
838D
C007. P020 11
838B
To SP18 - 3
R/ H Main Beam .
C001 2 SC03 C007. P020 46 To P002 - 8

YELLOW 834A 834B 834B 834
R/ H Dip Beam .
834A
C001 4
RED 830B 830B
R/ H Side Lam p.
600Y
C001 6
600Y
To SC06 - 1
WHI TE
P028
Fog Lam p Swit ch.
8 7
To Fusebox B - 14
To Fusebox B - 6 2 3
830E
905
C
To SP6 - 2
829A
To SP7 - 4 805D
941
To SP6 - 7. 829AE
601DC
To SP5 - 3
P017
Brake Lam ps Relay.
To Fusebox C - 12 P029 To P003 - 10 4
Roadlight s Swit ch. 108B

1
Page 33-43
2 816
8 7
To P102 - 1
817 3 5
601GZ
1
P017 307
2
3
To SP21 - 2
942B
To SP20 - 1
To Fusebox D - 8. 9
Foot Brake Swit ch.
306 6 4
7
828A 5
To SP5 - 4 To P102 - 2 817A
A
6
To SP19 - 4 832
817B
100C
8 10 To P102 - 4 817C B C
To SP34 - 9 To SP19 - 5
601V 601BF
100D
B
L/ H Headlam p - C002
C002 6
To SC06 - 2
WHI TE 600Y 600AH
C002 4
To SC09 - 1
RED 830B 829
L/ H Side Lam p.
P008
Flasher Unit .
C002 2
To SC03 - 2
YELLOW 834A 834A 2 6
4 8
802
C002 3
To SC07 - 2
BLUE 838A 838A
L/ H Main Beam . P025
Hazzard Swit ch.
C002 5
To SC08 - 1 10 601AD
GREEN 806D 805C
L/ H I ndicat or. 1
104
2
3
300
5
17
804A
To R/ H Colum n Swit ch P058- 14 18
803A 805
1 2 3
33 - 42 9823/1700-1 33 - 42
Page Page
33-42 33-43
Figure 1067. (Part4 2 of 2) 5 6
C017
To SP8 - 4 Reverse Alarm .
C007. P020 39
415 SC12
D
807A P020 C007. 31 807C 807C 1
To Fusebox A - 20 601 603

To C008 - 6 2
SC10
807E
R/ H Rear Com binat ion Lam p.

C013 2 SRL4 RL003 5
807E 807E
Reverse Lam p.
C013 6
806E RL003 3
603C
R/ H I ndicat or.
SC04 C013 4
830C 830C
RL003 2
C013 3
R/ H Side Lam p.
SRL2 RL003 1
816 816B
R/ H Brake Lam p.
RL003 4
941B
Fog Lam p.
P020 C007. 50 830 RL003 6
P020 C007. 7 816 C

P020 C007. 47
829E
P020 C007. 40 805

C033
P020 C007. 53
Num ber Plat e Lam p.
C033 1
C033 2
ake Lam ps Relay.

C030
Towing Link
Page 33-42
816
C030 1
To SP34 - 8
601GZ C030 2
C034
To P102 - 3 C034 1
817B C013 5
829B
SC09 C034 2
C013 7
805D
SC08
C013 8
941 941
To C008 - 5 603A
C013 1
603A
B
SRL1
RL002 6
To C012 - 2 601DP
SC05 603B
To C011 - 2 601CH 807A

RL002 5
Reverse Lam p.
RL002 1
To SP3 - 3 816A
601U
L/ H Brake Lam p.
RL002 2
829B
L/ H Side Lam p.
To SP10 - 7
601AD RL002 3
805D
104 To Fusebox A - 12 L/ H I ndicat or.
300
To Fusebox C - 20 941A RL002 4
Fog Lam p.
SRL3
To SP8 - 1
804A 806
P042- 1 P042- 5
805 To SP7 - 1
332/D5983-2
4 5 6
33 - 43 9823/1700-1 33 - 43
33 - 44 9823/1700-1 33 - 44
Page 33-46 Figure 1068. Wiper and Motors -

332/D5983 Issue 2 (Sheet 9 of 16) Page 33-47
1 2 3 4 5 6
D D
To Fusebox B - 7
833
To Fusebox B - 9 To Rear Cab Ground AF - 7.
P076 2 P058. 7
840 840
Roof Wiper Mot or ( AJ) Rear Wiper Mot or ( AD)
P076 5 P058. 12
841 841 AJ 4 AJ 1 To Rear Cab Ground AF - 3.
836
4 1
849 600 4 4
925
4 1
601AW
M M
1 1
P076 3 P058. 2
982 982
AJ 2 2
854 2 2 2
AJ 3 926
P076 4 P058. 3 3
133F 3
983 983
3 3 133D
C Wiper Mot or To SP20 - 2. C

832A
P058
2 Spd, I nt P076 R/ H Colum n Swit ch.
P058. 9
P076 1
To Ground P040 - 2 P057 1
133B
6 5 600P P058. 8 133B
M SC
8
P058. 13 Rear Cab
4
P076 6 To Hazzard Swit ch P025 - 5. P057 4
110D
P058. 14 P057 2
803A P058. 10
SP38
3 P057 5
To Fusebox B - 4 13
J P058. 11 P057 3
110
7
O 12
P058. 1
2 To Fusebox C - 14 110E 8
I 10
To SP33 - 1 To SP33 - 2
P058. 4 II 11 P026 P027
304A Roof Wiper Swit ch. Rear Wiper Swit ch.
9
To SP6 - 8 To SP6 - 9 8 7 601DX
P076 7 829M 8 7 601BH 829AF
839B 1
854
14
2
1 926
849 925
2
3
3 133C
133E
SP16
To SP7 - 2
Front Washer Mot or. 839A
P069 2
839A 839
P058. 6
839 805A 4
5
4
6
SP37 5 901B
2 1
601KL
M P069 3
806A
To SP8 - 2 6
901
SP17
601JG 610JG
B SA
B
P069 1
901A 901A
Rear Washer Mot or.

To Face Level Fan P068 - 1 To P077 - 2
2 1 601AS
601KM
M 601DD
P040 Eart h
M10 Ring Term inal
A A
332/D5983-2
1 2 3 4 5 6
33 - 45 9823/1700-1 33 - 45
Page Page
33-46 33-47
Figure 1068. (Part

1 1 of 2) 2 3
To Fusebox B - 7
833
P076 2 P058. 7 To Fusebox B - 9
840 840
P076 5 P058. 12
841 841
836
P076 3 P058. 2
982 982
P076 4 P058. 3
983 983
C Wiper Mot or To SP20 - 2. P058

832A
P058. 9
P076 1
To Ground P040 - 2
6 5 600P P058. 8
M
8
P058. 13
4
P076 6 To Hazzard Swit ch P025 - 5.
110D
P058. 14
803A P058. 10
SP38
3
To Fusebox B - 4 13
J P058. 11
110
7
O 12
P058. 1
2 To Fusebox C - 14 110E 8
I 10
To SP33 - 1
Page 33-47
II 11
P058. 4
304A
P076 7
9
To SP6 - 8
839B
14
To SP7 - 2
P069 2
839A 839
P058. 6
839 805A
SP37
2 1
601KL
M P069 3
806A
To SP8 - 2
601JG 610JG
B SA
P069 1
901A 901A
Rear Washer Mot or.

To Face Level Fan P068 - 1 To P077 - 2
2 1 601AS
601KM
M 601DD
P040 Eart h
M10 Ring Term inal
1 2 3
33 - 46 9823/1700-1 33 - 46
Page Page
33-46 33-47
Figure 1068. (Part4 2 of 2) 5 6
To Fusebox B - 7
To Fusebox B - 9 To Rear Cab Ground AF - 7.

849
AJ 4 4 1
AJ 1
4 4 4 1
To Rear Cab Ground AF - 3.
600 925 601AW
M M
1 1
AJ 2 2
854 2 2 2
3
AJ 3 926
133F 3 3 3 133D
P057 1
133B 133B
SC
Rear Cab
P057 4
P057 2
P057 5
P057 3
To SP33 - 1 To SP33 - 2
Page 33-46
P026 P027
Roof Wiper Swit ch. Rear Wiper Swit ch.
To SP6 - 8 To SP6 - 9 8 7 601DX
829M 8 7 601BH 829AF
1
854
2
1 926
849 925
2
3
3 133C
133E
SP16
To SP7 - 2 4
4
5
6
5 901B
To SP8 - 2 6 SP17
901
332/D5983-2
4 5 6
33 - 47 9823/1700-1 33 - 47
33 - 48 9823/1700-1 33 - 48
Figure 1069. Worklight, Rotating
Page 33-50 Beacon, Heated Seat and Interior lamp

1 2 3 4 5 6
D D
To SP6 - 10
R/ H Rear Worklam p.
P030 945B
1 1
R/ H Front Worklam p. Worklam ps Swit ch. To SP5 - 5

601AC 601KG 2 2
1 1 829J 8 7
1
2 2
To Front Working Lam ps P011 - 2 2 To Rear Cab Ground AF - 6.
3
831
4
To Front Working Lam ps P011 - 7 5
P057 6
6 945 945
SB
Rear Cab
P088 1
RED 831B
P088 2
RED 831K
BLACK
P088 3
601BU
To Ground P040 - 4
BLACK
P088 4
601AL
To Ground P040 - 5
831J 942A
C To Fusebox B - 13 SP22
942E
P042- 2 P042- 6
C
To Fusebox B - 11 942D
947A 942C 942B

To Roadlam p Swit ch P029- 3.
P063- 2 P063- 4
L/ H Front Worklam p. SP21
1 1
C007. P020 1
2 2
AK
I nt erior Lam p.
To SP32 - 2. 301J
P057 9
301J 1 AK 1 1
AK 2
601AV 2 2

P032
To SP6 - 12 Beacon Swit ch. To SP5 - 1.
829U 8 7 601AY
310 2 3 844A
AC
To Fusebox C - 16 P057 8
Rot at ing Beacon.
1 1
844A
2 2
601AX
B To Rear Cab Ground AF - 5. B
Heat ed Seat Elem ent s.

1 1
Swit ch
151B

601EF 2 2
To Fusebox D - 16 151
P057 7
151
SA Rear Cab
Air Seat Com pressor. L/ H Rear Worklam p.
Swit ch
1 1
945A
M
151A 1 1
2 2
601DG
2 2
601FK
A A
332/D5983-2
1 2 3 4 5 6
33 - 49 9823/1700-1 33 - 49
Page Page
33-50 33-51
Figure 1069. (Part

1 1 of 2) 2 3
R/ H Front Worklam p. Worklam ps Swit ch

1 1 829J
2 2
To Front Working Lam ps P011 - 2
To Front Working Lam ps P011 - 7
P088 1
RED 831B
P088 2
RED 831K
BLACK
P088 3
601BU
To Ground P040 - 4
BLACK
P088 4
601AL
To Ground P040 - 5
831J
P042- 2
C To Fusebox B - 13 SP22
942E
To Fusebox B - 11 942D
947A
P063- 2
L/ H Front Worklam p.
1 1
C007. P020 1
2 2
Page 33-51
P032
To SP6 - 12 Beacon Swit ch.
829U 8 7 601AY
310 2 3 844A
To Fusebox C - 16
151B 1 1

601EF 2 2
P057 7
151
SA Rear Cab
151A 1 1

2 2
601FK
1 2 3
33 - 50 9823/1700-1 33 - 50
Page Page
33-50 33-51
Figure 1069. (Part4 2 of 2) 5 6
D
To SP6 - 10
P030 945B
1 1
Worklam ps Swit ch. To SP5 - 5

601AC 601KG 2 2
829J 8 7
1
2 To Rear Cab Ground AF - 6.
3
831
4
5
P057 6
6 945 945
SB
Rear Cab
831J 942A
942E
P042- 2 P042- 6
C
947A 942C 942B

To Roadlam p Swit ch P029- 3.
P063- 2 P063- 4
SP21
AK
I nt erior Lam p.
To SP32 - 2. P057 9
301J AK 1
Page 33-50
1 1
301J
AK 2
601AV 2 2

P032
Beacon Swit ch. To SP5 - 1.
7 601AY
3 844A
AC
P057 8
Rot at ing Beacon.
1 1
844A
2 2
601AX
To Rear Cab Ground AF - 5. B

1
Swit ch

Swit ch
1 1
945A
M
1
2 2
601DG
2
332/D5983-2
4 5 6
33 - 51 9823/1700-1 33 - 51
33 - 52 9823/1700-1 33 - 52
Page 33-54 Figure 1070. Air Con and Cold start

1 2 3 4 5 6
D D
Blower Mot or.

P037 1
Blower Speed Resist or.
P037 2 M
Heat er Mot or Swit ch ( P038)
P037 3
Freeze Valve. EK
L
800 EP / ER Air Condit ioning
To Fusebox A - 10 Binary Swit ch.
102 B M
801
P037 4 Com pressor Clut ch.
1 2
H EK 1
995 P037 5 884 886 RED 1
P037 6 EK 2
BLACK
886B
602E 2
C
997
600T
To Cab Ground P040 - 3
SC
884
P020 C007. 12
884
C003. EA 9 To Splice SB - 6.
Engine
P020 C007. 64 C003. EA 10

886B 886A
P023 / P024
Air Condit ioning Swit ch
883
C P023- 1 P024- 1
C
C012
Cold St art Connect or
To Fusebox D - 4 P020 C007. 34 C012 1
125 125 125
P020 C007. 35
To Warning Lam ps P052 - 4. 2805 C012 2
Cold St art ECU.
C012 3 602B 1 12
Grid Heat er. 2 11
C012 4
2805 3 10
RED
2805 4 9
5 8
CB 601DR
6 7
Cold St art Relay.

To Cold St art Fuse. 5
RED 3
B 4
107C B
1 2
601DP
2810
2811
CC P020 C007. 38
To SP66 - 1
109
Am bient Sensor. 109
1 2 SC02
109J
To C014 - 12
109K
To SC05 - 2
601DP
A A
332/D5983-2
1 2 3 4 5 6
33 - 53 9823/1700-1 33 - 53
Page Page
33-54 33-55
Figure 1070. (Part

1 1 of 2) 2 3
P037 1
P037 2

P037 3
L
Freeze Valve.
800
To Fusebox A - 10 P037 4
102 B M
801
H
995 P037 5
P037 6
C
997
600T
P020 C007. 12
884
P020 C007. 64
P023 / P024
883
C P023- 1 P024- 1
C012
To Fusebox D - 4
Page 33-55
P020 C007. 34 C012 1
125 125
P020 C007. 35
To Warning Lam ps P052 - 4. 2805 C012 2
Cold St art ECU.
C012 3 602B 1 12
Grid Heat er. 2 11
C012 4
2805 3 10
RED
2805 4 9
5 8
CB 601DR
6 7
Cold St art Relay.

RED 3
B 4
107C
1 2
601DP
2810
2811
CC
Am bient Sensor.
1 2
109J
601DP
1 2 3
33 - 54 9823/1700-1 33 - 54
Page Page
33-54 33-55
Figure 1070. (Part4 2 of 2) 5 6
Blower Mot or.

er Speed Resist or.
M
EK
EP / ER Air Condit ioning
Binary Swit ch. Com pressor Clut ch.
1 2
EK 1
884 886 RED 1
EK 2
BLACK
886B
602E 2

SC
P020 C007. 12
884
C003. EA 9 To Splice SB - 6.
Engine
P020 C007. 64 C003. EA 10

886B 886A
C
Page 33-54
125
Cold St art ECU.

12
11
10
P020 C007. 38
To SP66 - 1
109 109
SC02
To C014 - 12
109K
To SC05 - 2
332/D5983-2
4 5 6
33 - 55 9823/1700-1 33 - 55
33 - 56 9823/1700-1 33 - 56
Page 33-58 Figure 1071. In-Cab Entertainment -

1 2 3 4 5 6
D D
AD
Left Speaker.
1
AB
Radio Supply.
1
To SP32 - 5 P082 2
C
301F 301F 4
C
5
To SP6 - 6 P082 3
576 575 6
P082 1
559 7
To Cab Ground P040 - 7. 601AG

P082 4
601AB 8
446
445
AC
Radio Speakers.
1
3 AE
Right Speaker.
4 1
5 2
8
B B
448
447
A A
332/D5983-2
1 2 3 4 5 6
33 - 57 9823/1700-1 33 - 57
Page Page
33-58 33-59
Figure 1071. (Part

1 1 of 2) 2 3
AB
Radio Supply.
1
To SP32 - 5 301F
P082 2
301F 4
C
5
To SP6 - 6 P082 3
576 575 6
P082 1
559 7
To Cab Ground P040 - 7. 601AG

P082 4
601AB 8
446
445
AC
Page 33-59
Radio Speakers.
1
8
B
448
447
1 2 3
33 - 58 9823/1700-1 33 - 58
Page Page
33-58 33-59
Figure 1071. (Part4 2 of 2) 5 6
AD
Left Speaker.
1
446
445
Page 33-58
AE
Right Speaker.
1
448
447
332/D5983-2
4 5 6
33 - 59 9823/1700-1 33 - 59
33 - 60 9823/1700-1 33 - 60
Page 33-62 Figure 1072. RAS Controller - 332/

1 2 3 4 5 6
D PA006 PA007 D
RAS CONTROLLER J1 RAS CONTROLLER J2
PA007 1
To PA002 - 8
815
PA006 1
To PA001 - 1
505
PA007 2
To PA001 - 6
510
PA006 2
To SRA2 - 2
212A
PA007 3
To PA001 - 9
513
PA006 3
To SRA2 - 3
212B
PA007 4
PA006 4
To SRA2 - 4
212C
PA006 5
To SRA2 - 5 PA007 5
212D
PA006 6
To SRA2 - 6 PA007 6
212E
PA007 7
PA006 7
PA006 8
To PA001 - 2 PA007 8
506
To PA002 - 12 PA007 9
To PA001 - 14
PA006 9 516
808B
To PA003 - 1 C
C PA006 10
809B
To PA002 - 11 PA007 10
817
PA006 11 To PA002 - 4 PA007 11

817B
To PA003 - 3
900
PA006 12
PA007 12
514
To PA001 - 10
614
To PA001 - 4 PA007 13
To PA001 - 3
PA006 13 507
508
PA006 14
To PA004 - 2 PA007 14
610
PA009 PA008
CAN Term inat or CAN PA006 15
To SRA1 - 2 PA007 15
610A
To PA002 - 2
2 2
PA006 16
To SRA1 - 3 PA007 16
872C
3 1 1 3 610B
PA007 17
To PA002 - 3
PA006 17
To SRA1 - 4 874F
610C
SRA3 PA007 18
CAN H CAN H
PA006 18
CAN HI PA007 19
PA006 19
SRA4 PA007 20
CAN L CAN L
PA006 20 815D
CAN LO PA007 21
SRA5 PA006 21 To PA002 - 13

SCR SCR
810J
PA007 22
To SRA1 - 5
610D
PA006 22
610
To PA002 - 5
PA007 23
515
To PA001 - 11
B SCR
PA006 23 B
PA007 24
815A
PA006 24
511 To PA001 - 7
PA007 25 To PA001 - 5
509
PA006 25
PA007 26
512
To PA001 - 8
PA006 26
PA007 27
871C
To PA002 - 1
PA006 27
To PA003 - 7
1802
PA007 28
873
To PA002 - 14
PA006 28
PA007 29
PA006 29
PA004
PA007 30
Ground Speed
RH Feed Back
PA006 30
PA005 To PA006 - 14 To PA001 - 12
PA007 31 604 2 3 614
PA006 31
Park Brake Swit ch.
1 4
PA005 2
2
815H PA005 3 PA007 32
3 601BC
PA006 32 1
815B 815
PA007 33
PA006 33 PA005 1 480
PA007 34
To PA003 - 4
PA006 34 817C
PA007 35
To PA003 - 2
PA006 35
650A To PA003 - 10 817A
A A
332/D5983-2
1 2 3 4 5 6
33 - 61 9823/1700-1 33 - 61
Page Page
33-62 33-63
Figure 1072. (Part

1 1 of 2) 2 3
D PA006 PA007
RAS CONTROLLER J1
PA006 1
To PA001 - 1
505
PA006 2
To SRA2 - 2
212A
PA006 3
To SRA2 - 3
212B
PA006 4
To SRA2 - 4
212C
PA006 5
To SRA2 - 5
212D
PA006 6
To SRA2 - 6
212E
PA006 7
PA006 8
To PA001 - 2
506
PA006 9
To PA002 - 12
808B
C PA006 10
809B
To PA002 - 11
PA006 11
900
To PA002 - 4
PA006 12
614
PA006 13
To PA001 - 4
508
PA006 14
To PA004 - 2
610
PA009 PA008
CAN Term inat or CAN PA006 15
To SRA1 - 2
610A
2 2
PA006 16
To SRA1 - 3
3 1 1 3 610B
Page 33-63
PA006 17
To SRA1 - 4
610C
SRA3
CAN H CAN H
PA006 18
CAN HI
PA006 19
SRA4
CAN L CAN L
PA006 20 815D
CAN LO
SRA5 PA006 21
810J
To PA002 - 13
SCR SCR
PA006 22
610
To PA002 - 5
B SCR
PA006 23
PA006 24
511 To PA001 - 7
PA006 25
PA006 26
PA006 27
To PA003 - 7
1802
PA006 28
PA006 29
PA006 30
PA005
PA006 31
Park Brake Swit ch.
PA005 2
2
815H PA005 3
3 601BC
PA006 32 1
815B 815
PA006 33 PA005 1
PA006 34
PA006 35
650A To PA003 - 10
1 2 3
33 - 62 9823/1700-1 33 - 62
Page Page
33-62 33-63
Figure 1072. (Part4 2 of 2) 5 6
PA007 D
RAS CONTROLLER J2
PA007 1
To PA002 - 8
815
PA007 2
To PA001 - 6
510
PA007 3
To PA001 - 9
513
PA007 4
PA007 5
PA007 6
PA007 7
PA007 8
PA007 9
To PA001 - 14
516
PA007 10
817
To PA003 - 1 C
PA007 11
817B
To PA003 - 3
PA007 12
514
To PA001 - 10
PA007 13
To PA001 - 3
507
PA007 14
PA007 15
PA007 16
To PA002 - 2
872C
To PA002 - 3
Page 33-62
PA007 17
874F
PA007 18
PA007 19
PA007 20
PA007 21
PA007 22
To SRA1 - 5
610D
PA007 23
515
To PA001 - 11
B
PA007 24
815A
PA007 25 To PA001 - 5
509
PA007 26
512
To PA001 - 8
PA007 27
871C
To PA002 - 1
PA007 28
873
To PA002 - 14
PA007 29
PA004
PA007 30
Ground Speed
RH Feed Back
To PA006 - 14 To PA001 - 12
PA007 31 604 2 3 614
Park Brake Swit ch.
1 4
PA005 3 PA007 32
601BC
PA007 33
480
PA007 34
To PA003 - 4
817C
PA007 35
To PA003 - 2
817A
332/D5983-2
4 5 6
33 - 63 9823/1700-1 33 - 63
33 - 64 9823/1700-1 33 - 64
Page 33-66 Figure 1073. RAS Interface - 332/

1 2 3 4 5 6
D RAS I NTERFACE 1 D
PA002 / P101
To PA007 - 27 To SP25 - 4
871C
PA002 P101 1
871C FOR NON RAS OPTI ON
To PA007 - 16 PA002 P101 2
To SP26 - 4 AL
872C 872C
Park Brake Swit ch.
To PA007 - 17 PA002 P101 3
To SP27 - 5 2 To AF Rear Cab Ground - 9
874F 3 601
874F
1
815
To PA006 - 11 PA002 P101 4

To P001 - 4
900 900
To PA006 - 22 PA002 P101 5

To SP10 - 10
610 610
PA002 P101 6 P057 12

815B
PA002 P101 7 P057 14

815D P019.
St abiliser I solat ion
To PA007 - 1 PA002 P101 8
To P018 - 10 C006
815 815
To PA006 - 15 To SP1 - 3 9 St ab I solat ion Valve
121R 6
To SC10 - 4
C
610A 7
450
P020 C007. 6
449 1 2 815 815 C
PA002 P101 9 P057 10
815A
To PA006 - 16 908A 8 10
601DK
610B
SRA1 PA002 P101 10
To SP5 - 7
610A
To PA006 - 17
610A To SP34 - 7
610C
To PA006 - 10 PA002 P101 11
To SP63 - 3
809B 809B P034
To PA007 - 22 St abiliser I solat ion Swit ch.
610D
To PA006 - 9 PA002 P101 12
To SP64 - 3 To SP6 - 3 To SP33 - 3
808B 808B 829AX 8 7 601DZ
To PA006 - 21 PA002 P101 13

To SP24 - 4 1 2
810J 810J
To SP66 - 4
To PA007 - 28 PA002 P101 14
To P041 - 5
873 873
RAS I NTERFACE 2
PA003 / P102
To PA007 - 10 To P017 - 3
B 817
PA003 P102 1
817 B
To PA007 - 35 PA003 P102 2
To P066 - 1
817A 817A
To PA007 - 11 To P066 - 3 P105 P106

PA003 P102 3
817B 817B RAS Relay Right Ground Speed
9 614A
3 2 604
To PA007 - 34 To P066 - 2 614 6
7
To P020 - 68
PA003 P102 4
817C 8178C 4 1 480
To P020 - 32
1805B 8 10 610JX
PA003 P102 5
To SP10 - 11
PA003 P102 6
P105
To PA006 - 27 PA003 P102 7
To P056 - 17 RAS Relay Left
1802 1802
4
601JZ
1
SRA2 PA003 P102 8

To P004 - 6 2
212 108A
To SP10 - 9
3 5
To PA001 - 13 PA003 P102 9
615 650
SP65
1805 1805
To PA006 - 35 PA003 P102 10
650A 650A
A A
332/D5983-2
1 2 3 4 5 6
33 - 65 9823/1700-1 33 - 65
Page Page
33-66 33-67
Figure 1073. (Part

1 1 of 2) 2 3
D RAS I NTERFACE 1
PA002 / P101
To PA007 - 27 PA002 P101 1
To SP25 - 4
871C 871C
To PA007 - 16 PA002 P101 2

To SP26 - 4
872C 872C
To PA007 - 17 PA002 P101 3

To SP27 - 5
874F 874F
To PA006 - 11 PA002 P101 4

To P001 - 4
900 900
To PA006 - 22 PA002 P101 5

To SP10 - 10
610 610
PA002 P101 6 P057 12

815B
PA002 P101 7 P057 14

815D
To PA007 - 1 PA002 P101 8

To P018 - 10
815 815
To PA006 - 15
610A
C PA002 P101 9 P057 10
815A
To PA006 - 16
610B
SRA1 PA002 P101 10
To SP5 - 7
610A 610A
To PA006 - 17
610C
To PA006 - 10 PA002 P101 11
To SP63 - 3
809B 809B
To PA007 - 22
610D
To PA006 - 9 PA002 P101 12
To SP64 - 3
808B 808B
To PA006 - 21 PA002 P101 13

To SP24 - 4
810J 810J
To PA007 - 28 PA002 P101 14

To P041 - 5
Page 33-67
873 873
RAS I NTERFACE 2
PA003 / P102
To PA007 - 10 To P017 - 3
B 817
PA003 P102 1
817
To PA007 - 35 PA003 P102 2

To P066 - 1
817A 817A
To PA007 - 11 PA003 P102 3 To P066 - 3

817B 817B
To PA007 - 34 PA003 P102 4

To P066 - 2
817C 8178C
PA003 P102 5
PA003 P102 6
To PA006 - 27 PA003 P102 7

To P056 - 17
1802 1802
SRA2 PA003 P102 8

To P004 - 6
212 108A
To PA001 - 13 PA003 P102 9

615 650
To PA006 - 35 PA003 P102 10

650A 650A
1 2 3
33 - 66 9823/1700-1 33 - 66
Page Page
33-66 33-67
Figure 1073. (Part4 2 of 2) 5 6
To SP25 - 4
FOR NON RAS OPTI ON
To SP26 - 4 AL
Park Brake Swit ch.
To SP27 - 5 2 To AF Rear Cab Ground - 9
3 601
1
815
To P001 - 4
To SP10 - 10
P057 12
P057 14
P019.
St abiliser I solat ion
To P018 - 10 C006
To SP1 - 3 9 St ab I solat ion Valve
121R 6
To SC10 - 4
7
450
P020 C007. 6
449 1 2 815 815 C
P057 10
908A 8 10
601DK
To SP5 - 7
To SP34 - 7
To SP63 - 3
P034
St abiliser I solat ion Swit ch.
To SP64 - 3 To SP6 - 3 To SP33 - 3
829AX 8 7 601DZ
To SP24 - 4 1 2
To SP66 - 4
To P041 - 5
Page 33-66
To P017 - 3
B
To P066 - 1
To P066 - 3 P105 P106

RAS Relay Right Ground Speed
9 614A
3 2 604
To P066 - 2 614 6
7
To P020 - 68
4 1 480
To P020 - 32
1805B 8 10 610JX
To SP10 - 11
P105
To P056 - 17 RAS Relay Left
4
601JZ
1
To P004 - 6 2
To SP10 - 9
3 5
SP65
1805 1805
332/D5983-2
4 5 6
33 - 67 9823/1700-1 33 - 67
33 - 68 9823/1700-1 33 - 68
Page 33-70 Figure 1074. RAS Chassis/Panel -

1 2 3 4 5 6
D D
RA003
Righ Ras Cylinder
RA003 1 514 1
RA003 2 614
2
PANEL TO CHASSI S.
RA004
PA001 / PA001 Sway Swit ch
1
505
2
506
To PA006 - 1 PA001 RA001 1 RA004 1
505 505 507 3
To PA006 - 8 506
PA001 RA001 2
506
RA004 2
C To PA007 - 13 507
PA001 RA001 3
507
RA004 3 C
To PA006 - 13 508
PA001 RA001 4
508
RA005 1
To PA007 - 25 509
PA001 RA001 5
509
RA005 2
To PA007 - 2 510
PA001 RA001 6 510 RA005 3
To PA006 - 24 511
PA001 RA001 7
511
RA006 1 RA005
Left St ab Swit ch
To PA007 - 26 512
PA001 RA001 8
512
RA006 2 508 1
2
509
To PA007 - 3 513
PA001 RA001 9
513
RA006 3
3
510
To PA007 - 12 514
PA001 RA001 10
514
To PA007 - 23 515
PA001 RA001 11 515
To PA004 - 3 614
PA001 RA001 12
614
To PA003 - 9 615
PA001 RA001 13
615
To PA007 - 9 516
PA001 RA001 14 516
RA006
Right St ab Swit ch
1
511
B 512 2
B
3
513
RA007
I nloader Valve
RA007 1
516 1
RA002
Left Ras Cylinder
RA002 1
515 2
RA007 2
600 600
2
RA002 2
615
1
RA008
Eart h
A A
332/D5983-2
1 2 3 4 5 6
33 - 69 9823/1700-1 33 - 69
Page Page
33-70 33-71
Figure 1074. (Part

1 1 of 2) 2 3
PANEL TO CHASSI S.
PA001 / PA001
To PA006 - 1 PA001 RA001 1

505 505
To PA006 - 8 506
PA001 RA001 2
506
C To PA007 - 13 507
PA001 RA001 3
507
To PA006 - 13 508
PA001 RA001 4
508
To PA007 - 25 509
PA001 RA001 5
509
To PA007 - 2 510
PA001 RA001 6 510
To PA006 - 24 511
PA001 RA001 7
511
To PA007 - 26 512
PA001 RA001 8
512
To PA007 - 3 513
PA001 RA001 9
513
To PA007 - 12
Page 33-71
PA001 RA001 10
514 514
To PA007 - 23 515
PA001 RA001 11 515
To PA004 - 3 614
PA001 RA001 12
614
To PA003 - 9 615
PA001 RA001 13
615
To PA007 - 9 516
PA001 RA001 14 516
RA007
I nloader Valve
RA007 1
516 1
RA007 2
600 600
2
RA008
Eart h
1 2 3
33 - 70 9823/1700-1 33 - 70
Page Page
33-70 33-71
Figure 1074. (Part4 2 of 2) 5 6
RA003
Righ Ras Cylinder
RA003 1 514 1
RA003 2 614
2
RA004
Sway Swit ch
1
505
2
506
RA004 1
3
507
RA004 2
RA004 3 C
RA005 1
RA005 2
RA005 3
RA006 1 RA005
Left St ab Swit ch
RA006 2 508 1
2
509
RA006 3
3
510
Page 33-70
RA006
Right St ab Swit ch
1
511
512 2
B
3
513
RA002
Left Ras Cylinder
RA002 1
515 2
RA002 2
615
1
332/D5983-2
4 5 6
33 - 71 9823/1700-1 33 - 71
33 - 72 9823/1700-1 33 - 72
Page 33-74 Figure 1075. Splices and Resistors

1 2 3 4 5 6
D D
SP53 To P092 - B
CAN L
To SP10 - 5 SP56 To P091 - B

60 1G
P046
To P010 - 6 W Diagnost ic Socket CAN LO
To P093 - 10
CAN LO
To Prim ary Fuse P065 - 1 20 4A A D
SP35
204
204B To P010 - 1 B C
To P093 - 9
CAN H
C I GNI TI ON RELAYS
To SP32 - 3 30 1H To P091 - A
C
SP55
CAN HI GH
SP52 To Clust er J1 P055 - 13
CAN H
To P092 - A
Term inat ing Resist or P091 I nst rum ent Term inat or P092
B To SP55 - 2 To SP52 - 2 B
To Clust er J1 P055 - 15 P091 A P092 A
441
439
P092.
433 P091. 1
1
SP54 SP57 P092 C

To SP54 - 3
435 P091 C 426
423
SCREEN
434 2 2
To SP56 - 2 P091 B
120.00 Ohm s 120.00 Ohm s P092 B
To SP53 - 2
440 442
To P092 - C
A A
332/D5983-2
1 2 3 4 5 6
33 - 73 9823/1700-1 33 - 73
Page Page
33-74 33-75
Figure 1075. (Part

1 1 of 2) 2 3
To SP10 - 5
601
P046
To P010 - 6 GW Diagnost ic Socket
To Prim ary Fuse P065 - 1 204A A D

SP35
204
20 4B To P010 - 1 B C
C I GNI TI ON RELAYS
To SP32 - 3 301
H
Page 33-75
Term inat ing Resist or P091
B To SP55 - 2
To Clust er J1 P055 - 15 P091 A
439
43 3 P091. 1
SP54 SP57
435 P091 C
423
SCREEN
43 4 2
120.00 Ohm s
To SP56 - 2 P091 B
440
To P092 - C
1 2 3
33 - 74 9823/1700-1 33 - 74
Page Page
33-74 33-75
Figure 1075. (Part4 2 of 2) 5 6
SP53 To P092 - B
CAN L
SP56 To P091 - B
P046
Diagnost ic Socket CAN LO
To P093 - 10
CAN LO
D
C
To P093 - 9
CAN H
To P091 - A
C
SP55
CAN HI GH
SP52 To Clust er J1 P055 - 13
CAN H
Page 33-74
To P092 - A
m inat ing Resist or P091 I nst rum ent Term inat or P092
P092 A
To SP52 - 2 B
441
P092.
1
P092 C
To SP54 - 3
426
2
120.00 Ohm s 120.00 Ohm s P092 B
To SP53 - 2
442
332/D5983-2
4 5 6
33 - 75 9823/1700-1 33 - 75
(For: 510-56 [T2/T3], 512-56 [T2/T3])

Figure 1076. Fusebox A P001, Ignition - 332/F0906 Issue 2 (Sheet 1 of 16)........................ Page 33-77
Figure 1077. Fusebox B P002, Sensors - 332/F0906 Issue 2 (Sheet 2 of 16).......................Page 33-81
Figure 1078. Fusebox C P003, ESOS - 332/F0906 Issue 2 (Sheet 3 of 16)..........................Page 33-85
Figure 1079. Fusebox D P004, Ignition - 332/F0906 Issue 2 (Sheet 4 of 16)........................ Page 33-89
Figure 1080. Speed sensors, Immobiliser and Transmission control - 332/F0906 Issue 2 (Sheet 5 of
16)........................................................................................................................................... Page 33-93
Figure 1081. Right hand Cluster Connectors, P055 and P056 - 332/F0906 Issue 2 (Sheet 6 of
16)........................................................................................................................................... Page 33-97
Figure 1082. Instruments and warning lamps - 332/F0906 Issue 2 (Sheet 7 of 16)............. Page 33-101
Figure 1083. Road lamps, Reverse Alarm and Trailer Electrics - 332/F0906 Issue 2 (Sheet 8 of
16)......................................................................................................................................... Page 33-105
Figure 1084. Wiper and Motors - 332/F0906 Issue 2 (Sheet 9 of 16)..................................Page 33-109
Figure 1085. Worklight, Rotating Beacon, Heated Seat and Interior lamp - 332/F0906 Issue 2 (Sheet
10 of 16)................................................................................................................................Page 33-113
Figure 1086. Air Con and Cold start - 332/F0906 Issue 2 (Sheet 11 of 16)......................... Page 33-117
Figure 1087. In-Cab Entertainment - 332/F0906 Issue 2 (Sheet 12 of 16).......................... Page 33-121
Figure 1088. RAS Controller - 332/F0906 Issue 2 (Sheet 13 of 16).................................... Page 33-125
Figure 1089. Stabiliser, Transducers and Proxy Switches - 332/F0906 Issue 2 (Sheet 14 of
16)......................................................................................................................................... Page 33-129
Figure 1090. RAS Chassis/Panel - 332/F0906 Issue 2 (Sheet 15 of 16)............................. Page 33-133
Figure 1091. Splices and Resistors - 332/F0906 Issue 2 (Sheet 16 of 16)..........................Page 33-137
33 - 76 9823/1700-1 33 - 76
Page 33-78 Figure 1076. Fusebox A P001, Ignition

- 332/F0906 Issue 2 (Sheet 1 of 16) Page 33-79
1 2 3 4 5 6
D D
900
To P020 - 38. ( Sheet 11)
112
To RAS P106 - 11 ( Sheet 13)
102
To Heat er Swit ch - B ( Sheet 11)
Fuse 1
1 2
10.0 Am ps P006
I gnit ion Relay 1 To P020 - 32 ( Sheet 14)
110
3
Fuse 2 4
9
6
7 011
10.0 Am ps
8 10 601X SP3
Fuse 3
5 6
25.0 Am ps SP19
100A
Fuse 4
7 8
200S SP41
20.0 Am ps
Fuse 5
9 10
C 25.0 Am ps P009 C
To P010 - 7 ( Sheet 1) Fuse 6 I gnit ion Relay 2
012 11 12
4
15.0 Am ps 1
2 010
13
Fuse 7 14
3 5 601EK
10.0 Am ps
15
Fuse 8 16
100B
25.0 Am ps
Fuse 9 200T
17 18
7.5 Am ps
To SP28 - 1 ( Sheet 5) P010
Fuse 10
4
10.0 Am ps
1
2 013
To Fusebox B - 1 ( Sheet 2)
3 5 601HL To SP3 - 5 ( Sheet 1)
100H
To SP19 - 7 ( Sheet 1)
204B
SP35 To Prim ary Fuse P065 - 1 ( Sheet 4)
204
204A
I GNI TI ON RELAYS
B P010. B
I gnit ion Relay 4
9
6
7
8 10
To Fusebox A - 11 ( Sheet 1)
012
601HK
100G To SP19 - 6 ( Sheet 1)
To Hazard Swit ch - 1 ( Sheet 8)

104
106 SP9 To P020 - 64 ( Sheet 5)

106D
To Hydraulic I solat ion - 1 ( Sheet 3)

109
To P020 - 31 ( Sheet 8)
807
A A
332/F0906-2
1 2 3 4 5 6
33 - 77 9823/1700-1 33 - 77
Page Page
33-78 33-79
Figure 1076. (Part

1 1 of 2) 2 3
Fuse 1
1 2
10.0 Am ps P006
I gnit ion Relay 1
3
Fuse 2 4
9
6
7 011
10.0 Am ps
8 10
Fuse 3
5 6
25.0 Am ps
Fuse 4
7 8
20.0 Am ps
Fuse 5
9 10
C 25.0 Am ps P009
To P010 - 7 ( Sheet 1) Fuse 6 I gnit ion Relay 2
012 11 12
4
15.0 Am ps 1
2 010
13
Fuse 7 14
3 5
10.0 Am ps
15
Fuse 8 16
25.0 Am ps
Fuse 9
17 18
7.5 Am ps
To SP28 - 1 ( Sheet 5) P010
Fuse 10
Page 33-79
4
10.0 Am ps
1
2
3 5
B P010.
I gnit ion Relay 4
9
6
7
8 10
1 2 3
33 - 78 9823/1700-1 33 - 78
Page Page
33-78 33-79
Figure 1076. (Part4 2 of 2) 5 6
D
900
To P020 - 38. ( Sheet 11)
112
To RAS P106 - 11 ( Sheet 13)
102
To Heat er Swit ch - B ( Sheet 11)
To P020 - 32 ( Sheet 14)

110
601X SP3
SP19
100A
200S SP41
601EK
100B
200T
Page 33-78
013
601HL To SP3 - 5 ( Sheet 1)
100H
204B
SP35 To Prim ary Fuse P065 - 1 ( Sheet 4)
204
204A
I GNI TI ON RELAYS
To Fusebox A - 11 ( Sheet 1)
012
601HK
100G To SP19 - 6 ( Sheet 1)
To Hazard Swit ch - 1 ( Sheet 8)

104
106 SP9 To P020 - 64 ( Sheet 5)

106D
To Hydraulic I solat ion - 1 ( Sheet 3)

109
To P020 - 31 ( Sheet 8)
807
332/F0906-2
4 5 6
33 - 79 9823/1700-1 33 - 79
33 - 80 9823/1700-1 33 - 80
Page 33-82 Figure 1077. Fusebox B P002, Sensors

1 2 3 4 5 6
133
TO SP16 - 1 ( Sheet 9)
D D
110
To Fog Lam p Swit ch - 2 ( Sheet 8)

905
834 P020 C007. 46
838 SP18 P020 C007. 11

838B
To P010 - 2 ( Sheet 1) Fuse 1
013 1 2
EO
10.0 Am ps
COOLANT TEMP
EA C003. 4 C007. P020 17
To P055 - 4 ( Sheet 6)
To SP61 - 1 ( Sheet 7) A 409 409 409
3
Fuse 2 4
C007. P020 60
2801
602B C
B
To SC02 - 3 ( Sheet 11) To C003 - 2 ( Sheet 7)

10.0 Am ps 109H 406
Fuse 3 C005
SP20 832B 5 6
Agglom erat or. C007. P020 58
2800
25.0 Am ps A
To SC10 - 3 ( Sheet 8) To SC02 - 2 ( Sheet 11)

To P058 - 9 ( Sheet 9) Fuse 4 2801 B C 601FL 109G
833 7 8
20.0 Am ps C004
To P058 - 13 ( Sheet 9) Fuse 5 Low Coolant Level Sender.
836 9 10 To SC10 - 2 ( Sheet 8)
C 25.0 Am ps C011
1 3 601FK
C
To SP21 - 3 ( Sheet 10) Fuse 6
942D 11 12 Vacuum Swit ch. To SC05 - 1 ( Sheet 8)
2800 2
402 1 2 600CH
To Chassis Con' EA - 12 ( Sheet 5)
15.0 Am ps 602

942E 13 14
To Clust er J1 P055 - 8 ( Sheet 6) To Air- Con Com pressor - 2 ( Sheet 11)
C007. P020 19 SP58 602A
10.0 Am ps 402 402B SB
TO I gnit ion Swit ch - 6 ( Sheet 4) To Cold St art Solenoid - 2 ( Sheet 3)

Fuse 8 602D
014 15 16
25.0 Am ps To E.S.O.S - 2 ( Sheet 3)

Fuse 9 To Clust er J1 P055 - 10 ( Sheet 6) 602C
17 18 EA C003. 1 C007. P020 20
403 403 SP59 403B
7.5 Am ps ES
Fuse 10 EL Trans Tem p.
19 20 EA C003. 11
Engine Oil Pressure 602F 404E
2 1
10.0 Am ps
403 1 2 602A 602A
To P052 - 15 ( Sheet 7)
404B
40
4A
C010 To P056 - 10 ( Sheet 6) 404B 404

P020 C007. 21
404 404A
C014 T001. 14
To SC10 - 4 ( Sheet 8) Fuel Level Sender To Clust er J1 P055 - 5 ( Sheet 6)

C007. P020 18
600E 1 2 240 241 SP60 SC11
RED B+
412 W
Alt ernat or
B St art er Mot or Solenoid
407 D+
B
To Bat t ery B+ .
RED B+
S 2
To P005 - 2 ( Sheet 4) P100 1

EA C003. 3 C007. P020 41 SP14
P020 C007. 33 C003. EA 7 407 407 407G
842 842 842
To P055 - 3 ( Sheet 6)
M EA C003. 5
412 C007. P020 25 412
St art er Mot or
829E To SP6 - 1 ( Sheet 3)
830 To Chassis Connect or - 50 ( Sheet 8)
119 P077 1
AUXI LLI ARY
To P040 - 6 ( Sheet 9) 601AS
P077 2 SOCKET
180 P071 1
SPARE
To SP6 - 14 ( Sheet 3) 180
P071 2
A A
332/F0906-2
1 2 3 4 5 6
33 - 81 9823/1700-1 33 - 81
Page Page
33-82 33-83
Figure 1077. (Part

1 1 of 2) 2 3

013 1 2
10.0 Am ps
3
Fuse 2 4
C007. P020 60
2801
10.0 Am ps 109H
To SC02 - 3 ( Sheet 11)
Fuse 3 C005
SP20 832B 5 6
Agglom erat or.
25.0 Am ps A
To SC10 - 3 ( Sheet 8)
To P058 - 9 ( Sheet 9) Fuse 4 2801 B C 601FL
833 7 8
20.0 Am ps
836 9 10
C To SP21 - 3 ( Sheet 10)

25.0 Am ps C011
Fuse 6 Vacuum Swit ch.
942D 11 12 To SC05 - 1 ( Sheet 8)
402 1 2 600CH
15.0 Am ps

942E 13 14
To Clust er J1 P055 - 8 ( Sheet 6)
C007. P020 19 SP58
10.0 Am ps 402 402B
TO I gnit ion Swit ch - 6 ( Sheet 4)

Fuse 8
014 15 16
25.0 Am ps
Fuse 9 To Clust er J1 P055 - 10 ( Sheet
17 18 EA C003. 1 C007. P020 20
403 403 SP59 403B
7.5 Am ps
Fuse 10 EL
Page 33-83
19 20
Engine Oil Pressure
10.0 Am ps
403 1 2 602A
C010
To SC10 - 4 ( Sheet 8) Fuel Level Sender To Clust er J1 P055 - 5 ( She
C007. P020 18
600E 1 2 240 241
B
To Bat t ery B+ .
RED
To P005 - 2 ( Sheet 4)
P020 C007. 33 C003. EA 7
842 842 842
St art er Mot or
1 2 3
33 - 82 9823/1700-1 33 - 82
Page Page
33-82 33-83
Figure 1077. (Part4 2 of 2) 5 6
133
D
110
To Fog Lam p Swit ch - 2 ( Sheet 8)

905
834 P020 C007. 46
838 SP18 P020 C007. 11

838B
EO
COOLANT TEMP
EA C003. 4 C007. P020 17
To P055 - 4 ( Sheet 6)
To SP61 - 1 ( Sheet 7) A 409 409 409
602B C
B
To SC02 - 3 ( Sheet 11) To C003 - 2 ( Sheet 7)

406
C007. P020 58
2800
To SC10 - 3 ( Sheet 8) To SC02 - 2 ( Sheet 11)

109G
C004
Low Coolant Level Sender.
1 3 601FK
C
2800 2
To SC05 - 1 ( Sheet 8) To Chassis Con' EA - 12 ( Sheet 5)
602
To Clust er J1 P055 - 8 ( Sheet 6) To Air- Con Com pressor - 2 ( Sheet 11)

602A
SB
To Cold St art Solenoid - 2 ( Sheet 3)

602D
To E.S.O.S - 2 ( Sheet 3)
To Clust er J1 P055 - 10 ( Sheet 6) 602C
403B
ES
Trans Tem p.
Page 33-82
EA C003. 11
602F 404E
2 1
602A
To P052 - 15 ( Sheet 7)
404B
40
4A
To P056 - 10 ( Sheet 6) 404B 404

P020 C007. 21
404 404A
C014 T001. 14
241 SP60 SC11
RED B+
412 W
Alt ernat or
407 D+
B
B+
S 2
EA C003. 3 C007. P020 41 SP14 P100 1

407 407 407G
To P055 - 3 ( Sheet 6)
M EA C003. 5
412 C007. P020 25 412
St art er Mot or
829E To SP6 - 1 ( Sheet 3)
830 To Chassis Connect or - 50 ( Sheet 8)
119 P077 1
AUXI LLI ARY
To P040 - 6 ( Sheet 9) 601AS
P077 2 SOCKET
180 P071 1
SPARE
To SP6 - 14 ( Sheet 3) 180
P071 2
A
332/F0906-2
4 5 6
33 - 83 9823/1700-1 33 - 83
33 - 84 9823/1700-1 33 - 84
Page 33-86 Figure 1078. Fusebox C P003, ESOS

1 2 3 4 5 6
100
D D
To P093 - 3 ( Sheet 8)
105
SP23 P057 11
107 107AC
To P012 - 1 ( Sheet 5)
182
To P017 - 1 ( Sheet 8)
108
To I gnit ion Swit ch - 5 ( Sheet 4) Fuse 1
001 1 2
10.0 Am ps To P029 - 2 ( Sheet 8)

307
3
Fuse 2 4
10.0 Am ps
Fuse 3
5 6
25.0 Am ps
Fuse 4
7 8
20.0 Am ps
Fuse 5
9 10
C To P062 - 2 ( Sheet 4) 25.0 Am ps

EJ 1
E.S.O.S. C
Fuse 6 105
1
200G 11 12
To P093 - 4 ( Sheet 5) EJ 2 2
15.0 Am ps P020 C007. 26 C003. EA 6
105 105 600
Fuse 7 EJ 3 3
502
13 14
502
10.0 Am ps
602C To Splice SB - 4 ( Sheet 2)

Fuse 8
15 16
EM
25.0 Am ps 105A Cold St art Advance Swit ch.
Fuse 9 SA 105B 1 2
17 18
105
7.5 Am ps
19
Fuse 10 20
105C
10.0 Am ps
EH
Cold St art Advance Solenoid. To Splice SB - 5 ( Sheet 2)
1 2 602D
To P105 - 5 ( Sheet 13)

To Spare P071 - 2 ( Sheet 2) 610
82 9A
R
SP6 P097 601GX

SP10 601GY P099 1
P078 1
AUX SOCKET I LLUMI NATI ON C018
829 AK 829AT 8 7 To Chassis Ground
Hydraulic I solat ion C008 - 3 ( Sheet 5)
1 2 2988 P020 C007. 70 1900 1 2 603C
109B
B To P001 - 18 ( Sheet 1)
B
304A
To R/ H Colum n Swit ch - 4 ( Sheet 9)
To P093 - 7 ( Sheet 5)
To L/ H Colum n Swit ch - 11 ( Sheet 5) 301N
304B
To P046 - B ( Sheet 16)
301H
To Beacon Swit ch - 2 ( Sheet 10)
310
To P055 - 11 ( Sheet 6)
301E
SP32
301
To P082 - 2 ( Sheet 12)
301F
300
To Hazard Swit ch - 3 ( Sheet 8) 301L
P057 9
A 301P
P098 1
A
332/F0906-2
1 2 3 4 5 6
33 - 85 9823/1700-1 33 - 85
Page Page
33-86 33-87
Figure 1078. (Part

1 1 of 2) 2 3
To I gnit ion Swit ch - 5 ( Sheet 4) Fuse 1

001 1 2
10.0 Am ps
3
Fuse 2 4
10.0 Am ps
Fuse 3
5 6
25.0 Am ps
Fuse 4
7 8
20.0 Am ps
Fuse 5
9 10
C To P062 - 2 ( Sheet 4) 25.0 Am ps

Fuse 6
200G 11 12
To P093 - 4 ( Sheet 5)
15.0 Am ps P020 C007. 26 C003. EA 6
105 105
13
Fuse 7 14
C003. EA 8
10.0 Am ps
15
Fuse 8 16
25.0 Am ps
Fuse 9
17 18
7.5 Am ps
Fuse 10
Page 33-87
19 20
10.0 Am ps
To Spare P071 - 2 ( Sheet 2)

829
AR
P078 1
AUX SOCKET I LLUMI NATI ON K
82 9A
B To P001 - 18 ( Sheet 1)
1 2 3
33 - 86 9823/1700-1 33 - 86
Page Page
33-86 33-87
Figure 1078. (Part4 2 of 2) 5 6
100
D
To P093 - 3 ( Sheet 8)
105
SP23 P057 11
107 107AC
To P012 - 1 ( Sheet 5)
182
To P017 - 1 ( Sheet 8)
108
To P029 - 2 ( Sheet 8)
307
EJ 1
E.S.O.S. C
1
105
EJ 2 2
C003. EA 6
600
EJ 3 3
502
502
602C To Splice SB - 4 ( Sheet 2)

EM
105A Cold St art Advance Swit ch.
SA 105B 1 2
105
105C
Page 33-86
EH
Cold St art Advance Solenoid. To Splice SB - 5 ( Sheet 2)
1 2 602D
To P105 - 5 ( Sheet 13)

610
829
AR
SP6 P097 601GX

SP10 601GY P099 1
82 9A
K
829AT 8 7 C018 To Chassis Ground
Hydraulic I solat ion C008 - 3 ( Sheet 5)
1 2 2988 P020 C007. 70 1900 1 2 603C
109B
To P001 - 18 ( Sheet 1)
B
304A
To R/ H Colum n Swit ch - 4 ( Sheet 9)
To P093 - 7 ( Sheet 5)
To L/ H Colum n Swit ch - 11 ( Sheet 5) 301N
304B
To P046 - B ( Sheet 16)
301H
To Beacon Swit ch - 2 ( Sheet 10)
310
To P055 - 11 ( Sheet 6)
301E
SP32
301
To P082 - 2 ( Sheet 12)
301F
300
To Hazard Swit ch - 3 ( Sheet 8) 301L
P057 9
301P
P098 1
A
332/F0906-2
4 5 6
33 - 87 9823/1700-1 33 - 87
33 - 88 9823/1700-1 33 - 88
Page 33-90 Figure 1079. Fusebox D P004, Ignition

1 2 3 4 5 6
D D
125 To P020 - 34 ( Sheet 11)
To P017 - 6 ( Sheet 8)
306
Fuse 1
005 1 2
To SP66 - 1 ( Sheet 13)
108A
10.0 Am ps
Fuse 2 P005.
003 3 4
10.0 Am ps 4
P062 004 1 To P020 - 33 ( Sheet 2)
To Fusebox C - 11 ( Sheet 3) Prim ary Fuse Fuse 3 2 842
200G 200H 5 6
25.0 Am ps 3 5
601Z
Fuse 4 SP24
7 8
810G
20.0 Am ps
C Fuse 5 C
I gnit ion Swit ch ( P059 - P060) 9 10
25.0 Am ps
3
Fuse 6
4
To Fusebox C - 1 11 12 P005
( Sheet 3) 15.0 Am ps Neut ral St art Relay 2
5
001 9
1 6
014 13
Fuse 7 14
6 To FuseBox D - 13 ( Sheet 4)
015 7 015
2 7
8 ( Sheet 2) 8 10 To SP3 - 9 ( Sheet 1)
9 15
Fuse 8 16
601HB
10 25.0 Am ps 100J
17 18
203 To P064 - 1 Prim ary Fuse ( Sheet 4)

7.5 Am ps
19
Fuse 10 20
200
10.0 Am ps
P011
Prim ary Fuse P061 4
To SP41 - 3 ( Sheet 1) 834A 1 2

308 1 To P030 - 2 ( Sheet 10)
2 943
150.0 Am ps
3 5 To SP3 - 6 ( Sheet 1)
601FG
PO64 1851A
Prim ary Fuse To P005 - 6 ( Sheet 4)
B 2 1 203
B
60.0 Am ps P011.
P083 - P084 Rear Working Lam ps Relay
20 3D
Bat t ery P065
9
Prim ary Fuse To SP35 - 1 ( Sheet 1) 309 6 To P030 - 5 ( Sheet 10)
204C 2 1 204 7 944
60.0 Am ps
8 10
601FH
I solat or Swit ch
1851B
To P034 - 2 ( Sheet 13)

908
To P057 - 7 ( Sheet 10)

151
P067 1
151A
To Radio Connect or - 1 ( Sheet 12)

181
A A
332/F0906-2
1 2 3 4 5 6
33 - 89 9823/1700-1 33 - 89
Page Page
33-90 33-91
Figure 1079. (Part

1 1 of 2) 2 3
Fuse 1
005 1 2
10.0 Am ps
Fuse 2 P005.
003 3 4
10.0 Am ps
P062 004 1
To Fusebox C - 11 ( Sheet 3) Prim ary Fuse Fuse 3

200G 200H 5 6
25.0 Am ps 3
Fuse 4
7 8
20.0 Am ps
C Fuse 5
I gnit ion Swit ch ( P059 - P060) 9 10
25.0 Am ps
3
Fuse 6
4
To Fusebox C - 1 11 12 P005
( Sheet 3) 15.0 Am ps Neut ral St art Relay 2
5
001
1 6
014 13
Fuse 7 14
6
015
2 7
8 ( Sheet 2) 8
9 15
Fuse 8 16
10 25.0 Am ps
17 18
Page 33-91
7.5 Am ps
19
Fuse 10 20
200
10.0 Am ps
P011
Prim ary Fuse P061 308
To SP41 - 3 ( Sheet 1) 834A 1 2
1
150.0 Am ps
3
PO64
Prim ary Fuse To P005 - 6 ( Sheet 4)
B 2 1 203
60.0 Am ps P011.
P083 - P084 D
203
Bat t ery P065
Prim ary Fuse To SP35 - 1 ( Sheet 1) 309 6
204C 2 1 204
60.0 Am ps
8
I solat or Swit ch
1 2 3
33 - 90 9823/1700-1 33 - 90
Page Page
33-90 33-91
Figure 1079. (Part4 2 of 2) 5 6
125 To P020 - 34 ( Sheet 11)
To P017 - 6 ( Sheet 8)
306
To SP66 - 1 ( Sheet 13)

108A
P005.
4
004 1 To P020 - 33 ( Sheet 2)
2 842
3 5
601Z
SP24
810G
P005
9
6 To FuseBox D - 13 ( Sheet 4)
7 015
8 10 To SP3 - 9 ( Sheet 1)
601HB
100J
To P064 - 1 Prim ary Fuse ( Sheet 4)

Page 33-90
203
P011
4
308 1 To P030 - 2 ( Sheet 10)
2 943
3 5 To SP3 - 6 ( Sheet 1)
601FG
1851A
B
P011.
9
309 6 To P030 - 5 ( Sheet 10)
7 944
8 10
601FH
1851B
To P034 - 2 ( Sheet 13)

908
To P057 - 7 ( Sheet 10)

151
P067 1
151A
To Radio Connect or - 1 ( Sheet 12)

181
A
332/F0906-2
4 5 6
33 - 91 9823/1700-1 33 - 91
33 - 92 9823/1700-1 33 - 92
Figure 1080. Speed sensors,
Page 33-94 Immobiliser and Transmission control

1 2 3 4 5 6
To 107 - 33 ( Sheet 13)

P093 480
P020 C007. 69
480 T010
I m obiliser. Speed Sensor
To SP23 - 2 ( Sheet 3) To 106 - 14 ( Sheet 13) P020 C007. 68 C014 T001. 11
604 604 604 A
D 107A 1 12 601KC
To SP33 - 5 ( Sheet 5) D
To P003 - 4 ( Sheet 3) 107Z
2 11
To SC02 - 1 ( Sheet 11) C014 T001. 12
109K
109K B
3 10
105 CAN LO
To SP56 - 4 ( Sheet 16)
To P020 - 26 ( Sheet 3) 105 4 9
CAN H C014 T001. 13
480 C
To SP55 - 4 ( Sheet 16)
5 8
100M
To SP19 - 9 ( Sheet 3) To Fusebox A P001 - 19 ( Sheet 1)
6 7 301N
To SP32 - 6 ( Sheet 3) 811A
SP28
P014 T003
P020 C007. 29 T001. C014 4
4 1863 860 860 1 2 600AS
1
811E
2 P020 C007. 28
1 12 1862 1811
P094 C016 T002
LI NKED I F NO
2 11
Horn. 874D 3 5
601CY T001. C014 3
811 1 2
600AC
1
814
4 9 600F
2
5 8
To P107 - 17 ( Sheet 13)
6 7
874F
To Ground C008 - 4 ( Sheet 5) T005
874E
Mainshaft Solenoid.
P013 T001. C014 6
858 1 2
600AQ
P041 872A Driveshaft Relay
9
1865
P020 C007. 13
858 T004
Horn Swit ch P041 8 P020 C007. 57
872B 6
7
Layshaft Solenoid.
814 1866 P020 C007. 14 T001. C014 7
857 857 1 2
C Fusebox C - 14 ( Sheet 3) P041 11

P042- 4 P042- 8 600AP
C
304B P041 13 872C
To P107 - 16 ( Sheet 13 ) 8 10
601CZ
874
To P107 - 28 ( Sheet 13) P041 5
Gear Select or Swit ch. SP27 C003 12
385
To SB - 1 ( Sheet 2)
873
4t h 871A
C014 T001. 9
To SP23 - 4 ( Sheet 3) P041 14
3rd
P041 9
872 SP26 871B
60
2 601DB
107J
2nd
P006 P013 To SC05 - 4 ( Sheet 8)
1st
P041 12
871 SP25 Forward Relay. Drive Relay 601A
601DB
ST1
4 4
861B
871C 852B 1
SP30
1 890 C008 Eart h To SC10 - 6 ( Sheet 8)
2 861 811D 2 600G
F 809A M10 Ring Term inal
P041 7 N To SC06 - 3 ( Sheet 5)
P041 6 To SP24 - 1 ( Sheet 4) 809 3 5 601T 811C 3 5
601EJ
810 600A
R
P041 10
808 SP64 T006
P009 P014. Forward Low Solenoid.
T001. C014 2
859 1 2
Reverse Drive Relay Forward Hi/ Low Relay 600AR
To SP23 - 5 ( Sheet 3) SP29 9
P020 C007. 30
6
9
861A 6
1861 859 T007
852A
P012 P018 7
811B
7 1860 P020 C007. 24 T001. C014 1 Forward High Solenoid.
812 812 1 2
600AB
4 808 8 10 874C 8 10 601CX
1852 9
852 601AA
Fusebox C - 8 ( Sheet 3) 182 1 6
2 7 1854
P019
To SP23 - 3 ( Sheet 3) Parkbrake/ 2WD Relay T009
107H 3 5 8 10 815
107AB
4 Two/ Four Wheel Drive Solenoid.
856 1855A
1 T001. C014 10
2
818 1 2 600M
601KG
B 3 5
601KF
B
C015 T008
To C002 - 7 ( Sheet 8) SP34 Transm ission Oil Pressure
Transm ission Dum p Eart h To P055 - 6 ( Sheet 6)
P020 C007. 48 SC06 P020 C007. 22 T001. C014 8
856 1 2 600AN 382 405 405 1 2
600J
To C008 - 7 ( Sheet 5) To SP5 - 2 ( Sheet 7) To SP10 - 8 ( Sheet 3)

601JD
601JH
601JE
To C002 - 6 ( Sheet 14)

P012 606A
Parkbrake warning Lam p Relay SP33 To SP3 - 10 ( Sheet 1)
601JF 601JC C031
9 1853
401 6
Eart h Speed Sensor 2
To P052 - 14 ( Sheet 7) 7 P063- 1 P063- 3 To P056 - 19 ( Sheet 6) P020 C007. 27
606 SC14 606 A
606
810H 8 10
To SP3 - 8 ( Sheet 1) To P107 - 27 ( Sheet 13 )
To SP24 - 2 ( Sheet 4) 601R
871C
To SP9 - 4 ( Sheet 1) 106F
P020 C007. 64
106E B
815
P039 Eart h To P056 - 13 ( Sheet 6) 480A
P020 C007. 63
480A C
To P107 - 1 ( Sheet 13) M10 Ring Term inal
A A
332/F0906-2
1 2 3 4 5 6
33 - 93 9823/1700-1 33 - 93
Page Page
33-94 33-95
Figure 1080. (Part

1 1 of 2) 2 3
To 107 - 33 ( Sheet 13)

P093
To SP23 - 2 ( Sheet 3) I m obiliser.
To 106 - 14 ( Sheet 13)
D 107A 1 12 601KC
To P003 - 4 ( Sheet 3) 107Z
2 11
3 10
105 CAN LO
To SP56 - 4 ( Sheet 16)
To P020 - 26 ( Sheet 3) 105 4 9
CAN H
To SP55 - 4 ( Sheet 16)
5 8
100M
To SP19 - 9 ( Sheet 3) To Fusebox A P001 - 19 ( Sheet 1)
6 7 301N
To SP32 - 6 ( Sheet 3) 811A
SP28
1 12
P094 C016
LI NKED I F NO
2 11
Horn. 874D
1
814
4 9 600F
2
5 8
To P107 - 17 ( Sheet 13)
6 7
874F
To Ground C008 - 4 ( Sheet 5)
874E
P041 872A
872B
Horn Swit ch P041 8
814
P020 C007. 57
P042- 4
C Fusebox C - 14 ( Sheet 3) P041 11

P042- 8
304B P041 13 872C

To P107 - 16 ( Sheet 13 )
874
To P107 - 28 ( Sheet 13) P041 5
873
4t h 871A
To SP23 - 4 ( Sheet 3) P041 14

3rd
P041 9
872 SP26 871B
107J
2nd
P006
1st
P041 12
871 SP25 Forward Relay.
4
871C 852B 1
SP30
2 861
F 809A
P041 7 N
P041 6 To SP24 - 1 ( Sheet 4) 809 3 5 601T
810
R
Page 33-95
P041 10 SP64
808
P009
Reverse Drive Relay
To SP23 - 5 ( Sheet 3) SP29
9
6
852A
P012 P018 7
811B
4 808 8 10
1852 9
852 601AA
Fusebox C - 8 ( Sheet 3) 182 1 6
2 7 1854
P019
To SP23 - 3 ( Sheet 3) Parkbrake/ 2WD Relay
107H 3 5 8 10 815
107AB
4
1
856 1855A
2
601KG
B 3 5
601KF
C015 To C002 - 7 ( Sheet 8)
Transm ission Dum p
P020 C007. 48 SC06
856 1 2 600AN
To C008 - 7 ( Sheet 5) To SP5 - 2 ( Sheet 7)

601JD
P012
601JF
9 1853
6
Eart h
401
To P052 - 14 ( Sheet 7) 7 P063- 1 P063- 3
810H 8 10
To SP3 - 8 ( Sheet 1) To P107 - 27 ( Sheet 13 )
601R
To SP24 - 2 ( Sheet 4) 871C
815
To P107 - 1 ( Sheet 13)
1 2 3
33 - 94 9823/1700-1 33 - 94
Page Page
33-94 33-95
Figure 1080. (Part4 2 of 2) 5 6
To 107 - 33 ( Sheet 13)

480
P020 C007. 69
480 T010
Speed Sensor
To 106 - 14 ( Sheet 13) P020 C007. 68 C014 T001. 11
604 604 604 A
D
To SC02 - 1 ( Sheet 11) 109K
C014 T001. 12
109K B
C014 T001. 13
480 C
SP28
P014 T003
P020 C007. 29 T001. C014 4
4 1863 860 860 1 2 600AS
1
811E
2 P020 C007. 28
1862 1811
T002
3 5
601CY T001. C014 3
811 1 2
600AC
T005
Mainshaft Solenoid.
P013 T001. C014 6
858 1 2
600AQ
Driveshaft Relay
P042- 7
9
1865
P020 C007. 13
858 T004
6
7
Layshaft Solenoid.
1866 P020 C007. 14 T001. C014 7
857 857 1 2
P042- 8 600AP
C
8 10
601CZ
C003 12
385
To SB - 1 ( Sheet 2)
601DB C014 T001. 9

2
60
P013 To SC05 - 4 ( Sheet 8)
Drive Relay 601A
601DB
ST1
4
861B
SP30
1 890 C008 Eart h To SC10 - 6 ( Sheet 8)
811D 2 600G
M10 Ring Term inal
811C 3 5
601EJ
600A
T006
Page 33-94
P014. Forward Low Solenoid.

T001. C014 2
859 1 2
Forward Hi/ Low Relay 600AR
9
P020 C007. 30
861A 6
1861 859 T007
7 1860 P020 C007. 24 T001. C014 1 Forward High Solenoid.
812 812 1 2
600AB
874C 8 10 601CX
T009
Two/ Four Wheel Drive Solenoid.
T001. C014 10
818 1 2 600M
B
T008
SP34 Transm ission Oil Pressure
Eart h To P055 - 6 ( Sheet 6) P020 C007. 22
405
T001. C014 8
405 1 2
382 600J
601JD
601JH
601JE
To C002 - 6 ( Sheet 14)

606A
601JF 601JC C031
Speed Sensor 2
To P056 - 19 ( Sheet 6) P020 C007. 27
606 SC14 606 A
606
To SP9 - 4 ( Sheet 1) 106F

P020 C007. 64
106E B
P039 Eart h To P056 - 13 ( Sheet 6) 480A

P020 C007. 63
480A C
M10 Ring Term inal
A
332/F0906-2
4 5 6
33 - 95 9823/1700-1 33 - 95
33 - 96 9823/1700-1 33 - 96
Figure 1081. Right hand Cluster
Page 33-98 Connectors, P055 and P056 - 332/

F0906 Issue 2 (Sheet 6 of 16) Page 33-99
1 2 3 4 5 6
D D
CLUSTER J1 CLUSTER J2
Clust er J1 P055 Clust er J2 P056
C C
To SP14 - 2 ( Sheet 2) To SP61 - 3 ( Sheet 7)
1 2 407B 2801B 1 2
To P020 - 25 ( Sheet 2) To P020 - 17 ( Sheet 2) To SP63 - 4 ( Sheet 5)

412 3 4 409 3 4 809C
To P020 - 18 ( Sheet 2) To P020 - 22 ( Sheet 5) To SP24 - 5 ( Sheet 4)

408 5 6 405 5 6 810M
To SP62 - 3 ( Sheet 7) To SP58 - 3 ( Sheet 2) To SP64 - 4 ( Sheet 5)

2800B 7 8 402B 808C 7 8

9 10 403B 410A 9 10 404B

301E 11 12 601G 11 12 481A
To SP52 - 3 ( Sheet 16) To SP53 - 3 ( Sheet 16) To P020 - 63 ( Sheet 5) To P052 - 17 ( Sheet 7)
CAN HI 13 14 CAN LO 480A 13 14 405A
B To SP54 - 2 ( Sheet 16) To SP65 - 1 ( Sheet 13) To P052 - 16 ( Sheet 7) B

SCREEN 15 16 1805 15 16 411
To P106 - 27 ( Sheet 13) To P043 - 3 ( Sheet 7)

17 18 1802 17 18 2910
To SP9 - 2 ( Sheet 1) To SP6 - 4 ( Sheet 3) To P020 - 27 ( Sheet 5)

106B 19 20 829AA 606 19 20
A A
332/F0906-2
1 2 3 4 5 6
33 - 97 9823/1700-1 33 - 97
Page Page
33-98 33-99
Figure 1081. (Part

1 1 of 2) 2 3
CLUSTER J1
Clust er J1 P055
C
To SP14 - 2 ( Sheet 2) To SP61 - 3 ( Sheet
1 2 407B

412 3 4 409

408 5 6 405
To SP62 - 3 ( Sheet 7) To SP58 - 3 ( Sheet 2) To SP64 - 4 ( Sheet 5

2800B 8 402B
Page 33-99
7
To SP59 - 3 ( Sheet 2) To SP72 - 2 ( Sheet 1

9 10 403B

301E 11 12 601G
To SP52 - 3 ( Sheet 16) To SP53 - 3 ( Sheet 16) To P020 - 63 ( Sheet

CAN HI 13 14 CAN LO
B To SP54 - 2 ( Sheet 16) To SP65 - 1 ( Sheet 1

SCREEN 15 16
17 18
To P106 - 27 ( Sheet 1
To SP9 - 2 ( Sheet 1) To SP6 - 4 ( Sheet 3) To P020 - 27 ( Sheet

106B 19 20 829AA
1 2 3
33 - 98 9823/1700-1 33 - 98
Page Page
33-98 33-99
Figure 1081. (Part4 2 of 2) 5 6
CLUSTER J2
Clust er J2 P056
C
1 2
2801B
3 4
809C
5 6 810M
808C 7 8
Page 33-98

410A 9 10 404B
To SP73 - 2 ( Sheet 14)

11 12 481A

480A 13 14 405A
To SP65 - 1 ( Sheet 13) To P052 - 16 ( Sheet 7) B

1805 15 16 411

1802 17 18 2910
To P020 - 27 ( Sheet 5) 606 19 20
A
332/F0906-2
4 5 6
33 - 99 9823/1700-1 33 - 99
33 - 100 9823/1700-1 33 - 100

Page 33-102 Figure 1082. Instruments and warning

lamps - 332/F0906 Issue 2 (Sheet 7 of 16) Page 33-103
1 2 3 4 5 6
D D
To P020 - 60 ( Sheet 2)
1802
L.I .M. Unit
To P056 - 1 ( Sheet 6) Wat er in Fuel

SP61 2801A P052 19
2801B
To SP58 - 2 ( Sheet 2) Vacuum Swit ch

P052 6
602C
Engine Oil Pressure

To SP59 - 2 ( Sheet 2) P052 7
403A

To SP60 - 2 ( Sheet 2) P052 15
404A
To P056 - 14 ( Sheet 6) Transm ission Oil Pressure

P052 17
405A
To EO - B ( Sheet 2) Coolant Tem perat ure

406 EA C003. 2 406 C007. P020 23 P052 8
C
406
C
To SP14 - 3 ( Sheet 2) Charge Warning

P052 9
407C
To P025 - 18 ( Sheet 15)

Main Beam
P036
To P058 - 10 ( Sheet 9) SP7
I ndicat or Diode To SP18 - 2 ( Sheet 2)
805B P036 - 1 P036 - 3 807C P052 3
838A
To P020 - 40 ( Sheet 8) I ndicat ors
SP13 P052 2
807B
To P042 - 5 ( Sheet 8) Crab St eer
P036
To P058 - 11 ( Sheet 9) SP8
I ndicat or Diode P052 11
806B P036 - 2 P036 - 4 807A
To P020 - 39 ( Sheet 8) All Wheel St eer
P052 1

P043
I nfo Swit ch.
To SP6 - 5 ( Sheet 3) 829AH 601HP To SP10 - 3 ( Sheet 3) To P056 - 16 ( Sheet 6) P052 16
8 7
411
B 2 3 B
Park Brake
To P012 - 6 ( Sheet 5) P052 14
To SP10 - 2 ( Sheet 3) 601JK 338
To P056 - 18 ( Sheet 6) 401
Low Coolant
To P055 - 7 ( Sheet 6) 2800B
SP62 2800A P052 18
P018
Engine Running Relay. To P011 - 3 ( Sheet 4) To SP9 - 3 ( Sheet 1) P052 20
1851A 106C
4
To SP19 - 10 ( Sheet 1) 100N 1
2 SP39
1851
Cold St art
SP5
To SP14 - 4 ( Sheet 2) 3 5 To P011 - 8 ( Sheet 4) 601P P052 10
407F 601KD 1851B
To P020 - 35 ( Sheet 11)

To SP34 - 11 ( Sheet 5) 2805
P052 4
P052 13
A A
332/F0906-2
1 2 3 4 5 6
33 - 101 9823/1700-1 33 - 101

Page Page
33-102 33-103
Figure 1082. (Part

1 1 of 2) 2 3
D
To P020 - 60 ( Sheet 2)
1802
To P056 - 1 ( Sheet 6)
2801B SP61
To P056 - 14 ( Sheet 6)
To EO - B ( Sheet 2) C007. P020 23

406 EA C003. 2 406
C
To P025 - 18 ( Sheet 15)

P036
To P058 - 10 ( Sheet 9) SP7
I ndicat or Diode To SP18 - 2 ( Sheet 2)
805B P036 - 1 P036 - 3 807C
To P020 - 40 ( Sheet 8)
SP13
Page 33-103
To P042 - 5 ( Sheet 8)
P036
To P058 - 11 ( Sheet 9) SP8
I ndicat or Diode
806B P036 - 2 P036 - 4 807A
To P020 - 39 ( Sheet 8)
P043
I nfo Swit ch.
To SP6 - 5 ( Sheet 3) 829AH 601HP To SP10 - 3 ( Sheet 3) To P056 - 16 ( Sheet 6)
8 7
B 2 3
To P012 - 6 ( Sheet 5)
To SP10 - 2 ( Sheet 3) 601JK 338
To P056 - 18 ( Sheet 6)
To P055 - 7 ( Sheet 6) 2800B

SP62
P018
Engine Running Relay. To P011 - 3 ( Sheet 4) To SP9 - 3 ( Sheet 1)
1851A
4
To SP19 - 10 ( Sheet 1) 100N 1
2 SP39
1851
SP5
To SP14 - 4 ( Sheet 2) 3 5 To P011 - 8 ( Sheet 4)
407F 601KD 1851B
To P020 - 35 ( Sheet 11)

To SP34 - 11 ( Sheet 5)
1 2 3
33 - 102 9823/1700-1 33 - 102

Page Page
33-102 33-103
Figure 1082. (Part4 2 of 2) 5 6
L.I .M. Unit

Wat er in Fuel
2801A P052 19
SP58 - 2 ( Sheet 2) Vacuum Swit ch

P052 6
602C
Engine Oil Pressure

P59 - 2 ( Sheet 2) P052 7
403A

SP60 - 2 ( Sheet 2) P052 15
404A
56 - 14 ( Sheet 6) Transm ission Oil Pressure

P052 17
405A
Coolant Tem perat ure

P052 8
406
C
SP14 - 3 ( Sheet 2) Charge Warning

P052 9
407C
Main Beam
SP18 - 2 ( Sheet 2) P052 3

838A
I ndicat ors
P052 2
Page 33-102
807B
Crab St eer
P052 11
All Wheel St eer
P052 1
To P056 - 16 ( Sheet 6) P052 16

411
B
Park Brake
P012 - 6 ( Sheet 5) P052 14
401
Low Coolant
2800A P052 18
SP9 - 3 ( Sheet 1) P052 20

106C
Cold St art
601P P052 10
P052 4
2805
P052 13
A
332/F0906-2
4 5 6
33 - 103 9823/1700-1 33 - 103

33 - 104 9823/1700-1 33 - 104

Figure 1083. Road lamps, Reverse
Page 33-106 Alarm and Trailer Electrics - 332/

1 2 3 4 5 6
To SP8 - 4 ( Sheet 7) C017

Reverse Alarm .
D 806C
C007. P020 39
415 To Fusebox A - 20 ( Sheet 1)
D
807A P020 C007. 31 807C 1
RL005 C002 9 SC01 601 603

806D 806C
R/ H Headlam p - RL003 2
SC10
To C008 - 6 ( Sheet 5)
GREEN 806D
RL003. 5
806D
To RL004 - 3 ( Sheet 8)
BLUE 838A
RL003. 3
838B
SRL2
838D
RL005 C002 13
838B
To C007 - 11 ( Sheet 1)
R/ H Main Beam . R/ H Rear Com binat ion Lam p.
C013 2 SRL4 RL003 5
RL003. 2 SRL1 RL005 C002 12 To C007 - 46 ( Sheet 1) 807E 807E
Reverse Lam p.
YELLOW 834A 834B 834B 834
R/ H Dip Beam . C013 6
806E RL003 3
To RL004 - 2 ( Sheet 8) 603C
834A R/ H I ndicat or.
RL003. 4 RL005 C002 11 SC04 C013 4
RED 830B 830B 830B 830C 830C
R/ H Side Lam p.
RL003 2
RL003. 6 To SRL5 - 3 ( Sheet 8) C013 3
WHI TE 600Y 600Y R/ H Side Lam p.
SRL2 RL003 1
816 816B
R/ H Brake Lam p.
P028 RL003 4
Fog Lam p Swit ch. 941B
Fog Lam p.
8 7
To Fusebox B - 14 ( Sheet 2) P020 C007. 50 RL003 6
To Fusebox B - 6 ( Sheet 2) 2 3
830E 830
905
C P020 C007. 7 816 C
To SP6 - 2 ( Sheet 3) P020 C007. 47
829A 829E
To SP7 - 4 ( Sheet 7) 805D P020 C007. 40 805

C033
P020 C007. 53
941 Num ber Plat e Lam p.
C033 1
To SP6 - 7 ( Sheet 3) 829AE
601DC
To SP5 - 3 ( Sheet 7) P017 C033 2
Brake Lam ps Relay.
To P003 - 10 ( Sheet 3) 1
4
108B
2
816
To Fusebox C - 12 ( Sheet 3) P029 To P107 - 10 ( Sheet 13) To SP34 - 8 ( Sheet 5) C030

817
Roadlight s Swit ch. 3 5
601GZ Towing Link
C030 P108 1
8 7
C030 P108 2
1
P017 307
2
3
To SP21 - 2 ( Sheet 10)
942B
To Fusebox D - 8 ( Sheet 4) 6
9
4
306
7 5 To P107 - 35 ( Sheet 13) Num ber Plat e Lam p.
828A
6 To SP5 - 4 ( Sheet 7) 817A
A
To P107 - 11 ( Sheet 13) C034 1
To SP19 - 4 ( Sheet 1) 100C
832
817C B C
817B C013 5
8 10
829B
SC09 C034 2
To SP34 - 9 ( Sheet 5) To SP19 - 5 ( Sheet 1) To P107 - 34 ( Sheet 13) C013 7
601V 601BF 805D
SC08
100D C013 8
941 941
B To C008 - 5 ( Sheet 5) 603A

C013 1
603A
B
SRL1
L/ H Headlam p - RL004 600YB
To RL003 - 6 ( Sheet 8)
RL002 6
To C012 - 2 ( Sheet 11) 601DP
SC05 603B
600Y
RL004 6
600AH
SRL5
600AH
RL005 C002 7 To SC06 - 1 ( Sheet 5)
WHI TE 600AH
To C011 - 2 ( Sheet 2) 601CH 807A
RL002 5
RED 830B
RL004 4
829
RL005 C002 10
829 Reverse Lam p.
L/ H Side Lam p. To SC09 - 1 ( Sheet 8)
P008
Flasher Unit .
RL004 2
To SRL1 - 2 ( Sheet 8) To SP3 - 3 ( Sheet 1) 816A RL002 1
YELLOW 834A 834A 2 6 L/ H Brake Lam p.
4 8
802
RL004 3
To SRL2 - 2 ( Sheet 8) 829B
RL002 2
BLUE 838A 838A
L/ H Main Beam . P025 L/ H Side Lam p.
Hazzard Swit ch.
RL004 5 RL005 C002 8 To SC08 - 1 ( Sheet 8) 10 601AD RL002 3
GREEN 806D 805C 805C 805D
L/ H I ndicat or. 1
104 To Fusebox A - 12 ( Sheet 1) L/ H I ndicat or.
2
3
300
To Fusebox C - 20 ( Sheet 3) 941A RL002 4
Fog Lam p.
SRL3
5
17
804A 806
To R/ H Colum n Swit ch P058- 14 18 P042- 1 P042- 5
803A 805 To SP7 - 1 ( Sheet 7)
8
A A
332/F0906-2
1 2 3 4 5 6
33 - 105 9823/1700-1 33 - 105

Page Page
33-106 33-107
Figure 1083. (Part

1 1 of 2) 2 3
D 806C
C007. P020 39
RL005 C002 9 SC01

806D 806C
R/ H Headlam p - RL003
GREEN 806D
RL003. 5
806D
To RL004 - 3 ( Sheet 8)
BLUE 838A
RL003. 3
838B
SRL2
838D
RL005 C002 13
838B
To C007 - 11 ( Sheet 1)
R/ H Main Beam .
RL003. 2 SRL1 RL005 C002 12 To C007 - 46 ( Sheet 1)

YELLOW 834A 834B 834B 834
R/ H Dip Beam .
834A
To RL004 - 2 ( Sheet 8)
RL003. 4 RL005 C002 11
RED 830B 830B 830B
R/ H Side Lam p.
600Y
RL003. 6
600Y
To SRL5 - 3 ( Sheet 8)
WHI TE
P028
Fog Lam p Swit ch.
8 7
To Fusebox B - 6 ( Sheet 2) 2 3
830E
905
C
829A
To SP7 - 4 ( Sheet 7) 805D
941
To SP6 - 7 ( Sheet 3) 829AE

601DC
To SP5 - 3 ( Sheet 7) P017
Brake Lam ps Relay.
To P003 - 10 ( Sheet 3) 1
4
108B
2
816
To Fusebox C - 12 ( Sheet 3) P029 To P107 - 10 ( Sheet 13)

817 3 5
Roadlight s Swit ch.
Page 33-107
601GZ
8 7
P017 307
2
3
To SP21 - 2 ( Sheet 10)
942B
9
Foot Brake Swit ch.
4
306
7 5 To P107 - 35 ( Sheet 13)
828A
6 To SP5 - 4 ( Sheet 7) 817A
A
To P107 - 11 ( Shee
To SP19 - 4 ( Sheet 1) 100C
832
817C B C
817B
8 10
To SP34 - 9 ( Sheet 5) To SP19 - 5 ( Sheet 1) To P107 - 34 ( Sheet 13)

601V 601BF
100D
B To C008 - 5 ( Sheet 5
L/ H Headlam p - RL004 600YB
To RL003 - 6 ( Sheet 8)
600Y
RL004 6
600AH
SRL5
600AH
RL005 C002 7 To SC06 - 1 ( Sheet 5)
WHI TE 600AH
To C011 - 2 ( Sheet
RL004 4 RL005 C002 10
RED 830B 829 829
L/ H Side Lam p. To SC09 - 1 ( Sheet 8)
P008
Flasher Unit .
RL004 2
YELLOW 834A 834A 2 6
4 8
802
RL004 3
BLUE 838A 838A
L/ H Main Beam . P025
Hazzard Swit ch.
RL004 5 RL005 C002 8 To SC08 - 1 ( Sheet 8) 10 601AD
GREEN 806D 805C 805C
L/ H I ndicat or. 1
104
2
3
300
5
17
804A
To R/ H Colum n Swit ch P058- 14 18
803A 805
1 2 3
33 - 106 9823/1700-1 33 - 106

Page Page
33-106 33-107
Figure 1083. (Part4 2 of 2) 5 6
To SP8 - 4 ( Sheet 7) C017

Reverse Alarm .
C007. P020 39
415 To Fusebox A - 20 ( Sheet 1)
D
807A P020 C007. 31 807C 1
601 603
2
SC10
To C008 - 6 ( Sheet 5)
R/ H Rear Com binat ion Lam p.

C013 2 SRL4 RL003 5
807E 807E
Reverse Lam p.
C013 6
806E RL003 3
603C
R/ H I ndicat or.
SC04 C013 4
830B 830C 830C
RL003 2
C013 3
R/ H Side Lam p.
SRL2 RL003 1
816 816B
R/ H Brake Lam p.
RL003 4
941B
Fog Lam p.
P020 C007. 50 830 RL003 6
P020 C007. 7 816 C

P020 C007. 47
829E
P020 C007. 40 805

C033
P020 C007. 53
C033 1
P017 C033 2
Brake Lam ps Relay.
4
2
816
To SP34 - 8 ( Sheet 5) C030

5
Towing Link
Page 33-106
601GZ
C030 P108 1
C030 P108 2
P066
To P107 - 11 ( Sheet 13) C034 1
C
817B C013 5
829B
SC09 C034 2
C013 7
805D
SC08
C013 8
941 941
To C008 - 5 ( Sheet 5) 603A

C013 1
603A
B
SRL1
RL002 6
To C012 - 2 ( Sheet 11) 601DP
SC05 603B
To C011 - 2 ( Sheet 2) 601CH 807A

RL002 5
Reverse Lam p.
RL002 1
To SP3 - 3 ( Sheet 1) 816A
601U
L/ H Brake Lam p.
RL002 2
829B
L/ H Side Lam p.
601AD RL002 3
805D
104 To Fusebox A - 12 ( Sheet 1) L/ H I ndicat or.
300
To Fusebox C - 20 ( Sheet 3) 941A RL002 4
Fog Lam p.
SRL3
804A 806
P042- 1 P042- 5
805 To SP7 - 1 ( Sheet 7)
A
332/F0906-2
4 5 6
33 - 107 9823/1700-1 33 - 107

33 - 108 9823/1700-1 33 - 108

Page 33-110 Figure 1084. Wiper and Motors -

332/F0906 Issue 2 (Sheet 9 of 16) Page 33-111
1 2 3 4 5 6
D D
833
P076 2 P058. 7
840 840
P076 5 P058. 12
836
841 841 AJ 4 AJ 1
4 1
849 600 4 4
925
4 1
838A
M M
1 1
P076 3 P058. 2
982 982
AJ 2 2
854 2 2 2
AJ 3 926
P076 4 P058. 3 3
133F 3
983 983
3 3 133D
C Wiper Mot or
C
To SP20 - 2 ( Sheet 2) P058
P058. 9
P076 1 P057 1
6 5
600Y
To P040 - 2 ( Sheet 9) P058. 8 133B 133B
M 832A SC
8
P058. 13 Rear Cab
To P025 - 5 ( Sheet 8) P057 4
4
P076 6
110D
P058. 14 P057 2
803A P058. 10
SP38
3 P057 5
J 13 P058. 11 P057 3
7
To P002 - 4 ( Sheet 2)
110 O 12
P058. 1
2 110E 8
I 10
To P003 - 14 ( Sheet 3) P058. 4 II 11 P026 P027
304A Roof Wiper Swit ch. Rear Wiper Swit ch.
9 To SP6 - 8 ( Sheet 3) To SP6 - 9 ( Sheet 3) 8 7 601DX
P076 7 829M 8 7 204 834A
839B 1
854
14
2
1 926
849 133 925
2
3
3 133C
133E
SP16
P069 2
839A 839
P058. 6
839 805A 4
5
4
6
SP37 5 901B
2 1
601KL
M P069 3
806A
To SP8 - 2 ( Sheet 7) 6
901
SP17
601JG 610JG
B SA
B
P069 1
901A 901A
Rear Washer Mot or. To Fusebox B - 2

2 1
P068 1
601AS
To P077 - 2 ( Sheet 2) ( Sheet 2)
601KM
M 601DD
P040 Eart h
M10 Ring Term inal
A 332/F0906-2
A
1 2 3 4 5 6
33 - 109 9823/1700-1 33 - 109

Page Page
33-110 33-111
Figure 1084. (Part

1 1 of 2) 2 3
To Fusebox B - 7 ( Shee
To Fusebox B - 9 ( Shee
833
P076 2 P058. 7
840 840
P076 5 P058. 12
836
841 841
P076 3 P058. 2
982 982
P076 4 P058. 3
983 983
C Wiper Mot or P058

2 Spd, I nt P076 To SP20 - 2 ( Sheet 2)
R/ H Colum n Swit ch.
P058. 9
6 5
P076 1 To P040 - 2 ( Sheet 9)
600Y P058. 8
M 832A
8
P058. 13
To P025 - 5 ( Sheet 8)
4
P076 6
110D
P058. 14
803A P058. 10
SP38
3
J 13 P058. 11
7
To P002 - 4 ( Sheet 2)
110 O 12
P058. 1
2 110E 8
I 10
Page 33-111
To P003 - 14 ( Sheet 3) P058. 4 II 11
304A
9 To SP6 - 8 ( Sheet 3)
P076 7
839B
14
P069 2
839A 839
P058. 6
839 805A
SP37
2 1
601KL
M P069 3
806A
601JG 610JG
B SA
P069 1
901A 901A
Rear Washer Mot or.

2 1
P068 1
601AS
To P077 - 2 ( Sheet 2)
601KM
M 601DD
P040 Eart h
M10 Ring Term inal
1 2 3
33 - 110 9823/1700-1 33 - 110

Page Page
33-110 33-111
Figure 1084. (Part4 2 of 2) 5 6
849
AJ 4 4 1
AJ 1
4 4 4 1
600 925 838A
M M
1 1
AJ 2 2
854 2 2 2
3
AJ 3 926
133F 3 3 3 133D
P057 1
133B 133B
SC
Rear Cab
P057 4
P057 2
P057 5
P057 3

Page 33-110
P026 P027
Roof Wiper Swit ch. Rear Wiper Swit ch.
To SP6 - 8 ( Sheet 3) To SP6 - 9 ( Sheet 3) 8 7 601DX
829M 8 7 204 834A
1
854
2
1 926
849 133 925
2
3
3 133C
133E
SP16
To SP7 - 2 ( Sheet 7) 4
4
5
6
5 901B
To SP8 - 2 ( Sheet 7) 6 SP17
901
To Fusebox B - 2
( Sheet 2)
332/F0906-2
A
4 5 6
33 - 111 9823/1700-1 33 - 111

33 - 112 9823/1700-1 33 - 112

Figure 1085. Worklight, Rotating
Page 33-114 Beacon, Heated Seat and Interior lamp

1 2 3 4 5 6
D D
P030 945B
1 1
R/ H Front Worklam p. Worklam ps Swit ch. To SP5 - 5 ( Sheet 7)

601AC 601KG 2 2
1 1 829J 8 7
1
2 2
To P011 - 2 ( Sheet 4) 2 To Rear Cab Ground AF - 6.
3
831
4
To P011 - 7 ( Sheet 4) 5
P057 6
6 945 945
SB
Rear Cab
P088 1
RED 831B
P088 2
RED 831K
BLACK
P088 3
601BU
To P040 - 4 ( Sheet 9)
BLACK
P088 4
601AL
To P040 - 5 ( Sheet 9)
831J 942A
C To Fusebox B - 13 ( Sheet 2) SP22

942E
P042- 2 P042- 6
C
To Fusebox B - 11 ( Sheet 2) 942D
942B
To P029- 3 ( Sheet 8)
L/ H Front Worklam p. SP21
1 1
2 2
AK
I nt erior Lam p.
P057 9 AK 1
301J 301J 1 1
AK 2
601AV 2 2

P032
To SP6 - 12 ( Sheet 3) Beacon Swit ch. To SP5 - 1 ( Sheet 7)
829U 8 7 600AH
310 2 3 844A
AC
To Fusebox C - 16 ( Sheet 3) P057 8
Rot at ing Beacon.
1 1
844A
2 2
601AX
B To Rear Cab Ground AF - 5. B

1 1
Swit ch
151B

601EF 2 2

P057 7
151
SA Rear Cab
Swit ch
1 1
945A
M
151A 1 1
2 2
601DG
2 2
601FK
A 332/F0906-2 A
1 2 3 4 5 6
33 - 113 9823/1700-1 33 - 113

Page Page
33-114 33-115
Figure 1085. (Part

1 1 of 2) 2 3
R/ H Front Worklam p. Worklam ps Swit ch

1 1 829J
2 2
To P011 - 2 ( Sheet 4)
To P011 - 7 ( Sheet 4)
P088 1
RED 831B
P088 2
RED 831K
BLACK
P088 3
601BU
To P040 - 4 ( Sheet 9)
BLACK
P088 4
601AL
To P040 - 5 ( Sheet 9)
831J
P042- 2
C To Fusebox B - 13 ( Sheet 2) SP22

942E
To Fusebox B - 11 ( Sheet 2) 942D
L/ H Front Worklam p.
1 1
2 2
Page 33-115
P032
To SP6 - 12 ( Sheet 3) Beacon Swit ch.
829U 8 7 600AH
310 2 3 844A
To Fusebox C - 16 ( Sheet 3)
151B 1 1

601EF 2 2

P057 7
151
SA Rear Cab
151A 1 1

2 2
601FK
1 2 3
33 - 114 9823/1700-1 33 - 114

Page Page
33-114 33-115
Figure 1085. (Part4 2 of 2) 5 6
D
P030 945B
1 1
Worklam ps Swit ch. To SP5 - 5 ( Sheet 7)

601AC 601KG 2 2
829J 8 7
1
2 To Rear Cab Ground AF - 6.
3
831
4
5
P057 6
6 945 945
SB
Rear Cab
831J 942A
942E
P042- 2 P042- 6
C
942B
To P029- 3 ( Sheet 8)
SP21
AK
I nt erior Lam p.
Page 33-114
P057 9 AK 1
301J 301J 1 1
AK 2
601AV 2 2

P032
Beacon Swit ch. To SP5 - 1 ( Sheet 7)
7 600AH
3 844A
AC
P057 8
Rot at ing Beacon.
1 1
844A
2 2
601AX
To Rear Cab Ground AF - 5. B

1
Swit ch

Swit ch
1 1
945A
M
1
2 2
601DG
2
332/F0906-2 A
4 5 6
33 - 115 9823/1700-1 33 - 115

33 - 116 9823/1700-1 33 - 116

Page 33-118 Figure 1086. Air Con and Cold start

1 2 3 4 5 6
D D
Blower Mot or.

P037 1
P037 2 M
P037 3
Freeze Valve. EK
L
800 EP Air Condit ioning
To Fusebox A - 10 ( Sheet 1) P037 4 Binary Swit ch. Com pressor Clut ch.
102 B M
801
1 2
H EK 1
995 P037 5 884 886 RED 1
P037 6 EK 2
BLACK
886B
817B 2
C
997
817
To P040 - 3 ( Sheet 9)
SC
884
P020 C007. 12
884
C003. EA 9 To Splice SB - 6 ( Sheet 2)
Engine
C003. EA 10
886A
P023 / P024
883
C P023- 1 P024- 1
C
C012
P020 C007. 34 C012 1
125 125 125
To Fusebox D - 4 ( Sheet 4)
P020 C007. 35 C012 2
To P052 - 4 ( Sheet 7) 2805 Cold St art ECU.
C012 3 602B 1 12
Grid Heat er. 2 11
C012 4
2805 3 10
RED
2805 4 9
5 8
CB 601DR
6 7
Cold St art Relay.

RED 3
B 4
107C B
1 2
601DP
2810
2811
CC P020 C007. 38
109
Am bient Sensor. 109
To P001 - 4 ( Sheet 1)
1 2 SC02
109J
109K
To C014 - 12 ( Sheet 5)
601DP
A 332/F0906-2 A
1 2 3 4 5 6
33 - 117 9823/1700-1 33 - 117

Page Page
33-118 33-119
Figure 1086. (Part

1 1 of 2) 2 3
P037 1
P037 2

P037 3
L
Freeze Valve.
800
To Fusebox A - 10 ( Sheet 1) P037 4
102 B M
801
H
995 P037 5
P037 6
C
997
817
To P040 - 3 ( Sheet 9)
P020 C007. 12
884
P023 / P024
883
C P023- 1 P024- 1
C012
Page 33-119
P020 C007. 34 C012 1
125 125
P020 C007. 35 C012 2
To P052 - 4 ( Sheet 7) 2805 Cold St art ECU.
C012 3 602B 1 12
Grid Heat er. 2 11
C012 4
2805 3 10
RED
2805 4 9
5 8
CB 601DR
6 7
Cold St art Relay.

RED 3
B 4
107C
1 2
601DP
2810
2811
CC
Am bient Sensor.
1 2
109J
601DP
1 2 3
33 - 118 9823/1700-1 33 - 118

Page Page
33-118 33-119
Figure 1086. (Part4 2 of 2) 5 6
Blower Mot or.

er Speed Resist or.
M
EK
EP Air Condit ioning
Binary Swit ch. Com pressor Clut ch.
1 2
EK 1
884 886 RED 1
EK 2
BLACK
886B
817B 2
To P040 - 3 ( Sheet 9)
SC
P020 C007. 12
884
C003. EA 9 To Splice SB - 6 ( Sheet 2)
Engine
C003. EA 10
886A
C
Page 33-118
125
Cold St art ECU.

12
11
10
P020 C007. 38
109 109
To P001 - 4 ( Sheet 1)
SC02
109K
To C014 - 12 ( Sheet 5)
332/F0906-2 A
4 5 6
33 - 119 9823/1700-1 33 - 119

33 - 120 9823/1700-1 33 - 120

Page 33-122 Figure 1087. In-Cab Entertainment

1 2 3 4 5 6
D D
AD
Left Speaker.
1
AB
Radio Supply.
1
P082 2
301F 301F 4
C
5
P082 3
576 575 6
P082 1
560 559 7
P082 4
601AG 601AB 8
To P040 - 7 ( Sheet 9)
446
445
AC
Radio Speakers.
1
3 AE
Right Speaker.
4 1
5 2
8
B B
448
447
332/F0906-2
A A
1 2 3 4 5 6
33 - 121 9823/1700-1 33 - 121

Page Page
33-122 33-123
Figure 1087. (Part

1 1 of 2) 2 3
AB
Radio Supply.
1
P082 2
301F 301F 4
5
P082 3
576 575 6
P082 1
560 559 7
P082 4
601AG 601AB 8
To P040 - 7 ( Sheet 9)
446
445
AC
Page 33-123
Radio Speakers.
1
8
B
448
447
1 2 3
33 - 122 9823/1700-1 33 - 122

Page Page
33-122 33-123
Figure 1087. (Part4 2 of 2) 5 6
AD
Left Speaker.
1
446
445
Page 33-122
AE
Right Speaker.
1
448
447
332/F0906-2
A
4 5 6
33 - 123 9823/1700-1 33 - 123

33 - 124 9823/1700-1 33 - 124

Page 33-126 Figure 1088. RAS Controller - 332/

1 2 3 4 5 6
P106 P107
D D
RAS CONTROLLER J1 RAS CONTROLLER J2
P106 1
To P020 - 65 ( Sheet 15) P107 1
To P018 - 10 ( Sheet 5)
505 815
P106 2
212A
SP66
212 P107 2
To P020 - 49 ( Sheet 15)
510
To P004 - 6 ( Sheet 4)
P106 3
212B P107 3
To P108 - 3 ( Sheet 15)
513
P106 4
212C
P107 4
To P020 - 10 ( Sheet 14)
1870 C029
P106 5
212D
St ab I solat ion Valve
P107 5 P020 C007. 6 C007. P020 36
910 910 1 2 603D
P106 6
212E
P107 6
To P020 - 4 ( Sheet 14)
903
P106 7
To P020 - 55 ( Sheet 15) P107 7
To P020 - 3 ( Sheet 14)
P106 8
To P020 - 67 ( Sheet 15) 902
506
P105 P107 8
To P020 - 2 ( Sheet 14)
To SP64 - 3 ( Sheet 5) 901
P106 9
808B
RAS Relay Right
9 P107 9
P106 10
809B
To SP63 - 3 ( Sheet 5) 614 6
7
To P017 - 3 ( Sheet 8) C
C P106 11
900
To P001 - 6 ( Sheet 1) 1805B 8 10 610JX To SP10 - 11 ( Sheet 3)
P107 10
817
P107 11
817B
To P066 - 3 ( Sheet 8)
P106 12
614A
To P020 - 59 ( Sheet 15) P105 P107 12

514
To P020 - 54 ( Sheet 15)
P106 13
508 RAS Relay Left
4 P107 13
To P020 - 66 ( Sheet 15)
P106 14
To P020 - 68 ( Sheet 5) 615 1 507
610 2
P107 14 To P020 - 9 ( Sheet 14)

P106 15
To SP67 - 2 ( Sheet 14) To SP10 - 9 ( Sheet 3) 1851
610A 3 5
601JZ
P107 15
1850
To P020 - 8 ( Sheet 14)
P106 16
To SP67 - 3 ( Sheet 14) To P056 - 15 ( Sheet 6)
610B SP65
1805 1805
P107 16
872C
P106 17
To SP67 - 4 ( Sheet 14)
610C
To P020 - 62 ( Sheet 15) P107 17
874F
P106 18
P107 18
1851
To SP72 - 3 ( Sheet 14)
P034
P106 19 P109 St abiliser I solat ion Swit ch.
Park Brake Swit ch.
P107 19
1853 To P020 - 16 ( Sheet 14)
829AX 8 7 601DZ To SP33 - 3 ( Sheet 5)
P106 20 P109 2
815D 2 P107 20
815H
3 601BC
P109 3 1855 To P020 - 43 ( Sheet 14) 908A 1 2
908
1
815
P106 21
810J To SP24 - 4 ( Sheet 4) P107 21 To P004 - 14 ( Sheet 4)
P109 1
P101
P106 22 To P020 - 52 ( Sheet 14)
610 Boom Raise Relay P107 22
610D
To SP67 - 5 ( Sheet 14)
4 600 BJ
P106 23 1
2
P107 23
515
To P020 - 61 ( Sheet 15)
B P106 24 To P108 - 1 ( Sheet 15)
To P020 - 5 ( Sheet 14) B
511 P107 24 815A
3 5 600BL
P106 25 To P020 - 56 ( Sheet 15)

560 P107 25
600BK 509
P106 26
559
600BM
P107 26
512
To P108 - 2 ( Sheet 15)
P106 27
To P056 - 17 ( Sheet 6) P101 To SP25 - 4 ( Sheet 5)
1802 P107 27
871C
Sway / St ab I so' Relay
P106 28 9 603D P107 28
873
To P041 - 5 ( Sheet 5)
6
7
P106 29
P107 29
To P020 - 51 ( Sheet 14)
510A
8 10
600BP
P106 30 SP68
P107 30
To SP73 - 3 ( Sheet 14)
481B
P106 31
P107 31
To P020 - 15 ( Sheet 14)
1852
P106 32
815B
P107 32
To P020 - 42 ( Sheet 14)
1854
P106 33
To SP70 - 3 ( Sheet 16)
CAN L
600BS P107 33
To P020 - 69 ( Sheet 5)
To SP10 - 10 ( Sheet 3) 480
P106 34
CAN H
To SP69 - 3 ( Sheet 16)
P107 34
To P066 - 2 ( Sheet 8)
817C
P106 35
650A
P107 35
817A To P066 - 1 ( Sheet 8)
A A
332/F0906-2
1 2 3 4 5 6
33 - 125 9823/1700-1 33 - 125

Page Page
33-126 33-127
Figure 1088. (Part

1 1 of 2) 2 3
P106 P107
D
RAS CONTROLLER J1
P106 1
To P020 - 65 ( Sheet 15)
505
P106 2 SP66
212A 212
To P004 - 6 ( Sheet 4)
P106 3
212B
P106 4
212C
P106 5
212D
P106 6
212E
P106 7
To P020 - 55 ( Sheet 15)
P106 8
To P020 - 67 ( Sheet 15)
506
P105
P106 9
To SP64 - 3 ( Sheet 5) RAS Relay Right
808B
9
P106 10
809B
To SP63 - 3 ( Sheet 5) 614 6
7
C P106 11
900
To P001 - 6 ( Sheet 1) 1805B 8 10 610JX To SP10 - 11 ( Sheet 3)
P106 12
614A
To P020 - 59 ( Sheet 15) P105

P106 13
508 RAS Relay Left
4
P106 14
To P020 - 68 ( Sheet 5) 615 1
610 2
P106 15
610A 3 5
601JZ
P106 16
To SP67 - 3 ( Sheet 14) To P056 - 15 ( Sheet 6)
610B SP65
1805 1805
To SP67 - 4 ( Sheet 14)
Page 33-127
P106 17
610C
To P020 - 62 ( Sheet 15)
P106 18
P106 19 P109
Park Brake Swit ch.
P106 20 P109 2
815D 815H 2
P109 3
3 601BC
1
815
P106 21
810J To SP24 - 4 ( Sheet 4)
P109 1
P101
P106 22 To P020 - 52 ( Sheet 14)
610 Boom Raise Relay
4 600 BJ
P106 23 1
2
B P106 24 To P108 - 1 ( Sheet 15)

To P020 - 5 ( Sheet 14)
511
3 5 600BL
P106 25
560
600BK
P106 26
559
600BM
P106 27
To P056 - 17 ( Sheet 6) P101
1802
Sway / St ab I so' Relay
P106 28 9 603D
6
7
P106 29
8 10
600BP
P106 30
P106 31
P106 32
815B
P106 33
To SP70 - 3 ( Sheet 16)
CAN L
600BS
To SP10 - 10 ( Sheet 3)
P106 34
CAN H
To SP69 - 3 ( Sheet 16)
P106 35
650A
1 2 3
33 - 126 9823/1700-1 33 - 126

Page Page
33-126 33-127
Figure 1088. (Part4 2 of 2) 5 6
P107 D
RAS CONTROLLER J2
P107 1
To P018 - 10 ( Sheet 5)
815
P107 2
To P020 - 49 ( Sheet 15)
510
P107 3
To P108 - 3 ( Sheet 15)
513
P107 4
To P020 - 10 ( Sheet 14)
1870 C029
St ab I solat ion Valve
P107 5 P020 C007. 6 C007. P020 36
910 910 1 2 603D
P107 6
To P020 - 4 ( Sheet 14)
903
To P020 - 55 ( Sheet 15) P107 7

To P020 - 3 ( Sheet 14)
902
P107 8
To P020 - 2 ( Sheet 14)
901
P107 9
P107 10
817
To P017 - 3 ( Sheet 8) C
To SP10 - 11 ( Sheet 3)
P107 11
817B
To P066 - 3 ( Sheet 8)
P107 12
514
To P020 - 54 ( Sheet 15)
P107 13
To P020 - 66 ( Sheet 15)
507
P107 14
1851
To P020 - 9 ( Sheet 14)
P107 15
1850
To P020 - 8 ( Sheet 14)
P107 16
872C
Page 33-126
To P020 - 62 ( Sheet 15) P107 17

874F
P107 18
1851
To SP72 - 3 ( Sheet 14)
P034
St abiliser I solat ion Swit ch.
P107 19
1853 To P020 - 16 ( Sheet 14)
829AX 8 7 601DZ To SP33 - 3 ( Sheet 5)
P107 20 To P020 - 43 ( Sheet 14)
1855 908A 1 2
908
P107 21 To P004 - 14 ( Sheet 4)
Boom Raise Relay P107 22

610D
To SP67 - 5 ( Sheet 14)
600 BJ
P107 23
515
To P020 - 61 ( Sheet 15)
To P020 - 5 ( Sheet 14) B
P107 24 815A
600BL
P107 25 To P020 - 56 ( Sheet 15)

600BK 509
600BM
P107 26
512
To P108 - 2 ( Sheet 15)
P107 27
871C
way / St ab I so' Relay
603D P107 28
873
To P041 - 5 ( Sheet 5)
P107 29
To P020 - 51 ( Sheet 14)
510A
600BP
SP68
P107 30
To SP73 - 3 ( Sheet 14)
481B
P107 31
To P020 - 15 ( Sheet 14)
1852
P107 32
To P020 - 42 ( Sheet 14)
1854
600BS P107 33
To P020 - 69 ( Sheet 5)
480
P107 34
To P066 - 2 ( Sheet 8)
817C
P107 35
817A To P066 - 1 ( Sheet 8)
A
332/F0906-2
4 5 6
33 - 127 9823/1700-1 33 - 127

33 - 128 9823/1700-1 33 - 128

Page 33-130 Figure 1089. Stabiliser, Transducers and Proxy

Switches - 332/F0906 Issue 2 (Sheet 14 of 16) Page 33-131
1 2 3 4 5 6
RLOO1
D R/ H STAB TRANS D
1 4
606B
2 3
110B
RL005 C002 5 P020 C007. 52

To P106 - 22 ( Sheet 13)
581 581 581
RL005 C002 3 P020 C007. 45 SP73

481 481 481
RL005 C002 6
606 606A
SRL3
RL005 C002 1 P020 C007. 32

110 110
SRL4
RL005 C002 4 P020 C007. 51

To P107 - 29 ( Sheet 13)
510 510 510
RL005 C002 2 P020 C007. 44 SP72

410 410 410
RL002
L/ H STAB TRANS
2 4
110A
606A 1 3
C C009
C
45 Degree Proxy
SC12 C007. P020 1 SP67
3 4
605A 605D 605 615
To P039 - 6 ( Sheet 5)
C007. P020 2
2 1 901 901
To P107 - 8 ( Sheet 13)
1850 C007. P020 8
1850
To P107 - 15 ( Sheet 13)
C007. P020 9
1851 1851
To P107 - 14 ( Sheet 13)
C019
60 Degree Proxy
3 4
605B
C007. P020 3
2 1
902 902
To P107 - 7 ( Sheet 13)
C007. P020 16
1853 1853
To P107 - 19 ( Sheet 13)
C007. P020 15
1852 1852
To P107 - 31 ( Sheet 13)
C023
Boom Ext end Proxy
B 3 4 605C B
C007. P020 4
2 1 903 903
To P107 - 6 ( Sheet 13)
C007. P020 43
1855 1855
To P107 - 20 ( Sheet 13)
C007. P020 42
1854 1854
To P107 - 32 ( Sheet 13)
C024
Lift I solat ion
Solenoid
P020 C007. 10 C007. P020 5
1870 1870 1 2 600BJ
To P107 - 4 ( Sheet 13)
To P101- 4 ( Sheet 13)

600BJ
A A
332/F0906-2
1 2 3 4 5 6
33 - 129 9823/1700-1 33 - 129

Page Page
33-130 33-131
Figure 1089. (Part

1 1 of 2) 2 3
RLOO1
D R/ H STAB TRANS
1 4
606B
2 3
110B
RL005 C002 5 P020 C007. 52

581 581
RL005 C002 3 P020 C007. 45

481 481
RL005 C002 6
606 606A
SRL3
RL005 C002 1 P020 C007. 32

110 110
SRL4
RL005 C002 4 P020 C007. 51

510 510
RL005 C002 2 P020 C007. 44

410 410
RL002
L/ H STAB TRANS
2 4
110A
606A 1 3
C C009
45 Degree Proxy
3 4 SC12 605D
605A
2 1 901
1850
1851
C019
60 Degree Proxy
Page 33-131
3 4
605B
2 1
902
1853
1852
C023
Boom Ext end Proxy
B 3 4 605C
2 1 903
1855
1854
P020 C007. 10
1870
To P107 - 4 ( Sheet 13)
To P101- 4 ( Sheet 13)
1 2 3
33 - 130 9823/1700-1 33 - 130

Page Page
33-130 33-131
Figure 1089. (Part4 2 of 2) 5 6
P020 C007. 52
To P106 - 22 ( Sheet 13)
581
P020 C007. 45 SP73

481
P020 C007. 32
P020 C007. 51
To P107 - 29 ( Sheet 13)
510
P020 C007. 44 SP72

410
C007. P020 1 SP67

605D 605 615
To P039 - 6 ( Sheet 5)
C007. P020 2
901
To P107 - 8 ( Sheet 13)
C007. P020 8
1850
To P107 - 15 ( Sheet 13)
C007. P020 9
1851
To P107 - 14 ( Sheet 13)
Page 33-130
C007. P020 3
902
To P107 - 7 ( Sheet 13)
C007. P020 16
1853
To P107 - 19 ( Sheet 13)
C007. P020 15
1852
To P107 - 31 ( Sheet 13)
B
C007. P020 4
903
To P107 - 6 ( Sheet 13)
C007. P020 43
1855
To P107 - 20 ( Sheet 13)
C007. P020 42
1854
To P107 - 32 ( Sheet 13)
C024
Lift I solat ion
Solenoid
P020 C007. 10 C007. P020 5
1870 1 2 600BJ
600BJ
A
332/F0906-2
4 5 6
33 - 131 9823/1700-1 33 - 131

33 - 132 9823/1700-1 33 - 132

Page 33-134 Figure 1090. RAS Chassis/Panel -

332/F0906 Issue 2 (Sheet 15 of 16) Page 33-135
1 2 3 4 5 6
D D
C020
Right Ras Cylinder
C020 1 514 1
C020 2 614
2
PANEL TO CHASSI S. C025

Sway Swit ch
1
505
2
506
C007. P020 65 C025 1
505 505
To P106 - 1 ( Sheet 13) 507 3
C007. P020 67 C025 2

506 506
To P106 - 8 ( Sheet 13)
C 507
C007. P020 66
507
C025 3 C
To P107 - 13 ( Sheet 13)
C007. P020 59 C027 1
508 508
To P106 - 13 ( Sheet 13)
C007. P020 56 C027 2
509 509
To P107 - 25 ( Sheet 13)
C007. P020 49 510 C027 3
510
To P107 - 2 ( Sheet 13)
514
C007. P020 54
514
C027
To P107 - 12 ( Sheet 13) Left St ab Swit ch
C007. P020 62 508 1
515 515
To P105 - 1 ( Sheet 13) 509 2
C007. P020 55
614 614 3
To P105 - 6 ( Sheet 13) 510
C007. P020 61 615
615
To P107 - 23 ( sheet 13)
C021
Left Ras Cylinder
C021 2
515 2
C021 1
615
1
B B
C026
Right St ab Swit ch
P108 C030 1 C026 1
511 511 511 1
To P106 - 24 ( Sheet 13)
P108 C030 2 C026 2
512 512 512 2
To P107 - 26 ( Sheet 13)

P108 C030 3 C026 3
513 513 513 3
To P107 - 3 ( Sheet 13)
A A
332/F0906-2
1 2 3 4 5 6
33 - 133 9823/1700-1 33 - 133

Page Page
33-134 33-135
Figure 1090. (Part

1 1 of 2) 2 3
PANEL TO CHASSI S.
C007. P020 65
505 505
To P106 - 1 ( Sheet 13)
C007. P020 67
506 506
To P106 - 8 ( Sheet 13)
C 507
C007. P020 66
507
To P107 - 13 ( Sheet 13)
C007. P020 59
508 508
To P106 - 13 ( Sheet 13)
C007. P020 56
509 509
To P107 - 25 ( Sheet 13)
C007. P020 49 510
510
To P107 - 2 ( Sheet 13)
C007. P020 54
514 514
To P107 - 12 ( Sheet 13)
C007. P020 62
515 515
To P105 - 1 ( Sheet 13)
C007. P020 55
614 614
To P105 - 6 ( Sheet 13)
Page 33-135
C007. P020 61 615
615
To P107 - 23 ( sheet 13)
P108 C030 1
511 511
To P106 - 24 ( Sheet 13)
P108 C030 2
512 512
To P107 - 26 ( Sheet 13)
P108 C030 3
513 513
To P107 - 3 ( Sheet 13)
1 2 3
33 - 134 9823/1700-1 33 - 134

Page Page
33-134 33-135
Figure 1090. (Part4 2 of 2) 5 6
C020
Right Ras Cylinder
C020 1 514 1
C020 2 614
2
C025
Sway Swit ch
1
505
2
506
C025 1
3
507
C025 2
C025 3 C
C027 1
C027 2
C027 3
C027
Left St ab Swit ch
1
508
2
509
3
510
Page 33-134
C021
Left Ras Cylinder
C021 2
515 2
C021 1
615
1
C026
Right St ab Swit ch
C026 1
511 511 1
C026 2
512 512 2
C026 3
513 513 3
A
332/F0906-2
4 5 6
33 - 135 9823/1700-1 33 - 135

33 - 136 9823/1700-1 33 - 136

Page 33-138 Figure 1091. Splices and Resistors

1 2 3 4 5 6
D D
SP53 To P092 - B ( Sheet 16)
CAN L
To P106 - 33 ( Sheet 13)

SP70 CAN L
440
To SP10 - 5 SP56 To P091 - B ( Sheet 16)

60 1G
P046
W Diagnost ic Socket CAN LO
A D
B C
C To SP32 - 3 30 1H
CAN HI GH
To P091 - A ( Sheet 16)
C
SP55
To P106 - 34 ( Sheet 13)

CAN H
SP69
SP52
CAN H
B 439
P091 A P092 A 441 SP71 B
P092.
P091.1
1 SCR
SP57 P092 C SP54
P091 C 426
SCR
SCREEN SCR
2 2
P091 B
120.00 Ohm s 120.00 Ohm s P092 B
To SP53 - 2
442
To P055 - 15 ( Sheet 6)
A 332/F0906-2
A
1 2 3 4 5 6
33 - 137 9823/1700-1 33 - 137

Page Page
33-138 33-139
Figure 1091. (Part

1 1 of 2) 2 3
440
To SP10 - 5
601
P046
GW Diagnost ic Socket
A D
B C
C To SP32 - 3 301
H
Page 33-139
B 439
P091 A
P092.
P091. 1
1
SP57
P091 C
SCR
2 2
120.00 Ohm s 120.00 Ohm s
P091 B
1 2 3
33 - 138 9823/1700-1 33 - 138

Page Page
33-138 33-139
Figure 1091. (Part4 2 of 2) 5 6
SP53 To P092 - B ( Sheet 16)
CAN L
To P106 - 33 ( Sheet 13)

SP70 CAN L
SP56 To P091 - B ( Sheet 16)

P046
Diagnost ic Socket CAN LO
CAN HI GH
To P091 - A ( Sheet 16)
C
SP55
To P106 - 34 ( Sheet 13)

CAN H
SP69
Page 33-138
SP52
CAN H
nt Term inat or P092
P092 A 441 SP71 B

SCR
P092 C SP54
426
SCREEN SCR
P092 B
To SP53 - 2
442
To P055 - 15 ( Sheet 6)
332/F0906-2
A
4 5 6
33 - 139 9823/1700-1 33 - 139

90 - Earth Point
90 - Earth Point Introduction

Introduction .................................................. 33-140 The ground or earth refers to the reference point in an
Component Identification ............................. 33-141 electrical circuit from which voltages are measured,
a common return path for electrical current, or a
direct physical connection to earth. Electrical circuits
may be connected to ground or earth to prevent
user contact with dangerous voltage if the electrical
insulation fails.
Earth points can be useful when tracing electrical

faults typically when several electrical devices are
malfunctioning.
33 - 140 9823/1700-1 33 - 140

90 - Earth Point
Figure 1092.
D C
Table 444. Cables and straps

Item Description Location
A Earth cable, battery to chassis. Under cab, and battery compart-
ment
B Earth strap, cab to chassis. Inside the external lower front pan-
el of the cab.
33 - 141 9823/1700-1 33 - 141

90 - Earth Point
Item Description Location

C Earth cable, starter motor to chas- Inside engine compartment.
sis.
D Earth cable, engine block to chas- Inside engine compartment, cable
sis. bolted to engine at the rear of the
cylinder block.
Table 445. Harness earths

Item Wire number Description Location
E -001 Earth point, chassis har- Inside engine compart-
ness. ment.
F -003 Earth point, cab harness. Inside the cab instrument
-004 panels. Access required
to the cab frame on the
right side of the steering
column.
G -006 Earth point, cab rear har- Inside the cab roof lining
ness.
33 - 142 9823/1700-1 33 - 142

03 - Battery
03 - Battery
Contents Page No.
33-03-00 General ......................................................................................................................... 33-145

33-03-03 Isolator Switch .............................................................................................................. 33-158
33 - 143 9823/1700-1 33 - 143

Notes:
33 - 144 9823/1700-1 33 - 144

03 - Battery
00 - General
Introduction .................................................. 33-145 Batteries used in normal temperate climate
Health and Safety ........................................ 33-146 applications should not need topping up. However,
Technical Data ............................................. 33-147 in certain conditions (such as prolonged operation
Operation ..................................................... 33-148 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Diagram ....................................................... 33-150 frequently and topped up as necessary.
Fault-Finding ................................................ 33-151
Disconnect and Connect ............................. 33-152 The electrolyte level should be checked in
Check (Condition) ........................................ 33-155 accordance with the routine maintenance schedule.
Shorter maintenance intervals are required if the
Charge ......................................................... 33-156 machine is operating at high ambient temperatures
Remove and Install ..................................... 33-157 or continuously for long periods.
Later Machines may have the new type batteries

installed which include a sight glass to check the
condition of the battery. New batteries should be
used as replacements if replacing the battery on
earlier machines.
Figure 1093.
A Maintenance free battery
Maintenance
To make sure that the battery provides optimum
performance the following steps should be observed:
• Make sure that the electrical connections are

clean and tight. Smear petroleum jelly on
connectors to prevent corrosion.
• When applicable - never allow the electrolyte
level to fall below the recommended level of 6
mm above the plates. Use only distilled water
for topping up.
• Keep the battery at least three quarters
charged, otherwise the plates may become
sulphated (hardened) - this condition makes
recharging the battery very difficult.
Extra precautions must be taken when bench

charging maintenance free batteries, they are more
prone to damage by overcharging than the standard
type of battery:
• Never boost charge a maintenance free battery

(if installed).
33 - 145 9823/1700-1 33 - 145

03 - Battery
00 - General
• Never charge a battery at a voltage in excess Health and Safety

of 15.8 V.
• Never continue to charge a battery after it DANGER Batteries give off an explosive gas.
begins to gas. Do not smoke when handling or working on the
battery. Keep the battery away from sparks and
Quiescent Current Drain flames.
Battery electrolyte contains sulphuric acid. It can
If the machine has no permanently live circuits there burn you if it touches your skin or eyes. Wear
should be zero quiescent current drain, when the goggles. Handle the battery carefully to prevent
key-switch is off and all the lights are switched off. spillage. Keep metallic items (watches, rings, zips
etc) away from the battery terminals. Such items
It should be noted that some permanently live circuits could short the terminals and burn you.
will place a quiescent drain on the battery. Typically
the quiescent drain will be in the range of 10–20 Set all switches to off before disconnecting and
mA. If the quiescent drain measures 40 mA or more, connecting the battery. When disconnecting the
there is a problem with the wiring insulation or the battery, take off the earth (-) lead first.
accessories, if the fault is not rectified it will continue Re-charge the battery away from the machine,
to drain the battery. in a well ventilated area. Switch the charging
circuit off before connecting or disconnecting the
battery. When you have installed the battery in the
machine, wait 5 min before connecting it up.
When reconnecting, attach the positive (+) lead
first.
WARNING Keep metal watch straps and any
metal fasteners on your clothes, clear of the
positive (+) battery terminal. Such items can short
between the terminal and nearby metal work. If it
happens you can get burned.
WARNING Battery electrolyte is toxic and
corrosive. Do not breathe the gases given off
by the battery. Keep the electrolyte away from
your clothes, skin, mouth and eyes. Wear safety
glasses.
WARNING Do not top the battery up with acid.
The electrolyte could boil out and burn you.
CAUTION Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION The machine is negatively earthed.
Always connect the negative pole of the battery
to earth.
When connecting the battery, connect the earth
(-) lead last.
When disconnecting the battery, disconnect the
earth (-) lead first.
DANGER If you try to charge a frozen battery, or
jump start and run the engine, the battery could
explode. Do not use a battery if its electrolyte
is frozen. To prevent the battery electrolyte from
freezing, keep the battery at full charge.
CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a
33 - 146 9823/1700-1 33 - 146

03 - Battery
00 - General
suitable closed receptacle and must be disposed Technical Data

of in accordance with local environmental waste
regulations.
Table 446.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to Voltage Cold Cranking Battery Type
protect the circuits and components. The battery Amps (CCA)
must still be disconnected even if a battery 12V 1000 1131XMF Main-
isolator is installed. tenance free
33 - 147 9823/1700-1 33 - 147

03 - Battery
00 - General
Operation
The positive terminal of the battery is connected to When the engine is running the FEAD (Front End
the machine primary fuses, the starter motor and Accessory Drive) drives the alternator. The power
alternator. generated keeps the battery charged which in turn
feeds all the electrical devices and systems.
The negative terminal of the battery is connected to
the chassis of the machine to provide an earth for the
electrical systems and devices.
Figure 1094.
C
E
A Alternator B FEAD
C Centre display panel D LMS (Loadall Monitoring System) display panel
33 - 148 9823/1700-1 33 - 148

03 - Battery
00 - General
E Battery
At the rear of the alternator there are three terminals.

• The W terminal supplies a signal to the LMS.

• The D+ terminal supplies a splice which
supplies power to the LMS ECU (Electronic
Control Unit) and the centre warning light panel.
If there is a charging fault this signal will operate
a warning light on the centre display panel.
• The B+ terminal returns the charge to the
battery through a common connection on the
starter motor relay switch terminal.
Figure 1095.
D+
B+
33 - 149 9823/1700-1 33 - 149

03 - Battery
00 - General
Diagram
Figure 1096.
Table 447.
Connector Key Description
+022 Battery connector A
+023 Battery connector B
A Alternator
B Battery
D+ Alternator terminal
W Alternator terminal
B+ Alternator terminal
2053 Starter motor
4012 LMS (Loadall Monitoring
System) display connec-
tor J1
6017 Centre display panel
9007 Primary fuse 1
9008 Primary fuse 2
33 - 150 9823/1700-1 33 - 150

03 - Battery
00 - General
Fault-Finding
The most obvious sign of a battery problem is a
machine not being able to start. However, because
the battery is part of a larger electrical system
connected to other parts of the machine, a flat battery
may indicate another problem.
If something else is going wrong in the electrical
system, for example, a weak alternator, corrosion or
loose connections, cold weather starting, electrical
equipment being left on without the engine running,
interrogate the cause of the problem.
The best way to test the condition of the battery is
with an electronic battery tester. Refer to Battery-
Check Condition.
When the machine is not in use, make sure that the
electrical system is not causing a drain on the battery.
On machines with electronically controlled engines
check the operation of the power hold relay. Refer to
PIL 33-09-06.
33 - 151 9823/1700-1 33 - 151

03 - Battery
00 - General
Disconnect and Connect
Notice: Before you install a pair of batteries to Figure 1097. Parallel and
a machine, make sure you know the machines Series Connection (Example)
voltage. Some machines require two batteries but
have a 12 V electrical system. This means the
batteries need to be connected in parallel.
For 24 V machines, the batteries must be
_ _
connected in series. Incorrect voltage may result
in serious damage to the electrical system. + +
A
C
C
The illustrations show typical battery connections.
The actual battery connections installed on your
machine may look different. _ + _ +
Make sure you connect the batteries correctly for
your machine.
Disconnect 12 V 24 V
1. Make the machine safe. D B D B
Refer to: PIL 01-03-27. Figure 1098. Twin Battery 12V Ma-
chines- Parallel Connection (Example)
2. Get access to the battery or batteries (depending
on the specification of your machine). The actual B
installation on your machine may vary from those
shown below.
3. If the machine has a battery isolator, move the
switch to the OFF position, then remove the key. C
4. Disconnect the battery negative lead first.
5. Disconnect the battery positive lead and store
away from the batteries.
A
A D
6. Disconnect and remove the battery link lead or
leads.
A Battery
B Positive lead
C Battery link lead
D Negative lead
33 - 152 9823/1700-1 33 - 152

03 - Battery
00 - General
Figure 1099. 24 Volt Machines- Series Connection (Example)

C
_ _ + +
A Battery B Positive lead

C Battery link lead D Negative lead
33 - 153 9823/1700-1 33 - 153

03 - Battery
00 - General
Connect
1. Check the battery as follows:
1.1. If any terminals are dirty, clean them.
1.2. If the terminal is corroded and has white
powder, wash the terminal with hot water.
Make sure the water does not enter the
battery cells.
1.3. If considerable corrosion is found, then
clean with a wire brush or abrasive
paper. Make sure you use eye and hand
protection. Refer to Figure 1100.
Figure 1100.
1.4. After cleaning, apply a thin coat of

petroleum jelly to the terminals.
2. Connect the leads.
2.1. For single battery machines, connect the
positive lead then the negative lead.
2.2. For twin battery machines, first connect the
link lead or leads, then the positive terminal,
and finally the negative terminal.
3. If the machine has a battery isolator, move the
switch to the ON position.
4. Close and lock the access panels.
33 - 154 9823/1700-1 33 - 154

03 - Battery
00 - General
Check (Condition) Table 448. Fault Diagnosis

Battery Tester Read- Remedy
ings
Battery Test CHECK: 0 -12.6 Volts: Renew battery
LOAD: less than 6 Volts
This test is to determine the electrical condition of
the battery and to give an indication of the remaining CHECK: 6 -12.4 Volts: Recharge and re-test. If
useful life. LOAD: less than 9 Volts tests are still unsatisfac-
and falls steadily but re- tory renew battery
Before you test the battery, make sure that the mains in yellow zone
battery is at least 75% charged (Specific Gravity of CHECK: less than 10 Indicates battery has
1.23 to 1.25 for ambient temperature up to 27°C). Volts: LOAD: less than 3 been over-discharged
Volts and unlikely to recover.
Make sure that the battery is completely Renew battery
disconnected from the vehicle. CHECK: more than 11 Charge battery which
Volts: LOAD: 6 - 10 Volts will probably recover
Figure 1101. steady
Specific Gravity Test

The specific gravity of the electrolyte gives an idea
of the state of charge of the battery. Readings
should be taken using a hydrometer, when the
electrolyte temperature is 15°C (60°F). If the battery
has recently been on charge, wait approximately one
hour (or slightly discharge the battery) to dissipate
the surface charge before testing.
Readings should be as tabulated and should not vary

between cells by more than 0.04. A greater variation
indicates an internal fault on that particular cell.
If the electrolyte temperature is other than 15°C

(60°F) a 'correction factor' must be applied to the
reading obtained. Add 0.07 per 10°C (18°F) if the
A Battery voltage switch temperature is higher than 15°C (60°F) and subtract
B Check load switch the same if the temperature is lower.
Connect up the battery tester as follows: Table 449. Specific Gravity at 15°C (60°F))
1. Set the Check Load switch to OFF. Ambient Fully Half Dis- Fully Dis-
Temper- Charged charged charged
2. Set the battery voltage switch to 12V. ature de-
grees C
3. Connect the red flying lead to the battery positive (degrees
(+) terminal and the black flying lead to the F)
battery negative (-) terminal.
Below 27 1.270-1.290 1.190-1.210 1.110-1.130
4. Set the Check/Load switch to CHECK to read the ( 80 )
battery no-load voltage which should be at least Above 27 1.240-1.260 1.170-1.190 1.090-1.110
12.4 volts. ( 80 )
5. Set the Check/Load switch to LOAD and hold

down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
6. If the tests are unsatisfactory, refer to the fault
diagnosis table.
33 - 155 9823/1700-1 33 - 155

03 - Battery
00 - General
Charge
Precautions Before Charging

Follow all the precautions described below, to
prevent damage to the alternator and battery.

2. Make sure that the battery negative terminal is
connected to the earth cable.
3. Do not connect or disconnect the battery
or alternator connections, or any part of the
charging circuit while the engine is in operation.
If you disregard this instruction, the regulator or
rectifying diodes will be damaged.
4. Main output cables are always in an active state
of current flow even when the engine is not in
operation. If the alternator connector is removed,
do not earth the moulded plug.
5. When you do arc welding on the machine,
remove the moulded plug (or if the separate
output cables are installed, remove the cables)
to protect the alternator.
6. If it is necessary to jump start the battery, do the
following steps.
6.1. Connect a secondary battery in parallel
without disconnecting the vehicle battery
from the charging circuit.
6.2. Connect the batteries using suitable jump
leads. Connect the positive lead to the
positive terminals of both batteries. Connect
the negative lead to the negative terminals
of both batteries.
6.3. After the jump start, safely disconnect the
jump leads and remove the secondary
battery.
33 - 156 9823/1700-1 33 - 156

03 - Battery
00 - General
Remove and Install
CAUTION This component is heavy. It must only 4. Disconnect the battery. Refer to (PIL 33-03).
method and device. 5. Make sure that all battery connection wires are
clear of battery top cover.
Remove 6. Remove the wing nuts and disconnect the battery

clamp.
7. Lift the clamp clear of the battery.
2. Follow the hydraulic care and safety procedures.
Refer to (PIL 33-00). 8. Remove the battery from the compartment and
make sure that you do not use the access cover
3. Get access to the battery. Refer to (PIL to support the weight of the battery.
06-06-03).
Figure 1102.
A
B
A Battery B Wing nuts

C Battery clamp
Install
removal procedure.
33 - 157 9823/1700-1 33 - 157

03 - Battery
03 - Isolator Switch
03 - Isolator Switch Introduction

Introduction .................................................. 33-158 The battery isolator switch is used to disconnect the
Disconnect and Connect ............................. 33-159 battery from the machine electrics. The switch must
be turned to the OFF position if any maintenance
work is to be performed on the machine.
Some machine systems perform shut down cycles

after the engine stops. Wait until shut down cycles
are complete before setting the battery isolator
switch to the OFF position. For more information
refer to Disconnect and Connect. Refer to: PIL
33-03-00.
33 - 158 9823/1700-1 33 - 158

03 - Battery
03 - Isolator Switch
Disconnect and Connect
Disconnect
If the machine has an electronically controlled
engine, you must wait a period of time before you
isolate the battery. This is to allow the ECM (Engine
Control Module) to shutdown correctly. The time
period starts when you turn the ignition off. Check the
isolator switch label and the operators manual for the
correct time period.
In the event of an emergency, if required, remove the

isolator key without waiting.
If a radio is installed, you may lose any settings.

2. Turn the ignition key to the off position.
3. Wait for the engine ECM to shutdown correctly (if
applicable).
4. Get access to the isolator key.
5. Turn the battery isolator key in the indicated
direction and remove.
Connect
1. Make sure the ignition is set to off.
2. Insert the battery isolator key and turn in the
indicated direction.
33 - 159 9823/1700-1 33 - 159

06 - Battery Cable
06 - Battery Cable
Contents Page No.
33-06-00 General ......................................................................................................................... 33-161
33 - 160 9823/1700-1 33 - 160

06 - Battery Cable
00 - General
00 - General
Introduction
The cables connect the battery positive and negative

terminals to the machine electrical system.
33 - 161 9823/1700-1 33 - 161

09 - Power Distribution
Contents Page No.
33-09-00 General ......................................................................................................................... 33-163

33-09-03 Fuse ............................................................................................................................. 33-165
33-09-06 Relay ............................................................................................................................ 33-168
33 - 162 9823/1700-1 33 - 162

00 - General
Introduction .................................................. 33-163 The electrical circuits are protected by fuses. If a
Health and Safety ........................................ 33-164 fuse blows, find out why and rectify the fault before
installing a new one.
A full up to date list of fuses and relays and their

locations can be found in the relevant operator
manual, maintenance section.
33 - 163 9823/1700-1 33 - 163

00 - General
Health and Safety

Notice: Always replace fuses with ones of correct
ampere rating to avoid electrical system damage.
Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
33 - 164 9823/1700-1 33 - 164

03 - Fuse
03 - Fuse Figure 1104.
Technical Data 1 10A 11 20A
2 10A 12 15A
Fusebox
3 10A 13 3A
Access the fuses as follows.
4 10A 14 15A
5 30A 15 20A
6 10A 16 7.5A
2. Obey all electrical system health and safety
information. 7 3A 17 5A
8 7.5A 18 15A
3. Open the operator station door.
9 10A 19 10A
4. Hold the cover and remove the screws (x2).
10 10A 20 5A
5. Remove the cover.
Figure 1103. 21 3A 31 30A
22 10A 32 10A
23 5A 33 25A
A
24 20A 34 20A
25 10A 35 25A
26 10A 36 15A
27 25A 37 10A
28 7.5A 38 20A
29 10A 39 10A
30 20A 40 5A
B Table 450.
Fuse Number Circuit De- Rating
scription
Fuse Box A - 9001
1 Sway hy- 10 A
draulics
2 Hydraulic Isola- 10 A
A Fuses tion
B Cover 3 RAS (Rear Axle 10 A
Stabilization) (if
6. Make a note that the additional fuse links are installed)
installed at the battery positive terminal and
inside the engine compartment cover. 4 Stabiliser trans- 10 A
ducer supply (if
installed)
5 Heater 30 A
6 Turn signals 10 A
7 Spare 3A
33 - 165 9823/1700-1 33 - 165

03 - Fuse
Fuse Number Circuit De- Rating Link Fusebox

scription
8 Instruments 7.5 A Access the link fuses as follows.
9 Steer mode se- 10 A 1. Make the machine safe with the lift arm lowered.
lector
10 Reversing 10 A Refer to: PIL 01-03-27.
alarm/lights 2. Obey all electrical system health and safety
Fuse Box B - 9002 information.
11 Rear/roof wiper 30 A Refer to: PIL 33-00-00.
12 Front wiper 15 A
13 Fog light 3A 3. Open the battery compartment cover.
14 Dipped beam 15 A Refer to: PIL 06-06-03.
15 High beam 20 A
Figure 1105.
16 Left hand side- 7.5 A
lights
17 Right hand 5A
sidelights
18 Cell phone/cig- 15 A
arette lighter
19 Spare 10 A
20 Spare 5A
Fuse Box C - 9003
21 Starter relay 3A
22 ESOS (Engine 10 A
Shut-Off Sole- A
noid)
23 Transmission 5A 5
24 Transmission 20 A
6
dump
25 Brake lights 10 A 1
26 Parking lights 10 A 2
27 Headlight flash- 25 A 3 4
er, horn
28 Beacon 7.5 A A Battery Compartment cover
29 Interior light, ra- 10 A
dio
30 Four-way flash- 20 A
ers
Fuse Box D - 9004
31 Neutral start 30 A
32 Cold start 10 A
33 Boom worklight 25 A
34 Roadlights 20 A
35 Front worklight 25 A
36 Rear worklight 15 A
37 Stabiliser isola- 10 A
tion (if installed)
38 Heated seat, 20 A
Face fan
39 Radio 10 A
40 Spare 5A
33 - 166 9823/1700-1 33 - 166

03 - Fuse
Figure 1106.
Table 451.
Fuse Number Circuit De- Rating
scription
1 Horn, Side- 50 A
lights, 4-way
flashers, Bea-
con, Interior
light
2 Road lights, 80 A
Working lights,
Boom light
3 Sway, Auxiliary, 60 A
Heater
4 SRS (Smooth 70 A
Ride System)5,
Starting circuit,
Transmission,
Brake lights
6 Heater, Wipers, 60 A
Radio, Instru-
ments
7 Seat, Electric 60 A
mirrors, Heated
glass
8 Cold start grid 150 A
heater (if in-
stalled)
33 - 167 9823/1700-1 33 - 167

06 - Relay
06 - Relay Figure 1108.
Technical Data A B C D E
Access the fuses as follows.
1. Make the machine safe with the lift arm lowered. 2

2. Obey all electrical system health and safety 3
information.
Refer to: PIL 33-00-00. 4
3. Open the operator station door.
5
4. Hold the cover and remove the screws (x2).
5. Remove the cover. 6
Figure 1107.
7
8
A
Table 452.
Relay No. Connector Circuit de-
scription
A1 2050 Neutral start
A2 2028 Park brake
A3 2023 Ignition 3
A4 2030 Rear worklight
A5 Blank
A6 2052 RAS (Rear Axle
Stabilization)
solenoid return
B
isolation con-
trol (Right) (if in-
stalled)
A7 2029 Park brake
lamp
A8 2033 Roadlights
B1 2026 Neutral start
A Fuses B2 2012 Engine running
B Cover B3 2024 Ignition 4
6. Make a note that the additional fuse links are B4 2019 Front worklight
installed at the battery positive terminal and B5 2WD (Two
inside the engine compartment cover. Wheel Drive)
Brake
B6 2051 RAS solenoid
return isolation
control (Left) (if
installed)
B7 2048 Transmission
dump
33 - 168 9823/1700-1 33 - 168

06 - Relay
Relay No. Connector Circuit de-

scription
B8 2005 Brake lights
C1 2021 Ignition 1
C2 2032 Reverse
C3 2008 Drive
C4 2017 Forward high/
low
C5 2054 Sway / Stabilis-
er isolation (if
installed)
D1 2018 Forward
D2 2022 Ignition 2
D3 2009 Driveshaft
D4 2031 Reverse high/
low
D5 2053 Lift isolation (if
installed)
E1 2013 Flasher unit
33 - 169 9823/1700-1 33 - 169

12 - Harness
12 - Harness
Contents Page No.
33-12-00 General ......................................................................................................................... 33-171

33-12-04 Chassis ......................................................................................................................... 33-189
33-12-06 Lift Arm ......................................................................................................................... 33-206
33-12-09 Engine .......................................................................................................................... 33-211
33-12-12 Operator Station ........................................................................................................... 33-220
33-12-15 Front Console ............................................................................................................... 33-225
33-12-30 Gearbox ........................................................................................................................ 33-322
33-12-34 Trailer ........................................................................................................................... 33-343
33-12-36 Work Lights .................................................................................................................. 33-345
33-12-39 Road Lights .................................................................................................................. 33-346
33-12-53 Stabiliser ....................................................................................................................... 33-351
33-12-56 Extreme Cold Climate Heater ...................................................................................... 33-365
33 - 170 9823/1700-1 33 - 170

12 - Harness
00 - General
Introduction .................................................. 33-171
Harness Drawings
Component Identification ............................. 33-173 Drawings are reproduced from production electrical
Operation ..................................................... 33-178 harness drawings. Each harness drawing includes
Repair .......................................................... 33-183 tables showing wire connections and destinations
for all the connectors on the harness. To identify
Check (Condition) ........................................ 33-185
the correct harness drawing for a particular machine
refer to the relevant Harness Interconnection page
for the machine serial number range.
33 - 171 9823/1700-1 33 - 171

12 - Harness
00 - General
Health and Safety

Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
Harness Repair (Butane Heater)

WARNING In addition to the warnings
incorporated into this procedure, extreme care
should be taken when handling the gas heating
tool to ensure that the flame does not damage or
set fire to any items in the vicinity of the repair,
i.e. other wires, floor panels, floor mats, sound
proofing, paintwork, etc. This tool should not be
used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas
or similar safety parameters apply. No other heat
source should be used to attempt a sealed joint.
CAUTION When the heater is in use, the reflector
and the air coming out are extremely hot. Keep
away to avoid accidental burns. Do not touch the
reflector until it has had time to cool down after
switching off. If flame reappears at the reflector
when the heater is in use, the catalytic element is
damaged or used up. Stop work immediately and
replace the heater.
33 - 172 9823/1700-1 33 - 172

12 - Harness
00 - General
Wire and Harness Number Identification

This section details the allocation of wire numbers
and the identification of wires in the wiring harness.
Figure 1109.
The illustration shows a typical connector and wires. it's length. The number stamped on the wire identifies
Each wire has an individual identification number the following:
permanently marked on it, at regular intervals along
Table 453. Wire and Harness Number Identification

Identification Number Description
# The # indicates the start of the identification num-
ber. It is always printed to the left of the identification
number.
B If applicable- The colour of the flying lead that the
harness wire should mate with. For instance, if wire
819 from harness 719/37100 mated with a flying lead
coloured black (colour code B) then the number print-
ed on the wire would be B-819 9/371.
819 The wire's unique identification number. The wire
functions and numbers allocated to them are consis-
tent through out the JCB range of products. Refer to
Wire Numbers and Functions.
9/371 If applicable- The part number of the harness that the
wire originates from. If the harness part number is
719/37100, the number printed on the harness wires
will be 9/371 (71 and 00 are common numbers and
therefore deleted).
Wire Numbers and Functions Table 455. Wires 200-399 (These

numbers are reserved for battery feeds)
Table 454. Wires 000-199 (These Wire Number Description
numbers are reserved for ignition feeds,
heater start circuits and start circuits) Wires 200 - 299 Unfused battery feeds
Wires 300 - 399 Fused battery feeds
Wire Number Description
Wires 000 - 099 Unfused ignition feeds
Wires 100 - 199 Fused ignition feeds
33 - 173 9823/1700-1 33 - 173

12 - Harness
00 - General
Table 456. Wires 400-599 Figure 1111.

Wires 400-599 These numbers are re-
served for instruments,
i.e. alternators to tachos,
temperature switches
to warning lights, etc.
and signal wires used in
electronic systems
Table 457. Wires 600-799

Wires 600-799 These numbers are
used for earth wires.
When the number is
printed on to a wire it General Points
is prefixed by the Earth
1. Wires continue to have the same number even
symbol. This symbol is
after passing through a connector block to
printed onto the wire, it
another harness.
may however be omitted
from harness drawings 2. If all the numbers in a category have been
allocated, then the category is re-used with an
additional prefix '1', i.e. 1832.
Figure 1110.
Electrical Connectors- RAS System
The RAS (Rear Axle Stabilization) system is not
600 installed on all Loadall machines.
The table shows the harness connectors that

connect to the electrical devices. The connectors
are shown looking at the mating face when
disconnected. Remember that the drawings show
Table 458. Wires 800-999 the harness connectors and not the device
Wire Number Description connectors.
Wires 800-999 These numbers are re- Use the table and the relevant electrical schematic
served for switched sup- to identify the pins in the harness connectors.
plies to electrical loads, Continuity checks on the harness wires can be
i.e. to lights, etc. carried out using a multimeter. Do not touch the ECU
(Electronic Control Unit) connector pins. Do not use
a multimeter on ECU connector pins.
Table 459. Wires In Splices
Various The main input wire is
allocated with a wire
number and a suitable
description, i.e. Wire 640
earth splice to earth.
The additional wires in
the splice are allocated
the same wire number
and a postfix, i.e. 640A,
640B, etc.
33 - 174 9823/1700-1 33 - 174

12 - Harness
00 - General
Table 460. Electrical Connectors- RAS System

Device Description Location Harness Con-
nector
1042A Stabiliser isolation switch Located on the instrument panel. Re-
move the switch to get access to the
connector.
1058 Sway spool switch Located on the parallel valve block

sway valve spool.
1062A Right stabiliser pressure trans- Located on the stabiliser cylinder

ducer body.
1062B Left stabiliser pressure trans- Located on the stabiliser cylinder

ducer body.
1063 Left stabiliser switch Located on the parallel valve block

left stabiliser valve spool.
1064 Right stabiliser switch Located on the parallel valve block

right stabiliser valve spool.
1065 Lift arm proximity switch- 60 ° Inside face of the right side chassis
(stabiliser isolation) near the lift arm pivot.
1066 Lift arm proximity switch- 60 ° Inside face of the left side chassis
near the lift arm pivot.
1067 Lift arm extend proximity TBA

switch
2000 Relays Refer to electrical system- fuse and

relay, refer to (PIL 33-09).
3054 Sway / stabiliser isolation Located on the parallel valve block.
valve solenoid
3055 Lift pilot pressure supply isola- Located on the pilot pressure supply
tion valve solenoid valve.
4013 LMS (Loadall Monitoring Sys- The ECU connectors are located be- 10 1
tem) display connector J2 hind the LMS display unit. Be sure to
identify the correct connector. Con- 20 11
nector J2 is coloured black.

4018A ECU connector1 (black) The ECU is installed below the oper-
ators seat. The panel harness con-
nector connects directly to the ECU. 12
23
1
13
35 24
4018B ECU connector2 (white) The ECU is installed below the oper-
ators seat. The panel harness con-
nector connects directly to the ECU. 12
23
1
13
35 24
33 - 175 9823/1700-1 33 - 175

12 - Harness
00 - General
Device Description Location Harness Con-

nector
8000 Harness interconnections Refer to electrical system- harness,
9000 Fuses Refer to electrical system- fuse and
relay, refer to (PIL 33-09).
Electrical Connectors- Gearbox Harness Use the table and the relevant electrical schematic
to identify the pins in the harness connectors.
The table shows the harness connectors that Continuity checks on the harness wires can be
connect to the electrical devices. The connectors carried out using a multimeter. Do not touch ECU
are shown looking at the mating face when connector pins. Do not use a multimeter on ECU
disconnected. The drawings show the harness connector pins.
connectors, not the device connectors.
Table 461. Gearbox Harness Electrical Connectors

Device Description Location Harness connector
1013 Column Switch L/H A cable and connector
connects to the panel har-
ness at the steering col-
umn below the steering
wheel. Refer to driveline-
semi-automatic gearbox,
1068 Transmission Dump The switch is installed
Switch to the hydraulic control
lever. A cable and con-
necter connects to the
chassis harness below
the hydraulic control
lever. Refer to driveline-
1057 Park Brake Switch The switch is installed to
the park brake lever. A
cable and connector con-
nects to the rear cab har-
ness at the park brake
lever. Refer to driveline-
2000 Relays Refer to electrical system-
fuse and relay, refer to
(PIL 33-09).
3021 Forward high solenoid Located on the gearbox.
3022 Forward low solenoid Refer to driveline- se-
mi-automatic gearbox, re-
fer to (PIL 27-06).
3033 Mainshaft solenoid
3040 Reverse high solenoid Located on the gearbox.
3041 Reverse low solenoid Refer to driveline- se-
mi-automatic gearbox, re-
fer to (PIL 27-06).
7014 Diode Gate- Gearbox Connects to the panel
harness below the left
side instrument console.
33 - 176 9823/1700-1 33 - 176

12 - Harness
00 - General
Device Description Location Harness connector

8000 Harness interconnections Refer to electrical sys-
tem- harness, refer to
(PIL 33-12).
9000 Fuseboxes Refer to electrical system-
fuse and relay, refer to
(PIL 33-09).
-000 Earth Points Refer to electrical sys-
tem- harness, refer to
(PIL 33-12).
33 - 177 9823/1700-1 33 - 177

12 - Harness
00 - General
Operation
Figure 1112. Example- Horn Energised................................................................................Page 33-179

This section contains sets of electrical schematics for cases it will be necessary to trace wires across more
different machine variants. than one schematic sheet.
Use the applicable schematic set to trace the wires The example shows how to follow a typical set of
and connections between electrical devices. In most wires from a power supply (+ ve) through to the path
to earth (- ve).
33 - 178 9823/1700-1 33 - 178

12 - Harness
00 - General
Page 33-180 Figure 1112. Example- Horn Energised Page 33-181

SHEET 14 SHEET 7
33 - 179 9823/1700-1 33 - 179

12 - Harness
00 - General
Page Page
33-180 33-181
SHEET 14 SHEET 7
Page 33-181
33 - 180 9823/1700-1 33 - 180

12 - Harness
00 - General
Page Page
33-180 33-181

Page 33-180
33 - 181 9823/1700-1 33 - 181

12 - Harness
00 - General
Table 462.
Item
(1)
Description State Pins
(2)
Wire No. Sheet Explanation
CP27 Fuse box B + ve supply 6 118 14 Power supply
from 7.5 fuse
CP18 Relay closed 1-2 7 completes cir-
cuit to horn
CP06 / MF01 Harness inter- 30 871 7
connection
MF40A / Harness inter- 16 7
RL15A connection
MF33 Horn energised 1-2 7
SRL2 Splice
(3)
600EL 7
MF40A / Harness inter- 8 600ET 7
RL15A connection
SMF3 Splice 7
MF22 Earth - ve earth 600A 7 Connects to
chassis earth
point
(1) Item identification code is the same as the connector code shown on the applicable harness drawing.
(2) The pin number is the same as the pin number of the harness connector shown on the applicable harness
drawing.
(3) Splices are not normally accessible. Splices are inside the harness sheath and not visible on the outside.
33 - 182 9823/1700-1 33 - 182

12 - Harness
00 - General
Repair 2. Using the correct sized splice, attach the new

section of wire required or auxiliary flying
Special Tools lead to the existing harness and secure using
Description Part No. Qty. the crimp tool. Note that each of the splices
Wiring Crimp Tool 892/00349 1 detailed is colour-coded to make size and range
readily visible. They are secured using the
Butane Heater 892/00350 1 corresponding size and matching colour-coded
jaws of the crimp tool to ensure joint security.
Consumables This tool also incorporates a ratchet closing
Description Part No. Size mechanism which will not release until the splice
Wiring Splice 892/00351 - is fully closed to the correct compression size.
(0.5-1.5mm Red,
Consumable: Wiring Splice (0.5-1.5mm Red,
contains 50 off)
contains 50 off)
Wiring Splice 892/00352 - Consumable: Wiring Splice (1.5-2.5mm Blue,
(1.5-2.5mm Blue, contains 50 off)
contains 50 off) Consumable: Wiring Splice (3-6mm Yellow,
Wiring Splice (3-6mm 892/00353 - contains 50 off)
Yellow, contains 50 off)
3. With the Butane heater assembly, seal the
Instances occur where it is necessary to incorporate connection.
auxiliary electrical components into existing electrical Special Tool: Butane Heater (Qty.: 1)
circuits and although unlikely with present wiring
harnesses, repair or replace specific individual wires 3.1. Remove the cap from the end of the
within a harness. This will also apply to other disposable gas cartridge.
machines in addition to those of manufacture.
Figure 1114.
To make sure that either the inclusion of an auxiliary
electrical component or a repair within a harness is
completed to an acceptable standard it is strongly A
recommended that the following tools, equipment
and procedures are always used. Note that JCB
harnesses have an Ingress Protection rating of 67
(I.P.67). B
The sheath covering of the recommended splice is A Cap

heat shrunk onto the original wire insulation. This B Gas cartridge
results in a seal and corresponding joint to IP 67
specifications. 3.2. Before assembling the gas cartridge to the
reflector element, turn the red ring to the left,
Procedure (in the direction of the minus sign marked
on the ring).
1. Cut the wire and remove the protective insulation
for a suitable distance dependent upon the size Figure 1115.
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 1113.
A
C Reflector element
D Red ring
3.3. Position the tube hanging down from inside
the reflector assembly into the hole at the
top of the gas cartridge. Then press the gas
A Distance for splice (check size)
33 - 183 9823/1700-1 33 - 183

12 - Harness
00 - General
cartridge up into the reflector assembly as Figure 1118.

far as possible until the two elements are
clasped firmly together. An audible click will
be heard.
Figure 1116.
D Red ring
3.6. Hold the heater vertically and, using a
match or cigarette lighter, light the gas as
shown. Hold the heater vertically for 1 to 2
minutes until the catalytic reaction occurs.
This is indicated when the blue flame fades
3.4. Turn the small ring so that the air holes are and the ceramic element glows red. Then
completely closed. turn the small ring until the air holes at
are completely open. The tool is ready
Figure 1117. for use. Note: The fact that the sound of
liquid cannot be heard when the cartridge is
shaken does not mean it is empty. No sound
will be heard even when the cartridge is full.
Figure 1119.
E Small ring
F Air holes
3.5. Turn the red ring to the right (in the direction
of the plus sign) in order to turn on the E Small ring
gas. Important: Before turning the heater F Air holes
on, make sure that the cartridge is not hotter
than the reflector element. This may occur 3.7. The heater can be used in two modes:
if the cartridge is held in the hand for a long
time. The temperature difference between 3.8. Side wings down, reflector head completely
the cartridge and the reflector element may open. In this mode the infra-red heat waves
cause long yellow flames to appear on are dominant (recommended for the light
ignition. coloured plastic splices).
33 - 184 9823/1700-1 33 - 184

12 - Harness
00 - General
Figure 1120. Check (Condition)
This section describes how to use electrical

measuring devices that are used in electrical fault
finding.
Use of Multimeters
In order to obtain the maximum benefit from the
fault finding information contained in the Electrical
Section, it is important that the technician fully
understands the approach to fault finding and the
use of the recommended test equipment, in this case
a FLUKE 85 or AVO 2003 digital multimeter, or a
moving pointer analogue multimeter. The approach
is based on a fault finding check list. In tracing
G Side wings the fault from the symptoms displayed you will be
directed to make measurements using a multimeter.
3.9. Side wings up, reflector head opening These instructions are intended to cover the use of
reduced. In this mode the heating is done the recommended meters.
only by the hot gas (use for dark coloured
plastic splices). 1. Make sure that the test leads are plugged into
the correct sockets. The black test lead should
Figure 1121.
be plugged into the black socket (sometimes, this
socket is also marked by a -, or E or marked as
COMMON or COM). The red test lead should be
plugged into the red socket marked with +, V or
Ω.
2. When you make a measurement, make sure that
the test probes have a good clean contact with
bare metal, free from grease, dirt, and corrosion
as these can cause a false reading.
3. When you measure a voltage, make sure that
the correct range is selected, that it is set to the
selector value equal to or greater than that you
are about to measure. e.g. If asked to measure
12 Volts, set the selector to the 12V range. If
D Red ring there is no 12V range, set the selector to the next
G Side wings range higher, 20V for instance. If the meter is set
to a range that is too low, it may be damaged.
e.g. setting to the 2V range to measure 12V.
Measuring DC Voltage
1. Select the correct range on the multimeter.
1.1. On the digital multimeter, turn the switch to
position B.
33 - 185 9823/1700-1 33 - 185

12 - Harness
00 - General
Figure 1122. Fluke 85 Multimeter Figure 1123. AVO 2003 Multimeter
1.2. On the AV0 meter, move the right slider

switch to position A, and the left hand slider 1.3. On an analogue meter, turn the dial to the
switch to the appropriate range. appropriate DC Volts range.
Figure 1124. Typical Analogue Multimeter
2. Connect the black probe to the nearest available

suitable earth point, usually this will be the starter
motor earth, the battery negative, or the chassis.
Connect the red probe to the wire or contact from
which you are measuring the voltage.
33 - 186 9823/1700-1 33 - 186

12 - Harness
00 - General
Measuring Resistance Measuring Frequency

1. Make sure that there is no power to the part of The AVO meter and the analogue meter are not
the circuit you are about to measure. capable of measuring frequency, therefore a digital
multimeter must be used.
2. Connect one probe at one end of the component
or wire to be checked and the other probe at the 1. Insert the black plug into the COM socket on
other end. It does not matter which way round the the meter and attach the probe to the nearest
two probes are placed. suitable earth point on the chassis, for example,
the battery negative terminal.
3. Select the correct range on the multimeter.
2. Insert the red probe into socket J.
3.1. On the digital multimeter. Turn the switch to
position C and check that the W sign at the 3. Turn the selector switch to position A and
right hand side of the display window is on. depress G repeatedly until F is highlighted on the
If the F sign is on instead, press the blue top row of the display.
button G to change the reading to Ω. Touch
the meter lead probes together and press 4. Press button H once.
the REL3 key on the meter to eliminate the
lead resistance from the meter reading. 5. Touch or connect the red probe to the frequency
source to be measured. Press and hold the
3.2. On the AV0 meter, move the right hand button if an average reading is required.
slider switch to position B, and the left hand
slider switch to the appropriate Ohms (Ω) Testing a Diode or a Diode Wire
range.
3.3. On an analogue meter, move the dial to the A diode wire is a diode with male connector installed
appropriate Ohms (Ω) range. on one end and a female connector installed on the
other end. The diode is sealed in heatshrink sleeving.
Measuring Continuity To test a Diode or a Diode Wire.
1. Make sure that there is no power to the part of 1. On the digital multimeter:
the circuit you are checking for continuity.
1.1. Turn the switch to position D.
2. Connect one probe to one end of the component 1.2. Press the HOLD button and check that the
or wire to be checked and the other probe to the H sign appears at the top right hand side of
other end. It does not matter which way round the the display window.
two probes are placed.
1.3. Connect the black probe to the end of the
3. Select the correct range on the multimeter. diode with a band or to the male connector
of the diode wire. Connect the red probe
3.1. On the digital multimeter, turn the switch to the other end of the diode or diode wire.
to position C and check that the beeper If the beeper does not sound the diode or
symbol appears at the left hand side of diode wire is faulty.
the display window. If the F sign is on
instead, press the button labelled F. If there 1.4. Connect the red probe to the end of the
is continuity in the circuit, the beeper will diode marked with a band, or to the male
sound. If there is no continuity (open circuit), connector of the diode wire, the black probe
the beeper will not sound. should be connected to the other end of the
diode or diode wire. If the beeper sounds or
3.2. On the AV0 meter, move the right hand the meter does not read O.L., the diode or
slider switch to position B, and the left diode wire is faulty.
hand slider switch to position C. If there is
continuity (i.e. very low resistance) between 1.5. Press the HOLD button and check that the
two points the buzzer will sound. H sign disappears from the right hand side
of the display window.
3.3. On an analogue meter, turn the dial to
the lowest Ohms (Ω) range. If there is 2. On the AV0 meter:
continuity (i.e. very low resistance) between
two points the needle will move across fully 2.1. Move the right hand slider to position A, and
(or almost fully) to the right hand side of the the left hand slider switch to position C.
scale. 2.2. Connect the black probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the red probe
should be connected to the other end of the
33 - 187 9823/1700-1 33 - 187

12 - Harness
00 - General
diode or diode wire. If the Avo meter does

not buzz the diode is faulty.
2.3. Connect the red probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the black probe
diode or diode wire. If the Avo meter does
not read 1 the diode is faulty.
3. On an analogue meter:
3.1. Select the Ohms 1000s (1k) range, connect
the black probe to the end of the diode
marked with a band, or to the male
connector of the diode wire, the red probe
diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the
diode is faulty.
3.2. Select the Ohms 100s range, connect the
red probe to the end of the diode marked
with a band, or to the male connector of
the diode wire, the black probe should
be connected to the other end of the
diode or diode wire. The meter should read
300-400Ω, if it reads less than this the diode
is faulty.
33 - 188 9823/1700-1 33 - 188

12 - Harness
04 - Chassis
04 - Chassis
Diagram
For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42

[T2/T3] ..................................... Page 33-189
For: 510-56 [T2/T3], 512-56 [T2/T3]
................................................. Page 33-198
(For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42 [T2/T3])

Figure 1125. Rear Chassis Harness - 332/D8487-1 (Sheet 1 of 2)......................................Page 33-191
33 - 189 9823/1700-1 33 - 189

Notes:
33 - 190 9823/1700-1 33 - 190

12 - Harness
04 - Chassis
Page 33-192 Figure 1125. Rear Chassis Harness

- 332/D8487-1 (Sheet 1 of 2) Page 33-193
332/D8487-1
33 - 191 9823/1700-1 33 - 191

12 - Harness
04 - Chassis
Page Page
33-192 33-193
Page 33-193
33 - 192 9823/1700-1 33 - 192

12 - Harness
04 - Chassis
Page Page
33-192 33-193

Page 33-192
332/D8487-1
33 - 193 9823/1700-1 33 - 193

12 - Harness
04 - Chassis
33 - 194 9823/1700-1 33 - 194

12 - Harness
04 - Chassis

- 332/D8487-1 (Sheet 2 of 2) Page 33-197
332/D8487-1
33 - 195 9823/1700-1 33 - 195

12 - Harness
04 - Chassis
Page Page
33-196 33-197
Page 33-197
33 - 196 9823/1700-1 33 - 196

12 - Harness
04 - Chassis
Page Page
33-196 33-197

Page 33-196
332/D8487-1
33 - 197 9823/1700-1 33 - 197

12 - Harness
04 - Chassis
(For: 510-56 [T2/T3], 512-56 [T2/T3])

33 - 198 9823/1700-1 33 - 198

12 - Harness
04 - Chassis

- 332/D8492-1 (Sheet 1 of 2) Page 33-201
332/D8492-1
33 - 199 9823/1700-1 33 - 199

12 - Harness
04 - Chassis
Page Page
33-200 33-201
Page 33-201
33 - 200 9823/1700-1 33 - 200

12 - Harness
04 - Chassis
Page Page
33-200 33-201

Page 33-200
332/D8492-1
33 - 201 9823/1700-1 33 - 201

12 - Harness
04 - Chassis
33 - 202 9823/1700-1 33 - 202

12 - Harness
04 - Chassis

- 332/D8492-1 (Sheet 2 of 2) Page 33-205
332/D8492-1
33 - 203 9823/1700-1 33 - 203

12 - Harness
04 - Chassis
Page Page
33-204 33-205
Page 33-205
33 - 204 9823/1700-1 33 - 204

12 - Harness
04 - Chassis
Page Page
33-204 33-205

Page 33-204
332/D8492-1
33 - 205 9823/1700-1 33 - 205

12 - Harness
06 - Lift Arm
06 - Lift Arm
Diagram
(For: 510-56 [T2/T3], 512-56 [T2/T3])

Figure 1129. Lift Arm Harness 332/D7010- Issue 1 (sheet 1 of 1).......................................Page 33-207
33 - 206 9823/1700-1 33 - 206

12 - Harness
06 - Lift Arm
Page 33-208 Figure 1129. Lift Arm Harness

332/D7010- Issue 1 (sheet 1 of 1) Page 33-209
33 - 207 9823/1700-1 33 - 207

12 - Harness
06 - Lift Arm
Page Page
33-208 33-209
Page 33-209
33 - 208 9823/1700-1 33 - 208

12 - Harness
06 - Lift Arm
Page Page
33-208 33-209

Page 33-208
33 - 209 9823/1700-1 33 - 209

12 - Harness
06 - Lift Arm
B001 Proximity switch B002 Chassis harness connector
33 - 210 9823/1700-1 33 - 210

12 - Harness
09 - Engine
09 - Engine
Diagram
Figure 1130. ESOS harness - 721/11872-1 (Sheet 1 of 1).................................................. Page 33-213

Figure 1131. Engine Harness - 721/11835-2 (Sheet 1 of 1).................................................Page 33-217
33 - 211 9823/1700-1 33 - 211

Notes:
33 - 212 9823/1700-1 33 - 212

12 - Harness
09 - Engine
Page 33-214 Figure 1130. ESOS harness

- 721/11872-1 (Sheet 1 of 1) Page 33-215
721/11872-1
33 - 213 9823/1700-1 33 - 213

12 - Harness
09 - Engine
Page Page
33-214 33-215
Page 33-215
33 - 214 9823/1700-1 33 - 214

12 - Harness
09 - Engine
Page Page
33-214 33-215
721/11872-1
Page 33-214
33 - 215 9823/1700-1 33 - 215

12 - Harness
09 - Engine
33 - 216 9823/1700-1 33 - 216

12 - Harness
09 - Engine
Page 33-218 Figure 1131. Engine Harness

- 721/11835-2 (Sheet 1 of 1) Page 33-219
ID
6 5 4 3 2 1
SC SA
EA
7 8 9 10 11 12
EB
M10
EC
SB
EH
1 2
EJ ES 2 1
1 2
EK 2 1
A B
EO
C EP
ER
EL
2 1
EM
ADD RED 2 1
MARKER TAPE
5
M EF ED
M8
EG
M
5
721/11835-2
33 - 217 9823/1700-1 33 - 217

12 - Harness
09 - Engine
Page Page
33-218 33-219
ID
6 5 4 3 2 1
SC
EA
7 8 9 10 11 12
EB
0
M1
EC
Page 33-219
A B
EO
C
ADD RED
MARKER TAPE
5
M EF ED
M8
EG
M
5
33 - 218 9823/1700-1 33 - 218

12 - Harness
09 - Engine
Page Page
33-218 33-219
SC SA
SB
EH
1 2
EJ ES 2 1
Page 33-218
1 2
EK 2 1
A B
EO
C EP
ER
EL
2 1
EM
2 1
721/11835-2
33 - 219 9823/1700-1 33 - 219

12 - Harness
Diagram
Figure 1132. Rear Cab Harness 721/12005-2..................................................................... Page 33-221
Rear Cab Harness
33 - 220 9823/1700-1 33 - 220

12 - Harness
Page 33-222 Figure 1132. Rear Cab Harness 721/12005-2 Page 33-223
33 - 221 9823/1700-1 33 - 221

12 - Harness
Page Page
33-222 33-223
Page 33-223
33 - 222 9823/1700-1 33 - 222

12 - Harness
Page Page
33-222 33-223

Page 33-222
33 - 223 9823/1700-1 33 - 223

12 - Harness
AA Cab / panel harness connector AB Heated seat

AC Air suspension seat AD Rear wiper
AE Left hand work light AF Earth
AG Beacon AH Right hand work light
AJ Roof wiper AK1 Interior light (+ve)
AK2 Interior light (-ve) AL Park brake switch
33 - 224 9823/1700-1 33 - 224

12 - Harness
15 - Front Console
15 - Front Console
Diagram
For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42

[T2/T3] ..................................... Page 33-225
For: 510-56 [T2/T3], 512-56 [T2/T3]
................................................. Page 33-274
(For: 506-36 [T2/T3], 507-42 [T2/T3], 509-42 [T2/T3])

Figure 1133. Instrument Panel Harness - 332/D8488-1 (Sheet 1 of 6)................................ Page 33-227
Figure 1139. Instrument Panel Harness - 721/G2468-2 (Sheet 1 of 6)................................ Page 33-251
For Machines up to Serial number 1402035
33 - 225 9823/1700-1 33 - 225

Notes:
33 - 226 9823/1700-1 33 - 226

12 - Harness
15 - Front Console
Page 33-228 Figure 1133. Instrument Panel

Harness - 332/D8488-1 (Sheet 1 of 6) Page 33-229
332/D8488-1
33 - 227 9823/1700-1 33 - 227

12 - Harness
15 - Front Console
Page Page
33-228 33-229
Page 33-229
33 - 228 9823/1700-1 33 - 228

12 - Harness
15 - Front Console
Page Page
33-228 33-229

Page 33-228
332/D8488-1
33 - 229 9823/1700-1 33 - 229

12 - Harness
15 - Front Console
33 - 230 9823/1700-1 33 - 230

12 - Harness
15 - Front Console

332/D8488-1
33 - 231 9823/1700-1 33 - 231

12 - Harness
15 - Front Console
Page Page
33-232 33-233
Page 33-233
33 - 232 9823/1700-1 33 - 232

12 - Harness
15 - Front Console
Page Page
33-232 33-233

Page 33-232
332/D8488-1
33 - 233 9823/1700-1 33 - 233

12 - Harness
15 - Front Console
33 - 234 9823/1700-1 33 - 234

12 - Harness
15 - Front Console

332/D8488-1
33 - 235 9823/1700-1 33 - 235

12 - Harness
15 - Front Console
Page Page
33-236 33-237
Page 33-237
33 - 236 9823/1700-1 33 - 236

12 - Harness
15 - Front Console
Page Page
33-236 33-237

Page 33-236
332/D8488-1
33 - 237 9823/1700-1 33 - 237

12 - Harness
15 - Front Console
33 - 238 9823/1700-1 33 - 238

12 - Harness
15 - Front Console

332/D8488-1
33 - 239 9823/1700-1 33 - 239

12 - Harness
15 - Front Console
Page Page
33-240 33-241
Page 33-241
33 - 240 9823/1700-1 33 - 240

12 - Harness
15 - Front Console
Page Page
33-240 33-241

Page 33-240
332/D8488-1
33 - 241 9823/1700-1 33 - 241

12 - Harness
15 - Front Console
33 - 242 9823/1700-1 33 - 242

12 - Harness
15 - Front Console

332/D8488-1
33 - 243 9823/1700-1 33 - 243

12 - Harness
15 - Front Console
Page Page
33-244 33-245
Page 33-245
33 - 244 9823/1700-1 33 - 244

12 - Harness
15 - Front Console
Page Page
33-244 33-245

Page 33-244
332/D8488-1
33 - 245 9823/1700-1 33 - 245

12 - Harness
15 - Front Console
33 - 246 9823/1700-1 33 - 246

12 - Harness
15 - Front Console

332/D8488-1
33 - 247 9823/1700-1 33 - 247

12 - Harness
15 - Front Console
Page Page
33-248 33-249
Page 33-249
33 - 248 9823/1700-1 33 - 248

12 - Harness
15 - Front Console
Page Page
33-248 33-249

Page 33-248
332/D8488-1
33 - 249 9823/1700-1 33 - 249

12 - Harness
15 - Front Console
For Machines from Serial number 1402036
33 - 250 9823/1700-1 33 - 250

12 - Harness
15 - Front Console

Harness - 721/G2468-2 (Sheet 1 of 6) Page 33-253
M5
P067
10
FI T
11
10
12
9
7
8
12 11 10 9 8 7
I NSULATE RI NG TERMI NAL WI TH PVC TAPE : 1 : 1
P094 AFTER
19
17
15
13
11
1 2 3 4 5 6
9
7
5
3
1
TEST
2
6
1
90
A P001 P093
20
18
16
14
12
10
8
6
4
2
90 10
P068
M5
70
14
22
0
500
0 49 P020
19
17
15
13
11
9
7
5
3
1
B 0
P002 220 20
20
18
16
14
12
10
8
6
4
2
50 SP18 30 SP38 30 40 SP20 20 SP63 30 SP64 50 30 SP66 30
64
8
10
0
0 SP1
18 10
63
7
15 0
19
17
15
13
11
9
7
5
3
1
0 0
C P003 50
10 0
0
20
18
16
14
12
10
40
8
6
4
2
18
4 3 2 1
57
45
1
150
P076
8 7 6 5
P058
19
17
15
13
11
9
7
5
3
1
3 2 1 ENSURE DUST CAP I S FI TTED

SP37
0
D SP21
35
7 6 5 4
P004
20
18
16
14
12
10
11 10 9 8
8
6
4
2
14 13 12
40 0
RED MARKER TAPE : 1 : .
50 2 1 1 2 2 Way HW090 Pin Housing : 1 : 7212/ 0002
50
P071 2 Way HW090 Pin Ret ainer : 1 : 7212/ 0004

Cavit y Seal HW090 : 2 : 7210/ 0001
13 50
P041
50
3 2 1 P069
90
7 6 5 4 3 2 1 1 2 3
11 10 9 8 50 7 6 5 4 4 5 6 7
14 13 12 P101 11 10 9 8
8
12
9
13
10
14
11
P103 2 1
14 13 12
6
3
3
50
200
2
5
P037
1 2 3 2 1 1 2 3
2 1 50 50
7 6 5 4 4 5 6 7
P106 P102
10
10 9 8 8 9 10
P104
3 4
1
4
4 3
SP16
4 Way HW090 Male Blanking Plug : 1 : 719/ 10102
15
60A Maxi Fuse : 1 : 716/ 16400 SP17
M8
P083 1 2 P064
650 P057
15
M8
P084 650 1 2 P065

10
0 3 2 1
PVC SLEEVE : 1 : 1
60A Maxi Fuse : 1 : 716/ 16400 100
7 6 5 4
FUSE HOLDERS TO BE SUPPLI ED CLI PPED TOGETHER : 1 : 1
SP8
11 10 9 8
BLUE
14 13 12
P061
A B 100
SEE SHEET 3 ZONE 7F
200
P062
GREY
A B
721/G2468-2
33 - 251 9823/1700-1 33 - 251

12 - Harness
15 - Front Console
Page Page
33-252 33-253
M5
P067
10
19
17
15
13
11
9
7
5
3
1
90
A P001
20
18
16
14
12
10
8
6
4
2
90 10
P068
M5
22
0 0
49
19
17
15
13
11
9
7
5
3
1
B P002 220
20
18
16
14
12
10
8
6
4
2
50 SP18 30 SP38 30 40 SP20 20
0
18
15
19
17
15
13
11
9
7
5
3
1
0 0
C P003 50
0
20
18
16
14
12
10
8
6
4
2
18
0
45
150
P076
P058
19
17
15
13
11
9
7
5
3
1
3 2 1
D P004 7 6 5 4
20
18
16
14
12
10
11 10 9 8
8
6
4
2
14 13 12
RED MARKER TAPE : 1 : .

50 2 1
50 P071
P041
50
3 2 1
7 6 5 4 3 2 1
11 10 9 8 50 7 6 5 4
P101
Page 33-253
14 13 12 11 10 9 8
14 13 12
50
1 2 3 2 1
2 1 50 50
7 6 5 4
P106 P102 9 8
10
3 4
4 3
60A Maxi Fuse : 1 : 716/ 16400

M8
P083 1
650
M8
P084 650 1
PVC SLEEVE : 1 : 1
60A Maxi Fuse : 1 : 716/ 16400
33 - 252 9823/1700-1 33 - 252

12 - Harness
15 - Front Console
Page Page
33-252 33-253
FI T
11
10
12
9
7
12 11 10 9 8 7
P094 AFTER
1 2 3 4 5 6
TEST
5
2
6
P093
70
14
500
P020
0
20
SP20 20 SP63 30 SP64 50 30 SP66 30
64
8
10
0
SP1
10
63
7
15 0
0
100
40
4 3 2 1
57
1
P076
8 7 6 5
ENSURE DUST CAP I S FI TTED
SP37
0
SP21
35
400
2 1 1 2 2 Way HW090 Pin Housing : 1 : 7212/ 0002

P071 2 Way HW090 Pin Ret ainer : 1 : 7212/ 0004
Cavit y Seal HW090 : 2 : 7210/ 0001
1350
P069
90
3 2 1 1 2 3
4 5 6 7
7 6 5 4
P101 8 9 10 11
P103 2 1
Page 33-252
11 10 9 8
12 13 14
14 13 12
6
3
3
200
2
5
P037
3 2 1 1 2 3
7 6 5 4 4 5 6 7
P102
10
10 9 8 8 9 10
P104
1
4
SP16
15
60A Maxi Fuse : 1 : 716/ 16400 SP17
1 2 P064
P057
15
1 2 P065
10
0 3 2 1
60A Maxi Fuse : 1 : 716/ 16400 100
7 6 5 4
SP8
11 10 9 8
BLUE
14 13 12
P061
A B 100
SEE SHEET 3 ZONE 7F
200
P062
GREY
A B
721/G2468-2
33 - 253 9823/1700-1 33 - 253

12 - Harness
15 - Front Console
33 - 254 9823/1700-1 33 - 254

12 - Harness
15 - Front Console

SEE SHEET 3 ZONE 6D

80
10
1
3
2
8
P043
6
9
7
4
5
SP14
30
817/ 17257 817/ 17258 817/ 17260 817/ 17256
SP32
30
10 9 10 9 10 9 10 9
3 6 3 6 3 6 3 6
2 5 2 5 2 5 2 5 SP9 3 Way DT04 CAN Term inat ing Resist or J1939/ 11 : 1 : 727/ 00002
60
1 4 1 4 1 4 1 4
8 7 8 7 A B
30
8 7 8 7
P029 P030 P032 P028 C

SP6 BOOT P055 P056
ADAPTOR
P092
30
100
100
100
100
100
150
SP7
50
30
30 30 30 200 50 85 45 30 30 30 30 50 150 50 50 50 50
SP5 SP65 SP58 SP59 SP60 SP62 SP10 SP52 SP53 SP54
75
50
SP13
100
50
SP61
75
Two Diode 4 Way Sum i Pin Hsg : 1 : 716/ 17100
P025 P036
250
30
30
30
10 18
3 17 2 1
2 5
1 4
8 7 4 3
P100 P099 P098
S + 817/ 17277
- 11 12 13
P052
14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10
721/G2468-2
33 - 255 9823/1700-1 33 - 255

12 - Harness
15 - Front Console
Page Page
33-256 33-257
SEE SHEET 3 ZONE 6D
SP14
30
817/ 17257 817/ 17258 817/ 17260 817/ 17256
SP32
30
10 9 10 9 10 9 10 9
3 6 3 6 3 6 3 6
2 5 2 5 2 5 2 5 SP9
1 4 1 4 1 4 1 4
8 7 8 7
30
8 7 8 7
P029 P030 P032 P028

SP6
30
100
100
100
100
SP7
30
30 30 30 200 50 85 45 30
SP5 SP65 SP58 SP59

75
50
Page 33-257
SP13
100
50
SP61
75
Two Diode 4 Way Sum i Pin Hsg : 1 : 716/ 17100
P025 P036
250
30
30
30
10 18
3 17 2 1
2 5
1 4
8 7 4 3
P100 P099 P098
S + 817/ 17277
- 11 12 13
P052
14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10
33 - 256 9823/1700-1 33 - 256

12 - Harness
15 - Front Console
Page Page
33-256 33-257
80
10
1
3
2
8
P043
6
9
7
4
5
3 Way DT04 CAN Term inat ing Resist or J1939/ 11 : 1 : 727/ 00002
60
A B
C
BOOT P055 P056
ADAPTOR
P092
100
150
50
30 30 30 30 50 150 50 50 50 50
SP58 SP59 SP60 SP62 SP10 SP52 SP53 SP54

Page 33-256
721/G2468-2
33 - 257 9823/1700-1 33 - 257

12 - Harness
15 - Front Console
33 - 258 9823/1700-1 33 - 258

12 - Harness
15 - Front Console

8 8 8 8 8 8 8 8
9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6
10 10 10 10 10 10 10 10
5 5 5 5 5 5 5 5
1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4
3 3 3 3 3 3 3 3 4 Way HW090 Male Blanking Plug : 1 : 719/ 10102
P017 P012 P105 P019 P011 P010 P018 P005

1 2
4 3 2 1
50
50
50
50
50
50
50
50
2 1 3 4
30 30 30 30 15 15 30 30 60 60 8 7 6 5
4 3
SP35 SP30
P063 P042
Four Diode 8 Way Sum i Pin Hsg : 1 : 716/ 16100
SEE SHEET 1
0

50
15
M10 ZONE 9D 2 1
M1
0
P039
P040 4 3
50 50 50 50 SP39
P046 P082
25
0
280
SP55 SP56 SP57
10
50
150
15
SP41
10
0
28
0
25
P091
A B 25 25 40 40 30 20 20 30 50 50 50 50 50 100 50 50 2 1
P088
C
SP28 SP19 SP24 SP23 SP3 SP25 SP34 SP26 SP22 4 3
40
BOOT
ADAPTOR
50
150
SP27
8 8 8 8
50
7 4 1 9 7 6 9 7 6 9 7 6 9 7 6
60
10 10 10 10 P066
50
8 5 2
5 5 5 5
3 2 1
1 2 4 1 2 4 1 2 4 1 2 4
9 6 3 3 3 3 3 300 30 30 30 30
SP29
P008 P014 P013 P009 P006
SP33
200
50
50
50
50
50
50
50
50
50
30 30 30 30 50 50
35
SEE SHEET 2 ZONE 4F
0
100
8 P026 P027 P097 P034
10
2 P077 9 10 9 10 9 10 9 10 9
0
100
10
3 6 3 6 3 6 3 6
P060 7
1 50 2 5 2 5 2 5 2 5
5 6 1 4 1 4 1 4 1 4
8 7 8 7 8 7 8 7
50
P078
P059
2 1
100 817/ 17282 817/ 17283
10 4
0 3
10
0
P038
P023
H M L
P024
C B
721/G2468-2
33 - 259 9823/1700-1 33 - 259

12 - Harness
15 - Front Console
Page Page
33-260 33-261
8 8 8 8 8 8 8 8
9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6 9 7 6
10 10 10 10 10 10 10 10
5 5 5 5 5 5 5 5
1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4 1 2 4
3 3 3 3 3 3 3 3
P017 P012 P105 P019 P011 P010 P018 P005
50
50
50
50
50
50
50
30 30 30 30 15 15 30 50 30 60 60
SP35 SP30
50
15
50 50 50 50 SP39
P046
25
SP55 SP56 SP57
50
SP41
25
P091
A B 25 25 40 40
Page 33-261
C
BOOT
SP28 SP19
ADAPTOR
50
150
8 8 8 8
7 4 1 9 7 6 9 7 6 9 7 6 9 7 6
10 10 10 10 P066
50
8 5 2
5 5 5 5
3 2 1
1 2 4 1 2 4 1 2 4 1 2 4
9 6 3 3 3 3 3
SP29
P008 P014 P013 P009 P006
50
50
50
50
50
30 30 30 30 50
SEE SHEET 2 ZONE 4F
33 - 260 9823/1700-1 33 - 260

12 - Harness
15 - Front Console
Page Page
33-260 33-261
1 2
4 3 2 1
2 1 3 4
8 7 6 5
4 3
P063 P042
SEE SHEET 1 Four Diode 8 Way Sum i Pin Hsg : 1 : 716/ 16100
M10 ZONE 9D 2 1
M1
0
P039
P040 4 3
P082
0
280
10
150
15
10
0
28
0
40 40 30 20 20 30 50 50 50 50 50 100 50 50 2 1
P088
Page 33-260
SP19 SP24 SP23 SP3 SP25 SP34 SP26 SP22 4 3

40
SP27
50
60
300 30 30 30 30
SP33
200
50
50
50
50
50
35
SEE SHEET 2 ZONE 4F

0
100
8 P026 P027 P097 P034
10
2 P077 9 10 9 10 9 10 9 10 9
0
100
10
3 6 3 6 3 6 3 6
P060 7
1 50 2 5 2 5 2 5 2 5
5 6 1 4 1 4 1 4 1 4
8 7 8 7 8 7 8 7
50
P078
P059
2 1
817/ 17282 817/ 17283
100
10 4
0 3
10
0
P038
P023
H M L
P024
C B
721/G2468-2
33 - 261 9823/1700-1 33 - 261

12 - Harness
15 - Front Console
33 - 262 9823/1700-1 33 - 262

12 - Harness
15 - Front Console

P020 P023 P027 P032 P038
P001 P004 CHASSI S CONNECTOR AI R CON SWI TCH + VE REAR WI PER SWI TCH BEACON SWI TCH HEATER SWI TCH
SECONDARY FUSE BOX A SECONDARY FUSE BOX D P009 P014
Cav ID Tag Size Destination I GNI TI ON RELAY 2 REVERSE HI GH/ LOW Cav ID Tag Size Destination Cav ID Tag Size Destination Cav ID Tag Size Destination Cav ID Tag Size Destination Cav ID Tag Size Destination
Cav ID Tag Size Destination REVERSE DRI VE RELAY FORWARD HI GH/ LOW
1 005 6.0 P059- 3 1 947A 2.0 P063- 2 1 997 2.0 P038- C 1 926 2.0 P057- 4 1 B 102 2.0 P001-10
1 010 6.0 P009- 2 Cav ID Tag Size Destination Cav ID Tag Size Destination
2 004 4.0 P005- 1 2 7210/ 0030 6.3 Fem Pos Lock 0.7- 2.0 : 1 : 7201/ 0425 2 925 2.0 P057- 5 2 310 1.0 P003-16 C 997 2.0 P023- 1
2 121 1.0 SP1- 1 1 200T 6.0 SP41- 2 1 811E 2.0 SP28- 5 1 Way Pos Lock Housing St raight : 1 : 7201/ 0403
3 003 6.0 P060- 7 3 7210/ 0030 P024 3 133C 2.0 SP16- 3 3 844A 1.0 P057- 8 H 995 2.0 P037- 3
3 BUS BAR LI NKED WI TH CELL 1 2 010 6.0 P001- 1 2 1862 2.0 P020-28 AI R CON SWI TCH - VE
4 125 2.0 P020-34 4 7210/ 0030 Cav ID Tag Size Destination 4 4 L 800 2.0 P037- 1
4 900 1.0 P101- 4 3 100B 0.75 SP19- 3 3 874D 0.75 SP27- 3
5 200H 6.0 P062- 1 5 7210/ 0030 1 883 2.0 P037- 4 5 5 M 801 2.0 P037- 2
5 BUS BAR LI NKED WI TH CELL 1 4 4 1863 2.0 P020-29
6 108A 1.0 P102- 8 6 910 1.0 P019- 7 6 901B 2.0 SP17- 3 6 5 Way 6.3 Fem Hsg Heat er Swit ch : 1 : 7235/ 0006
6 5 601EK 0.75 SP3- 4 5 601CY 0.75 SP34- 5 1 Way Pos Lock Housing St raight : 1 : 7201/ 0403
6.3 Fem Pos Lock 0.7- 2.0 : 1 : 7201/ 0425 P039
7 7 816 1.0 P017- 2 7 601DX 1.0 SP33- 2 7 601AY 1.0 SP5- 1 GROUND
7 011 6.0 P006- 7 BUS BAR LI NKED WI TH CELL 5 6 852A 2.0 SP29- 2 6 861A 2.0 SP30- 2 P025
8 306 2.0 P017- 6 8 7210/ 0030 HAZZARD SWI TCH 8 829AF 1.0 SP6- 9 8 829U 1.0 SP6- 12 Cav ID Tag Size Destination
8 7 811B 2.0 SP28- 2 7 1860 2.0 P020-24 Cav ID Tag Size Destination
9 BUS BAR LI NKED WI TH CELL 5 9 7210/ 0030 9 9 1 601JC 3.0 SP3- 11
9 BUS BAR LI NKED WI TH CELL 7 8 808 0.75 SP64- 1 8 874C 0.75 SP27- 4 1 104 1.0 P001-12
10 308 2.0 P011- 1 10 7210/ 0030 10 10 2 601JE 3.0 SP10- 8
10 102 2.0 P038- B 9 9 1861 2.0 P020-30 2 802 2.0 P008- 4
11 BUS BAR LI NKED WI TH CELL 5 11 838B 2.0 SP18- 3 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
3 601JF 2.0 SP33- 4
11 012 6.0 P010- 7 10 601AA0.75 SP34- 2 10 601CX 0.75 SP34- 6 3 300 2.0 P003-20
Beacon Swit ch Decal : 1 : 817/ 17260
12 309 2.0 P011- 6 St raight10Passive 12 884 2.0 P037- 5 P028 P034

4 601JD 2.0 SP5- 2
12 104 1.0 P025- 1 Way Twin Micro Relay Base : 1 : 7241/ 0003 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
4
FOG LAMP SWI TCH STABI LI SER I SOLATI ON SWI TCH
13 015 6.0 P005- 7

Bracket for Relay Housings : 1 : 7241/ 0006
13 1865 2.0 P013- 9 Cav ID Tag Size Destination Cav ID Tag Size Destination 5 601JH 3.0 SP34-10
13 BUS BAR LI NKED WI TH CELL 11 5 803,803A 2.0 P008-2,P058-14
14 14 1866 2.0 P013- 7 1 1 908A 1.0 P019- 8 Ring Term inal M10 6.0- 10.0 : 1 : 7207/ 1510
14 P010 P017
7 P040
15 BUS BAR LI NKED WI TH CELL 13
I GNI TI ON RELAY 3 BRAKELI GHTS
Roadlam ps 15 7210/ 0030 2 905 0.75 P002- 6 2 109C 1.0 SP66- 4 GROUND
15 BUS BAR LI NKED WI TH CELL 11 I GNI TI ON RELAY 4
8
16 151,151A 2.0 P057-7,P067-1 Cav ID Tag Size Destination Cav ID Tag Size Destination 16 7210/ 0030 3 941 0.75 P020-53 3 Cav ID Tag Size Destination
16 106 1.0 SP9- 1 10 601AD 2.0 SP10- 7
17 BUS BAR LI NKED WI TH CELL 13 1 204B 6.0 SP35- 3 1 108 1.0 P003-10 17 409 1.0 P055- 4 4 4 1 601JG 2.0 P069- 3
17 BUS BAR LI NKED WI TH CELL 11 17 804A 2.0 P042- 1
18 181 1.0 P082- 1 2 013 6.0 P002- 1 2 816 1.0 P020- 7 18 408 1.0 P055- 5 5 5 2 600P 2.0 P076- 1
18 109A 1.0 SP66- 2 18 805 2.0 SP7- 1
19 BUS BAR LI NKED WI TH CELL 13 3 100H 0.75 SP19- 7 3 817 1.0 P102- 1 19 402 0.5 SP58- 1 6 6 3 600T 2.0 P037- 6
19 811A 2.0 SP28- 1
20 4 4 20 403 0.5 SP59- 1 10 Way 6.3 Fast in Swit ch Hsg Red : 1 : 7219/ 0014
7 601DC1.0 SP5- 3 7 601DZ 1.0 SP33- 3 4 601BU 2.0 P088- 3
20 807 1.0 P020-31 Hazards Decal : 1 : 817/ 17277
10 Way Sec Fusebox Housing : 1 : 7241/ 0001 10 Way Sec Fusebox Housing : 1 : 7241/ 0001 5 601HL 0.75 SP3- 6 5 601GZ 0.75 SP34- 8 21 404 0.5 SP60- 1 P026
ROOF WI PER SWI TCH 8 829AE 1.0 SP6- 7 8 829AS 1.0 SP6- 3 5 601AL 2.0 P088- 4
10 Way Sec Fusebox Ret ainer : 1 : 7241/ 0002
P002 P005 6 204A 6.0 SP35- 2 6 306 2.0 P004- 8 22 405 0.5 P055- 6 Cav ID Tag Size Destination 9 9 6 601AS 1.5 P077- 2
SECONDARY FUSE BOX B NEUTRAL START RELAY
7 012 6.0 P001-11 7 828A 2.0 P029- 5 23 406 0.5 P052- 8 1 854 2.0 P057- 2 10 10 7 601AG1.5 P082- 4
Cav ID Tag Size Destination Cav ID Tag Size Destination
8 100G 0.75 SP19- 6 8 100C 0.75 SP19- 4 24 1860 2.0 P014- 7 2 849 2.0 P057- 3 8 601DD1.0 P068- 1
1 013 6.0 P010- 2 1 004 4.0 P004- 2 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
Rear Fog Swit ch Decal : 1 : 817/ 17256
10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
Lock Decal : 1 : 817/ 17319
9 9 25 412 1.0 P055- 3 3 133E 2.0 SP16- 4
Ring Term inal M10 6.0- 10.0 : 1 : 7207/ 1510
2 133 2.0 SP16- 1 2 842 2.0 P020-33 P029 P036 P041

10 601HK 0.75 SP3- 5 10 601V 0.75 SP34- 9 26 105 1.0 P093- 4 4
ROAD LI GHTS SWI TCH I NDI CATOR DI ODE L/ H COLUMN SWI TCH
3 BUS BAR LI NKED WI TH CELL 1 3 810G 0.75 SP24- 3 Cav ID Tag Size Destination Cav ID Tag Size Destination
10 Way Twin Micro Relay Base : 1 : 7241/ 0003 10 Way Twin Micro Relay Base : 1 : 7241/ 0003 27 7210/ 0030 Cav ID Tag Size Destination
4 110 1.5 SP38- 1 4 5 1 805B 2.0 SP7- 3
28 1862 2.0 P014- 2 1 1 7210/ 0001
5 832B 2.0 SP20- 3 5 601Z 0.75 SP3- 1 6 901 2.0 SP17- 1 2 806B 2.0 SP8- 3
P018 29 1863 2.0 P014- 4 2 307 1.0 P003-12 2 7210/ 0001
6 905 0.75 P028- 2 6 203 6.0 P064- 1 P011
ENGI NE RUNNI NG RELAY 7 601BH 1.0 SP33- 1 3 807C 2.0 SP13- 1
FRONT WORKI NG LAMPS
REAR WORKI NG LAMPS PARKBRAKE 30 1861 2.0 P014- 9 3 942B 2.0 SP21- 2 3 7210/ 0001
7 833 2.0 P058- 9 7 015 6.0 P004-13 8 829M 1.0 SP6- 8 4 807A 2.0 SP13- 2
Cav ID Tag Size Destination Cav ID Tag Size Destination 31 807 1.0 P001-20 4 4 809A 1.0 SP63- 2
8 834 1.5 P020-46 8 100J 0.75 SP19- 8 9
1 308 2.0 P004-10 1 100N 0.75 SP19-10 32 480 1.0 P106- 1 5 828A 2.0 P017- 7 4 Way HW090 Socket Housing : 1 : 7214/ 0001
5 873 1.0 P101-14
9 836 2.0 P058-13 9 10 4 Way HW090 Socket Ret ainer : 1 : 7214/ 0003
2 943 2.0 P030- 2 2 1851 0.75 SP39- 1 33 842 2.0 P005- 2 6 832 2.0 SP20- 1 P037
HEATER CONNECTOR 6 810 0.75 SP24- 1
10 838 2.0 SP18- 1 10 601HB 0.75 SP3- 10 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
7 107A 0.75 P093- 1
3 1851A 0.75 SP39- 2 3 407F 1.0 SP14- 4 34 125 2.0 P004- 4 Rear/ Roof Wiper Swit ch Decal : 1 : 817/ 17297
7 601BF 0.75 SP5- 4 Cav ID Tag Size Destination
11 942D 2.0 SP21- 4 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
P006
4 35 2805 0.5 P052- 4 8 100D 0.75 SP19- 5 1 800 2.0 P038- L 8 814 2.0 P020-57
I GNI TI ON RELAY 1 4
12 829E 1.5 SP6- 1 FORWARD DRI VE RELAY
5 601KD0.75 SP34-11 36 121C 1.0 SP1- 2 9 2 801 2.0 P038- M 9 872 0.75 SP26- 1
5 601FG 0.75 SP3- 7
13 942E 2.0 SP21- 5 Cav ID Tag Size Destination 6 1852 2.0 P012- 4 37 7210/ 0030 10 3 995 2.0 P038- H 10 808A 1.0 SP64- 2
6 309 2.0 P004-12
14 830 0.75 P020-50 1 852B 2.0 SP29- 3 7 1854 2.0 P019- 3 38 109 1.0 SP66- 1 4 883 2.0 P024- 1 11 304B 2.0 P003-14
7 944 2.0 P030- 5 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
Roadlight Swit ch Decal : 1 : 817/ 17257
15 014 4.0 P060- 6 2 861 2.0 SP30- 1 8 107AB 0.75 SP23- 5 39 806C 2.0 SP8- 4 5 884 2.0 P020-12 12 871 0.75 SP25- 1
8 1851B 0.75 SP39- 3 P030
16 119 1.5 P077- 1 3 809 0.75 SP63- 1 9 852 2.0 SP29- 1 40 805D 2.0 SP7- 4 WORKLAMPS SWI TCH
6 600T 2.0 P040- 3 13 874 0.75 SP27- 1
9
17 BUS BAR LI NKED WI TH CELL 15 4 10 815 0.75 P101- 8 41 407 1.0 SP14- 1 Cav ID Tag Size Destination 14 107J 0.75 SP23- 4
10 601FH 0.75 SP3- 8 6 Way .250 Fem ale Housing : 1 : 7236/ 0007
18 180 1.0 P071- 1 5 601T 0.75 SP34- 1 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
10 Way Twin Micro Relay Base : 1 : 7241/ 0003
42 7210/ 0030 1 14 Way HW090 Socket Housing : 1 : 7219/ 0005
14 Way HW090 Socket Ret ainer : 1 : 7219/ 0007
St raight Passive Bracket for Relay Housings : 1 : 7241/ 0006
19 BUS BAR LI NKED WI TH CELL 15 6 200S 6.0 SP41- 1 P012 P019 43 7210/ 0030 2 943 2.0 P011- 2 P042
DI ODE GATE
TRANSMI SSI ON DUMP PARKBRAKE/ 2 WHEEL DRI VE
20 7 011 6.0 P001- 7 PARKBRAKE WARNI NG LAMP STABI LI SER I SOLATI ON
44 7210/ 0030 3 831 2.0 SP22- 1 Cav ID Tag Size Destination
10 Way Sec Fusebox Housing : 1 : 7241/ 0001
8 100A 0.75 SP19- 2 Cav ID Tag Size Destination Cav ID Tag Size Destination 45 7210/ 0030 4 1 804A 2.0 P025-17
9 1 182 2.0 P003- 8 1 1855A 1.5 P063- 3 46 834 1.5 P002- 8 5 944 2.0 P011- 7 2 831J 2.0 SP22- 3
P003
SECONDARY FUSE BOX C 10 601X 0.75 SP3- 2 2 2 601KG 1.5 SP34-13 47 829A 1.0 SP6- 2 6 945 2.0 P057- 6 3 872A 0.75 SP26- 2
Cav ID Tag Size Destination 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
P008
3 107H 0.75 SP23- 3 3 1854 2.0 P018- 7 48 856 0.75 P012- 5 7 601AC 1.0 SP5- 5 4 872B 0.75 SP26- 3
1 001 4.0 P060- 5 FLASHER RELAY
4 1852 2.0 P018- 6 4 49 7210/ 0030 8 829J 1.0 SP6- 10 5 806 2.0 SP8- 1
2 100 0.75 SP19- 1 Cav ID Tag Size Destination 5 856 0.75 P020-48 5 601KF 0.75 SP34-12 9
50 830 0.75 P002-14 6 942A 2.0 SP21- 1
3 BUS BAR LI NKED WI TH CELL 1 1 6 401 0.5 P052-14 6 121R 1.0 SP1- 3 10
51 7210/ 0030 7 874E 0.75 SP27- 2
4 105 1.0 P093- 3 2 803 2.0 P025- 5 7 7 910 1.0 P020- 6 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
52 7210/ 0030 Front Worklight Swit ch Decal : 1 : 817/ 17258 8 871A 0.75 SP25- 2
5 BUS BAR LI NKED WI TH CELL 1 3 8 810H 0.75 SP24- 2 8 908A 1.0 P034- 1 53 941 0.75 P028- 3 8 Way HW090 Socket Housing : 1 : 7218/ 0001
6 107 0.75 SP23- 1 4 802 2.0 P025- 2 9 1853 1.0 P063- 1 9

54 7210/ 0030
7 BUS BAR LI NKED WI TH CELL 1 5 10 601R 0.75 SP3- 9 10 601DK0.75 SP34- 7 55 7210/ 0030
8 182 2.0 P012- 1 6 601U 2.0 SP3- 3 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
P013 P105 56 7210/ 0030
9 BUS BAR LI NKED WI TH CELL 1 7 DRI VE RELAY RAS Relay Left
DRI VESHAFT RELAY RAS Relay Right 57 814 2.0 P041- 8
10 108 1.0 P017- 1 8 Cav ID Tag Size Destination
Cav ID Tag Size Destination 58 2800 0.5 SP62- 1
11 200G 6.0 P062- 2 9 1 615 1.0 P102- 9
1 890 2.0 P013- 6 59 301L 1.0 SP32- 6
12 307 1.0 P029- 2 9 Way Mini Relay Housing : 1 : 7241/ 0005
2 811D 2.0 SP28- 4 2 60 2801 0.5 SP61- 1
13 BUS BAR LI NKED WI TH CELL 11 3 811C 2.0 SP28- 3 3 1805A 1.0 SP65- 2 61 7210/ 0030
14 304A,304B 2.0 P058-4,P041-11 4 861B 2.0 SP30- 3 4 615A 1.0 P102-10 62 480A 1.0 P056-13
15 BUS BAR LI NKED WI TH CELL 11 5 601EJ 2.0 SP34- 3 5 601JZ 1.0 SP10- 9 63 106F 1.0 SP9- 4
16 310 1.0 P032- 2 6 890 2.0 P013- 1 6 614 1.0 P106- 3 64 7210/ 0030
17 BUS BAR LI NKED WI TH CELL 11 7 1866 2.0 P020-14 7 65 7210/ 0030
18 301 1.0 SP32- 1 8 871B 0.75 SP25- 3 8 1805B 1.0 SP65- 3 66 7210/ 0030
19 BUS BAR LI NKED WI TH CELL 11 9 1865 2.0 P020-13 9 614A 1.0 P106- 4 67 7210/ 0030
20 300 2.0 P025- 3 10 601CZ 0.75 SP34- 4 10 610JX 1.0 SP10-11 68 604 1.0 P106- 2
10 Way Sec Fusebox Ret ainer : 1 : 7241/ 0002 10 Way Twin Micro Relay Base : 1 : 7241/ 0003 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
69 606 1.0 P056-19
70 2988 1.0 P097- 2
70 Way DRC Recept Hsg Pin Term s : 1 : 7219/ 0080
721/G2468-2
33 - 263 9823/1700-1 33 - 263

12 - Harness
15 - Front Console
Page Page
33-264 33-265

P001 P004
SECONDARY FUSE BOX A SECONDARY FUSE BOX D P009 P014
Cav ID Tag Size Destination I GNI TI ON RELAY 2 REVERSE HI GH/ LOW Cav ID
Cav ID Tag Size Destination REVERSE DRI VE RELAY FORWARD HI GH/ LOW
1 005 6.0 P059- 3 1

1 010 6.0 P009- 2 Cav ID Tag Size Destination Cav ID Tag Size Destination
2 004 4.0 P005- 1 2
2 121 1.0 SP1- 1 1 200T 6.0 SP41- 2 1 811E 2.0 SP28- 5
3 003 6.0 P060- 7 3
3 BUS BAR LI NKED WI TH CELL 1 2 010 6.0 P001- 1 2 1862 2.0 P020-28
4 125 2.0 P020-34 4
4 900 1.0 P101- 4 3 100B 0.75 SP19- 3 3 874D 0.75 SP27- 3
5 200H 6.0 P062- 1 5
5 BUS BAR LI NKED WI TH CELL 1 4 4 1863 2.0 P020-29
6 108A 1.0 P102- 8 6
6 5 601EK 0.75 SP3- 4 5 601CY 0.75 SP34- 5
7 BUS BAR LI NKED WI TH CELL 5 7
7 011 6.0 P006- 7 6 852A 2.0 SP29- 2 6 861A 2.0 SP30- 2
8 306 2.0 P017- 6 8
8 7 811B 2.0 SP28- 2 7 1860 2.0 P020-24
9 BUS BAR LI NKED WI TH CELL 7 8 808 0.75 SP64- 1 8 874C 0.75 SP27- 4
10 308 2.0 P011- 1 10
10 102 2.0 P038- B 9 9 1861 2.0 P020-30
11 012 6.0 P010- 7 10 601AA0.75 SP34- 2 10 601CX 0.75 SP34- 6
12 309 2.0 P011- 6 St raight10Passive 12
12 104 1.0 P025- 1 Way Twin Micro Relay Base : 1 : 7241/ 0003 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
13 015 6.0 P005- 7

Bracket for Relay Housings : 1 : 7241/ 0006
13
14 14
14 P010 P017

I GNI TI ON RELAY 3 BRAKELI GHTS
Roadlam ps 15
15 BUS BAR LI NKED WI TH CELL 11 I GNI TI ON RELAY 4
16 151,151A 2.0 P057-7,P067-1 Cav ID Tag Size Destination Cav ID Tag Size Destination 16
16 106 1.0 SP9- 1
17 BUS BAR LI NKED WI TH CELL 13 1 204B 6.0 SP35- 3 1 108 1.0 P003-10 17
18 181 1.0 P082- 1 2 013 6.0 P002- 1 2 816 1.0 P020- 7 18
18 109A 1.0 SP66- 2
19 BUS BAR LI NKED WI TH CELL 13 3 100H 0.75 SP19- 7 3 817 1.0 P102- 1 19
19 811A 2.0 SP28- 1
20 4 4 20
20 807 1.0 P020-31
10 Way Sec Fusebox Housing : 1 : 7241/ 0001 10 Way Sec Fusebox Housing : 1 : 7241/ 0001 5 601HL 0.75 SP3- 6 5 601GZ 0.75 SP34- 8 21
P002 P005 6 204A 6.0 SP35- 2 6 306 2.0 P004- 8 22
SECONDARY FUSE BOX B NEUTRAL START RELAY
7 012 6.0 P001-11 7 828A 2.0 P029- 5 23
Cav ID Tag Size Destination Cav ID Tag Size Destination
8 100G 0.75 SP19- 6 8 100C 0.75 SP19- 4 24
1 013 6.0 P010- 2 1 004 4.0 P004- 2
9 9 25
2 133 2.0 SP16- 1 2 842 2.0 P020-33
10 601HK 0.75 SP3- 5 10 601V 0.75 SP34- 9 26
3 BUS BAR LI NKED WI TH CELL 1 3 810G 0.75 SP24- 3
10 Way Twin Micro Relay Base : 1 : 7241/ 0003 10 Way Twin Micro Relay Base : 1 : 7241/ 0003 27
4 110 1.5 SP38- 1 4
28
5 832B 2.0 SP20- 3 5 601Z 0.75 SP3- 1
P018 29
6 905 0.75 P028- 2 6 203 6.0 P064- 1 P011
FRONT WORKI NG LAMPS ENGI NE RUNNI NG RELAY
REAR WORKI NG LAMPS PARKBRAKE 30
7 833 2.0 P058- 9 7 015 6.0 P004-13
Cav ID Tag Size Destination Cav ID Tag Size Destination 31
8 834 1.5 P020-46 8 100J 0.75 SP19- 8
1 308 2.0 P004-10 1 100N 0.75 SP19-10 32
9 836 2.0 P058-13 9
2 943 2.0 P030- 2 2 1851 0.75 SP39- 1 33
10 838 2.0 SP18- 1 10 601HB 0.75 SP3- 10
3 1851A 0.75 SP39- 2 3 407F 1.0 SP14- 4 34
11 942D 2.0 SP21- 4 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
P006
4 35
I GNI TI ON RELAY 1 4
Page 33-265
12 829E 1.5 SP6- 1 FORWARD DRI VE RELAY
5 601KD0.75 SP34-11 36
5 601FG 0.75 SP3- 7
13 942E 2.0 SP21- 5 Cav ID Tag Size Destination 6 1852 2.0 P012- 4 37
6 309 2.0 P004-12
14 830 0.75 P020-50 1 852B 2.0 SP29- 3 7 1854 2.0 P019- 3 38
7 944 2.0 P030- 5
15 014 4.0 P060- 6 2 861 2.0 SP30- 1 8 107AB 0.75 SP23- 5 39
8 1851B 0.75 SP39- 3
16 119 1.5 P077- 1 3 809 0.75 SP63- 1 9 852 2.0 SP29- 1 40
9
17 BUS BAR LI NKED WI TH CELL 15 4 10 815 0.75 P101- 8 41
10 601FH 0.75 SP3- 8
18 180 1.0 P071- 1 5 601T 0.75 SP34- 1 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
42
St raight Passive Bracket for Relay Housings : 1 : 7241/ 0006
19 BUS BAR LI NKED WI TH CELL 15 6 200S 6.0 SP41- 1 P012 P019 43
TRANSMI SSI ON DUMP PARKBRAKE/ 2 WHEEL DRI VE
20 7 011 6.0 P001- 7 PARKBRAKE WARNI NG LAMP STABI LI SER I SOLATI ON
44
8 100A 0.75 SP19- 2 Cav ID Tag Size Destination Cav ID Tag Size Destination 45
9 1 182 2.0 P003- 8 1 1855A 1.5 P063- 3 46
P003
SECONDARY FUSE BOX C 10 601X 0.75 SP3- 2 2 2 601KG 1.5 SP34-13 47
Cav ID Tag Size Destination 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
P008
3 107H 0.75 SP23- 3 3 1854 2.0 P018- 7 48
1 001 4.0 P060- 5 FLASHER RELAY
4 1852 2.0 P018- 6 4 49
2 100 0.75 SP19- 1 Cav ID Tag Size Destination 5 856 0.75 P020-48 5 601KF 0.75 SP34-12 50
3 BUS BAR LI NKED WI TH CELL 1 1 6 401 0.5 P052-14 6 121R 1.0 SP1- 3 51
4 105 1.0 P093- 3 2 803 2.0 P025- 5 7 7 910 1.0 P020- 6 52
5 BUS BAR LI NKED WI TH CELL 1 3 8 810H 0.75 SP24- 2 8 908A 1.0 P034- 1 53
6 107 0.75 SP23- 1 4 802 2.0 P025- 2 9 1853 1.0 P063- 1 9 54
7 BUS BAR LI NKED WI TH CELL 1 5 10 601R 0.75 SP3- 9 10 601DK0.75 SP34- 7 55
8 182 2.0 P012- 1 6 601U 2.0 SP3- 3 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
P013 P105 56
9 BUS BAR LI NKED WI TH CELL 1 7 DRI VE RELAY RAS Relay Left
DRI VESHAFT RELAY RAS Relay Right 57
10 108 1.0 P017- 1 8 Cav ID Tag Size Destination
Cav ID Tag Size Destination 58
11 200G 6.0 P062- 2 9 1 615 1.0 P102- 9
1 890 2.0 P013- 6 59
12 307 1.0 P029- 2 9 Way Mini Relay Housing : 1 : 7241/ 0005
2 811D 2.0 SP28- 4 2 60
13 BUS BAR LI NKED WI TH CELL 11 3 811C 2.0 SP28- 3 3 1805A 1.0 SP65- 2 61
14 304A,304B 2.0 P058-4,P041-11 4 861B 2.0 SP30- 3 4 615A 1.0 P102-10 62
15 BUS BAR LI NKED WI TH CELL 11 5 601EJ 2.0 SP34- 3 5 601JZ 1.0 SP10- 9 63
16 310 1.0 P032- 2 6 890 2.0 P013- 1 6 614 1.0 P106- 3 64
17 BUS BAR LI NKED WI TH CELL 11 7 1866 2.0 P020-14 7 65
18 301 1.0 SP32- 1 8 871B 0.75 SP25- 3 8 1805B 1.0 SP65- 3 66
19 BUS BAR LI NKED WI TH CELL 11 9 1865 2.0 P020-13 9 614A 1.0 P106- 4 67
20 300 2.0 P025- 3 10 601CZ 0.75 SP34- 4 10 610JX 1.0 SP10-11 68
10 Way Sec Fusebox Ret ainer : 1 : 7241/ 0002 10 Way Twin Micro Relay Base : 1 : 7241/ 0003 10 Way Twin Micro Relay Base : 1 : 7241/ 0003
69
70
70 Way DRC Recept Hsg Pin Term s : 1 : 7
33 - 264 9823/1700-1 33 - 264

12 - Harness
15 - Front Console
Page Page
33-264 33-265
Figure 1142. (Part 2 of 2) P020

CHASSI S CONNECTOR
P023
AI R CON SWI TCH + VE
P027
REAR WI PER SWI TCH
P032
BEACON SWI TCH
P038
HEATER SWI TCH
Cav ID Tag Size Destination Cav ID Tag Size Destination Cav ID Tag Size Destination Cav ID Tag Size Destination Cav ID Tag Size Destination
1 947A 2.0 P063- 2 1 997 2.0 P038- C 1 926 2.0 P057- 4 1 B 102 2.0 P001-10
2 7210/ 0030 6.3 Fem Pos Lock 0.7- 2.0 : 1 : 7201/ 0425
1 Way Pos Lock Housing St raight : 1 : 7201/ 0403
2 925 2.0 P057- 5 2 310 1.0 P003-16 C 997 2.0 P023- 1
3 7210/ 0030 P024
AI R CON SWI TCH - VE
3 133C 2.0 SP16- 3 3 844A 1.0 P057- 8 H 995 2.0 P037- 3
4 7210/ 0030 Cav ID Tag Size Destination 4 4 L 800 2.0 P037- 1
5 7210/ 0030 1 883 2.0 P037- 4 5 5 M 801 2.0 P037- 2
6 910 1.0 P019- 7 1 Way Pos Lock Housing St raight : 1 : 7201/ 0403
6 901B 2.0 SP17- 3 6 5 Way 6.3 Fem Hsg Heat er Swit ch : 1 : 7235/ 0006
6.3 Fem Pos Lock 0.7- 2.0 : 1 : 7201/ 0425 P039
7 816 1.0 P017- 2 P025
7 601DX 1.0 SP33- 2 7 601AY 1.0 SP5- 1 GROUND
8 7210/ 0030 HAZZARD SWI TCH 8 829AF 1.0 SP6- 9 8 829U 1.0 SP6- 12 Cav ID Tag Size Destination
9 7210/ 0030 Cav ID Tag Size Destination 9 9 1 601JC 3.0 SP3- 11
10 7210/ 0030 1 104 1.0 P001-12 10 10 2 601JE 3.0 SP10- 8
11 838B 2.0 SP18- 3 2 802 2.0 P008- 4 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
Beacon Swit ch Decal : 1 : 817/ 17260 3 601JF 2.0 SP33- 4
12 884 2.0 P037- 5 3 300 2.0 P003-20 P028
FOG LAMP SWI TCH
P034
STABI LI SER I SOLATI ON SWI TCH 4 601JD 2.0 SP5- 2
13 1865 2.0 P013- 9 4 Cav ID Tag Size Destination 5 601JH 3.0 SP34-10
Cav ID Tag Size Destination
14 1866 2.0 P013- 7 5 803,803A 2.0 P008-2,P058-14 1 908A 1.0 P019- 8 Ring Term inal M10 6.0- 10.0 : 1 : 7207/ 1510
1 P040
15 7210/ 0030 7 2 109C 1.0 SP66- 4 GROUND
2 905 0.75 P002- 6
16 7210/ 0030 8 3 Cav ID Tag Size Destination
3 941 0.75 P020-53
17 409 1.0 P055- 4 10 601AD 2.0 SP10- 7 4 1 601JG 2.0 P069- 3
4
18 408 1.0 P055- 5 17 804A 2.0 P042- 1 5 2 600P 2.0 P076- 1
5
19 402 0.5 SP58- 1 18 805 2.0 SP7- 1 6 3 600T 2.0 P037- 6
6
20 403 0.5 SP59- 1 10 Way 6.3 Fast in Swit ch Hsg Red : 1 : 7219/ 0014
Hazards Decal : 1 : 817/ 17277
7 601DC1.0 SP5- 3 7 601DZ 1.0 SP33- 3 4 601BU 2.0 P088- 3
21 404 0.5 SP60- 1 P026
ROOF WI PER SWI TCH 8 829AE 1.0 SP6- 7 8 829AS 1.0 SP6- 3 5 601AL 2.0 P088- 4
22 405 0.5 P055- 6 Cav ID Tag Size Destination 9 9 6 601AS 1.5 P077- 2
23 406 0.5 P052- 8 1 854 2.0 P057- 2 10 10 7 601AG1.5 P082- 4
24 1860 2.0 P014- 7 2 849 2.0 P057- 3 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013 8 601DD1.0 P068- 1
Rear Fog Swit ch Decal : 1 : 817/ 17256 Lock Decal : 1 : 817/ 17319
25 412 1.0 P055- 3 3 133E 2.0 SP16- 4 P036
Ring Term inal M10 6.0- 10.0 : 1 : 7207/ 1510
P041
P029
26 105 1.0 P093- 4 4
ROAD LI GHTS SWI TCH I NDI CATOR DI ODE L/ H COLUMN SWI TCH
27 7210/ 0030 Cav ID Tag Size Destination Cav ID Tag Size Destination Cav ID Tag Size Destination
5 1 805B 2.0 SP7- 3
28 1862 2.0 P014- 2 1 1 7210/ 0001
6 901 2.0 SP17- 1 2 806B 2.0 SP8- 3
29 1863 2.0 P014- 4 2 307 1.0 P003-12 2 7210/ 0001
7 601BH 1.0 SP33- 1 3 807C 2.0 SP13- 1
30 1861 2.0 P014- 9 3 942B 2.0 SP21- 2 3 7210/ 0001
8 829M 1.0 SP6- 8 4 807A 2.0 SP13- 2
31 807 1.0 P001-20 4 4 809A 1.0 SP63- 2
9
32 480 1.0 P106- 1 5 828A 2.0 P017- 7 4 Way HW090 Socket Housing : 1 : 7214/ 0001
5 873 1.0 P101-14
10
33 842 2.0 P005- 2 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
6 832 2.0 SP20- 1 P037
HEATER CONNECTOR 6 810 0.75 SP24- 1
34 125 2.0 P004- 4 Rear/ Roof Wiper Swit ch Decal : 1 : 817/ 17297
7 601BF 0.75 SP5- 4 Cav ID Tag Size Destination 7 107A 0.75 P093- 1
35 2805 0.5 P052- 4 8 100D 0.75 SP19- 5 1 800 2.0 P038- L 8 814 2.0 P020-57
Page 33-264
36 121C 1.0 SP1- 2 9 2 801 2.0 P038- M 9 872 0.75 SP26- 1

37 7210/ 0030 10 3 995 2.0 P038- H 10 808A 1.0 SP64- 2
38 109 1.0 SP66- 1 10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
Roadlight Swit ch Decal : 1 : 817/ 17257 4 883 2.0 P024- 1 11 304B 2.0 P003-14
39 806C 2.0 SP8- 4 P030
5 884 2.0 P020-12 12 871 0.75 SP25- 1
40 805D 2.0 SP7- 4 WORKLAMPS SWI TCH
6 600T 2.0 P040- 3 13 874 0.75 SP27- 1
41 407 1.0 SP14- 1 Cav ID Tag Size Destination 6 Way .250 Fem ale Housing : 1 : 7236/ 0007 14 107J 0.75 SP23- 4
42 7210/ 0030 1 14 Way HW090 Socket Housing : 1 : 7219/ 0005
43 7210/ 0030 2 943 2.0 P011- 2 P042

DI ODE GATE
44 7210/ 0030 3 831 2.0 SP22- 1 Cav ID Tag Size Destination

45 7210/ 0030 4 1 804A 2.0 P025-17
46 834 1.5 P002- 8 5 944 2.0 P011- 7 2 831J 2.0 SP22- 3
47 829A 1.0 SP6- 2 6 945 2.0 P057- 6 3 872A 0.75 SP26- 2
48 856 0.75 P012- 5 7 601AC 1.0 SP5- 5 4 872B 0.75 SP26- 3
49 7210/ 0030 8 829J 1.0 SP6- 10 5 806 2.0 SP8- 1
50 830 0.75 P002-14 9 6 942A 2.0 SP21- 1
51 7210/ 0030 10 7 874E 0.75 SP27- 2
10 Way 6.3 Fast in Swit ch Hsg : 1 : 7219/ 0013
52 7210/ 0030 Front Worklight Swit ch Decal : 1 : 817/ 17258 8 871A 0.75 SP25- 2
53 941 0.75 P028- 3 8 Way HW090 Socket Housing : 1 : 7218/ 0001
54 7210/ 0030
55 7210/ 0030
56 7210/ 0030

Service Manual: Foreword

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Foreword

The Operator's Manual

You and others can be killed or seriously injured

SERVICE MANUAL Do not operate the machine without an Operator's

Treat the Operator's Manual as part of the machine.

LOADALL (ROUGH TERRAIN

Copyright 2018 Â© JCB SERVICE

SERVICE MANUAL SERVICE MANUAL

506-36, 507-42, 506-36, 507-42,

SERVICE MANUAL SERVICE MANUAL

506-36, 507-42, 506-36, 507-42,

Acronyms Glossary .................................................................................................................................... 01-2

FOPS Falling Object Protective Structure

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual there are safety notices. Each notice

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system symbol (shown) also helps

Figure 1. The safety alert system symbol

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety exhaust extractor. If you begin to feel drowsy, stop

Machine Limits Unguarded machines in public places can be

Exhaust Gases This machine is designed for use in normal out

Regulations clearly. Modification of the machine's configuration

Electrical Power Cables Hands and Feet

Working Platform Passengers

Travelling at high speeds can cause accidents. Confined Areas

Operating the machine on hillsides can be Safe Working Loads

has passed. Do not attempt to mount or enter the

21 - Worksite Safety An applicable worksite organisation is required in

24 - Risk Assessment Loading/Unloading Area

27 - Maintenance Positions Introduction

Lift Arm Lowered

A Lift arm lowered

Lift Arm Raised

Health and Safety

06 - About this Manual

Contents Page No.

01-06-00 General ........................................................................................................................... 01-17

This supplement must be used in conjunction with

Study this supplement, the operator manual and

This supplement is arranged to give you a good

Do not operate the machine without this supplement.

Treat this supplement as part of the machine.

If there is anything you are not sure about, ask your

The illustrations in this supplement are for guidance

The manufacturer's policy is one of continuous

03 - Model and Serial Number

06 - Using the Manual

Machine Variants • Use the applicable Servicemaster diagnostics

Contents Page No.

01-09-00 General ........................................................................................................................... 01-21

A main structural support is designed to carry an