JCB Pilnas Manualas

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
526-56, 531-70, 535-95, 536-60, 536-70,
01 - Machine
536-70LP, 541-70, 550-80, 560-80
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 - 9813/7600 - ISSUE 3 - 03/2018
25 - Steering System
27 - Driveline
30 - Hydraulic System
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
Copyright 2018 © JCB SERVICE

78 - After Sales
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Notes:
9813/7600-3
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
526-56, 531-70, 535-95, 526-56, 531-70, 535-95,

536-60, 536-70, 536-70LP, 536-60, 536-70, 536-70LP,
541-70, 550-80, 560-80 541-70, 550-80, 560-80
EN 9813/7600 EN 9813/7600
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
526-56, 531-70, 535-95, 526-56, 531-70, 535-95,

536-60, 536-70, 536-70LP, 536-60, 536-70, 536-70LP,
541-70, 550-80, 560-80 541-70, 550-80, 560-80
EN 9813/7600 EN 9813/7600
9813/7600-3
Notes:
9813/7600-3
01 - Machine
Contents Page No.
Acronyms Glossary .................................................................................................................................... 01-2
01-03 Safety
01-03-03 Safety - Yours and Others ............................................................................................... 01-3
01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01-06 About this Manual
01-06-03 Model and Serial Number .............................................................................................. 01-15
01-06-06 Using the Manual ........................................................................................................... 01-16
01-09 Description
01-09-00 General ........................................................................................................................... 01-19
01-09-03 Log Moving/Object Handling .......................................................................................... 01-21
01-09-06 Optional Equipment and Attachments ........................................................................... 01-22
01-09-12 Main Component Locations ........................................................................................... 01-23
01-09-15 Service Point Locations ................................................................................................. 01-24
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-33
9813/7600-3
2018-02-05
Acronyms Glossary
FOPS Falling Object Protective Structure

PIL Parts Identification List
ROPS Roll-Over Protective Structure
9813/7600-3
2018-02-05
01 - Machine
03 - Safety
03 - Safety
Contents Page No.
01-03-03 Safety - Yours and Others ............................................................................................... 01-3

01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-03-21 Worksite Safety .............................................................................................................. 01-10
01-03-24 Risk Assessment ............................................................................................................ 01-11
01-03-27 Maintenance Positions ................................................................................................... 01-12
01 - 1 9813/7600-3 01 - 1
Notes:
01 - 2 9813/7600-3 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 9813/7600-3 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 9813/7600-3 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 9813/7600-3 01 - 5
01 - Machine
03 - Safety
12 - Maintenance Safety
12 - Maintenance Safety Hydraulic Pressure

Hydraulic fluid at system pressure can injure you.
Introduction Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
Raised Machine service line has been vented before connecting or
Never position yourself or any part of your body removing hoses. Make sure the engine cannot be
under a raised machine which is not correctly started while the hoses are open.
supported. If the machine moves unexpectedly you 'O' rings, Seals and Gaskets
could become trapped and suffer serious injury or be
killed. Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
Air Conditioning Maintenance accidents. Renew whenever disturbed unless
The air conditioning system is a closed loop system otherwise instructed. Do not use Triochloroethane or
and contains pressurised refrigerant. No part of the paint thinners near 'O' rings and seals.
system should be disconnected until the system Arc Welding
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely To prevent the possibility of damage to electronic
frostbitten or injured by escaping refrigerant. components, disconnect the battery and the
alternator before arc-welding on the machine or
Compressed Air attached implements.
Compressed air is dangerous. Wear personal If the machine is equipped with sensitive electrical
protective equipment. Never point a compressed air equipment, i.e. amplifier drivers, electronic control
jet at yourself or others. units (ECUs), monitor displays, etc., then disconnect
Springs them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Always wear personal protective equipment when
irreparable damage to these components.
dismantling assemblies containing components
under pressure from springs. This will protect against Parts of the machine are made from cast iron, welds
eye injury from components accidentally flying out. on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
Metal Splinters
or apply any weld to any part of the engine.
You can be injured by flying metal splinters when
Always connect the welder earth (ground) cable to
driving metal pins in or out. Use a soft faced hammer
the same component that is being welded to avoid
or copper drift to remove and install metal pins.
damage to pivot pins, bearings and bushes. Attach
Always wear personal protective equipment.
the welder earth (ground) cable a distance from the
Communications part being welded no more than 0.6m.
Bad communications can cause accidents. If two Counterweights
or more people are working on the machine, make
Your machine may be installed with counterweights.
sure each is aware of what the others are doing.
They are extremely heavy. Do not attempt to remove
Before starting the engine make sure the others are
them.
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the Accumulators
attachments and linkages, and anywhere beneath or The accumulators contain hydraulic fluid and gas at
behind the machine. People can be killed or injured high pressure. Prior to any work being carried out
if these precautions are not taken. on systems incorporating accumulators, the system
Repairs pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
If your machine does not function correctly in
cause serious injury or death.
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect Hot Components
your health. Do not try to do repairs or any other Touching hot surfaces can burn skin. The engine and
type of maintenance work you do not understand. To machine components will be hot after the unit has
avoid injury and/or damage get the work done by a been running. Allow the engine and components to
specialist engineer. cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
01 - 6 9813/7600-3 01 - 6
01 - Machine
03 - Safety
12 - Maintenance Safety
Working Under the Machine

Make the machine safe before getting beneath it.
Make sure that any attachments on the machine are
correctly attached. Engage the park brake, remove
the ignition key, disconnect the battery. If the machine
has wheels use blocks to prevent unintentional
movement.
Lifting the Machine
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
Chemicals
Certain seals and gaskets (e.g. crankshaft oil
seal) on JCB machines contain fluoroelastomeric
materials such as Viton®, FluorelTM and
Technoflon®. Fluoroelastomeric materials subjected
to high temperatures can produce highly
corrosive hydrofluoric acid. This acid can severely
burn. New fluoroelastomeric components at
ambient temperature require no special safety
precautions. Used fluoroelastomeric components
whose temperatures have not exceeded 300°C
(571.6°F) require no special safety precautions. If
evidence of decomposition (e.g. charring) is found,
refer to the next paragraph for safety instructions.
Do not touch component or surrounding area.
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (571.6°F) (e.g.
engine fire) must be treated using the following
safety procedure. Make sure that heavy duty gloves
and special safety glasses are worn: Thoroughly
wash contaminated area with 10% calcium hydroxide
or other suitable alkali solution, if necessary use
wire wool to remove burnt remains. Thoroughly
wash contaminated area with detergent and water.
Contain all removed material, gloves etc. used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations. Do not
burn fluoroelastiometric materials.
Hydraulic Hoses
Never re-use hydraulic hose end crimps or use
reusable hose end crimps.
Personal Protective Equipment
Use the appropriate personal protective equipment
before performing maintenance on the machine,
otherwise you could be injured.
Working at Height
Use appropriate access equipment such as ladders
or a working platform if it is necessary to work at
height to perform maintenance tasks on the machine.
If you do not use suitable access equipment there is
a risk of falling, resulting in personal injury or death.
01 - 7 9813/7600-3 01 - 7
01 - Machine
03 - Safety
18 - Operating Safety
18 - Operating Safety Worksites

Worksites can be hazardous. Examine the site
Introduction before working on it. You could be killed or injured
if the ground gives way under your machine or if
piled material collapses onto it. Check for potholes
Training and hidden debris, logs, ironwork etc. Any of these
Make sure that you have had adequate training and could cause you to lose control of your machine.
that you are confident in your ability to operate the Check for utilities such as electric cables (overhead
machine safely before you use it. Practice using the and underground), gas and water pipes etc. Mark
machine and its attachments until you are completely the positions of the underground cables and pipes.
familiar with the controls and what they do. With Make sure that you have enough clearance beneath
a careful, well trained and experienced operator, overhead cables and structures.
your machine is a safe and efficient machine. With Communications
an inexperienced or careless operator, it can be
dangerous. Do not put your life, or the lives of others, Bad communications can cause accidents. Keep
at risk by using the machine irresponsibly. Before you people around you informed of what you will be
start to work, tell your colleagues what you will be doing. If you will be working with other people,
doing and where you will be working. On a busy site, make sure any hand signals that may be used are
use a signalman. understood by everybody. Worksites can be noisy, do
not rely on spoken commands.
Before doing any job not covered in this manual, find
out the correct procedure. Your local JCB distributor Parking
will be glad to advise you. An incorrectly parked machine can move without an
Fuel operator. Follow the instructions in the Operator's
Manual to park the machine correctly.
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel Banks and Trenches
leak is suspected. Do not smoke while refuelling or Banked material and trenches can collapse. Do not
working on the fuel system. Do not refuel with the work or drive too close to banks and trenches where
engine running. Completely wipe off any spilt fuel there is danger of collapse.
which could cause a fire. There could be a fire and
injury if you do not follow these precautions. Safety Barriers
Machine Condition Unguarded machines in public places can be
dangerous. In public places, or where your visibility
A defective machine can injure you or others. Do not is reduced, place barriers around the work area to
operate a machine which is defective or has missing keep people away.
parts. Make sure the maintenance procedures in this
manual are completed before using the machine. Sparks
Machine Limits Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
Operating the machine beyond its design limits can machine in closed areas where there is flammable
damage the machine, it can also be dangerous. material, vapour or dust.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with Hazardous Atmospheres
unapproved modifications or additional equipment. This machine is designed for use in normal out
Engine/Steering Failure door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
If the engine or steering fails, stop the machine as Do not use the machine in a potentially explosive
quickly as possible. Do not operate the machine until atmosphere, i.e. combustible vapours, gas or dust,
the fault has been corrected. without first consulting your JCB dealer.
Exhaust Gases Regulations
Machine exhaust gases can harm and possibly kill Obey all laws, worksite and local regulations which
you or bystanders if they are inhaled. Do not operate affect you and your machine.
the machine in closed spaces without making sure
there is good ventilation. If possible, install an
exhaust extractor. If you begin to feel drowsy, stop
the machine at once and get into fresh air.
01 - 8 9813/7600-3 01 - 8
01 - Machine
03 - Safety
18 - Operating Safety
Electrical Power Cables Hands and Feet

You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine.
the machine or its attachments too close to electrical When using the machine, keep your hands and feet
power cables. clear of moving parts. Keep your hands and feet
You are strongly advised to make sure that the safety within the operator compartment while the vehicle is
arrangements on site comply with the local laws in motion.
and regulations concerning work near electric power Controls
lines.
You or others can be killed or seriously injured
Before you start using the machine, check with your if you operate the control levers from outside the
electricity supplier if there are any buried power machine. Operate the control levers only when you
cables on the site. are correctly seated.
There is a minimum clearance required for working Passengers
beneath overhead power cables. You must obtain
details from your local electricity supplier. Passengers in or on the machine can cause
accidents. Do not carry passengers.
Working Platform
Fires
Using the machine as a working platform is
hazardous. You can fall off and be killed or injured. If your machine is equipped with a fire extinguisher,
Never use the machine as a working platform make sure it is checked regularly. Keep it in the
unless with approved man-basket or man-crate (if correct machine location until you need to use it.
applicable). Do not use water to put out a machine fire, you could
Machine Safety spread an oil fire or get a shock from an electrical
fire. Use carbon dioxide, dry chemical or foam
Stop work at once if a fault develops. Abnormal extinguishers. Contact your nearest fire department
sounds and smells can be signs of trouble. Examine as quickly as possible.
and repair before resuming work.
Roll Over Protection
Hot Components
If the machine starts to roll over, you can be crushed
Touching hot surfaces can burn skin. The engine and if you try to leave the cab. If the machine starts to roll
machine components will be hot after the unit has over, do not try and jump from the cab. Stay in the
been running. Allow the engine and components to cab, with your seat belt fastened.
cool before servicing the unit.
Confined Areas
Travelling at High Speeds
Pay extra attention to proximity hazards when
Travelling at high speeds can cause accidents. operating in confined areas. Proximity hazards
Always travel at a safe speed to suit working include buildings, traffic and bystanders.
conditions.
Safe Working Loads
Hillsides
Overloading the machine can damage it and make it
Operating the machine on hillsides can be unstable. Study the specifications in the Operator's
dangerous if the correct precautions are not taken. Manual before using the machine.
Ground conditions can be changed by rain, snow, ice
etc. Check the site carefully. When applicable, keep Lightning
all attachments low to the ground. If you are inside the machine during a lightning storm
Visibility stay in the machine until the storm has passed. If
you are outside of the machine during a lightning
Accidents can be caused by working in poor visibility. storm stay away from the machine until the storm
Use your lights to improve visibility. Keep the road has passed. Do not attempt to mount or enter the
lights, windows, mirrors and cameras clean (when machine.
fitted).
If the machine is struck by lightning do not use the
Do not operate the machine if you cannot see clearly. machine until it has been checked for damage and
Modification of the machine's configuration by the malfunction by trained personnel.
user (e.g. the fitting of large and non-approved
attachments) may result in a restriction of the
machine visibility.
01 - 9 9813/7600-3 01 - 9
01 - Machine
03 - Safety
21 - Worksite Safety
21 - Worksite Safety An applicable worksite organisation is required in

order to minimise hazards that are caused by
restricted visibility. The worksite organisation is a
Introduction collection of rules and procedures that coordinates
the machines and people that work together in
WARNING You or others can be killed or seriously the same area. Examples of worksite organisation
injured if you do unfamiliar operations without first include:
practising them. Practise away from the worksite
on a clear area. Keep other people away. Do not • Restricted areas
perform new operations until you are sure you can • Controlled patterns of machine movement
do them safely. • A system of communication.
WARNING There could be dangerous materials
such as asbestos, poisonous chemicals or other You and/or your company could be legally liable for
harmful substances buried on the site. If you any damage you may cause to public utilities. It is
uncover any containers or you see any signs of your responsibility to make sure that you know the
toxic waste, stop the machine and advise the site locations of any public utility cables or pipes on the
manager immediately. worksite which could be damaged by your machine.
WARNING Before you start using the machine,
check with your local gas company if there are
any buried gas pipes on the site.
If there are buried gas pipes we recommend that
you ask the gas company for any specific advice
regarding the way you must work on the site.
Some modern gas pipes cannot be detected by
metal detectors, so it is essential that an accurate
map of buried gas pipes is obtained before any
excavation work commences.
Hand dig trial holes to obtain precise pipe
locations. Any cast iron pipes found must be
assumed to be gas pipes until contrary evidence
is obtained.
Older gas pipes can be damaged by heavy
vehicles driving over the ground above them.
Leaking gas is highly explosive.
If a gas leak is suspected, contact the local gas
company immediately and warn all personnel on
the site. Ban smoking, make sure that all naked
lights are extinguished and switch off any engines
which may be running.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
gas pipes.
CAUTION Before you start using the machine,
check with your local public water supplier if there
are buried pipes and drains on the site. If there
are, obtain a map of their locations and follow the
advice given by the water supplier.
You are strongly advised to make sure that the
safety arrangements on site comply with the local
laws and regulations concerning work near buried
pipes and drains.
CAUTION If you cut through a fibre optic cable,
Do not look into the end of it, your eyes could be
permanently damaged.
01 - 10 9813/7600-3 01 - 10
01 - Machine
03 - Safety
24 - Risk Assessment
24 - Risk Assessment Loading/Unloading Area

• Is it level? Any slope of more than 2.5% (1 in
Introduction 40) must be carefully considered.
• Is more than one direction of approach to the
load possible? Approaching across the slope
It is the responsibility of the competent people that must be avoided, if possible.
plan the work and operate the machine to make a • Is the ground solid? Will it support the weight of
judgement about the safe use of the machine, they the machine when loaded?
must take into account the specific application and • How rough is the ground? Are there any
conditions of use at the time. sharp projections which could cause damage,
particularly to the tyres?
It is essential that a risk assessment of the work to be • Are there any obstacles or hazards in the area,
done is completed and that the operator obeys any for example, debris, excavations, manhole
safety precautions that the assessment identifies. covers, power lines?
• Is the space sufficient for safe manoeuvring?
If you are unsure of the suitability of the machine for • Are any other machines or persons likely to be
a specific task, contact your JCB dealer who will be in or to enter the area while operations are in
pleased to advise you. progress?
The following considerations are intended as
suggestions of some of the factors to be taken into The Route to be Travelled
account when a risk assessment is made. Other • How solid is the ground, will it provide sufficient
factors may need to be considered. traction and braking? Soft ground will affect the
stability of the machine and this must be taken
A good risk assessment depends on the training and into account.
experience of the operator. Do not put your life or the • How steep are any slopes, up/down/across?
lives of others at risk. A cross slope is particularly hazardous, is it
possible to detour to avoid them?
Personnel
• Are all persons who will take part in the Weather
operation sufficiently trained, experienced and • How windy is it? High wind will adversely affect
competent? Are they fit and sufficiently rested? the stability of a loaded machine, particularly if
A sick or tired operator is a dangerous operator. the load is bulky.
• Is supervision needed? Is the supervisor • Is it raining or is rain likely? The ground that
sufficiently trained and experienced? was solid and smooth when dry will become
• As well as the machine operator, are any uneven and slippery when wet, and it will not
assistants or lookouts needed? give the same conditions for traction, steering
or braking.
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres still at the correct pressure and
in good condition and is there sufficient fuel to
complete the job (if applicable)?
The Load
• How heavy is it? Is it within the capabilities of
the machine?
• How bulky is it? The greater the surface area,
the more affected it will be by wind speeds.
• Is it an awkward shape? How is the weight
distributed? Uneven loads are more difficult to
handle.
• Is there a possibility of the load shifting while
being moved?
01 - 11 9813/7600-3 01 - 11
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-12
Health and Safety .......................................... 01-13
(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1])
You can complete most of the maintenance
procedures with the lift arm lowered. Unless a
maintenance procedure instructs you differently, you
must lower the lift arm.
Lift Arm Lowered

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: 15s
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 - 12 9813/7600-3 01 - 12
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 - 13 9813/7600-3 01 - 13
01 - Machine
06 - About this Manual
Contents Page No.
01-06-03 Model and Serial Number .............................................................................................. 01-15

01-06-06 Using the Manual ........................................................................................................... 01-16
01 - 14 9813/7600-3 01 - 14
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:
536-70LP 2460601
2902000
2460601
526-56 2460601
2902000
531-70 2460601
2902000
2336575
535-95 2460601
2902000
2336575
536-60 2460601
2902000
2336575
536-70 2460601
2902000
2336575
541-70 2460601
2902000
2336575
550-80 2460601
2902000
2460601
560-80 2460601
2902000
2336575
01 - 15 9813/7600-3 01 - 15
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 - 16 9813/7600-3 01 - 16
01 - Machine
09 - Description
09 - Description
Contents Page No.
01-09-00 General ........................................................................................................................... 01-19

01-09-03 Log Moving/Object Handling .......................................................................................... 01-21
01-09-06 Optional Equipment and Attachments ........................................................................... 01-22
01-09-12 Main Component Locations ........................................................................................... 01-23
01-09-15 Service Point Locations ................................................................................................. 01-24
01 - 17 9813/7600-3 01 - 17
Notes:
01 - 18 9813/7600-3 01 - 18
01 - Machine
09 - Description
00 - General
00 - General Introduction
Introduction .................................................... 01-19 The JCB Loadall is a self propelled, seated operator,
Operation ....................................................... 01-20 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 - 19 9813/7600-3 01 - 19
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 - 20 9813/7600-3 01 - 20
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 - 21 9813/7600-3 01 - 21
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 - 22 9813/7600-3 01 - 22
01 - Machine
09 - Description
12 - Main Component Locations
12 - Main Component Locations
Component Identification
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 - 23 9813/7600-3 01 - 23
01 - Machine
09 - Description
15 - Service Point Locations
(For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY],
JCB T4F 4.4 over 55kw Electronic Dieselmax Turbocharged Aftercooled Engine)
Engine Compartment
Figure 4.
A B
H
C
G E
F
A Air filter B Transmission oil dipstick

C Water separator D Radiator
E Engine oil filter F Drive belt guard
G Engine oil dipstick H Engine oil filler cap
J Coolant expansion tank
01 - 24 9813/7600-3 01 - 24
01 - Machine
09 - Description
Battery Isolator
Figure 5.
A
A
A Battery isolator
01 - 25 9813/7600-3 01 - 25
01 - Machine
09 - Description
Hydraulic Oil Level Indicator

Machines with External Sight Gauge
Figure 6.
A Hydraulic oil level indicator
Figure 7.
A B
C
A Label - hydraulic oil filling point B Hydraulic oil level indicator

C Hydraulic tank filler cap
01 - 26 9813/7600-3 01 - 26
01 - Machine
09 - Description
Machines without External Sight Gauge

Figure 8.
A
A Hydraulic oil level indicator
Figure 9.
C
A
A Hydraulic oil level indicator B Label - hydraulic oil filling point

C Hydraulic tank filler cap
01 - 27 9813/7600-3 01 - 27
01 - Machine
09 - Description
Axles
For: 550-80
Figure 10.
A A
A Axle fill/level plug
01 - 28 9813/7600-3 01 - 28
01 - Machine
09 - Description
For: Other Models
Figure 11. Machines with Double Acting Cylinders
A
A
A Axle fill/level plug
Filling the Tank

Figure 12.
A
B
A Diesel exhaust fluid tank cap (blue)

B Diesel fuel tank cap (green - USA only, black -
all other territories)
01 - 29 9813/7600-3 01 - 29
01 - Machine
09 - Description
Figure 13.
A Diesel exhaust fluid tank cap (blue) B Diesel fuel tank cap (green - USA only, black -
all other territories)
01 - 30 9813/7600-3 01 - 30
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-33
01 - 31 9813/7600-3 01 - 31
Notes:
01 - 32 9813/7600-3 01 - 32
01 - Machine
33 - Cleaning
00 - General
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-33 or other chemicals, you must adhere to
Preparation .................................................... 01-34 the manufacturer's instructions and safety
precautions.
CAUTION To avoid burning, wear personal
protective equipment when handling hot
components. To protect your eyes, wear goggles
when using a brush to clean components.
Notice: Cleaning metal parts with incorrect
solvents can cause corrosion. Use only
recommended cleaning agents and solvents.
Notice: The efficiency of the rams will be affected
if they are not kept free of solidified dirt. Clean dirt
from around the rams regularly. When leaving or
parking the machine, close all rams if possible to
reduce the risk of weather corrosion.
Notice: Never use water or steam to clean inside
the operator station. The use of water or steam
could damage the machine electrics and render
the machine inoperable. Remove dirt using a
brush or damp cloth.
Clean the product with water and/or steam. Do not

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

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

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

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

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

CAUTION When using a steam cleaner, wear
safety glasses or a face shield as well as
protective clothing. Steam can cause personal
injury.
01 - 33 9813/7600-3 01 - 33
01 - Machine
33 - Cleaning
00 - General
Notice: The engine and other components could Preparation

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

after pressure washing or steam cleaning.
01 - 34 9813/7600-3 01 - 34
03 - Attachments, Couplings and Load Handling
Contents Page No.
03-00 Attachments
03-00-00 General ............................................................................................................................. 03-3
03-33 Fork
03-33-00 General ............................................................................................................................. 03-7
03-33-03 Carriage .......................................................................................................................... 03-10
03-82 Jib
03-82-00 General ........................................................................................................................... 03-15
03-82-06 Shackle ........................................................................................................................... 03-17
03-84 Hook
03-84-06 Snatch Block .................................................................................................................. 03-21
9813/7600-3
2018-01-17
Notes:
9813/7600-3
2018-01-17
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9813/7600-3 03 - 1
Notes:
03 - 2 9813/7600-3 03 - 2
00 - Attachments
00 - General
Introduction ...................................................... 03-3 A wide range of optional attachments are available
Health and Safety ........................................... 03-4 to increase the versatility of your machine. Only JCB
approved attachments are recommended for use
with your machine. Consult your JCB Distributor for
the full list of approved attachments available.
Some attachments are supplied complete with

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

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

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

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

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

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

until the machine hydraulic oil has reached its normal
working temperature.
03 - 3 9813/7600-3 03 - 3
00 - Attachments
00 - General
Health and Safety

Attachments
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or others.
The use of non-approved attachments could
invalidate your warranty.
Attachments
If you have an attachment which is not covered in the
Operator's Manual do not install it, use it or remove
it until you have obtained, read and understood the
pertinent information. Install attachments only on the
machines for which they were designed.
WARNING! Load and unload on firm, level ground.
Always be alert for possible hazards. Take special
care when turning or reversing.
DANGER! Before lowering the attachments to the
ground, make sure that the machine and the area
around it are clear of other people. Anyone on or
close to the machine could fall and be crushed by the
attachments, or get caught in the linkages.
DANGER! Using the forks alone as a working
platform is hazardous; you can fall off and be killed
or injured. Never use the forks as a working platform.
03 - 4 9813/7600-3 03 - 4
33 - Fork
33 - Fork
Contents Page No.
03-33-00 General ............................................................................................................................. 03-7

03-33-03 Carriage .......................................................................................................................... 03-10
03 - 5 9813/7600-3 03 - 5
Notes:
03 - 6 9813/7600-3 03 - 6
33 - Fork
00 - General
Introduction ...................................................... 03-7 Forks can be installed on many different types of
Health and Safety ........................................... 03-8 agricultural or construction machines. Forks can be
Adjust .............................................................. 03-8 directly mounted on to a lift arm or carriage or
mounted to a lift arm via a quickhitch assembly.
There are a vast amount and size of forks used for
numerous applications.
Forks can be used to lift, raise and carry heavy things

and stack them where required.
03 - 7 9813/7600-3 03 - 7
33 - Fork
00 - General
Health and Safety Adjust

DANGER Using the forks alone as a working WARNING Loads can fall off incorrectly spaced
platform is hazardous; you can fall off and be forks. Always space the forks correctly for the
killed or injured. Never use the forks as a working load. Make sure the forks are completely under
platform. the load before lifting.
WARNING Loads can fall off incorrectly spaced CAUTION To prevent unintentional detachment
forks. Always space the forks correctly for the of forks during travel or transportation, the forks
load. Make sure the forks are completely under must not overlap the lower removal notch or be
the load before lifting. secured in the central two positions on top of the
carriage.
WARNING If the fork/locking pin is not fully
engaged, the fork could become unintentionally CAUTION The forks are heavy. Make sure
disengeged. suitable lifting equipment is used to support and
transport them.
WARNING Do not try to correct the alignment
of the fork tips by bending the forks or adding WARNING If the fork/locking pin is not fully
shims. Never repair damaged forks by heating or engaged, the fork could become unintentionally
welding. Forks are made of special steel using disengeged.
special procedures. Always replace the damaged
forks.
Repositioning the Forks
WARNING Overloaded scaffolding can collapse.
Never load scaffolding beyond the regulation Industrial Carriage Fork Adjustment
capacity.
WARNING The forks project in front of the 1. Make the machine safe. Apply the park brake (if
machine. Make sure there is enough clearance installed).
for the forks when making turns.
2. Lower the forks as required to enable the use of
CAUTION A load lifted on one fork can slip off. suitable lifting equipment to move the forks.
Never lift a load with one fork.
3. Stop the engine. Remove the ignition key.
CAUTION Never unload the forks by stopping the
machine suddenly. Follow the procedures in the 4. Release the locking pins and slide the forks to the
Operator Manual for unloading. desired position using suitable lifting equipment.
CAUTION The forks are heavy. Make sure Your machine will have either 'twist and pull'
suitable lifting equipment is used to support and or 'pull' type fork locking pins. Forks must not
transport them. overlap the lower removal notch or be secured in
the central two positions on top of the carriage,
CAUTION Do not exceed the total rated load see shaded 'no fork' zone.
capacity of the forks being used. Forks can break
resulting in a loss of load and possible injury.
CAUTION Loads stacked on uneven ground can
topple. Never stack loads on uneven ground.
03 - 8 9813/7600-3 03 - 8
33 - Fork
00 - General
Figure 14.
A Locking pins
B Lower removal notch
C 'No fork' zone
5. Re-engage the locking pins. Make sure the pins
and forks are correctly located.
6. Remove the lifting equipment.
03 - 9 9813/7600-3 03 - 9
33 - Fork
03 - Carriage
03 - Carriage
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 536-60 Figure 15.

[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD] B C
................................................... Page 03-10
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 03-10
For: 526-56 [T4F] ...................... Page 03-11
(For: 531-70 [5AA], 531-70 [5TA], 536-60

[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
Two stage booms (P1) D A
Remove
2. Position the lift arm so that the fork carriage can
be safely supported when it is disconnected from
the lift arm assembly. A Fork carriage
B Bolt
3. Discharge the hydraulic pressure. C Tipping lever pivot
Refer to: PIL 30-00. D Pivot pin
4. Support the fork carriage. Install

5. Remove the bolt and tipping lever pivot pin. 1. The installation procedure is the opposite of the
removal procedure.
6. Remove the lock nut and bolt from the pivot pin
trunnion.
7. Remove the pivot pin from its location.
(For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY])
8. Remove the fork carriage.
Two stage booms (P2)
Remove
2. Position the lift arm so that the fork carriage can
be safely supported when it is disconnected from
the lift arm assembly.
3. Discharge the hydraulic pressure.
4. Support the fork carriage.
5. Remove the securing bolt and remove the pivot
pin 1 from the tipping link.
03 - 10 9813/7600-3 03 - 10
33 - Fork
03 - Carriage
6. Remove the securing bolt and remove the pivot 7. Remove the fork carriage.
pin 2.
Figure 16.
D
E
A
A Fork carriage B Pivot pin 1

C Tipping link D Bolt
E Pivot pin 2
Install 2. Remove the existing attachment.
1. The installation procedure is the opposite of the 3. Leave the tool carrier lock pin disengaged or
removal procedure. remove from stowage position.
4. Engage the attachment.
(For: 526-56 [T4F]) 4.1. Make sure that the carrier lock pin is
WARNING Do not retract the locking pins when withdrawn.
the attachment is raised, the attachment could fall 4.2. Use the control levers to align the carrier
and kill or seriously injure someone. Retract the with the attachment and just below the
locking pins only after the attachment has been attachment hook plates.
placed on the ground.
4.3. Apply the park brake.
Mechanical Pin Locking 4.4. Set the transmission to neutral.

4.5. Use the lift arm controls to engage the
Installing Attachments support bar on the carrier into the hook
plates on the attachment.
1. Position the attachment.
4.6. Make sure that both hook plates are
1.1. Make sure the attachment is on firm, level engaged equally.
ground.
4.7. Lift and tilt the carrier back, to align the
1.2. Make sure the attachment will not roll over. locking holes in the carrier with those in the
attachment.
03 - 11 9813/7600-3 03 - 11
33 - Fork
03 - Carriage
5. Insert the lock pin. ensure that he keeps clear of the machine and
attachment until signalled by you to proceed.
5.1. Make sure that the transmission is set to
neutral and that the park brake is on. 1. Lower the attachment to the ground.
5.2. Stop the engine.
2. If the attachment is hydraulically operated,
5.3. Remove the ignition key. connect the hoses.
5.4. At the carrier, insert the lock pin into the 3. Make sure the transmission is set to neutral and
locking holes in the carrier and attachment. the park brake is applied.
5.5. Secure with lynch pin.
4. Stop the engine.
5.6. If a second person is to do this job keep your
hands and feet away from the controls until 5. Remove the ignition key.
he is clear of the machine.
6. Remove the locking pin.
connect the hoses. 6.1. Remove the lynch pin and withdraw the
locking pin.
Figure 17.
6.2. Install the locking pin in stowage position.
6.3. Start the engine.
6.4. Tilt the carrier forward slowly to withdraw
the lower end of the carrier from the
attachment.
A
6.5. Then lower the lift arm slowly to withdraw
the carrier from the attachment hook plates.
6.6. Carefully reverse the machine away from
the attachment or retract the lift arm.
Hydraulic Pin Locking

The hydraulic pin locking option allows attachments
to be installed or removed without leaving the cab.
A Lock pin
Installing Attachments
Figure 18.
1. Park the machine on firm level ground.
C
2. Apply the park brake and set the transmission to
neutral.
D
3. Lower the lift arm to the ground.
4. Move the hydraulic pin locking isolation valve to
the horizontal position.
5. The hydraulic pin locking isolation valve is only
installed to machines with alternative lift arm
auxiliary options.
B
6. Use the lift arm controls to engage the support
B Lock pin bar on the carriage in to the hook plates.
C Hook plates 7. Make sure that both hook plates are engaged
D Lynch pin equally.
Removing Attachments 8. Lift and tilt the carriage back, to align the locking
WARNING Keep other people clear of the area holes in the carriage with those in the attachment.
while you disengage the attachment. If a second 9. Turn on the hitch/auxiliary switch.
person is to be involved in this procedure,
03 - 12 9813/7600-3 03 - 12
33 - Fork
03 - Carriage
10. Move the thumb switch backwards to engage the 4. If the attachment is hydraulically operated, then
locking pins. disconnect the hoses.
11. Move the hydraulic pin isolation valve to the 5. Move the hydraulic pin locking isolation valve to
vertical position. In this position the locking pins the horizontal position.
are isolated and the auxiliary circuit is active.
6. Turn on the hitch/auxiliary switch.
connect the hoses. 7. Move the thumb switch forwards to disengage
the locking pins.
Figure 19.
8. Tilt the carriage forward slowly to withdraw the
A lower end of the carriage from the attachment.
9. Lower the lift arm slowly to withdraw the carriage
from the attachment hook plates.
C 10. Carefully reverse the machine away from the

attachment or retract the lift arm.
11. Move the hydraulic pin locking isolation valve to
B the vertical position. In this position the locking
pins are isolated and the auxiliary circuit is active.
Figure 21.
A Hook plates
B Isolation valve- inactive position
C Isolation valve- active position
Figure 20.
A Forward- disengage locking pins
A Backward- engage locking pins
Removing Attachments
1. Park the machine on firm level ground.
2. Apply the park brake and set the transmission to
neutral.
03 - 13 9813/7600-3 03 - 13
82 - Jib
82 - Jib
Contents Page No.
03-82-00 General ........................................................................................................................... 03-15

03-82-06 Shackle ........................................................................................................................... 03-17
03 - 14 9813/7600-3 03 - 14
82 - Jib
00 - General
Introduction .................................................... 03-15
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 - 15 9813/7600-3 03 - 15
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 - 16 9813/7600-3 03 - 16
82 - Jib
06 - Shackle
06 - Shackle
Introduction
This a Q-fit attachment. It gives your machine greater Figure 23.

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 22.
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 - 17 9813/7600-3 03 - 17
82 - Jib
06 - Shackle
• Placing position • Travel position
Figure 24.
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 - 18 9813/7600-3 03 - 18
84 - Hook
84 - Hook
Contents Page No.
03-84-06 Snatch Block .................................................................................................................. 03-21
03 - 19 9813/7600-3 03 - 19
Notes:
03 - 20 9813/7600-3 03 - 20
84 - Hook
06 - Snatch Block
06 - Snatch Block Introduction

Introduction .................................................... 03-21 The fork mounted hook allows the machine to carry
Remove and Install ....................................... 03-22 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 - 21 9813/7600-3 03 - 21
84 - Hook
06 - Snatch Block
Remove and Install 3.4. Make sure that both mounting brackets are
installed securely.
Figure 25.
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 - 22 9813/7600-3 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
06-06-10 Transmission Compartment ........................................................................................... 06-16
06-06-12 Front Cover .................................................................................................................... 06-18
06-06-14 Rear Cover ..................................................................................................................... 06-20
06-06-30 Undershield .................................................................................................................... 06-21
06-06-33 Lift Arm ........................................................................................................................... 06-22
06-06-39 Cab/Canopy ................................................................................................................... 06-23
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-29
06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-65
06-12-24 Shim ............................................................................................................................... 06-66
06-30 Pivot Pins
06-30-00 General ........................................................................................................................... 06-77
06-42 Stabiliser
06-42-00 General ........................................................................................................................... 06-81
06-49 Step
06-49-00 General ........................................................................................................................... 06-85
06-54 Fender
06-54-00 General ........................................................................................................................... 06-89
06-57 Counterweight
06-57-00 General ........................................................................................................................... 06-93
06-63 Identification Label
06-63-00 General ........................................................................................................................... 06-95
06-63-03 Machine .......................................................................................................................... 06-96
06-63-06 Engine .......................................................................................................................... 06-100
06-63-09 Axle .............................................................................................................................. 06-102
06-63-12 Gearbox ........................................................................................................................ 06-103
06-63-15 Operator Protective Structure ...................................................................................... 06-105
06-66 Tools
06-66-00 General ......................................................................................................................... 06-109
06-69 Maintenance Strut
06-69-00 General ......................................................................................................................... 06-113
06-69-03 Lift Arm ......................................................................................................................... 06-114
06-75 Fire Extinguisher
06-75-00 General ......................................................................................................................... 06-117
9813/7600-3
2017-12-18
06-89 Window Guard
06-89-00 General ......................................................................................................................... 06-119
06-89-03 Front Window ............................................................................................................... 06-120
06-89-12 Roof Window ................................................................................................................ 06-121
9813/7600-3
2017-12-18
Acronyms Glossary
DTVT Dual Technology Variable

Transmission
FOPS Falling Object Protective Structure
OECD Organization for Economic
Cooperation and Development
PIN Product Identification Number
9813/7600-3
2017-12-18
Notes:
9813/7600-3
2017-12-18
Contents Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1 9813/7600-3 06 - 1
Notes:
06 - 2 9813/7600-3 06 - 2
00 - General
00 - General Clean
Clean ............................................................... 06-3 Keep all intakes and grilles clear from snow, ice and
Check (Condition) ............................................ 06-4 debris.
Debris can collect under the boom. Remove all

debris from under the boom.
Thoroughly dry the piston rams and protect them with

clean transmission or hydraulic oil if necessary.
06 - 3 9813/7600-3 06 - 3
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 - 4 9813/7600-3 06 - 4
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-7
06 - 5 9813/7600-3 06 - 5
Notes:
06 - 6 9813/7600-3 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 9813/7600-3 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 9813/7600-3 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
06-06-10 Transmission Compartment ........................................................................................... 06-16
06-06-12 Front Cover .................................................................................................................... 06-18
06-06-14 Rear Cover ..................................................................................................................... 06-20
06-06-30 Undershield .................................................................................................................... 06-21
06-06-33 Lift Arm ........................................................................................................................... 06-22
06-06-39 Cab/Canopy ................................................................................................................... 06-23
06 - 9 9813/7600-3 06 - 9
Notes:
06 - 10 9813/7600-3 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 9813/7600-3 06 - 11
03 - Battery Compartment
03 - Battery Compartment
Remove and Install
Close
Single Step Installation
1. Close the battery compartment cover.
Open 2. Make sure the battery compartment cover is
closed correctly.
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 26. 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 27.
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 9813/7600-3 06 - 12
06 - Engine Compartment
Remove and Install
CAUTION The exhaust pipe becomes extremely 4. Support the cover using suitable overhead lifting
hot when the engine is running and will remain so equipment.
for some time after the engine is stopped. If you
touch the hot pipe you could be severely burned. 5. Remove the gas strut mount securing nut and
remove the strut from the support bracket.
A typical engine cover removal and installation 6. Remove the hinge bolts.
procedure is given below. Your machine may differ
from that shown. 7. Take the top engine cover away from the
machine with the lifting equipment.
Remove 8. Remove the exhaust outlet pipe. Refer to fuel
1. Make the machine safe. Refer to (PIL 01-03). system- Exhaust. Refer to (PIL 18-24).
2. Follow the general safety precautions. Refer to 9. Support the engine pod base.
(PIL 01-03). 10. Remove the bolts and washers and lower the
3. Open the engine compartment cover. Refer to engine pod complete along with the guards to the
(PIL 06-06) ground.
06 - 13 9813/7600-3 06 - 13
Figure 28.
A
D
C
G
F
A Engine pod cover B Hinge bolts

C Support bracket D Strut mount securing nut
E Engine pod base F Bolts
G Washers
06 - 14 9813/7600-3 06 - 14
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
1.1. Tighten the bolts to the specified torque
value.
1.2. Tighten the strut mount securing nut to the
specified torque value.
Table 3. Torque Values

Item Description Nm
B Hinge bolts 18
D Strut mount securing nut 18
06 - 15 9813/7600-3 06 - 15
10 - Transmission Compartment
10 - Transmission Compartment Component Identification

Component Identification ............................... 06-16
Remove and Install ....................................... 06-17
(For: HM560 Variable Transmission)
Figure 29. Access cover- Dual
Tech Variable Transmission
A Chassis (components removed for clarity)

B Access cover- Gearbox valve block
C Access cover- Gearbox hydrostatic pump
priming pipe
06 - 16 9813/7600-3 06 - 16
10 - Transmission Compartment
Remove and Install

Figure 30. Access cover- Dual
Tech Variable Transmission
A Chassis (components removed for clarity)

B Access cover- Gearbox valve block
C Access cover- Gearbox hydrostatic pump
priming pipe
Remove
2. Raise the lift arm and install the maintenance
strut. Refer to (PIL 06-69).
3. Turn the battery isolator switch to the off position.
Refer to (PIL 33-03-03).
4. Remove the bolts that secure the access plates.
5. Remove the access plates.
Install
step.
2. Tighten the bolts to the correct torque value.
Refer to (PIL-72-00).
06 - 17 9813/7600-3 06 - 17
12 - Front Cover
12 - Front Cover Figure 31.
Remove and Install

For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................... Page 06-18
For: 526-56 [T4F] ...................... Page 06-19
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY])
A
Remove
2. Isolate the battery and remove the isolator key.
3. Open the top cover to gain access to the cover
securing bolts.
4. Remove the bolts (x3) located outside the cab
beneath the front window.
5. Remove the bolts (x3) located inside the cab.
6. Disconnect any pipes or electrical connectors.
B
7. Lift and remove the cover. A Cab
B Front cover assembly
06 - 18 9813/7600-3 06 - 18
12 - Front Cover
Figure 32. Figure 33.

A
C C
C
B
D D
B Front cover assembly
C Bolt locations- from outside cab
D Bolt locations- from inside cab (floor pan not A Cab
shown) B Front cover plate
Install Install
1. The installation procedure is the opposite of the 1. The installation procedure is the opposite of the
removal procedure. Additionally do the following removal procedure. Additionally do the following
steps. steps.
2. Tighten the fasteners to the correct torque value. 1.1. Make sure that any seal strip is intact and in
good condition. Renew if necessary.
3. Make sure the washer fluid level is correct and
that the window wash/wipe system operates 1.2. Tighten all fasteners to the correct torque
correctly. value.
(For: 526-56 [T4F])
Remove
2. Isolate the battery and remove the key. Refer to
(PIL 33-03-03).
3. Remove the bolts and washers (x4) located
outside the cab beneath the front window.
4. Lift and remove the cover.
06 - 19 9813/7600-3 06 - 19
14 - Rear Cover
14 - Rear Cover oil before you climb on the machine. Do not use
the exhaust as a handhold. It can burn you.
Remove and Install Remove the rear cover for access to the hydraulic oil
For: 531-70 [5AA], 531-70 [5TA], 535-95 and fuel tanks. Make sure you lock the rear cover to
[5AB], 535-95 [5TB], 536-60 [5AC], prevent theft and tampering.
536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1], Remove
541-70 [5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY] 1. Make the machine safe. Refer to (PIL 01-03).
................................................... Page 06-20
For: 526-56 [T4F] ...................... Page 06-20 2. Remove the bolts from top of the cover.
3. Hold the cover and remove the bolts from the
(For: 531-70 [5AA], 531-70 [5TA], 535-95 bottom of the cover.
[5AB], 535-95 [5TB], 536-60 [5AC],
4. Carefully lower the cover to the ground.
536-60 [5TC], 536-70 [5AE], 536-70 [5TE],
536-70LP [5A1], 536-70LP [5T1], 541-70 Figure 35.
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY]) B
Open the rear cover for access to the filler cap and
sight glass. A
Open
2. Use the key to unlock the rear cover.
3. Open the rear cover.
Figure 34.
B B
A Rear cover
B Bolts
A
Install
A Key 1. Position the cover.
B Rear cover
2. Hold the cover and install the bolts from the
bottom of the cover.
Close
3. Install the bolts from top of the cover.
1. Position the rear cover.
2. Use the key to lock the rear cover.
(For: 526-56 [T4F])

CAUTION You will have to climb on the machine
to install or remove the cover. Take care,
especially if the machine is wet. Remove mud and
06 - 20 9813/7600-3 06 - 20
30 - Undershield
30 - Undershield
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD])
Figure 36. Belly Guards- R28 Tyres

H J
C
E H
K
F
J
J
B
G
G
G A G J
D
A Side rail- pod side B Side rail- cab side

C Front panel- 28" tyre D Centre guard
E Rubber cover F Pop rivet and washer
G Edge seal
06 - 21 9813/7600-3 06 - 21
33 - Lift Arm
33 - Lift Arm Install

Remove and Install removal procedure. Additionally do the following
step.
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 06-22 2. Tighten all fastenings to the correct torque. Refer
For: 531-70 [5AA], 531-70 [5TA], 535-95 to (PIL 72).
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD] .................. Page 06-22 (For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
(For: 550-80 [5AW], 550-80 [5UW], 560-80 [5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AY], 560-80 [5UY]) [5AD], 541-70 [5TD])
Remove Remove- Lift Arm Nose Cover
1. Make the machine safe. Refer to (PIL 01-03). 1. Make the machine safe. Refer to (PIL 01-03).
2. Fully lower the lift arm. 2. Fully lower the lift arm.
3. Remove the securing bolts. 3. Remove the securing bolts.
4. Remove the cover from the inner lift arm nose. 4. Remove the cover from the inner lift arm nose.
2 1 1
1
1
2
1
1
1 1 Securing bolts
2 Cover
Install
removal procedure.
1 Securing bolts
2 Cover
06 - 22 9813/7600-3 06 - 22
39 - Cab/Canopy
39 - Cab/Canopy
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 535-95 Figure 39. Access Plate- Cab Floor
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................... Page 06-23
For: 526-56 [T4F] ...................... Page 06-25 A
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY])
Remove
Refer to (PIL 33-03-03). B
3. Lift and remove the floor mat. A Cab
B Access plate- cab floor
4. Remove the floor cover bolts (X6).
5. Remove the cover. Install
step.
1.1. Tighten the floor cover bolts to the correct
torque value.
Cab Rear Cover
Remove
3. Remove the rear cover bolts (X5).
4. Remove the cover.
06 - 23 9813/7600-3 06 - 23
39 - Cab/Canopy
Figure 40. Cab Rear Cover

A
C
A Cab B Rear cover

C Bolts (X5) D Rubber flap
06 - 24 9813/7600-3 06 - 24
39 - Cab/Canopy
Install (For: 526-56 [T4F])

Remove
steps. 1. Make the machine safe. Refer to (PIL 01-03).
1.1. Make sure that the rubber flap is located 2. Isolate the battery and remove the isolator key.
in the recess on the fuel tank during Refer to (PIL 33-03-03).
installation.Refer to Figure 40.
1.2. Tighten the bolts to the correct toque value. 3. Remove the rear cover bolts (x3).
4. Remove the cover.
Figure 41. Cab Rear Cover

A
A Cab B Rear cover
06 - 25 9813/7600-3 06 - 25
39 - Cab/Canopy
Install
steps.
1.1. Make sure that any edging strip / seal is
located correctly and is in good condition. If
not, install a new strip.
1.2. Tighten the bolts to the correct torque value.
06 - 26 9813/7600-3 06 - 26
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-29

06-12-12 Pivot Link Lever (Upper) ................................................................................................ 06-65
06-12-24 Shim ............................................................................................................................... 06-66
06 - 27 9813/7600-3 06 - 27
Notes:
06 - 28 9813/7600-3 06 - 28
12 - Lift Arm
00 - General
Introduction .................................................... 06-29
(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
Technical Data ............................................... 06-32
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
Operation ....................................................... 06-35
[5TE], 536-70LP [5A1], 536-70LP [5T1],
Calibrate ........................................................ 06-36
541-70 [5AD], 541-70 [5TD], 550-80
Lubricate ........................................................ 06-37
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY], JCB Tier 4F Engine 4 Cyl)
Disassemble and Assemble .......................... 06-52
Hydraulic Ram Operated Lift Arms
The lift arms on these machines are extended and
retracted by hydraulic rams. No chain system is
used. There are differences in the configuration
and location of components depending on machine
model. Refer to Table 4.
Refer to body and framework, lift arm, general,

component identification (PIL 06-12-00).
All lift arm sections are identified in a similar way

irrespective of the number of sections or method of
operation.
Table 4.
Machine Lift Arm
526-56 2 Section, 2 stage
06 - 29 9813/7600-3 06 - 29
12 - Lift Arm
00 - General
Figure 42.
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
All intermediate and inner lift arm sections slide

against adjustable / replaceable wear pads installed
in the lift arm sections. Refer to body and framework,
lift arm, general, (PIL 06-12-00) and body and
framework, lift arm, shims and wear pads, (PIL
06-12-24 and 06-12-30).
06 - 30 9813/7600-3 06 - 30
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 - 31 9813/7600-3 06 - 31
12 - Lift Arm
00 - General
Technical Data
For: 531-70 [5AA], 531-70 [5TA], 536-60 Figure 43. 2 Stage (2 section) Lift Arm
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY], 560-80
[5UY] ......................................... Page 06-32
For: 526-56 [T4F] ...................... Page 06-32
For: 535-95 [5AB], 535-95 [5TB] A
................................................... Page 06-33
(For: 531-70 [5AA], 531-70 [5TA], 536-60

[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY], B
560-80 [5UY])
Wear pad Clearance- 2 Stage (2 section)

Lift Arm C
Make sure that the wear pads are installed correctly

to prevent fouling. Refer to body and framework-
wear pads. Refer to (PIL 06-30).
Refer to Table 5.
Table 5. Maximum Gap

Dimension mm
A
Lift arm front 3mm (1.5mm)
(1)
Lift arm rear 1.5mm

B
Lift arm front 3mm (1.5mm)
(1)
Lift arm rear 1.5mm

(1) 550-80 machines only
(For: 526-56 [T4F])
Wear pad Clearance- 526-56 Machines

Make sure that the wear pads are installed correctly
to prevent fouling. Refer to body and framework-
wear pads, refer to (PIL 06-30).
Refer to Table 6.
06 - 32 9813/7600-3 06 - 32
12 - Lift Arm
00 - General
Figure 44. 2 Stage (2 section) Lift Arm

Dimension mm
A
Lift arm front 3mm
Lift arm rear 1.5mm
B
Lift arm front 3mm
Lift arm rear 1.5mm
Figure 45. 3 Stage Lift Arm

(For: 535-95 [5AB], 535-95 [5TB])
Wear Pad Clearance- 3 Stage (3 section)

Lift Arm 1
Make sure that the wear pads are installed in the

correct way round to prevent fouling. Refer to body
and framework- wear pads, refer to (PIL 06-30).
Use the dome headed Tuf-Lok bolts at position B and 2

position 3-C. 2
The intermediate to outer lift arm, bottom right hand

wear pad (shown at position A) may vary. Refer to 3
parts catalogue.
06 - 33 9813/7600-3 06 - 33
12 - Lift Arm
00 - General

Dimension Maximum Gap
1 3mm
2 1.5mm
3 21–25mm
4 37–41mm
06 - 34 9813/7600-3 06 - 34
12 - Lift Arm
00 - General
Operation
(For: 535-95 [5AB], 535-95 [5TB])
Figure 46. Telescopic Operation- 3 Stage (3 Section) Lift Arm

A B C D E J
F K G H
A Outer section B Intermediate section

C Inner section D Outer extension ram
E Inner extension ram F Hose guide roller
G Wear pad H Tilt ram
J Example hose routing- auxiliary service K Wear pad- inner extension ram
The telescopic boom consists of three sections, an Should a hose of the incorrect length be fitted
inner, intermediate and outer section. damage can also occur.
When the boom is extended or retracted the inner To ensure the reliable operation of the telescopic
and outer sections move simultaneously. This is function it is critical that the hoses are routed and
achieved by hydraulically interconnecting the inner fitted correctly.
and outer extension rams. For an explanation of the
hydraulic operation refer to (PIL 30-00). To ensure the correct clearances and smooth
movement between the boom sections, special wear
From the diagrams we can see that the hydraulic pads together with shims are fitted. Wear pads are
hoses connected to the tilt ram, auxiliary service fitted at the top, bottom and sides at both ends of
and inner extension ram (telescopic services) are the boom sections. The inner extension ram is also
arranged to follow the movement of the inner and fitted with a wear pad since the inner boom moves in
intermediate boom sections. As the boom extends relation to the ram cylinder.
the hose runs at the bottom of the inner boom are
drawn around the guide roller and along the top of
the inner extension ram.
If the inner and intermediate booms move out of

phase the telescopic service hoses will be damaged.
06 - 35 9813/7600-3 06 - 35
12 - Lift Arm
00 - General
Calibrate 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.
(For: 526-56 [T4F], 531-70 [5AA], 531-70 7. Add or remove the shim 1 and shim 2 as
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 necessary to align the carriage. Refer to adjust
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 (PIL 06-12-30).
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
8. Make sure that the difference in shim thickness of
[5AW], 550-80 [5UW], 560-80 [5AY], shim 1 and shim 2 does not exceed the specified
560-80 [5UY]) value.
When the boom is assembled, do a check of Length/Dimension/Distance: 3.2mm
the carriage alignment to make sure that the
9. Make sure that the maximum wear pad clearance
measurement is accurate.
does not exceed the specified value.
1. Make the machine safe. Refer to (PIL 01-03). Length/Dimension/Distance: 3mm
2. Make sure that the tyre pressures are correct. Figure 49.
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 47.
A
A Inclinometer
5. Measure the left and right side carriage height C F
from the ground to the top of the carriage and D E
note the dimensions. B Maximum wear pad clearance
C Lower wear pad 1
Figure 48. D Lower wear pad 2
E Shim 1
F Shim 2
X Y
X Left side dimension

Y Right side dimension
06 - 36 9813/7600-3 06 - 36
12 - Lift Arm
00 - General
Lubricate
For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY] .................. Page 06-37
For: 526-56 [T4F] ...................... Page 06-38
For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70LP [5A1],
536-70LP [5T1], 541-70 [5AD], 541-70 [5TD]
................................................... Page 06-39
For: 535-95 [5AB], 535-95 [5TB]
................................................... Page 06-40
For: 536-60 [5AC], 536-60 [5TC]
................................................... Page 06-41
(For: 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY])

Consumables
Description Part No. Size
Special HP Grease 4003/2020 0.5kg
4003/2017 0.4kg
4003/2006 12.5kg
4003/2005 50kg
Figure 50.
B C
1. Make the machine safe, refer to (PIL 01-03). Consumable: Special HP Grease
2. Apply grease to the points shown.
06 - 37 9813/7600-3 06 - 37
12 - Lift Arm
00 - General
(For: 526-56 [T4F])
Figure 51.
A D
C
J H

2. Apply the correct grease to all the points and
linkages shown in Refer to Figure 51. . Refer to
(PIL 75-06).
06 - 38 9813/7600-3 06 - 38
12 - Lift Arm
00 - General
(For: 531-70 [5AA], 531-70 [5TA], 536-60 [5AC], 536-60 [5TC], 536-70LP [5A1], 536-70LP
[5T1], 541-70 [5AD], 541-70 [5TD])
Figure 52.
B F
A
C
E
G H
J K
M N
P Q
1. Make the machine safe. Refer to (PIL 01-03). 2. Apply grease to all the points and linkages.
06 - 39 9813/7600-3 06 - 39
12 - Lift Arm
00 - General
(For: 535-95 [5AB], 535-95 [5TB])
Figure 53.
A
H

2. Apply the correct grease to all the points and
linkages.
06 - 40 9813/7600-3 06 - 40
12 - Lift Arm
00 - General
(For: 536-60 [5AC], 536-60 [5TC])
Figure 54.
B
5
A
1
C
3
2
E
4
D
7
F 8
G
P
H
7
N J
M
Q K
L

2. Apply grease to all the points and linkages.
06 - 41 9813/7600-3 06 - 41
12 - Lift Arm
00 - General
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 541-70 Remove

[5AD], 541-70 [5TD] .................. Page 06-42
For: 536-60 [5AC], 536-60 [5TC], 536-70 1. Make the machine safe. Refer to PIL (01-03).
[5AE], 536-70 [5TE] ................... Page 06-44
2. Fully lower the lift arm. Open the rear access
For: 550-80 [5AW], 550-80 [5UW], 560-80 cover and disconnect the displacement ram
[5AY], 560-80 [5UY] .................. Page 06-47
(if installed) by removing bolts 1, nuts 1 and
For: 526-56 [T4F] ...................... Page 06-49 washers 1.
(For: 531-70 [5AA], 531-70 [5TA], 541-70 3. Use the slide hammer kit to remove the pivot pin.
Refer to (PIL 06-30). Operate the carriage crowd
[5AD], 541-70 [5TD]) control to retract the displacement ram.
Special Tools Special Tool: Slide Hammer Kit (Qty.: 1)
Description Part No. Qty.
Slide Hammer Kit 993/68100 1 4. Lower the lift arm onto a suitable support in the
semi-raised position to gain access to the lift ram
The complete lift arm assembly has a mass of rod end and the displacement rams head end.
approximately the specified value. 3,000kg
5. Support the lift arm ready for removal with
The lift ram has a mass of approximately the suitable lifting equipment. Use lifting shackles of
specified value. 250kg suitable capacity fitted to the forward and rear
lifting points.
Support the ram with a suitable lifting equipment.
06 - 42 9813/7600-3 06 - 42
12 - Lift Arm
00 - General
Figure 55.
A Bolts 1, nuts 1 and washers 1 B Pivot pin 1

C Bolts 2, nuts 2 and washers 2 D Pivot pin 2
F Extension ram hose G Extension ram hose
H Pivot pin 3 J Bolt 3
06 - 43 9813/7600-3 06 - 43
12 - Lift Arm
00 - General
6. Support the lift ram and disconnect the lift ram (if Install
installed) rod end by removing bolt 2, nut 2 and
washers 2. 1. The installation procedure is the opposite of the
7. Use the slide hammer kit to remove the pivot pin. steps.
Refer to (PIL 06-30).
1.1. Check the hydraulic oil level and refill if
8. Lower the ram onto suitable packing material to necessary. Refer to (PIL 30-00).
protect the piston rod.
1.2. Grease all pivot pins. Refer to (PIL 75-06).
9. Discharge the hydraulic pressure. Refer to (PIL
1.3. For the main pivot pins types 2 and 3,
30-00).
identify the position and quantity of all
10. Put a label on the extension ram hoses to help washers and spacers for the machine
installation. model. Align the locking plate and install
spacer and large washer 1, washers 2 and
11. Make sure the lift arm is fully supported. Note bolt 1.
there will be one of three types of main pivot pin 1.4. For main pivot pins types 2 and 3, tighten
for the lift arm. the bolt to the specified torque value.
11.1. Type 1- Remove the bolt 3 and withdraw Torque: 476N·m
the pivot pin 3. Refer to Figure 55.
11.2. Types 2 and 3- Remove the items 1 to 6, (For: 536-60 [5AC], 536-60 [5TC], 536-70
noting the quantity and arrangement of the
spacers. Refer to Figure 56. [5AE], 536-70 [5TE])
Special Tools
Figure 56. Types 2 and 3
(531-70 and 541-70 Machines)
Slide Hammer Kit 993/68100 1
5
1 Consumables
6 Description Part No. Size
Special HP Grease 4003/2020 0.5kg
5 4003/2017 0.4kg
4003/2006 12.5kg
2
4003/2005 50kg
3
4
Remove
5
The complete lift arm assembly has a mass of
1 3,000kg. The lift ram has a mass of 250kg. Support
6
the ram at all times to prevent personal injury and
damage to the machine and equipment.
5 1. Make the machine safe. Refer to (PIL 01-03).

2
2. Remove the lift arm attachments, including forks
3 and fork bar.
4
3. Lower the lift arm onto a suitable support in the
1 Pivot pin semi raised position to get access to the lift ram
2 Spacer rod end and the displacement rams head end.
3 Large washer 1
4 Bolt 1 4. Support the lift arm from above with lifting
5 Washers 2 shackles of suitable capacity attached to the
6 Nut forward and rear lifting points.
12. Carefully lift the lift arm clear of the machine, 5. Discharge the hydraulic pressure. Refer to (PIL
checking for any remaining connections. Lower 30-00).
the lift arm onto suitable packing material.
6. Support the lift ram and disconnect the ram rod
end from the lift arm pivot.
06 - 44 9813/7600-3 06 - 44
12 - Lift Arm
00 - General
6.1. Remove the nut 1, bolt 1 and washers 1 (if 12.1. Hydraulic hose connections for 536
installed). machines shown at E.
6.2. Use the slide hammer kit to remove the 12.2. Hydraulic hose connections for 526
pivot pin 1. Refer to (PIL 06-30). machines shown at K.
Special Tool: Slide Hammer Kit (Qty.: 1) 13. Install cap or plug on all the open hydraulic hoses
and ports.
7. Support the displacement rams and disconnect
the ram head end from the lift arm pivots. 14. Disconnect the lift arm electrical harness
connectors from the chassis harness.
7.1. Remove the nuts 2, bolts 2 and the washers
2 (if installed). 15. Put a label on the hydraulic connections ato help
7.2. Use the slide hammer kit to remove the installation.
pivot pin 2. Refer to (PIL 06-30).
16. Disconnect the extension ram hoses.
Special Tool: Slide Hammer Kit (Qty.: 1)
17. Install a cap or plug on all the open hydraulic
8. Lower the displacement ram onto the packing connections.
material to prevent damage to the piston rod.
18. Make sure that the lift arm is fully supported.
30-00). 18.1. Remove the nut 3, bolt 3 and washers 3 (if
installed).
10. Loosen the filler cap to vent the hydraulic tank.
Refer to (PIL 30-00). 18.2. Use the slide hammer kit to remove the
11. Put label on the hydraulic hoses to help Special Tool: Slide Hammer Kit (Qty.: 1)
installation.
19. Carefully raise the lift arm clear of the machine,
12. Disconnect the hydraulic connections. checking for any remaining connections.
06 - 45 9813/7600-3 06 - 45
12 - Lift Arm
00 - General
Figure 57.
E
K
H B
C
A
J D
F
G
A Bolt 1 B Pivot pin 1

C Bolt 2 D Pivot pin 2
E Hydraulic hose connections for 536 machines F Extension ram hose 1
G Extension ram hose 2 H Bolt 3
J Pivot pin 3 K Hydraulic hose connections for 526 machines
06 - 46 9813/7600-3 06 - 46
12 - Lift Arm
00 - General
Install 6.1. Remove the nut 1, bolt 1 and washers 1 (if

installed).
6.2. Use the slide hammer kit to remove the
steps.
1.1. Check the hydraulic oil level and fill if
necessary. Refer to (PIL 30-00). 7. Support the displacement rams and disconnect
the ram head end from the lift arm pivots.
1.2. Apply grease on all the pivot pins. Refer to
(PIL 75-06). 7.1. Remove the nuts 2, bolts 2 and the washers
Consumable: Special HP Grease 2 (if installed).
(For: 550-80 [5AW], 550-80 [5UW], 560-80 pivot pin 2. Refer to (PIL 06-30).
[5AY], 560-80 [5UY]) Special Tool: Slide Hammer Kit (Qty.: 1)
Special Tools 7.3. Lower the displacement ram onto the
Description Part No. Qty. packing material to prevent damage to the
piston rod.
7.4. Do the step 7.1 to step 7.3 again for the
Consumables other displacement ram.
8. Put labels on the hydraulic hoses on each side of
Special HP Grease 4003/2020 0.5kg the lift arm to help installation.
4003/2017 0.4kg
4003/2006 12.5kg 9. Disconnect the hydraulic hoses from the metal
pipes on each side of the lift arm.
4003/2005 50kg
10. Plug all the open ports and hoses to prevent
Support the lift arm correctly at all times to prevent contamination.
personal injury and damage to the machine and
equipment. 11. Working on the underside of the lift arm,
disconnect the lift arm electrical harness
Remove connectors from the chassis harness.
1. Make the machine safe. Refer to (PIL 01-03). 12. Put labels on the hydraulic connections to help
installation.
and fork bar. 13. Disconnect the extension ram hoses.
3. Lower the lift arm onto a suitable support in the 14. Plug all the open ports and hoses to prevent
semi raised position to get access to the lift ram contamination.
rod end and the displacement rams head end. 15. Make sure that the lift arm is fully supported.
4. Support the lift arm from above with lifting 16. Remove the nut 3, bolt 3 and washers 3 (if
shackles of suitable capacity attached to the installed).
forward and rear lifting points.
17. Use the slide hammer kit to remove the pivot pin
5. Discharge the hydraulic pressure. Refer to (PIL 3. Refer to (PIL 06-30).
30-00).
end from the lift arm pivot. 18. Carefully lift the lift arm clear of the machine,
checking for any remaining connections.
06 - 47 9813/7600-3 06 - 47
12 - Lift Arm
00 - General
Figure 58.
B
B
C
C
D
D
E K
K
J
J
FF
K
K
H
H KK
G
G
L
L
K
K KK
A Lift arm B Bolt 1

C Pivot pin 1 D Lift ram
E Bolt 2 F Pivot pin 2
G Nut 2 H Displacement ram
J Bolt 3 K Hydraulic hoses
L Pivot pin 3
06 - 48 9813/7600-3 06 - 48
12 - Lift Arm
00 - General
Install 6.1. Remove the nut 1, bolt 1 and washers 1 (if

installed).
steps.
necessary. Refer to (PIL 30-00). 7. Support the displacement rams and disconnect
the ram head end from the lift arm pivots.
(PIL 75-06). 7.1. Remove the nuts 2, bolts 2 and the washers
Consumable: Special HP Grease 2 (if installed).
(For: 526-56 [T4F]) pivot pin 2. Refer to (PIL 06-30).
Special Tools
Description Part No. Qty. 8. Lower the displacement ram onto the packing
Slide Hammer Kit 993/68100 1 material to prevent damage to the piston rod.
Consumables 9. Discharge the hydraulic pressure. Refer to (PIL

30-00).
Special HP Grease 4003/2020 0.5kg 10. Loosen the filler cap to vent the hydraulic tank.
4003/2017 0.4kg Refer to (PIL 30-00).
4003/2006 12.5kg 11. Put label on the hydraulic hoses to help
4003/2005 50kg installation.
12. Disconnect the hydraulic connections.
Remove
The complete lift arm assembly has a mass of contamination.
3,000kg. The lift ram has a mass of 250kg. Support
the ram at all times to prevent personal injury and 14. Disconnect the lift arm electrical harness
damage to the machine and equipment. connectors from the chassis harness.
1. Make the machine safe. Refer to (PIL 01-03). 15. Put a label on the hydraulic connections to help
installation.
and fork bar. 16. Disconnect the extension ram hoses.
3. Lower the lift arm onto a suitable support in the 17. Plug all the open ports and hoses to prevent
semi raised position to get access to the lift ram contamination.
rod end and the displacement rams head end.
18. Make sure that the lift arm is fully supported.
4. Support the lift arm from above with lifting
shackles of suitable capacity attached to the 18.1. Remove the nut 3, bolt 3 and washers 3 (if
forward and rear lifting points. installed).
30-00).
end from the lift arm pivot. 19. Carefully lift the lift arm clear of the machine,
checking for any remaining connections.
06 - 49 9813/7600-3 06 - 49
12 - Lift Arm
00 - General
Figure 59.
F G
H B
C
A
J D
A Bolt 1 (Lift ram) B Pivot pin 1 (Lift ram)

C Bolt 2 (Displacement ram) D Pivot pin 2 (Displacement ram)
F Extension ram hose 1 G Extension ram hose 2
H Bolt 3 (Main lift arm pivot pin) J Pivot pin 3 (Main lift arm pivot pin)
K Hydraulic hose connections for 526 machines
06 - 50 9813/7600-3 06 - 50
12 - Lift Arm
00 - General
Install
steps.
necessary. Refer to (PIL 30-00).
(PIL 75-06).
Consumable: Special HP Grease
06 - 51 9813/7600-3 06 - 51
12 - Lift Arm
00 - General
Disassemble and Assemble
For: 531-70 [5AA], 531-70 [5TA], 536-60 7. Remove the telescopic hydraulic service hoses.
[5AC], 536-60 [5TC], 536-70 [5AE], To ensure that the hoses do not become
536-70 [5TE], 541-70 [5AD], 541-70 [5TD] damaged or tangled, they must be removed
................................................... Page 06-52 before attempting to separate the lift arm
For: 550-80 [5AW], 550-80 [5UW] sections. Remove the hoses as follows:
................................................... Page 06-55
For: 526-56 [T4F] ...................... Page 06-58 7.1. Remove the hose clamps.
For: 535-95 [5AB], 535-95 [5TB] 7.2. Put label on the hoses at the steel pipes
................................................... Page 06-60 on the underside of the lift arm to help
installation.
(For: 531-70 [5AA], 531-70 [5TA], 536-60 7.3. Disconnect and remove the hoses.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 7.4. Pull out the hoses through the guide
[5TE], 541-70 [5AD], 541-70 [5TD]) channels from the rear in the direction of the
arrow X.
Unless the lift arm fabrications are damaged there
is normally no requirement to separate the lift arm 7.5. Then pull out the hoses through the
sections. The lift arm sections can be separated with apertures under the lift arm in the direction
the lift arm assembly removed or installed to the of the arrow Y.
machine as required. 7.6. Plug all the open ports and hoses to prevent
contamination.
CAUTION! You can be injured if you use incorrect or
faulty lifting equipment. You must identify the weight 7.7. Put label on the auxiliary service hoses at
of the item to be lifted then choose lifting equipment the steel pipes on the underside of the lift
that is strong enough and suitable for the job. Make arm and at the front of the lift arm to help
sure that lifting equipment is in good condition and installation.
complies with all local regulations. 7.8. Disconnect and remove the hoses.
WARNING! Hydraulic fluid at system pressure can
7.9. Pull out the hoses in the same way as the
injure you. Before connecting or removing any
tilt ram hoses. Refer to 7.4 and 7.5.
hydraulic hose, residual hydraulic pressure trapped
in the service hose line must be vented. Make 7.10. Plug all the open ports and hoses to
sure the hose service line has been vented before prevent contamination.
connecting or removing hoses. Do not start the
engine with loose or open hose connections. 8. Remove the inner lift arm.
WARNING! Never position yourself or any part 8.1. Remove the front wear pads from the outer
of your body under a raised machine which is lift arm.
not properly supported. If the machine moves
unexpectedly you could become trapped and suffer 8.2. Make sure that the lift arm assembly is fully
serious injury or be killed. supported by the outer lift arm and then
remove the upper and side wear pads.
Disassemble 8.3. Lift the front of the inner lift arm clear of
the lower wear pads and then remove them.
The following procedures can be carried out without Label all the wear pads and keep them
the need to separate the lift arm sections or remove together with their shims.
the lift arm from the machine. 8.4. Support the front end of the inner lift arm
and draw it out from the outer section.
8.5. Before the inner section is all the way out
2. Discharge the hydraulic pressure. Refer to (PIL attach suitable lifting equipment. Make sure
30-00). the section is fully supported by the lifting
equipment and then draw it free from the
3. Remove the fork carriage. Refer to (PIL 03-33).
outer section.
4. Remove the tilt ram. Refer to (PIL 30-15).
If the lift arm assembly has been removed from the
5. Remove the lift arm nose cover (if installed). machine, make sure that it is securely supported.
Refer to (PIL 06-06). When the inner lift arm section is removed, forces
may cause the whole assembly to move.
6. Remove the extension ram. Refer to (PIL 30-15).
06 - 52 9813/7600-3 06 - 52
12 - Lift Arm
00 - General
Assemble not be the same length. Renew all four

telescopic service hoses if any of the hoses
1. The assembly procedure is the opposite of are damaged.
the disassembly procedure. Additionally do the
1.3. Assemble the lift arm sections so that the lift
following steps.
arm is fully retracted.
1.1. Check the length of the hose pairs. The 1.4. To enable alignment of the rod end pivot
hose lengths must be equal to within +/- of the extension ram, install the hydraulic
1mm for each service pair (tilt ram pair, and hoses so that the lift arm can be extended.
auxiliary service pair).
1.5. Make sure that the hose routing is correct.
1.2. Do not renew individual hoses. The hoses Do not cover any hoses.
can stretch over time. New hoses may
2. Do the following steps for 526-56 machines only:
Figure 60.
3 3
1 1 2
1 45° coupling 2 Cable tie

3 T-pieces 4 Hose natural curvature
5 Metal pipework
2.1. The tilt ram service hoses on the 526-56 2.4. Install a cable tie to secure the two hoses
machine must be phased as shown. Refer together.
to Figure 60. Make sure that the hoses
2.5. Position the head of the cable tie to the
do not become twisted whilst tightening
outside of the hoses.
the connectors. The hoses have a natural
curvature. 2.6. Do not secure the hoses to the metal
pipework.
2.2. Make sure to orient the 45º coupling against
the curvature to allow the hoses to lie along 2.7. Tighten the hoses to the specified torque
the top of the metal pipework. Refer to value.
Figure 60.
3. Do the following steps for other machines:
2.3. Stagger the position of the T-pieces to keep
the hoses and fittings together.
06 - 53 9813/7600-3 06 - 53
12 - Lift Arm
00 - General
Figure 61.
E E
J A
B
Y
E
Y
X X D
D
C F F C
A Tilt ram C Hose clamps

D Tilt ram hoses E Auxiliary service hoses
F Guide channels G Front wear pads
H Inner lift arm J Outer lift arm
06 - 54 9813/7600-3 06 - 54
12 - Lift Arm
00 - General
X Arrow X Y Arrow Y
3.1. The tilt ram and auxiliary service hoses 3. Remove the fork carriage. Refer to (PIL 03-33).
pass through the guide channels in the top
of the inner lift arm. When all the hoses are 4. Remove the tilt ram. Refer to (PIL 30-15).
correctly connected, install the clamps at
the inside of the inner lift arm. 5. Remove the lift arm nose cover (if installed).
3.2. Check that the lift arm wear pad shimming
is correct. Refer to Body and Framework- 6. Remove the extension ram. Refer to (PIL 30-15).
Lift Arm. Refer to (PIL 06-12).
7. Remove the bolts and remove the under lift arm
Table 8. Torque Values hose cover.
Item Description Nm 8. Put label on the lift arm hydraulic hoses to help
1 45º Coupling 50 installation.
9. Disconnect the hydraulic hoses.
(For: 550-80 [5AW], 550-80 [5UW]) 10. 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 11. Disconnect the lift arm hoses from the pipes on
sections. The lift arm sections can be separated with both the sides of the lift arm at point 10.
the lift arm assembly removed or installed to the
machine as required. 12. Disconnect the tilt service pipework:
12.1. Disconnect and separate the metal pipes
Disassemble from the hoses at point 5.
CAUTION You can be injured if you use incorrect 13. Disconnect the auxiliary service pipes:
or faulty lifting equipment. You must identify the
weight of the item to be lifted then choose lifting 13.1. Disconnect the hoses at the front of the lift
equipment that is strong enough and suitable for arm where they join the auxiliary coupling
the job. Make sure that lifting equipment is in good mounting block.
condition and complies with all local regulations.
14. Remove the pipe clamping bolts.
WARNING Hydraulic fluid at system pressure
can injure you. Before connecting or removing 15. Remove the nuts and bolts and remove the front
any hydraulic hose, residual hydraulic pressure hose clamps.
trapped in the service hose line must be vented.
Make sure the hose service line has been vented 16. Remove the bolts and the hose clamps 2.
before connecting or removing hoses. Do not start
the engine with loose or open hose connections. 17. Working on the underside of the lift arm,
disconnect the lift arm electrical harness from the
WARNING Never position yourself or any part chassis harness connectors.
of your body under a raised machine which is
not properly supported. If the machine moves 18. Using appropriate lifting equipment remove the
unexpectedly you could become trapped and inner lift arm from the outer lift arm.
suffer serious injury or be killed.
19. Remove the hoses and pipes from the lift arm.
2. Discharge the hydraulic pressure. Refer to (PIL machine, make sure that it is securely supported.
30-00). When the inner lift arm section is removed, forces
may cause the whole assembly to move.
06 - 55 9813/7600-3 06 - 55
12 - Lift Arm
00 - General
Figure 62.
3 4
2
3
5
4
5
1 7
8
6
9
6 9
10
10
11
8
12
12
8 13 13
1 Tilt ram 2 Fork carriage

3 Hoses 4 Metal pipes
5 Pipes and hoses at point 5 6 Bolts
06 - 56 9813/7600-3 06 - 56
12 - Lift Arm
00 - General
7 Lift arm hose cover 8 Clamping bolts

9 Service pipes 10 Pipes and hoses at point 10
11 Service pipework 12 Front hose clamps
13 Hose clamps 2
06 - 57 9813/7600-3 06 - 57
12 - Lift Arm
00 - General
Assemble 7. Remove the telescopic hydraulic service hoses.

To ensure that the hoses do not become
1. The assembly procedure is the opposite of damaged or tangled, they must be removed
the disassembly procedure. Additionally do the before attempting to separate the lift arm
followings steps. sections. Remove the hoses as follows:
1.1. Do not renew individual hoses. The hoses 7.1. Remove the hose clamps.
7.2. Put label on the hoses at the steel pipes
not be the same length. Renew all four
on the underside of the lift arm for correct
installation.
are damaged.
7.3. Disconnect and remove the hoses.
arm is fully retracted. 7.4. Pull out the hoses through the guide
channels from the rear in the direction of the
1.3. To enable alignment of the rod end pivot
arrow X.
of the extension ram, install the hydraulic
hoses so that the lift arm can be extended. 7.5. Then pull out the hoses through the
apertures under the lift arm in the direction
of the arrow Y.
Do not cross over any hoses.
7.6. Plug all the open ports and hoses to prevent
1.5. Replace the hose clamps and the clamping
contamination.
bolts.
7.7. Put label on the auxiliary service hoses at
1.6. Make sure that the lift arm wear pad
the steel pipes on the underside of the lift
shimming is correct. Refer to Technical
arm and at the front of the lift arm to help
Data (PIL 06-12).
installation.
7.8. Disconnect and remove the hoses.
(For: 526-56 [T4F])
7.9. Pull out the hoses in the same way as the
Unless the lift arm fabrications are damaged there tilt ram hoses. Refer to 7.4 and 7.5.
is normally no requirement to separate the lift arm 7.10. Plug all the open ports and hoses to
sections. The lift arm sections can be separated with prevent contamination.
machine as required. 8. Remove the inner lift arm.
Disassemble 8.1. Remove the front wear pads from the outer
lift arm.
CAUTION You can be injured if you use incorrect
or faulty lifting equipment. You must identify the 8.2. Make sure that the lift arm assembly is fully
weight of the item to be lifted then choose lifting supported by the outer lift arm and then
equipment that is strong enough and suitable for remove the upper and side wear pads.
the job. Make sure that lifting equipment is in good 8.3. Lift the front of the inner lift arm clear of
condition and complies with all local regulations. the lower wear pads and then remove them.
Label all the wear pads and keep them
The following procedures can be carried out without together with their shims.
the need to separate the lift arm sections or remove 8.4. Support the front end of the inner lift arm
the lift arm from the machine. and draw it out from the outer section.
1. Make the machine safe. Refer to (PIL 01-03). 8.5. Before the inner section is all the way out
attach suitable lifting equipment. Make sure
2. Discharge the hydraulic pressure. Refer to (PIL the section is fully supported by the lifting
30-00). equipment and then draw it free from the
outer section.
3. Remove the fork carriage. Refer to (PIL 03-33).
4. Remove the tilt ram. Refer to (PIL 30-15).
machine, make sure that it is securely supported.
5. Remove the lift arm nose cover (if installed). When the inner lift arm section is removed, forces
Refer to (PIL 06-06). may cause the whole assembly to move.
6. Remove the extension ram. Refer to (PIL 30-15).
06 - 58 9813/7600-3 06 - 58
12 - Lift Arm
00 - General
Assemble
1. The assembly procedure is the opposite of
following steps.
Figure 63.
3 3
1 1 2
1 45° coupling 2 Cable tie

3 T-pieces 4 Hose natural curvature
5 Metal pipework
1.1. Check the length of the hose pairs. The 1.7. Make sure to orient the 45° coupling against
hose lengths must be equal to within +/- the curvature to allow the hoses to lie along
1mm for each service pair (tilt ram pair, and the top of the metal pipework. Refer to
auxiliary service pair). Figure 63.
1.2. Do not renew individual hoses. The hoses 1.8. Stagger the position of the T-pieces to keep
can stretch over time. New hoses may the hoses and fittings together.
not be the same length. Renew all four
1.9. Install a cable tie to secure the two hoses
together.
are damaged.
1.10. Orient the head of the cable tie to the
outside of the hoses.
arm is fully retracted.
1.11. Do not secure the hoses to the metal
pipework.
of the extension ram, install the hydraulic
hoses so that the lift arm can be extended. 1.12. Tighten the hoses to the specified torque
value.
Do not cover any hoses. 1.13. Make sure the hydraulic fluid level is
correct and check for leaks.
1.6. The tilt ram service hoses must be phased
as shown. Refer to Figure 63. Make sure Table 9. Torque Values
that the hoses do not become twisted whilst
tightening the connectors. The hoses have Item Description Nm
a natural curvature. 1 45º coupling 50
06 - 59 9813/7600-3 06 - 59
12 - Lift Arm
00 - General
(For: 535-95 [5AB], 535-95 [5TB]) 7.14. Put a label on the inner extension ram
hoses on the underside of the lift arm to
Unless the lift arm fabrications are damaged there help installation.
is normally no requirement to separate the lift arm 7.15. Remove the inner extension ram hoses
sections. The lift arm sections can be separated with connected at the steel pipes.
machine as required. 7.16. Pull out the hoses through the apertures
under the lift arm in the direction of the
Disassemble arrow Y.
7.17. Plug all the open ports and hoses to
1. Make the machine safe. Refer to (PIL 01-03). prevent contamination.
2. Discharge the hydraulic pressure. Refer to (PIL 8. Remove the inner lift arm.
30-00).
8.1. Remove the front wear pads from the
3. Remove the fork carriage. Refer to (PIL 03-33). intermediate lift arm.
4. Remove the tilt ram. Refer to (PIL 30-15). 8.2. Make sure that the lift arm assembly is fully
supported by the outer lift arm and then
5. Remove the inner extension ram. Refer to (PIL remove the upper and side wear pads.
30-15).
8.3. Lift the front of the inner lift arm clear of the
6. Remove the outer extension ram. Refer to (PIL lower wear pads and then remove them.
30-15).
8.4. Put a label on the wear pads and keep them
7. Remove the telescopic hydraulic service hoses. together with the shims.
To ensure that the hoses do not become 8.5. Support the front end of the inner lift arm
damaged or tangled they must be removed and pull it out from the intermediate section.
before attempting to separate the lift arm
sections. Remove the hoses as follows: 8.6. Make sure that the intermediate section
does not move.
7.1. Remove the bolts 2 and remove the lift arm
hose guide roller assembly. 8.7. Before you pull out the inner lift
arm completely, attach suitable lifting
7.2. Remove the bolts 1 and remove the hose equipment.
guide.
8.8. Make sure that the section is fully supported
7.3. Put a label on the hoses at the steel pipes by the lifting equipment and then pull it out
on the underside of the lift arm to help from the intermediate section.
installation.
9. If the lift arm assembly has been removed
7.4. Disconnect the hoses at the steel pipes. from the machine, make sure that it is securely
7.5. Remove the tilt ram hoses. supported. When the inner lift arm sections is
removed, forces may cause the whole assembly
7.6. Pull out the hoses from the rear in the to move.
direction of the arrow X.
7.7. Then pull out the hoses through the 10. Remove the intermediate lift arm.
apertures under the lift arm in the direction 10.1. Remove the front wear pads from the outer
of arrow Y. lift arm.
7.8. Plug all the open ports and hoses to prevent 10.2. Make sure that the lift arm assembly is fully
contamination. supported by the outer lift arm and then
7.9. Put a label on the auxiliary service hoses on remove the upper and side wear pads.
the underside of the lift arm and at the front 10.3. Lift the front of the intermediate lift clear
of the lift arm to help installation. of the lower wear pads and then remove
7.10. Disconnect the auxiliary hoses connected them.
at the steel pipes. 10.4. Put label on the wear pads and keep them
7.11. Remove the auxiliary service hoses. together with the shims.
7.12. Pull out the hoses in the same way as the 10.5. Support the front end of the intermediate
tilt ram hoses. Refer to 7.6 and 7.7. lift arm and pull it out from the outer
section.
7.13. Plug all the open ports and hoses to
prevent contamination.
06 - 60 9813/7600-3 06 - 60
12 - Lift Arm
00 - General
10.6. Before you pull out the intermediate lift 11. If the lift arm assembly has been removed
arm completely, attach suitable lifting from the machine, make sure that it is securely
equipment. supported. When the intermediate lift arm section
is removed, forces may cause the whole
10.7. Make sure that the section is fully
assembly to move.
supported by the lifting equipment and
then pull it out from the outer section.
06 - 61 9813/7600-3 06 - 61
12 - Lift Arm
00 - General
Figure 64. 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 - 62 9813/7600-3 06 - 62
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 - 63 9813/7600-3 06 - 63
12 - Lift Arm
00 - General
Assembly
following steps.
1.1. Check the length of the hose pairs. The
hose lengths must be equal to within +/-
1mm for each service pair (tilt ram pair,
inner extension ram pair and auxiliary
service pair).
1.2. Do not renew individual hoses. The hoses
not be the same length. Renew all six
are damaged.
arm is fully retracted. Install the extension
ram followed by the inner ram. Refer to (PIL
30-00).
of the inner ram, the hydraulic hoses must
be installed so that the lift arm can be
extended. The length of the inner and
intermediate lift arm sections protruding
from the outer section must be kept equal
to avoid damage to the telescopic service
hoses.
Do not cross over any hose. The tilt ram and
auxiliary service hoses are routed through
the hose guide and along the tray fitted to
the top of the inner extension ram.
1.6. Lubricate the lift arm hose runs. Refer to
(PIL 06-00).
1.7. Make sure that the lift arm wear pad
shimming is correct. Refer to Technical
Data (PIL 06-12).
1.8. Pivot the hose guide roller assembly so
as to take up the hose slack. Do not
use excessive force when setting the roller
assembly.
06 - 64 9813/7600-3 06 - 64
12 - Lift Arm
12 - Pivot Link Lever (Upper)
12 - Pivot Link Lever (Upper)
Adjust
3. Make sure that the total gap is not more than the
(For: 526-56 [T4F], 531-70 [5AA], 531-70 specified value.
[5TA], 536-60 [5AC], 536-60 [5TC], 536-70 Length/Dimension/Distance: 3mm
[5AE], 536-70 [5TE], 541-70 [5AD], 541-70
4. If the gap is more than the specified value, add
[5TD], 550-80 [5AW], 550-80 [5UW], the correct quantity of shims to get the correct
560-80 [5AY], 560-80 [5UY]) measurement. Add the shims equally at the two
sides to make sure that the lift arm is at the centre
The figure (Refer to Figure 65. ) shows the lift arm of the pivot.
viewed from the rear of the machine.
Length/Dimension/Distance: 3mm
1. Measure the gap 1 and the gap 2 as shown in the
figure. Refer to Figure 65. 4.1. Later shims do not have handles.
2. Add the values of gap 1 and the gap 2. Total gap 5. When the total gap is of the correct value, if the
= gap 1 + gap 2. shim has handles, snap the handle from the shim
at the crease.
Figure 65.
X Y
X Gap 1 Y Gap 2
Figure 66.
B
A Handled shim (earlier type)

B Crease
C Handle
06 - 65 9813/7600-3 06 - 65
12 - Lift Arm
24 - Shim
24 - Shim Technical Data

Technical Data ............................................... 06-66 For: 526-56 [T4F] ...................... Page 06-66
Adjust ............................................................ 06-71 For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY], 560-80
[5UY] ......................................... Page 06-66
For: 535-95 [5AB], 535-95 [5TB]
................................................... Page 06-69
(For: 526-56 [T4F])
Number of plain washers to be installed under bolts

Table 10. 526-56 Machines
Wear Pad Shim Thickness Number of washers Number of Washers
(Front) (Rear)
Top 2.1–4.2mm 3
4.7–6.4mm 2
6.9–8mm 1
Side 0.5–2.5mm 2
3–4.5mm 1
5–6.5mm 0
7–8mm 0
1.6–4.2mm 2
4.7–6.4mm 1
Lower 1.6–4.2mm 3 2
4.7–6.4mm 2 1
6.9–8mm 1
(For: 531-70 [5AA], 531-70 [5TA], 536-60 [5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80
[5UY])
Number of plain washers to be installed under bolts
Table 11. Machines

Machine Table
536-60 Refer to Table 12.
536-70 and 531-70 Refer to Table 13.

Wear Pad Shim Thickness Number of Washers Number of Washers
(Front) (Rear)
Top 0–3mm 3 2
3.2–6mm 2 1
6.2–8mm 1 0
Side 0mm 3 2
06 - 66 9813/7600-3 06 - 66
12 - Lift Arm
24 - Shim

(Front) (Rear)
1.6–3mm 1 2
3.2–6mm 0 1
6.2–8mm 0 0
Lower 0mm 3 N/A
1.6–3mm 2 N/A
3.2–8mm 1 N/A
Table 13. 536-70 and 531-70 Machines

(Front) (Rear)
Top 0–3mm 3 2
3.2–6mm 2 1
6.2–8mm 1 0
Side 0mm 2 2
1.6–3mm 1 2
3.2–6mm 0 1
6.2–8mm 0 0
Lower 0mm 4 N/A
1.6–3mm 3 N/A
3.2–8mm 2 N/A

(Front) (Rear)
Top 0–3mm 3 2
3.2–6mm 2 1
6.2–8mm 1 0
Side 0mm 2 2
1.6–3mm 1 2
3.2–6mm 0 1
6.2–8mm 1 0
Lower 0mm 4 N/A
1.6–3mm 3 N/A
3.2–8mm 2 N/A

(Front) (Rear)
Top 2.1–4.2mm 3
4.7–6.4mm 2
6.9–8mm 1
Side 0.5–2.5mm 2
3–4.5mm 1
5–6.5mm 0
7–8mm 0
1.6–4.2mm 2
4.7–6.4mm 1
Lower 1.6–4.2mm 3 2
06 - 67 9813/7600-3 06 - 67
12 - Lift Arm
24 - Shim

(Front) (Rear)
4.7–6.4mm 2 1
6.9–8mm 1

(Front) (Rear)
Top 1.6–3.5mm 4 3
3.6–5.5mm 3 2
5.6–7.5mm 2 1
7.6–8mm 1 0
Side 1.6–3.5mm 4 3
3.6–5.5mm 3 2
5.6–7.5mm 2 1
Lower 0–3mm 3 N/A
0.7–3mm 2 N/A
3.2–6mm 1 N/A
06 - 68 9813/7600-3 06 - 68
12 - Lift Arm
24 - Shim
(For: 535-95 [5AB], 535-95 [5TB])
Figure 67. 3 Stage (3 section) Lift Arm
F
B
D
H J
K E
C
K
J
06 - 69 9813/7600-3 06 - 69
12 - Lift Arm
24 - Shim
Table 17. Number of Plain Washers to be installed under Bolt

Detail Shim Thickness Number of Washers
A
(1)
0mm 3
1.6–4.6mm 1
over 4.6mm 0
B
(1)
0mm 4
2–3mm 3
4–6mm 2
7–8mm 1
C
(1)
0–1.6mm 6
3–5mm 5
6mm 4
D
(1)
0mm 4
1.6–3.6mm 3
6mm 2
E
(1)
0mm 4
1.6–3.2mm 3
3.6–6mm 2
F
(2)
0mm 4
2–3mm 3
4–6mm 2
7–8mm 1
G
(2)
0–8mm 0
H
(2)
0–1.6mm 6
3–5mm 5
6mm 4
J
(2)
0mm 4
1.6–3.2mm 3
6mm 2
K
(2)
0mm 4
1.6–3.2mm 3
3.6–6mm 2
(1) Intermediate to the outer lift arm.
(2) Inner to the intermediate lift arm.
06 - 70 9813/7600-3 06 - 70
12 - Lift Arm
24 - Shim
Adjust Figure 68.

D
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
D Chamfer depth
Typical shimming Procedure Figure 69. 2 Section, 2 Stage Lift Arm
This procedure details a typical method for shimming

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

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

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

of specification. The clearances must be measured,
the chamfer is not a guide to the amount of wear
remaining.Refer to Figure 68.
Make sure that the threaded insert remains a tight fit

in the wear pad and does not rotate when tightened. A Inner boom
If the insert is loose in the wear pad, install a new B Outer boom
wear pad and threaded insert.
Figure 70. 3 Section 3 Stage Lift Arm
On 2 stage (2 section) machines, shim the inner
boom to the outer boom.
On 3 stage (3 section) machines, shim the

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

depending on the shim thickness. Make sure you A
install the correct number of washers for the
thickness of shims. Refer to Body and Framework-
C
Lift Arm, Technical data (PIL 06-12-30).
Do not install spring washers.

A Intermediate lift arm
B Outer lift arm
C Inner lift arm
06 - 71 9813/7600-3 06 - 71
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
Lower wear pads- Shimming Rear lower wear pads
Front lower wear pads 1. Rest the forks on the ground.
1. Make the machine safe. Refer to (PIL 01-03). 2. Remove the lift arm rear cover. Refer to (PIL
06-06).
2. Follow all safety procedures. Refer to (PIL
01-03). 3. Measure the distances between lift arm lower
faces which must be in the limit given. Refer to
3. Raise the lift arm slightly so that forks are just off (PIL 06-12).
the ground.
4. If this dimension is less than the limit, then install
4. Measure the distances between the lift arm lower shims under the lower wear pads to restore the
faces which must be in the limit given. Refer to dimension.
Technical Data (PIL 06-12).
5. Raise the lift arm slightly so that forks are just off
5. If this dimension is less than the limit, then install the ground and place wedges under the inner lift
shims under the lower wear pads to restore the arm.
dimension.
6. Remove the wear pad bolts and add shims as
6. Rest the forks on the ground so that there is no required.
weight on the lower wear pads.
7. Measure the total thickness of shims under each
7. Remove the wear pad bolts and add shims as pad.
required.
8. Add or remove plain washers under the heads
8. Measure the total thickness of shims under each of wear pad bolts. Make sure that the thread
pad. engages sufficiently. Refer to (PIL 06-12).
9. Add or remove the correct number of plain 9. Do not install spring washers.
washers under the heads of wear pad bolts.
Make sure that the thread engages sufficiently. 10. Remove the wedges, install the shims again and
Use the correct number of washers. Refer to tighten the bolts to the specified torque value.
10. Do not install spring washers.
11. Install the shims again and tighten the bolts to the
06 - 72 9813/7600-3 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
Top wear pads- Shimming Side wear pads- Shimming

The following procedure applies to both front and The following procedure applies to both front and
rear top wear pads. rear side wear pads.
1. Raise the lift arm until the inner lift arm is resting 1. Measure the distances between the lift arm side
on the lower wear pads. faces which must be in the limit given. Refer to
2. Measure the distances between the lift arm upper
faces which must be in the limit given. Refer to 2. If this dimension is less than the limit, install
(PIL 06-12-00). shims under the side wear pads to restore the
dimension.
3. If this dimension is less than the limit, install
shims under the top wear pads to restore the 3. Slacken the side wear pad bolts and install shims
dimension. as required. Divide number of shims equally each
side to ensure that inner lift arm runs centrally
4. Install or remove shims to obtain the correct within the outer lift arm.
vertical clearance.
4. Measure the total thickness of shims under each
5. Measure the total thickness of shims under each pad.
pad.
5. Add or remove the correct number of plain
6. Add or remove the correct number of plain washers under the heads of wear pad bolts.
washers under the heads of wear pad bolts. Make sure that the thread engages sufficiently.
Make sure that the thread engages sufficiently. Refer to (PIL 06-12-00).
Refer to Technical Data (PIL 06-12).
7. Install the shims again and tighten the bolts to the
8. Install the shims again and tighten the bolts to the specified torque value.
06 - 73 9813/7600-3 06 - 73
12 - Lift Arm
24 - Shim
Figure 75.
2
1
E Wear pad bolt

F Shim
G Washer
1 Wear pad
2 Threaded insert
Table 18. Torque Information

Item Description Torque
E For wear pads 98N·m
with M12 bolts
E For wear pads 58N·m
with M10 bolts
E 550-80 Ma- 56N·m
chines only
06 - 74 9813/7600-3 06 - 74
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ........................................................................................................................... 06-77
06 - 75 9813/7600-3 06 - 75
Notes:
06 - 76 9813/7600-3 06 - 76
30 - Pivot Pins
00 - General
Introduction .................................................... 06-77 Pivot pins are a short shaft or pin that supports
Lubricate ........................................................ 06-78 something that turns. Pivot pins are installed in
Remove and Install ....................................... 06-78 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 - 77 9813/7600-3 06 - 77
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 76.
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 - 78 9813/7600-3 06 - 78
30 - Pivot Pins
00 - General
Figure 77. Typical Machine
A Adaptor
B End stop
C End stop
D Spanner flats
E Slide bar
F Slide hammer
06 - 79 9813/7600-3 06 - 79
42 - Stabiliser
42 - Stabiliser
Contents Page No.
06-42-00 General ........................................................................................................................... 06-81
06 - 80 9813/7600-3 06 - 80
42 - Stabiliser
00 - General
Introduction .................................................... 06-81 The stabilisers are a safety device to stop the
Health and Safety .......................................... 06-82 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 - 81 9813/7600-3 06 - 81
42 - Stabiliser
00 - General
Health and Safety

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 - 82 9813/7600-3 06 - 82
49 - Step
49 - Step
Contents Page No.
06-49-00 General ........................................................................................................................... 06-85
06 - 83 9813/7600-3 06 - 83
Notes:
06 - 84 9813/7600-3 06 - 84
49 - Step
00 - General
00 - General Figure 78. Side Step
Remove and Install

For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................... Page 06-85
For: 526-56 [T4F] ...................... Page 06-85
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
B
[5UY])
Remove
1. Make the machine safe. Refer to (PIL 01-03). A
2. Remove the bolts and washers (x4) that secure

the steps to the machine.
3. Remove the assembly from the machine.
A Side step
B Bolts
Install
1. The installation procedure is the opposite of
step.
1.1. Tighten fasteners to the correct torque
value.
(For: 526-56 [T4F])
Remove
2. Remove the bolts and washers (x2) that secure
the steps to the machine.
3. Remove the assembly from the machine.
06 - 85 9813/7600-3 06 - 85
49 - Step
00 - General
Figure 79. Side Step
A Side step
B Bolts
Install
step.
1.1. Tighten fasteners to the correct torque
value.
06 - 86 9813/7600-3 06 - 86
54 - Fender
54 - Fender
Contents Page No.
06-54-00 General ........................................................................................................................... 06-89
06 - 87 9813/7600-3 06 - 87
Notes:
06 - 88 9813/7600-3 06 - 88
54 - Fender
00 - General
00 - General
Remove and Install
Top Guard Assembly 2.1. If the washers on top of the fender are
metal, discard them and obtain the correct
Remove new nylon shoulder washers.
1. Make the machine safe. Refer to (PIL 01-03). 3. Remove the lower saddle clamp.
2. Remove the nuts, bolts and washers. 4. Lift off the fender cover.
5. Inspect the fender for cracks, particularly around
the mounting holes.
Figure 80.
A
E B
A Bolts B Fender cover

C Lower saddle clamp D Nuts
E Washers
5.1. Also check all other fenders on the machine Figure 81.
for cracks.
5.2. If cracks are found, discard the fender and
install a new one.
Install
L
steps.
1.1. Make sure you install the correct nylon
shoulder washers. Do not reuse metal
washers (if they were installed originally).
L Nylon shoulder washer
06 - 89 9813/7600-3 06 - 89
54 - Fender
00 - General
1.2. Drill out the fender mounting holes to the 2. Remove the road wheel if greater access is
specified diameter and de-burr the hole if necessary. Refer to (PIL 27-29).
required.
3. Remove the top guard assembly.
1.3. Make sure the shoulder washers are 4. Remove the mounting arm bolts, nuts and
located correctly in the fender hole. washers.
1.4. Tighten the nuts to the specified torque 5. Remove the arm assembly.
value.
6. Remove the support bracket nuts.
Torque: 14N·m
7. Remove the bracket from the trunnion studs.
Complete Fender Assembly
Remove
Figure 82.
P
N
M
R
S
M Mounting arm nuts N Mounting arm washers

P Arm assembly Q Mounting arm bolts
R Bracket S Support bracket fastenings
Install Table 19. Torque table

1. The installation procedure is the opposite of the Item Value
removal procedure. Additionally do the following M 28N·m
step. S
(1)
139–154N·m
1.1. Tighten the bracket nuts to the correct S
(2)
28N·m
torque value. (1) 550-80 machines.
(2) Other machines.
06 - 90 9813/7600-3 06 - 90
57 - Counterweight
57 - Counterweight
Contents Page No.
06-57-00 General ........................................................................................................................... 06-93
06 - 91 9813/7600-3 06 - 91
Notes:
06 - 92 9813/7600-3 06 - 92
57 - Counterweight
00 - General
00 - General
Health and Safety

method and device.
CAUTION You can be injured if you use incorrect
or faulty lifting equipment. You must identify the
weight of the item to be lifted then choose lifting
equipment that is strong enough and suitable for
the job. Make sure that lifting equipment is in good
condition and complies with all local regulations.
WARNING Make sure the machine cannot be
used with the counterweight removed. Make sure
the ignition key is removed and the battery is
isolated.
WARNING Make sure the machine cannot tip
over when this component (or components) is
(are) removed during this operation.
06 - 93 9813/7600-3 06 - 93
63 - Identification Label
Contents Page No.
06-63-00 General ........................................................................................................................... 06-95

06-63-03 Machine .......................................................................................................................... 06-96
06-63-06 Engine .......................................................................................................................... 06-100
06-63-09 Axle .............................................................................................................................. 06-102
06-63-12 Gearbox ........................................................................................................................ 06-103
06-63-15 Operator Protective Structure ...................................................................................... 06-105
06 - 94 9813/7600-3 06 - 94
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 - 95 9813/7600-3 06 - 95
03 - Machine
03 - Machine
The machine identification plate fitted to European

(For: 531-70 [5AA], 531-70 [5TA], 535-95 Tractor Type Approved builds is different. Refer to
[5AB], 535-95 [5TB], 536-60 [5AC], Figure 84.
536-60 [5TC], 536-70 [5AE], 536-70 [5TE], Figure 83.
536-70LP [5A1], 536-70LP [5T1], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY], JCB T4F 4.4 over 55kw Electronic
Dieselmax Turbocharged Aftercooled
Engine)
Machine Identification Plate

Your machine has an identification plate mounted in
one of two positions as shown. The serial numbers
of the machine and its major units are shown on the
plate.
The machine model and build specification is

indicated by the PIN (Product Identification Number)
The serial number of each major unit is also shown

on the unit itself. If a major unit is replaced by a Typical Product Identification Number
new one, the serial number on the identification plate
will be wrong. Either get a replacement identification The machine model and build specification are
plate from your JCB Dealer or simply remove the indicated by the PIN. The PIN has 17 digits and must
old number. This will prevent the wrong unit number be read from left to right.
being quoted when replacement parts are ordered.
The machine and engine serial numbers can help
identify exactly the type of equipment you have.
Table 20. Typical PIN

JCB 5AA J E C G1234567
Table 21.
Digit 1 to 3 World Manufacturer Identification
JCB United Kingdom
GEO Georgia, US
HAR Haryana, India
SOR Sorocaba, Brazil
GET Gatersleben, Germany
PUN Pune, India
SHA Shanghai, China
JBP JCB Branded Products
Table 22.
Digit 4 to 6 Machine Model
5AA 531-70
5AB 535-95
5AC 536-60
06 - 96 9813/7600-3 06 - 96
03 - Machine
Digit 4 to 6 Machine Model

5AD 541-70
5AF 540-170
5AH 533-105
5AL 540-140
5AN 535-125 HiViz
5AP 535-140 HiViz
5AR 536-70
5AS 526-56
5AW 550-80
5AX 540-200
5AY 560-80
5A1 536-70 LP
5TA 531T70
5TB 541T70
5TC 536T60
5TD 535T95
5TE 536T70
5T1 536T70 LP
5UW 550U80
5UY 560U80
Table 23.
Digit 7 Engine Type
JCB Dieselmax (Tier 4):
7 (T4F) 55kW
2 (T4F) 81kW
3 (T4F) 93kW
4 (T4F) 108kW
Table 24.
Digit 8 Gearbox Model
E 3 Speed (PS750) Agri
F 3 Speed (PS760) Agri Plus
G 4 Speed (PS750) Agri
H 4 Speed (PS760) Agri Plus
J 6 Speed (PS760) Agri Super
M 4 Speed (SS700) Agri
N 4 Speed (PS750) Agri
W DTVT (Dual Technology Variable Transmission)
(HM560) Agri Pro
Table 25.
Digit 9
Random check letter. The check letter is used to verify the authenticity of a machine's PIN
Table 26.
Digit 10
Year of manufacture. 0= N/A G = 2016 H = 2017 etc.
06 - 97 9813/7600-3 06 - 97
03 - Machine
Table 27.
Digit 11 to 17
Machine serial number. Each machine has a unique serial number.
European Tractor Type Approved Builds

Figure 84.
A
B
C
D
E
F
G
Table 28. Hitch Descriptions

H1 JCB Hydraulic Pick-up Hitch
H2/H3 Rockinger Fixed Clevis (Auto & Manual)
H4/H5/H6 Rockinger Ladder Clevis (Top Position)
H4b/H5b/H6b Rockinger Ladder Clevis (Bottom Position)
H7/H8 Rockinger Ladder with Piton/ Ball Ø80
H9 JCB Ladder with Clevis (Manual)
H10 JCB Piton
Table 29.
5TA 5TB 5TC 5TD
Item 531-70 541-70 536-60 535-95
kg kg kg kg
A Maximum Permitted Laden Mass(1) 11,000 11,000 11,000 11,000
B Maximum Permitted Mass On Front From 6,900 6,900 6,900 8,000
Axle
(1)
To 8,500 8,500 8,500 8,500

C Maximum Permitted Mass On Rear From 6,900 6,900 6,900 7,500
Axle
(1)
To 7,500 7,500 7,500 7,500

D Unbraked Towable Mass 750 750 750 750
E Independently Braked Towable Mass 6,000 6,000 6,000 6,000
F Inertia Braked Towable Mass 3,500 3,500 3,500 3,500
G Towable Mass Fitted with a Propor- H1 10,305 9,540 10,810 8,695
tionally Assisted Braking System H2-H10 17,280 15,780 17,855 14,270
(1) Dependent on tyre option.
06 - 98 9813/7600-3 06 - 98
03 - Machine
Table 30.
5TE 5T1 5UW 5UY
Item 536-70 536-70LP 550-80 560-80
kg kg kg kg
A Maximum Permitted Laden Mass(1) 11,000 11,000 13,500 13,500
B Maximum Permitted Mass On Front From 6,900 8,500 9,000 9,000
Axle
(1)
To 8,500 8,500 10,000 10,000

C Maximum Permitted Mass On Rear From 6,900 7,500 9,000 9,000
Axle
(1)
To 7,500 7,500 10,000 10,000

D Unbraked Towable Mass 750 750 750 750
E Independently Braked Towable Mass 6,000 6,000 6,000 6,000
F Inertia Braked Towable Mass 3,500 3,500 3,500 3,500
G Towable Mass Fitted with a Propor- H1 9,510 9,375 7,460 7,350
tionally Assisted Braking System H2-H10 15,710 16,325 10,805 10,570
(1) Dependent on tyre option.
06 - 99 9813/7600-3 06 - 99
06 - Engine
06 - Engine
The engine data labels are attached to the cylinder

block as shown.
Figure 85.
B
A C
A Engine data label - rocker cover B Engine identification number

C Stamp
The data label includes the engine identification

number.
Table 31. Example of the engine identification number
SH 320/40001 U 00001 04
Digit 1-2 3-10 11 12-16 17-18
Table 32.
Digit 1-2 Engine Type
DA 4.8L naturally aspirated mechanical fuel injection (Tier 2)
DB 4.8L turbocharged mechanical fuel injection (Tier 2)
DC 4.8L turbocharged and aftercooled mechanical fuel injection (Tier 2)
DE 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 2)
DD 4.8L turbocharged mechanical fuel injection (Tier 3)
DF 4.8L turbocharged and aftercooled mechanical fuel injection (Tier 3)
DK 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
DH 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 4i)
DJ 4.8L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F)
FL 3L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F
SEF >55kW)
SA 4.4L naturally aspirated mechanical fuel injection (Tier 2)
SB 4.4L turbocharged mechanical fuel injection (Tier 2)
SC 4.4L turbocharged and aftercooled mechanical fuel injection (Tier 2)
SD 4.4L turbocharged mechanical fuel injection (Tier 3)
SE 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 3)
06 - 100 9813/7600-3 06 - 100

06 - Engine
Digit 1-2 Engine Type

SF 4.4L turbocharged and aftercooled mechanical fuel injection (Tier 3)
SH 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 4i)
SJ 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F)
SL 4.4L turbocharged and aftercooled electronic common rail fuel injection (Tier 4F
55kw)
Table 33. Explanation of the engine identification number

Digit Explanation
3-10 Engine part number
11 Country of manufacture. U = United Kingdom
12-16 Engine serial number
17-18 Year of manufacture
The country of manufacturer, engine serial number

and year of manufacture of the engine are also
stamped on the crankcase. Refer to Figure 85.
06 - 101 9813/7600-3 06 - 101

09 - Axle
09 - Axle (For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY])
Component Identification The axles have a serial number stamped on a data
plate label as shown.
For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 To view the front axle data plate remove the cover.
[5TE], 536-70LP [5A1], 536-70LP [5T1], The plate will be visible through hole.
541-70 [5AD], 541-70 [5TD] .... Page 06-102
Figure 88. Front axle
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] ................ Page 06-102 A
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD])
The axles have a serial number stamped on a data
plate as shown.
B
Figure 86. Front axle
A Cover
A B Data plate - front axle
Figure 89. Rear axle
A Data plate - front axle

Figure 87. Rear axle
C Data plate - rear axle
B Data plate - rear axle
06 - 102 9813/7600-3 06 - 102

12 - Gearbox
12 - Gearbox Figure 91. Power-shift Transmission
For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC],
536-60 [5TC], 536-70 [5AE], 536-70 [5TE],
536-70LP [5A1], 536-70LP [5T1], 541-70
[5AD], 541-70 [5TD] ................ Page 06-103
For: 526-56 [T4F] .................... Page 06-103
For: HM560 Variable Transmission
................................................. Page 06-103
(For: 531-70 [5AA], 531-70 [5TA], 535-95 A

[5AB], 535-95 [5TB], 536-60 [5AC], A Data plate
536-60 [5TC], 536-70 [5AE], 536-70 [5TE],
536-70LP [5A1], 536-70LP [5T1], 541-70 Figure 92. Syncro Shuttle Transmission
[5AD], 541-70 [5TD])
The gearbox has a serial number stamped on a data
plate as shown.
Figure 90. Power-shift Transmission
A
A Data plate
Unit Identification
A
The gearbox serial number is stamped on the
A Data plate 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
(For: 526-56 [T4F]) gear replacements, always check the part number
stamped on the gear, and the number of teeth.
The gearbox has a serial number stamped on a data
plate as shown.
06 - 103 9813/7600-3 06 - 103

12 - Gearbox
Figure 93.
A
RATIO
SERIAL No
817/02980
A Dual Tech Variable Transmission
B Data plate
06 - 104 9813/7600-3 06 - 104

15 - Operator Protective Structure
15 - Operator Protective Structure certification. If damage has occurred then an

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

WARNING You could be killed or seriously injured Structure) can be identified by referring to the
if you operate a machine with a damaged or cab identification plate. Work place (work site, job
missing ROPS/FOPS/FOGS. If the ROPS/FOPS/ site) risk assessment should facilitate the machine
FOGS has been in an accident, do not use the selection and the need for an machine with a ROPS.
machine until the structure has been renewed.
Modifications and repairs that are not approved Figure 94.
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS/FOGS certification.
WARNING Machines with a ROPS, FOPS,FOGS
or TOPS are equipped with a seat belt. The
ROPS, FOPS,FOGS or TOPS is designed to give
you protection in an accident. If you do not wear
the seat belt you could be thrown off the machine
Data plate - ROPS/FOPS standards
and crushed. You must wear a seat belt when
using the machine. Fasten the seat belt before Figure 95.
starting the engine.
FOPS Data Plate

WARNING Do not use the machine if the falling
objects protection level provided by the structure
is not sufficient for the application. Falling objects
can cause serious injury. Data plate - ROPS/FOPS and OECD
(Organization for Economic Cooperation and
If the machine is used in any application where there Development) standards
is a risk of falling objects then a FOPS (Falling Object
Protective Structure) must be installed. For further Protection Offered by the Cab
information, contact your JCB dealer.
Definition of Category 1
The FOPS has a data plate attached. The data
plate indicates what level of protection the structure The Cab meets the requirements defined in EN
provides. 15695-1. This means that the air delivery and
filtration system does not provide a specified level
There are two levels of FOPS: of protection against hazardous substances but only
from external atmospheric conditions (e.g. rain, wind,
• Level I Impact Protection - impact strength snow etc.).
for protection from small falling objects
(e.g. bricks, small concrete blocks, hand
Definition of Category 2
tools) encountered in operations such as
highway maintenance, landscaping and other The Cab meets the requirements defined in EN
construction site services. 15695-1. This means that the air delivery and
• Level II Impact Protection - impact strength for filtration system provides protection against dust and
protection from heavy falling objects (e.g. trees, the minimum differential pressure. The necessary
rocks) for machines involved in site clearing, filtered fresh air flow rate can be obtained using A/
overhead demolition or forestry. C system and by adjusting the maximum fan speed
provided that doors, windows and hatches are closed
ROPS Data Plate and the recirculation device is deactivated.
WARNING Your machine may be installed with a
Roll-Over Protective Structure (ROPS) indicating Comfort and Safety Inside the Cab
that the purchaser specified the machine for use
in applications where there is risk of roll-over. The cab category 1 does not guarantee full protection
ROPS is a device to protect the operator in the against dust, aerosols and vapours.
event of roll-over. Any damage or modification
The cab category 2 cab offers protection against
to the structure may invalidate the ROPS
dust but only partially for aerosols and vapours:
for application of plant protection products (e.g.
06 - 105 9813/7600-3 06 - 105

15 - Operator Protective Structure
pesticides, fungicides, herbicides), refer to the

instructions provided by the supplier of the chemical
agent as well as instructions provided by the
sprayer's manufacturer.
Personal protective equipment (PPE) must be used

inside the cab when specified by those directions.
The air delivery system cannot offer a full protection,

but a partial protection can be achieved by following
some basic rules:
• Keep doors windows and hatches closed during

the spraying operation.
• Keep the cab interior clean.
• Do not enter the cab with contaminated shoes
and/or clothing.
• Keep all used personal protective equipment
outside the cab.
• Bring the wire harness of the remote spray
control box into the tractor cab.
• Remove the outside air delivery cab filter after
the spraying operation and store it in a dry
dust free room. Reserve it for the next spraying
operation; replace with a service part filter.
• Active carbon filters must be properly stored
in a sealed plastic bag to preserve their
functionality.
• Use only genuine JCB filters and ensure that
the filter is correctly installed.
• Check the condition of the sealing material and
have it repaired when required.
06 - 106 9813/7600-3 06 - 106

66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ......................................................................................................................... 06-109
06 - 107 9813/7600-3 06 - 107

Notes:
06 - 108 9813/7600-3 06 - 108

66 - Tools
00 - General
Introduction .................................................. 06-109 All tools must be kept in the toolbox (if installed) when
Component Identification ............................. 06-110 not in use.
06 - 109 9813/7600-3 06 - 109

66 - Tools
00 - General
(For: 536-70LP [5A1], 536-70LP [5T1])

The toolbox is located under the cab door, next to
the fuel filler cap. The toolbox must be opened and
closed using the key.
Figure 96.
A Toolbox
06 - 110 9813/7600-3 06 - 110

69 - Maintenance Strut
Contents Page No.
06-69-00 General ......................................................................................................................... 06-113

06-69-03 Lift Arm ......................................................................................................................... 06-114
06 - 111 9813/7600-3 06 - 111

Notes:
06 - 112 9813/7600-3 06 - 112

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

machine, make sure that the relevant maintenance
strut is installed in its correct position and secure.
Refer to: PIL 01-03-27.
06 - 113 9813/7600-3 06 - 113

03 - Lift Arm
03 - Lift Arm Lift Arm Raised

If you raise the lift arm to get access for maintenance,
Remove and Install you must install the maintenance strut on the lift arm.
Before you install the maintenance strut remove any
WARNING You could be killed or injured if the lift
load on the forks and empty shovels or attachments.
arm drops while you are working under it. Install
the lift arm maintenance strut as instructed before Figure 98.
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.
WARNING Make sure that you use the correct
JCB maintenance strut for the machine. Make
sure that the safety strut is only used with the
correct JCB retaining bolt or securing device.
Never substitute this bolt or securing device,
always use the correct JCB part.
Make sure that the strut and bolt/securing device Lift arm raised
is installed correctly. Never use a strut intended
for another machine. If in doubt, consult your JCB Installing the Maintenance Strut
dealer.
WARNING Do not drive the machine with the
maintenance strut installed. 2. Retract the lift arm.
CAUTION You will have to climb onto the
machine to install or remove the strut. Take care, 3. Raise the lift arm.
especially if the machine is wet. Remove mud and 4. Stop the engine and remove the ignition key.
oil before climbing onto the machine. Do not use
the exhaust as a handhold. It can burn you. 5. Remove the maintenance strut from its stowage
position.
Lift Arm Lowered Figure 99.
Figure 97.
A
A
A Boom lowered
1. Park the machine on level, solid ground. A Maintenance strut
2. Lower the boom. 6. Install the maintenance strut.
3. Put the attachment flat on the ground. 7. Place the strut around the lift ram piston rod.
Secure it in position with the strap.
4. Stop the engine and remove the starter key.
6. Make sure there are no loose articles in the
enclosure.
7. If necessary, put chocks against the two sides of
06 - 114 9813/7600-3 06 - 114

03 - Lift Arm
Figure 100.
A Maintenance strut
B Lift arm
8. To prevent any chance of the lift arm creeping
down and trapping your fingers, the lift arm
should be lowered onto the strut. Lower the arm
carefully, to prevent possible damage to the strut.
Stop as soon as the weight of the lift arm is on
the strut.
10. If necessary, put blocks against the two sides of
Removing the Maintenance Strut

1. Raise the lift arm to take the weight off of the strut.
2. Stop the engine and remove the ignition key.
3. Remove the maintenance strut.
4. Secure the strut in its stowage position.
06 - 115 9813/7600-3 06 - 115

75 - Fire Extinguisher
Contents Page No.
06-75-00 General ......................................................................................................................... 06-117
06 - 116 9813/7600-3 06 - 116

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 101.
A Gauge
B Safety Pin
06 - 117 9813/7600-3 06 - 117

89 - Window Guard
89 - Window Guard
Contents Page No.
06-89-00 General ......................................................................................................................... 06-119

06-89-03 Front Window ............................................................................................................... 06-120
06-89-12 Roof Window ................................................................................................................ 06-121
06 - 118 9813/7600-3 06 - 118

89 - Window Guard
00 - General
00 - General Figure 102. 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 - 119 9813/7600-3 06 - 119

89 - Window Guard
03 - Front Window
03 - Front Window Figure 103. Front screen guard
Remove and Install A E
(For: 526-56 [T4F]) B
Screen Guard C
D
Remove
1. Make the machine safe. Refer to (PIL 01-03). A
2. Follow all general health and safety procedures.
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 - 120 9813/7600-3 06 - 120

89 - Window Guard
12 - Roof Window
12 - Roof Window
Remove and Install
(For: 526-56 [T4F])
Roof Guard
Remove
1. Park the machine and make it safe. Follow all
safety procedures (PIL 01-03).
2. Remove the rear mounting bolt and unscrew the
front guard mounting bolts from the windshield
guard.
Installation
Installation is the opposite of removal.
Figure 104.
A Rear mounting fastenings

B Front mounting fastenings
06 - 121 9813/7600-3 06 - 121

Notes:
06 - 122 9813/7600-3 06 - 122

Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-00-03 Cab Frame ....................................................................................................................... 09-8
09-09 Window
09-09-00 General ........................................................................................................................... 09-15
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-23
09-12-03 Seat Base ...................................................................................................................... 09-25
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-27
09-18 Door
09-18-00 General ........................................................................................................................... 09-31
09-18-03 Lock ................................................................................................................................ 09-36
09-18-12 Handle ............................................................................................................................ 09-37
09-27 Controls
09-27-36 Accelerator Pedal ........................................................................................................... 09-39
09-27-39 Gear Lever ..................................................................................................................... 09-41
09-27-57 Park Brake ..................................................................................................................... 09-45
09-28 Cables and Fittings
09-28-00 General ........................................................................................................................... 09-47
09-30 Trim Panel
09-30-03 Roof Trim ....................................................................................................................... 09-55
09-30-09 Dashboard ...................................................................................................................... 09-56
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-61
09-36 Steering Wheel
09-36-00 General ........................................................................................................................... 09-65
09-44 Sunblind
09-44-00 General ........................................................................................................................... 09-67
09-48 Floor mat
09-48-03 Front Floor mat .............................................................................................................. 09-71
9813/7600-3
2018-02-25
Acronyms Glossary
ECU Electronic Control Unit

HVAC Heating Ventilation Air Conditioning
LLMI Longitudinal Load Moment Indicator
TXV Thermal Expansion Valve
9813/7600-3
2018-02-25
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3

09-00-03 Cab Frame ....................................................................................................................... 09-8
09 - 1 9813/7600-3 09 - 1
Notes:
09 - 2 9813/7600-3 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
local regulations.
09 - 3 9813/7600-3 09 - 3
00 - General
For: 531-70 [5AA], 531-70 [5TA], 535-95 Cab Layout

[5AB], 535-95 [5TB], 536-60 [5AC],
536-60 [5TC], 536-70 [5AE], 536-70 The layout shown below is for a typical machine.
[5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 550-80 [5AW], There are different variants of hydraulic control
550-80 [5UW], 560-80 [5AY], 560-80 [5UY] levers. The cab layout is the same except the control
..................................................... Page 09-4
levers.
For: 526-56 [T4F] ........................ Page 09-7
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC],
536-60 [5TC], 536-70 [5AE], 536-70 [5TE],
536-70LP [5A1], 536-70LP [5T1], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY])
This cab is certified to category 1 according to
EN15695-1-2009.
09 - 4 9813/7600-3 09 - 4
00 - General
Figure 105. Cab Layout - Dual lever control
A
A
P
P S
S
R
P
B
B
TT
C
C N
N
M
M
D
D
L
U
R
E
E
G
G
F
HH
J
A Steering wheel B Transmission Lever and Gear Selection

C Console switches D Steer mode selector
E Service brake pedal F Park brake lever
G Control locks H Immobiliser
J Hydraulic tow hitch K Load charts
L HVAC (Heating Ventilation Air Conditioning) M Console switches
N Ignition switch P Instrument panel
R Inclinometer S LLMI (Longitudinal Load Moment Indicator)
T Load control system U Inclinometer
Single lever control variant

The single lever control can be mounted on the right
side console, in the arm rest or in an adjustable
control pod.
09 - 5 9813/7600-3 09 - 5
00 - General
Figure 106. Servo lever control variant (If installed, not

1 available on all models)
Figure 107.
3
2 1
3 3
1 Hydraulic control lever

2 Transmission dump switch
3 Drive direction selection switch 2
1 Transmission dump switch

2 Stabiliser control levers
3 Hydraulic control levers
09 - 6 9813/7600-3 09 - 6
00 - General
(For: 526-56 [T4F])
Figure 108.
B
A
V
C
F D
W
E
U
F
L
G
S H
R Q P N G,K
T
M
L
A Steering wheel B Instrument panel

C Multi-Purpose switch D Instrument panel
E Ignition switch F Console switches
G Transmission dump H Boom and carriage controls
J Auxiliary controls K Gear lever (syncro shuttle transmission)
L Steer mode selector M Hydraulic tow hitch release
N HVAC controls P Control locks
Q Accelerator pedal R Service brake pedal
S Steering column adjustment T Park brake
U Transmission lever and gear selection V Inclinometer
W LLMI
09 - 7 9813/7600-3 09 - 7
03 - Cab Frame
03 - Cab Frame
Remove and Install
7. Remove the heater cover (if installed). Undo the

(For: 526-56 [T4F], 531-70 [5AA], 531-70 hose clips and disconnect the heater hoses.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 8. If applicable, once the system has been
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 discharged, disconnect the air conditioning
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 hoses at the TXV (Thermal Expansion Valve).
[5AW], 550-80 [5UW], 560-80 [5AY], Some machines are installed with a cab roof
mounted air conditioning condenser. Disconnect
560-80 [5UY]) the condenser hoses at the rear of the cab.
9. Disconnect the engine accelerator cable (if
Make the machine safe before getting beneath it. installed).
correctly attached. Engage the park brake, remove 10. Disconnect the accelerator pedal electrical
the ignition key, disconnect the battery. If the machine connectors (if installed).
movement. 11. Make sure that all wheels are blocked to prevent
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
and contains pressurised refrigerant. No part of the 12. On machines with dual lever controls, disconnect
system should be disconnected until the system the control levers from the control valve
has been discharged by a refrigeration engineer 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
Notice: Make sure you label all hoses / pipes and control valves. Disconnect the control levers from
electrical connectors (if installed) before removal to the control valve connection rods.
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
Remove cab earth strap.
1. Make the machine safe. 16. Undo the fuel filler hose clip. Loosen the fuel tank
Refer to: PIL 01-03-27. filler hose on fuel tank filler neck so that the two
separate later.
2. Install the safety strut.
17. Disconnect the braking system components.
17.1. 550-80 and 560-80 Machines- For details
3. Discharge the hydraulic pressure. of disconnecting the brake valve.
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.
17.3. Disconnect brake pipe at the master
5. Remove the bolts and remove the cab front cylinder. Cap all open hoses and pipes to
cover. prevent fluid loss and ingress of dirt.
Refer to: PIL 06-06-12. 18. Disconnect hitch cable (if installed).
6. Disconnect all hydraulic hoses from the steering 19. For machines with manual transmission
unit. Cap all open hoses and ports to prevent fluid disconnect the cables to the gear lever.
loss and ingress of dirt.
20. Unscrew and remove the cab mounting bolts.
09 - 8 9813/7600-3 09 - 8
03 - Cab Frame
21. Attach appropriate lifting equipment to the ROPS 1.3. Adjust the accelerator cable and pedal (if
(Roll-Over Protective Structure). installed).
22. Carefully lift the cab from the machine, make sure 1.4. Correctly connect and adjust the cables to
that all connections have been released and are the gear lever (if installed).
clear of any obstruction. Cap off fuel tank filler 1.5. If applicable, recharge the air conditioning
neck to prevent contamination. system.
Install Refer to: PIL 12.
1.6. Check the hydraulic fluid level.
removal procedure. Additionally do the following Refer to: PIL 30-00-00.
steps. 1.7. Make sure that all cables are connected and
1.1. Tighten the cab mounting bolts to the correctly adjusted. Make sure that they are
correct torque value. routed and secured correctly.
1.2. Bleed the brakes. Refer to (PIL 24-00). 1.8. Make sure that all electrical and hydraulic
services operate correctly.
09 - 9 9813/7600-3 09 - 9
03 - Cab Frame
Figure 109.
B
J B
G
B
C
D
E
F
B
A Park brake cable B Cab mounting bolts

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 - 10 9813/7600-3 09 - 10
03 - Cab Frame
Figure 110.
K
K
R
Z
W
X
K Dual lever controls M Transmission gear lever
09 - 11 9813/7600-3 09 - 11
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 - 12 9813/7600-3 09 - 12
09 - Window
09 - Window
Contents Page No.
09-09-00 General ........................................................................................................................... 09-15
09 - 13 9813/7600-3 09 - 13
Notes:
09 - 14 9813/7600-3 09 - 14
09 - Window
00 - General
Introduction .................................................... 09-15 The service procedures, explain how to correctly
Health and Safety .......................................... 09-16 remove and install panes of glass that are directly
Preparation .................................................... 09-16 bonded to the cab frame apertures. When you carry
Remove and Install ....................................... 09-18 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 - 15 9813/7600-3 09 - 15
09 - Window
00 - General
Health and Safety Preparation

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

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

otherwise they may be absorbed into the old sealant
and ultimately prevent the new glass from bonding.
New Glass
1. Make sure that the new glass correctly fits the
frame aperture.
1.1. Put two spacer blocks on to the bottom part
of the frame aperture.
Special Tool: Rubber Spacer Blocks (Qty.:
2)
1.2. Install the new glass on the spacer blocks
- Always use glass lifters. Check that there
is an equal sized gap all round the edge
of the glass. Note: The spacer blocks are
rectangular in section to give two common
gap widths. If necessary they can be
trimmed to a smaller size to give an equal
sized gap around the glass. Important: The
glass edges must not touch the frame,
otherwise movement of the frame will chip
and eventually break the newly installed
glass.
Special Tool: Glass Lifter (Qty.: 2)
09 - 16 9813/7600-3 09 - 16
09 - Window
00 - General
4. Clean the glass.

4.1. Use surface cleaner to thoroughly clean
and prime the black ceramic ink band
printed on the glass (see Note). Use a lint
A Frame aperture free cloth to apply the cleaner, allow to
B Spacer blocks dry. Important: Do not touch the glass after
C Glass lifters cleaning with the surface cleaner.
2. After checking for size, remove the new glass Duration: 5min
and place it on a purpose made glass stand. Consumable: Surface Cleaning Fluid
Small panes of glass will need locating on a
600 x 700 mm x 15 to 19 mm thick plywood 4.2. If the glass does not have a black ceramic
board, sourced locally to fit the glass stand. It is ink band, paint a band on the glass using
recommended that an access hole is cut in the Black Primer. Make sure that the band
board to accommodate the glass lifter, making it measures the correct width and that the
easier and safer to handle small panes of glass. edge is a neat straight line.
The board should be covered with felt or carpet Dimension: 25mm
to give an anti-scratch surface. Resting the glass Consumable: Black Primer/Activator
on four spacer blocks will ensure clearance of
the cartridge nozzle tip during application of the Figure 114.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 112.
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 - 17 9813/7600-3 09 - 17
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 115.
Consumables
Black Polyurethane 4102/2310 0.31L
Sealant
A Black Primer/Activator 4104/2304 0.1L
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
B JCB Glass Cleaner 4006/3175 0.75L
Surface Cleaning Fluid 4103/1204 1L
A 12.5mm
B 9mm
Removal
6. Apply the pre-heated adhesive to the glass (do
not start in a corner). Keep the nozzle guide 1. Position the machine on level ground and apply
against the edge of the glass and make sure the park brake. Stop the engine. Put protective
that the adhesive forms a continuous pyramid' covers over the cab seat and control pedestals.
shape. Note: Once the pre-heated adhesive has
2. If a laminated pane breaks it will stay in one piece
been applied to the glass, install the glass in the
even though the glass is cracked. A toughened
aperture as soon as possible. If you wait too long
pane will shatter and fall apart. The method of
then the sealant will form a skin, this will prevent
removal of the glass depends upon which type
the glass from bonding.
it is.
Duration: 10min
2.1. Laminated glass - leave installed until the
Figure 116. 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 - 18 9813/7600-3 09 - 18
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 118.

the sealant will melt.
Figure 117.
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 119.
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 - 19 9813/7600-3 09 - 19
09 - Window
00 - General
Figure 120. 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 122. 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 123.
face of the cab frame aperture.
Figure 121.
A 1.5mm
6. Apply a coat of Black Primer to the paintwork if:
Consumable: Black Primer/Activator
6.1. Paintwork was damaged or scratched
during the glass/sealant removal
procedures. 2.3. Make sure that the glass is correctly
positioned, then gently press around the
6.2. The old sealant was inadvertently cut back edges of the glass and ensure full adhesive
to the cab frame during the glass/sealant contact is achieved. Do not press too hard
removal procedures. or too much adhesive will squeeze out.
Installing new Glass 3. Make the inside seal smooth:
1. If the internal trim strip is damaged, renew it (cut 3.1. Wearing surgical gloves, dip your finger in
to length as required) before installing the new a soapy water solution.
09 - 20 9813/7600-3 09 - 20
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 - 21 9813/7600-3 09 - 21
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-23

09-12-03 Seat Base ...................................................................................................................... 09-25
09 - 22 9813/7600-3 09 - 22
12 - Operator Seat
00 - General
00 - General Check (Condition)

Check (Condition) .......................................... 09-23 1. Check that the seat adjustments operate
Remove and Install ....................................... 09-24 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 - 23 9813/7600-3 09 - 23
12 - Operator Seat
00 - General
Remove and Install Install

(For: 526-56 [T4F], 531-70 [5AA], 531-70 removal procedure. Additionally do the following
step.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 1.1. Tighten the bolts to the correct torque value.
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 Refer to: PIL 72.
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
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 124.
A
A Bolt (x4)
4. Attach suitable lifting equipment to the seat.
5. Use the lifting equipment to remove the seat from
the machine.
09 - 24 9813/7600-3 09 - 24
12 - Operator Seat
03 - Seat Base
03 - Seat Base
Remove and Install
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
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 - 25 9813/7600-3 09 - 25
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-27
09 - 26 9813/7600-3 09 - 26
15 - Seat Belt
00 - General
WARNING When a seat belt is installed on your
Introduction .................................................... 09-27 machine replace it with a new one if it is damaged,
Check (Condition) .......................................... 09-28 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 - 27 9813/7600-3 09 - 27
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 - 28 9813/7600-3 09 - 28
18 - Door
18 - Door
Contents Page No.
09-18-00 General ........................................................................................................................... 09-31

09-18-03 Lock ................................................................................................................................ 09-36
09-18-12 Handle ............................................................................................................................ 09-37
09 - 29 9813/7600-3 09 - 29
Notes:
09 - 30 9813/7600-3 09 - 30
18 - Door
00 - General
00 - General
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 535-95 3. Divide the doors by releasing the locking handle
[5AB], 535-95 [5TB], 536-60 [5AC], (Two piece doors only- if installed).
536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1], 4. Make sure that the door upper is supported
541-70 [5AD], 541-70 [5TD], 550-80 [5AW], correctly.
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................... Page 09-31 5. To remove the hinge pin securing device,
For: 526-56 [T4F] ...................... Page 09-33 depending on your machine, do one of the
following actions:
(For: 531-70 [5AA], 531-70 [5TA], 535-95 5.1. Use a thin punch and hammer to tap the
[5AB], 535-95 [5TB], 536-60 [5AC], securing pin from the hinge assembles.
536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 5.2. Remove the grub screw.
536-70LP [5A1], 536-70LP [5T1], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW], 6. Use a thin punch and hammer to tap the hinge
pin from the hinge assembles.
550-80 [5UW], 560-80 [5AY], 560-80
[5UY]) 7. Do steps 4 and 5 for all other hinges on the door.
Consumables 8. Carefully remove the door from the hinge
Description Part No. Size assembly.
Extreme Performance 4003/1327 0.4kg
Moly Grease 9. If necessary, remove the hinge assembly by
4003/1326 12.5kg removing the nuts from inside the cab.
Remove 10. Do procedures 3 to 7 for the lower part of the

door. (Two piece doors only- if installed).
11. If necessary the door catch assembly can be
2. Follow the general health and safety procedures. removed by removing the nuts, bolts and locking
Refer to (PIL 01-03). plate.
09 - 31 9813/7600-3 09 - 31
18 - Door
00 - General
Figure 125. 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 - 32 9813/7600-3 09 - 32
18 - Door
00 - General
Install 4. Make sure that the door upper is supported

correctly.
removal procedure. Additionally do the following 5. To remove the hinge pin securing device, remove
steps. the grub screw.
1.1. Lubricate the door hinge. Refer to (PIL 6. Use a thin punch and hammer to tap the hinge
75-06). pin from the hinge assembles.
Consumable: Extreme Performance Moly 7. Do steps 4 and 5 for all other hinges on the door.
Grease
8. Carefully remove the door from the hinge
assembly.
(For: 526-56 [T4F])
9. If necessary, remove the hinge assembly by
Remove removing the nuts from inside the cab.
1. Make the machine safe. Refer to (PIL 01-03). 10. Do procedures 3 to 7 for the lower part of the
door. (Two piece doors only- if installed).
2. Follow the general health and safety procedures.
Refer to (PIL 01-03). 11. If necessary the door catch assembly can be
removed by removing the nuts, bolts and locking
3. Divide the doors by releasing the locking handle plate.
(Two piece doors only- if installed).
09 - 33 9813/7600-3 09 - 33
18 - Door
00 - General
Figure 126. Two piece door assembly (526-56)

C
A Cab frame B Cab door

C Hinge D Grub screw
E Door- lower
09 - 34 9813/7600-3 09 - 34
18 - Door
00 - General
Install
removal procedure.
09 - 35 9813/7600-3 09 - 35
18 - Door
03 - Lock
03 - Lock
Remove and Install
09 - 36 9813/7600-3 09 - 36
18 - Door
12 - Handle
12 - Handle Figure 127.
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 - 37 9813/7600-3 09 - 37
27 - Controls
27 - Controls
Contents Page No.
09-27-36 Accelerator Pedal ........................................................................................................... 09-39

09-27-39 Gear Lever ..................................................................................................................... 09-41
09-27-57 Park Brake ..................................................................................................................... 09-45
09 - 38 9813/7600-3 09 - 38
27 - Controls
36 - Accelerator Pedal
Remove and Install
Consumables
JCB Threadlocker 4101/0250 0.01L
and Sealer (Medium 4101/0251 0.05L
Strength)
Figure 128.
B B
E A
A Pedal assembly B Pedal bolts

C Spacer D Clip retaining nuts
E Electrical harness connectors F Access hole
Remove 5. Remove the clip retaining nuts to release the

clips and connectors from the cab floor.
6. Remove the pedal bolts.
7. Make sure to retain the spacer plate.
2. Make sure that the engine cannot be started.
8. Slowly remove the pedal assembly from inside
3. Remove the floor mat from the cab. the cab making sure to pull the connectors
Refer to: PIL 09-48. through the access hole in the cab floor.
4. Working below the cab, disconnect the electrical

connectors from the chassis harness.
09 - 39 9813/7600-3 09 - 39
27 - Controls
Install
step.
2. Apply JCB Threadlocker and Sealer to the
threads of the pedal bolts.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
09 - 40 9813/7600-3 09 - 40
27 - Controls
39 - Gear Lever
39 - Gear Lever Introduction

Introduction .................................................... 09-41
(For: 4 Speed Synchro Shuttle
Transmission)
On machines installed with a SS700 gearbox, the
gear change mechanism is operated by a lever in the
cab.
The movement of the lever operates cables which

are attached to the turret assembly on the gearbox.
The turret assembly operates the selection forks
within the gearbox.
This section contains procedures for the removal

and installation of the gear change lever assembly.
For details of the gear change cables, Refer to: PIL
09-28.
09 - 41 9813/7600-3 09 - 41
27 - Controls
39 - Gear Lever
Remove and Install
Figure 130.
Transmission)
Cableshift (Cab Gearshift Assembly)

Remove
U
Refer to Figure 132.

Refer to: PIL 01-03. T
2. Put the gear shift into neutral.

3. Loosen the gear knob lock nut
4. Carefully prise the gaiter securing clips from the
gear shift housing.
5. Lift the gaiter to get access to the gear shift
housing. U Bolts
T Access plate
6. Put marks on the cable ends and to help to
identify them when replacing. 12. Working outside the cab, remove bolt and access
plate. Refer to Figure 131.
7. Use a spanner to remove ball joint bolt.
Figure 131.
8. Remove the ball joint from the gear shift arms.
9. Do the same above process to disconnect the V
ball joint.
10. Working outside the cab, remove the bolts and
access panel from chassis. Refer to Figure 129.
Figure 129.
V Bolt
W Access plate
R 13. Remove the nuts, bolts and clamps.

14. Disconnect the transmission dump switch
S electrical connector located under the cab.
R Bolts
S Access panel 15. Pull the electrical cable through the grommet in
the gear shift housing and remove the cable tie.
11. Working to the rear of the cab, remove the bolts
and the rear cab access plate from cab. Refer to 16. Remove the gear knob from the gear shift lever.
Figure 129. 17. Remove the lock nut from the gear shift lever.
09 - 42 9813/7600-3 09 - 42
27 - Controls
39 - Gear Lever
18. Remove the gaiter from the shift lever. Install

19. Support the gear shift housing from outside the 1. The installation procedure is the opposite of the
cab. removal procedure. Additionally do the following
steps.
20. Remove the gear shift housing screws. The
housing will drop down from the underside of the 2. Tighten the nut to the correct torque value. Refer
cab. to Table 34.
Figure 132.
D
C
D
A
B E
F
H
C H
D
G
H K
3
H
1
N P
Q P
A Gear knob B Lock nut

C Gear shift lever D Gaiter securing clips
09 - 43 9813/7600-3 09 - 43
27 - Controls
39 - Gear Lever
E Gaiter F Gear shifting housing

G 3rd and 4th gear cable end ball joint H Gear shit housing securing screws
J 1st and 2nd gear cable end ball joint K Ball joint bolt
M Electrical cable grommet N U bolt
P Nut Q Clamp

Item Nm
P 12
09 - 44 9813/7600-3 09 - 44
27 - Controls
57 - Park Brake
57 - Park Brake Installation

step.
Removal 1.1. To align the switch correctly, engage the

switch location dowel with the hole in the
1. Make the machine safe. mounting bracket.
2. Put blocks under the wheels. Release the park
brake.
3. Remove the rubber gaiter.
4. Disconnect the electrical connector from the
switch connector.
5. Hold the switch and remove screw.
6. Remove the switch.
Figure 133.
A Rubber gaiter
B Switch
C Electrical connector
D Switch connector
E Screw
F Switch location dowel
G Hole in mounting bracket
09 - 45 9813/7600-3 09 - 45
28 - Cables and Fittings
Contents Page No.
09-28-00 General ........................................................................................................................... 09-47
09 - 46 9813/7600-3 09 - 46
00 - General
Introduction .................................................... 09-47
Transmission)
On machines installed with a SS700 gearbox, the
gear change mechanism is operated by a lever in the
cab.
The movement of the lever operates cables which

are attached to the turret assembly on the gearbox.
The turret assembly operates the selection forks
within the gearbox.
This section contains procedures for the removal

and installation of the gear change cables assembly.
For details of the gear change lever, Refer to: PIL
09-27-39.
09 - 47 9813/7600-3 09 - 47
00 - General
Remove and Install
Figure 135.
Transmission)
Gear Shift Cables

Removal
4
Access to the cables is limited. If necessary, follow

the cab removal procedure and raise the cab 3
sufficiently to get better access.

2. Put the gear shift into neutral.
3. Carefully prise the gaiter securing clips from the
gear shift housing. 3 Bolt
4 Access plate
4. Lift the gaiter to get access to the gear shift
housing. 8. Working outside the cab, remove the bolts and
access plate. Refer to Figure 136.
5. If re-using the existing cables, put marks on the
cable ends to identify them when replacing. Figure 136.
6. Working outside the cab, remove the bolts and
access panel from chassis. Refer to Figure 134. 5
Figure 134.
1
5 Bolt
2 6 Access plate
1 Bolt 9. Working outside the cab, remove the clamp nuts.

2 Access plate
10. Remove the U-bolt and clamp.
7. Working to the rear of the cab, remove the bolts
and the rear cab access plate from cab. Refer to 11. Remove the shifter weights.
Figure 135.
12. If re-using the existing cables, put marks on the
cables at the gearbox turret to identify them.
13. Loosen the nuts.
09 - 48 9813/7600-3 09 - 48
00 - General
14. Loosen the nut and then remove the cable. 1. Install the neutral locking tool to the gearshift
assembly. Refer to Figure 138.
15. Hold ball joint bolt with a spanner and remove
nut. Figure 138.
16. Remove the ball joint from the gearbox turret
finger.
17. Remove the cable.
18. Unscrew nut until it is loose on the cable.
19. Pull the outer cable towards the rear of the
machine until the inner cable can be pulled
through the securing bracket cut out.
19.1. Remove the cable.
20. Lift the cables from the securing bracket.
21. Pull the cables through the hole in the chassis
side plate.
Figure 137.
1 Locking tool
2 Gearshift assembly
2. Install ball joint to the shift arm with the neutral
locking plate holding the gearshift assembly in
the neutral position.
3. Use a spanner to install ball joint bolt
3.1. Make sure the grommet is installed in the
chassis where the cables go through the
side plate.
E Cable
G Cable 4. Feed the cables through the gearshift lever
7 Chassis side plate assembly aperture and through the chassis side
plate hole onto the gearbox.
22. Remove the cables and gearshift assembly from
the machine.
23. Use a spanner to remove the ball joint bolt.
24. Remove the ball joint from the gear shift arms.
25. Disconnect the ball joint.
Install
Make sure the cables connect to the correct turret

finger on the gearbox and the correct arm of the gear
shift assembly.
If installing new cables, the cable with the Red

marking is the 1st and 2nd gear cable. The cable with
the Yellow marking is the 3rd and 4th gear cable.
09 - 49 9813/7600-3 09 - 49
00 - General
Figure 139. 15. Remove the gearshift assembly from the cab.
16. Remove the neutral locking tool from the
gearshift assembly.
17. Install the gearshift assembly into the cab.
18. Move the gear shift lever and make sure all gears
can be selected.
19. Apply JCB Threadlocker to the shifter weight
securing screw and install the shifter weight to
the outside of the gear turret finger.
20. Install the gaiter onto the gear lever.
21. Press the gaiter retaining clips into the shift
housing.
E Cable 22. Working to the rear of the cab, replace the rear
G Cable cab access plate using bolts. Refer to Figure 140.
3 Chassis side plate
5 Chassis side plate Figure 140.
4.1. The cables will cross over each other. Refer

to Figure 139.
5. Position the cable along with the gearbox. Refer
to Figure 139.
6. Install the gearshift assembly to the inside of the 6
cab.
7. Working at the gearbox end of the cables. Put
the inner part of the cable into the cut out on the 7
securing bracket.
7.1. Install the cable.
8. Make sure the turret fingers and align in the
vertical position (Neutral). The gearbox has a
detent mechanism to hold the turret fingers in
neutral.
9. Install the ball joint to the turret finger 6 Access plate
7 Bolt
10. Hold the ball joint bolt with a spanner and tighten
the nut to the correct torque value. 23. Working outside the cab, replace the access
panel using bolts. Refer to Figure 141.
11. Make sure the cables are positioned correctly in
the securing bracket.
12. Use the nuts, adjust the outer cable so that it is
secure in the bracket without moving the gearbox
turret finger or twisting the cable.
13. Use the white line mark on the cables as a guide
to make sure the cable does not twist.
14. Clamp the cables using the clamps, U-bolt and
nuts. Make sure the cable is not twisted or
crushed in the clamp.
14.1. Tighten the nuts to the correct torque
value. Refer to Table 35.
09 - 50 9813/7600-3 09 - 50
00 - General
11
10
9
8 Access plate
9 Bolt 10 Access plate
11 Bolt
24. Working outside the cab, replace the access
plate using bolts. Refer to Figure 142.
Figure 143.
Q Q
C
E G
D
N
S
B Q
Q R
1 A
P U
F T
3
2
W
X Y
4 K
J
A 1st and 2nd gear cable end ball joint B Ball joint bolt
C Nut D 1st and 2nd gear gearbox turret finger
E 1st and 2nd gear cable (Red marking) F 3rd and 4th gear gearbox turret finger
G 3rd and 4th gear cable (Yellow marking) H Outer cable front adjustment nut
J Outer cable rear adjustment nut M Cable securing bracket
N 1st and 2nd gear shifter weight P 3rd and 4th gear shifter weight
Q Gaiter securing clips R Gaiter
09 - 51 9813/7600-3 09 - 51
00 - General
S 3rd and 4th gear cable end ball joint T 1st and 2nd gear cable end ball joint
U Ball joint bolt W U-bolt
X Clamp Y Nut

Item Nm
J 96
Y 12
09 - 52 9813/7600-3 09 - 52
30 - Trim Panel
30 - Trim Panel
Contents Page No.
09-30-03 Roof Trim ....................................................................................................................... 09-55

09-30-09 Dashboard ...................................................................................................................... 09-56
09 - 53 9813/7600-3 09 - 53
Notes:
09 - 54 9813/7600-3 09 - 54
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 144.
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 - 55 9813/7600-3 09 - 55
30 - Trim Panel
09 - Dashboard
09 - Dashboard
Remove and Install
16. Remove the screw 7, screw 8 and screw 9.

(For: 526-56 [T4F], 531-70 [5AA], 531-70 17. Remove the lower left hand panel.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 Figure 145.
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY], C C
560-80 [5UY])
Remove
D B D
2. Remove the steering wheel.
3. Remove the two button head screws 1.
4. Remove the steering column lower surround. 00: 00: 05
5. Remove the two button head screws 2 and the

two screws 1.
6. Remove the steering column upper surround.
7. Remove the two screws 2 that hold the centre
A
display panel in place, disconnect all connections
and remove the panel. A Button head screw 1
B Button head screw 2
8. If the steer mode select switch has a lockable C Screw 1
surround, then remove it as follows: D Screw 2
8.1. Remove the two screws that secure the Figure 146.
steer mode select switch panel.
8.2. Disconnect all connections and remove the
panel.
8.3. Remove the steer mode control knob.
E
9. Remove the heater control panel.
10. Remove the radio (if installed).
11. Remove the right hand Instrument panel.
F
12. Remove the left hand switch panel.
13. Remove the centre display panel.
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
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 - 56 9813/7600-3 09 - 56
30 - Trim Panel
09 - Dashboard
Figure 147.
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 - 57 9813/7600-3 09 - 57
30 - Trim Panel
09 - Dashboard
Install
removal procedure.
09 - 58 9813/7600-3 09 - 58
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-61
09 - 59 9813/7600-3 09 - 59
Notes:
09 - 60 9813/7600-3 09 - 60
00 - General
Introduction .................................................... 09-61 The safety labels are strategically placed around the
Health and Safety .......................................... 09-62 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 - 61 9813/7600-3 09 - 61
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 - 62 9813/7600-3 09 - 62
36 - Steering Wheel
36 - Steering Wheel
Contents Page No.
09-36-00 General ........................................................................................................................... 09-65
09 - 63 9813/7600-3 09 - 63
Notes:
09 - 64 9813/7600-3 09 - 64
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 149.
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 148.
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 - 65 9813/7600-3 09 - 65
44 - Sunblind
44 - Sunblind
Contents Page No.
09-44-00 General ........................................................................................................................... 09-67
09 - 66 9813/7600-3 09 - 66
44 - Sunblind
00 - General
00 - General
Remove and Install
2. Make sure that both blinds are fully retracted.

(For: 526-56 [T4F]) 3. Support the blinds.
Roller Blind 4. Remove the trim panel screws from each end of
the blind. Some machine variants only have 2
Remove securing screws at each side of the blind.
1. Make the machine safe. 5. Disconnect the trim panel to remove the blind
assembly.
Figure 150.
A
A
A A
A Screws B Trim panel

C Blind assembly X Roller blind with two securing screws
09 - 67 9813/7600-3 09 - 67
44 - Sunblind
00 - General
Install
removal procedure.
09 - 68 9813/7600-3 09 - 68
48 - Floor mat
48 - Floor mat
Contents Page No.
09-48-03 Front Floor mat .............................................................................................................. 09-71
09 - 69 9813/7600-3 09 - 69
Notes:
09 - 70 9813/7600-3 09 - 70
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 151.
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 - 71 9813/7600-3 09 - 71
Notes:
09 - 72 9813/7600-3 09 - 72
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 ........................................................................................................................... 12-21
12-03-03 Evaporator ...................................................................................................................... 12-23
12-03-06 Pressure Switch ............................................................................................................. 12-24
12-03-09 Expansion Valve ............................................................................................................. 12-27
12-03-12 Blower Motor .................................................................................................................. 12-28
12-03-15 Thermostat ..................................................................................................................... 12-29
12-03-18 Heater Coil ..................................................................................................................... 12-31
12-04 Heater Unit
12-04-00 General ........................................................................................................................... 12-33
12-09 Compressor
12-09-00 General ........................................................................................................................... 12-37
12-12 Receiver Drier
12-12-00 General ........................................................................................................................... 12-41
12-15 Condenser
12-15-00 General ........................................................................................................................... 12-45
12-18 Filter
12-18-00 General ........................................................................................................................... 12-53
12-18-06 Fresh Air ........................................................................................................................ 12-54
12-21 Heater Valve
12-21-00 General ........................................................................................................................... 12-57
12-96 Pipe
12-96-00 General ........................................................................................................................... 12-61
9813/7600-3
2018-02-23
Acronyms Glossary
FEAD Front End Accessory Drive

PAG Polyalkyline Glycol
RPM Revolutions Per Minute
TXV Thermal Expansion Valve
9813/7600-3
2018-02-23
12 - Heating, Ventilating and Air-Conditioning (HVAC)
Contents Page No.
12-00-00 General ............................................................................................................................. 12-3
12 - 1 9813/7600-3 12 - 1
Notes:
12 - 2 9813/7600-3 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
Fault-Finding .................................................. 12-12 air conditioning unit.
Discharge and Pressurise ............................. 12-15
Check (Operation) ......................................... 12-18 The air conditioning system is a closed circuit
through which the refrigerant is circulated, its state
Check (Pressure) .......................................... 12-18 changing from gas to liquid and back to gas again,
Adjust ............................................................ 12-19 as it is forced through the system. The major
components of the system are the:
• Compressor
• Condenser matrix
• Receiver drier
• Expansion valve
• Evaporator matrix
12 - 3 9813/7600-3 12 - 3
00 - General
Health and Safety • DO NOT steam clean refrigerant system

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

is used and that charging is done only by
qualified personnel. It is illegal to discharge
the refrigerant into the atmosphere but as
a precaution in case of accidental leakage,
discharging and charging of the vehicle
refrigerant system must be conducted in a well-
ventilated area.
• Containers of refrigerant should be stored in a
cool environment away from direct sunlight.
• DO NOT perform welding operations close to
refrigerant hoses (maintain a distance of at least
0.5m from hoses).
12 - 4 9813/7600-3 12 - 4
00 - General
Technical Data (For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC],
For: 526-56 [T4F] ........................ Page 12-5 536-60 [5TC], 536-70 [5AE], 536-70 [5TE],
For: 531-70 [5AA], 531-70 [5TA], 535-95 536-70LP [5A1], 536-70LP [5T1], 541-70
[5AB], 535-95 [5TB], 536-60 [5AC],
536-60 [5TC], 536-70 [5AE], 536-70 [5AD], 541-70 [5TD], 550-80 [5AW],
[5TE], 536-70LP [5A1], 536-70LP [5T1], 550-80 [5UW], 560-80 [5AY], 560-80
541-70 [5AD], 541-70 [5TD], 550-80 [5AW], [5UY])
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
..................................................... Page 12-5 Table 40. Binary pressure switch settings
Item Specification
(For: 526-56 [T4F])
Low pressure 2bar (29.0psi)
High pressure 26bar (376.8psi)
Table 36. Binary pressure switch settings
Item Specification Table 41. Thermostatic switch settings
Low pressure 2bar (29.0psi) Item Specification
High pressure 26bar (376.8psi) 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 37. Thermostatic switch settings
Table 42. Refrigerant
Item Specification
Item Specification
Cut out 0.2–1.4°C (32.4–34.5°F)
Type R134a gas
Cut in 3.4–4.8°C (38.1–40.6°F)
Charge amount (maxi- 1kg
mum)
(1)
Table 38. Refrigerant Charge amount (maxi- 1.7kg

Item Specification mum)
(2)
Type R134a gas (1) Systems with cooling pack mounted condenser.
Charge amount (maxi- 1.3kg (2) Systems with roof mounted condenser.
mum)
(1)
Table 43. Oil

Charge amount (maxi- 1.7kg
mum)
(2)
Item Specification
(1) Systems with cooling pack mounted condenser. Type PAG oil
(2) Systems with roof mounted condenser. Charge amount
(3)
-
Complete system 0.0426L
Table 39. Oil Condenser remove and 0.0284L
install
Item Specification
Evaporator remove and 0.0568L
Type PAG (Polyalkyline Gly-
install
col) oil
Hoses remove and in- 0.0085L
Charge amount
(3)
-
stall
Complete system 0.0426L Receiver drier remove 0.0142L
Condenser remove and 0.0284L and install
install Compressor remove and None- pre charged
Evaporator remove and 0.0568L install
install
(3) The quantity of oil replaced should be the same
Hoses remove and in- 0.0085L as that taken out during `Recovery' procedure.
stall
Receiver drier remove 0.0142L
and install
Compressor remove and None- pre charged
install
(3) The quantity of oil replaced should be the same
as that taken out during `Recovery' procedure.
12 - 5 9813/7600-3 12 - 5
00 - General
Heater Only
Figure 152.
E
D
D
D
C D
B
Item Description
D Cab heater vents
Table 44.
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 9813/7600-3 12 - 6
00 - General
Machines with Air Conditioning
Figure 153.
E
F
H F
A
B
C
D
Item Description
G Condenser (cooling
Table 45.
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 46. 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 9813/7600-3 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 9813/7600-3 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 154.
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 9813/7600-3 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 155.
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 clutch
1. The manual air conditioning on/off switch in the disengages, closing down the refrigeration cycle.
control console. As the temperature of the probe increases the
12 - 10 9813/7600-3 12 - 10
00 - General
thermostat switch contacts close. The compressor

clutch engages and refrigeration re-starts.
Figure 156.
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 9813/7600-3 12 - 11
00 - General
Fault-Finding
Fault
Poor performance (For system diagnosis using test gauges, refer to Check Table 47. Page 12-12
Operation, PIL 12-03)
Warm air or slightly cool air emitted from unit Table 48. Page 12-12
Compressor clutch continually cuts out Table 49. Page 12-12
Poor performance- Compressor function tests Table 50. Page 12-13
Compressor not achieving 24 bar pressure Table 51. Page 12-13
No air conditioning Table 52. Page 12-13
Table 47. 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 48. 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 49. 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 - 12 9813/7600-3 12 - 12
00 - General
Table 50. 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 51. 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 52. 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 - 13 9813/7600-3 12 - 13
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 - 14 9813/7600-3 12 - 14
00 - General
Discharge and Pressurise 10. Close the valves and remove all equipment.
Figure 157.
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system
has been discharged by a refrigeration engineer
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: 10min in) mercury vacuum reads on both gauges.
12 - 15 9813/7600-3 12 - 15
00 - General
Note: achievable vacuum will vary with altitude. 6. Switch on the vacuum pump and open the high
Maximum gauge reading will be 25mm (1 in) less pressure side valve.
for every 305 metres (1000 feet) above sea level.
7. Unscrew the oil injector cap and add the specified
6. Maintain suction for approximately the specified quantity of refrigerant oil.
time. Note: If the vacuum falls rapidly the system
is leaking. Check all connections and reseal. If 8. When 740mm (29 in) mercury shows on the
the point of leakage is not obvious, recharge the vacuum gauge, open the oil injector valve to
system and test again. allow the oil into the system.
Duration: 30min 9. If more oil is needed repeat the above procedure.
The quantity of oil should be the same as that
7. Close the valves and remove all equipment. taken out during the Recovery procedure. Note:
Figure 158. Use only PAG oil in R-134a systems.
Figure 159.

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 - 16 9813/7600-3 12 - 16
00 - General
Be sure to connect to the liquid port when Figure 161.

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 160.
A396790
Table 53.
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 - 17 9813/7600-3 12 - 17
00 - General
Check (Operation) Check (Pressure)

The air conditioning system needs to be checked
regularly to make sure it operates efficiently and The air conditioning system is a closed loop system
safely. and contains pressurised refrigerant. No part of the
system should be disconnected until the system
Before you do any service operation, carry out a has been discharged by a refrigeration engineer
basic service check as described below. or a suitably trained person. You can be severely
1. Start the engine and operate at fast idle speed of
1000 RPM (Revolutions Per Minute). WARNING! Leak testing of Air Conditioning systems
should only be carried out in well ventilated areas.
2. Switch on the air conditioning and set to
maximum cooling. The refrigerant is heavier than air and will leak
downwards from the defective component. Check in
3. The cab temperature should be above the a well ventilated area.
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
to operate the heating system to prevent the air It is essential that an electronic leak detector is used
conditioning system switching off. to locate leaks accurately. However, if a leak detector
is not available, an approximate source can be found
5. Operate the engine at operating temperature for by applying soap solution to the suspect area.
five to ten minutes.
To test for leaks in the high pressure side of
6. Close the cab door and windows and allow the the system i.e. from the compressor output to the
internal temperature to stabilize. expansion valve, run the air conditioning for a few
minutes then switch off the engine and test for
7. Measure the temperature at the evaporator leakage using an electronic leak detector or soapy
outlets. The temperature should change as the water.
compressor clutch cycles in and out.
To test for leakage in the low pressure side of the
8. The outlet temperature with the clutch engaged, system, switch off the air conditioning and leave for
should be significantly below the ambient a new minutes before you do the test.
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
9. Stop the engine when the tests are complete. fittings. The hose connectors have an O-ring seal
which compresses when the connection is tight and
Off-Season Operation create an air tight seal.
During the off-season, the air conditioning system Hoses are used to connect the inlets and outlets
should be operated for at least five minutes every of the compressor, condenser, receiver drier and
month to circulate the oil in the system to lubricate expansion valve (the evaporator coil is connected to
the fittings and seals. the expansion valve within the air conditioning unit
using rigid pipes).
When you operate the system, make sure of the
followings. If leakage is detected from a hose connector, either
by means of an electronic leak detector or soapy
• Engine idle speed is more than 1000 RPM. water, tighten the connector up and repeat the
• Ambient temperature is more than the specified leakage test. If leakage is still evident, it will be
value. 0°C (32.0°F) necessary to discharge the system and renew the
• Cab temperature is more than the specified connector O-ring seal.
value. 20°C (68.0°F)
• The engine is at normal operating temperature.
12 - 18 9813/7600-3 12 - 18
00 - General
Adjust
For compressor drive belt adjustment, please see

(PIL 15-18).
12 - 19 9813/7600-3 12 - 19
03 - HVAC Unit
03 - HVAC Unit
Contents Page No.
12-03-00 General ........................................................................................................................... 12-21

12-03-03 Evaporator ...................................................................................................................... 12-23
12-03-06 Pressure Switch ............................................................................................................. 12-24
12-03-09 Expansion Valve ............................................................................................................. 12-27
12-03-12 Blower Motor .................................................................................................................. 12-28
12-03-15 Thermostat ..................................................................................................................... 12-29
12-03-18 Heater Coil ..................................................................................................................... 12-31
12 - 20 9813/7600-3 12 - 20
03 - HVAC Unit
00 - General
00 - General 8. Remove the clip and disconnect the cable from

the heater valve.
Remove and Install 9. For 526-56 machines only:

9.1. Remove the cab frame from the machine.
(For: 531-70 [5AA], 531-70 [5TA], 535-95 Refer to: PIL 09-00-03.
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 9.2. Remove the chassis side cover from the
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 machine.
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY]) 10. Remove the bolt 1 and bolt 2 which secure the
HVAC unit to the machine.
The air conditioning system is a closed loop system 11. Carefully remove the unit sufficiently to access
and contains pressurised refrigerant. No part of the the electrical harness connector at the rear.
system should be disconnected until the system 12. The electrical harness connector is located
has been discharged by a refrigeration engineer behind the unit and cannot be disconnected until
or a suitably trained person. You can be severely the unit is pulled away from the machine.
13. Disconnect the electrical connector.
The heating and ventilation unit (HV) contains a
blower unit and heat exchanger matrix. It is located 14. Remove the assembly from the machine.
under the right front side of the cab.
Figure 162.
The HVAC (Heating Ventilation Air Conditioning) unit
is the same as the HV unit but also contains an
evaporator matrix and thermostat. F
G
Put labels on all the hoses before removal for easy
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.

E
A C B D
3. To remove the HVAC unit it is necessary to A Heater valve
discharge the refrigerant from the system. B Heater matrix
Refer to: PIL 12. C TXV (If installed)
D Bolt 1
4. Drain the cooling system. E Bolt 2
F Clip
Refer to: PIL 21. G Cable
5. If installed, remove the cab side cover to get
access to the HVAC unit. Install
6. Disconnect the heater hoses from the heater 1. The installation procedure is the opposite of the
valve and from the heater matrix. removal procedure. Additionally do the following
steps.
7. Disconnect the HVAC hoses from the TXV (if
installed).
12 - 21 9813/7600-3 12 - 21
03 - HVAC Unit
00 - General
1.1. Make sure that the TXV is installed correctly

with the diaphragm, located below the
valve.
Figure 163.
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 - 22 9813/7600-3 12 - 22
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 - 23 9813/7600-3 12 - 23
03 - HVAC Unit
06 - Pressure Switch
06 - Pressure Switch Introduction

Introduction .................................................... 12-24 The binary pressure switch assembly has a low and
Check (Operation) ......................................... 12-25 high pressure switch designed to operate at specified
Remove and Install ....................................... 12-26 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 - 24 9813/7600-3 12 - 24
03 - HVAC Unit
Check (Operation) Figure 164.
Binary Switch
The binary pressure switch is located in the
HVAC (Heating Ventilation Air Conditioning) system
pipework. Refer to: PIL 12-03.
Before testing the binary pressure switch, check the

refrigerant charge level. If the refrigerant charge level
is satisfactory, test the switch as described below:

2. Switch off the engine and remove the harness
connectors from the pressure switch.
3. Connect a link wire between the two harness B
connectors (effectively bypassing the pressure
switch). A
4. Switch on the engine and HVAC system. If the

system operates, one of the switches inside the
binary pressure switch assembly is faulty.
5. Install a new pressure switch assembly. If the
clutch still fails to operate, check the harness
electrical wiring for damage and open or short
circuits. A Binary pressure switch
B Harness connectors
12 - 25 9813/7600-3 12 - 25
03 - HVAC Unit
Remove and Install 4.1. If leaks are found, tighten the pressure
switch further until the leaking stops.
Remove
2. Discharge the HVAC (Heating Ventilation Air
Conditioning) system.
Refer to: PIL 12.
3. Remove the harness connectors.
4. Remove the screws and then remove the
pressure switch assembly.
Figure 165.
B
A
A Pressure switch
B Harness connectors
Install
1. Screw the pressure switch into the threaded port
and tighten sufficiently to form a gas tight seal.
2. Connect the harness connectors.
3. Charge the HVAC system.
Refer to: PIL 12.
4. Operate the HVAC system and check around the
pressure switch for leaks.
12 - 26 9813/7600-3 12 - 26
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 - 27 9813/7600-3 12 - 27
03 - HVAC Unit
12 - Blower Motor
12 - Blower Motor
Fault-Finding
Fault
Blower operates on fan speed 3 only Table 54. Page 12-28
Blower does not operate Table 55. Page 12-28
Table 54. 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 55. Blower does not operate

Cause Remedy
Fuse defective. Install new fuse and test again.
12 - 28 9813/7600-3 12 - 28
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 166.
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 - 29 9813/7600-3 12 - 29
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 - 30 9813/7600-3 12 - 30
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 - 31 9813/7600-3 12 - 31
04 - Heater Unit
04 - Heater Unit
Contents Page No.
12-04-00 General ........................................................................................................................... 12-33
12 - 32 9813/7600-3 12 - 32
04 - Heater Unit
00 - General
00 - General Operation
Operation ....................................................... 12-33 For the heater unit operation, refer to HVAC (Heating
Fault-Finding .................................................. 12-34 Ventilation Air Conditioning)- general, refer to (PIL
12-00).
12 - 33 9813/7600-3 12 - 33
04 - Heater Unit
00 - General
Fault-Finding
Fault
Blower operates on fan speed(3) only Table 56. Page 12-34
Blower does not operate Table 57. Page 12-34
Table 56. 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 57. Blower does not operate

Cause Remedy
Fuse blown Replace the fuse and re-check.
12 - 34 9813/7600-3 12 - 34
09 - Compressor
09 - Compressor
Contents Page No.
12-09-00 General ........................................................................................................................... 12-37
12 - 35 9813/7600-3 12 - 35
Notes:
12 - 36 9813/7600-3 12 - 36
09 - Compressor
00 - General
Introduction .................................................... 12-37 The compressor is located at the front of the engine,
Remove and Install ....................................... 12-38 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 - 37 9813/7600-3 12 - 37
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 167.
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 - 38 9813/7600-3 12 - 38
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 - 39 9813/7600-3 12 - 39
12 - Receiver Drier
12 - Receiver Drier
Contents Page No.
12-12-00 General ........................................................................................................................... 12-41
12 - 40 9813/7600-3 12 - 40
12 - Receiver Drier
00 - General
Introduction .................................................... 12-41 The receiver drier is a device that removes
Check (Condition) .......................................... 12-42 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 - 41 9813/7600-3 12 - 41
12 - Receiver Drier
00 - General
Check (Condition) Figure 169.
1. Make the machine safe with the lift arm lowered.

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 170.
5. Make sure that the pipes are correctly clamped.
Figure 170.
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.
Figure 168.
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 169.
12 - 42 9813/7600-3 12 - 42
15 - Condenser
15 - Condenser
Contents Page No.
12-15-00 General ........................................................................................................................... 12-45
12 - 43 9813/7600-3 12 - 43
Notes:
12 - 44 9813/7600-3 12 - 44
15 - Condenser
00 - General
Introduction .................................................... 12-45 A condenser is a component used to condense
Clean ............................................................. 12-46 a substance from its gaseous to its liquid state,
Check (Condition) .......................................... 12-46 typically by cooling it. In so doing the latent heat is
Remove and Install ....................................... 12-47 given up by the substance, and will transfer to the
condenser coolant.
12 - 45 9813/7600-3 12 - 45
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 - 46 9813/7600-3 12 - 46
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 - 47 9813/7600-3 12 - 47
15 - Condenser
00 - General
Figure 171.
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 - 48 9813/7600-3 12 - 48
15 - Condenser
00 - General
Install Remove
1. The installation procedure is the opposite of the 1. Make the machine safe.
steps.
2. Open the engine compartment cover.
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 - 49 9813/7600-3 12 - 49
15 - Condenser
00 - General
Figure 172.
A C
B
C
A Condenser matrix B Pipe stub

C Nuts
12 - 50 9813/7600-3 12 - 50
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 - 51 9813/7600-3 12 - 51
18 - Filter
18 - Filter
Contents Page No.
12-18-00 General ........................................................................................................................... 12-53

12-18-06 Fresh Air ........................................................................................................................ 12-54
12 - 52 9813/7600-3 12 - 52
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 - 53 9813/7600-3 12 - 53
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
1. Make the machine safe with the lift arm raised.
3. Remove the screw and the cover to access the
filter.
4. Remove the filter.
Figure 173.
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 - 54 9813/7600-3 12 - 54
21 - Heater Valve
21 - Heater Valve
Contents Page No.
12-21-00 General ........................................................................................................................... 12-57
12 - 55 9813/7600-3 12 - 55
Notes:
12 - 56 9813/7600-3 12 - 56
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 174.
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 - 57 9813/7600-3 12 - 57
21 - Heater Valve
00 - General
Install
steps.
1.1. Align the marks on the control cable outer
and valve body and then install a new clip 1.
1.2. Check the level of the engine coolant.
After installation
1. Start the engine and operate the cab heater at
the maximum temperature.
2. Operate the engine for the specified time.
Duration: 5min
3. Stop the engine and check for any coolant leaks.
12 - 58 9813/7600-3 12 - 58
96 - Pipe
96 - Pipe
Contents Page No.
12-96-00 General ........................................................................................................................... 12-61
12 - 59 9813/7600-3 12 - 59
Notes:
12 - 60 9813/7600-3 12 - 60
96 - Pipe
00 - General
Introduction .................................................... 12-61 The refrigeration pipes are responsible for carrying
Check (Condition) .......................................... 12-62 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 - 61 9813/7600-3 12 - 61
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 - 62 9813/7600-3 12 - 62
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-03 Crankcase
15-03-00 General ........................................................................................................................... 15-49
15-06 Cylinder Head
15-06-00 General ........................................................................................................................... 15-53
15-09 Bedplate
15-09-00 General ........................................................................................................................... 15-61
15-12 Crankshaft
15-12-00 General ........................................................................................................................... 15-69
15-12-03 Main Bearing .................................................................................................................. 15-78
15-12-06 Front Oil Seal ................................................................................................................. 15-80
15-12-09 Rear Oil Seal ................................................................................................................. 15-83
15-12-12 Pulley .............................................................................................................................. 15-87
15-15 Camshaft
15-15-00 General ........................................................................................................................... 15-89
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-99
15-18-03 Drive Belt ..................................................................................................................... 15-102
15-18-21 Tensioner ...................................................................................................................... 15-106
15-21 Oil Filter
15-21-00 General ......................................................................................................................... 15-109
15-24 Air Filter
15-24-00 General ......................................................................................................................... 15-117
15-24-09 Dust Valve .................................................................................................................... 15-120
15-27 Crankcase Ventilation Filter
15-27-00 General ......................................................................................................................... 15-123
15-30 Valve
15-30-00 General ......................................................................................................................... 15-127
15-30-12 Valve Spring ................................................................................................................. 15-136
15-30-24 Stem Seal .................................................................................................................... 15-137
15-33 Connecting Rod
15-33-00 General ......................................................................................................................... 15-139
15-33-06 Big-End Bearing ........................................................................................................... 15-143
15-36 Piston
15-36-00 General ......................................................................................................................... 15-149
15-36-03 Piston Ring ................................................................................................................... 15-161
15-39 Manifold
15-39-00 General ......................................................................................................................... 15-163
15-42 Rocker and Fittings
15-42-00 General ......................................................................................................................... 15-165
15-42-06 Rocker Cover ............................................................................................................... 15-174
9813/7600-3
2018-02-26
15-42-09 Push Rod ..................................................................................................................... 15-176
15-42-21 Tappet ........................................................................................................................... 15-178
15-42-24 Tappet Cover ................................................................................................................ 15-180
15-45 Oil Sump
15-45-00 General ......................................................................................................................... 15-183
15-48 Grid Heater
15-48-00 General ......................................................................................................................... 15-189
15-51 Timing Gear
15-51-00 General ......................................................................................................................... 15-193
15-51-03 Crankshaft Gear ........................................................................................................... 15-196
15-51-06 Camshaft Gear ............................................................................................................. 15-199
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-200
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-203
15-51-22 Rear Case .................................................................................................................... 15-206
15-54 Flywheel
15-54-00 General ......................................................................................................................... 15-211
15-54-03 Housing ........................................................................................................................ 15-215
15-54-09 Gear Ring ..................................................................................................................... 15-218
15-54-12 Drive Plate .................................................................................................................... 15-219
15-60 Oil Pump
15-60-00 General ......................................................................................................................... 15-223
15-63 Mount
15-63-00 General ......................................................................................................................... 15-231
15-69 Oil Cooler
15-69-00 General ......................................................................................................................... 15-235
15-72 Alternator
15-72-00 General ......................................................................................................................... 15-241
15-72-03 Pulley ............................................................................................................................ 15-247
15-72-06 Voltage Regulator ......................................................................................................... 15-248
15-75 Starter Motor
15-75-00 General ......................................................................................................................... 15-251
15-75-03 Solenoid ....................................................................................................................... 15-259
15-75-06 Brush Gear ................................................................................................................... 15-260
15-80 Glow Plug
15-80-00 General ......................................................................................................................... 15-263
15-84 Sensor
15-84-00 General ......................................................................................................................... 15-267
15-84-03 Crankshaft Position ...................................................................................................... 15-278
15-84-06 Camshaft Position ........................................................................................................ 15-282
15-84-09 Knock ........................................................................................................................... 15-286
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-289
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-292
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-295
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-298
15-84-19 Exhaust Temperature ................................................................................................... 15-301
15-84-24 Fuel Temperature ......................................................................................................... 15-304
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-307
15-84-29 Foot Throttle Control .................................................................................................... 15-310
15-84-33 Coolant Temperature .................................................................................................... 15-314
15-84-42 Engine Oil Temperature ............................................................................................... 15-317
15-84-43 Engine Oil Level ........................................................................................................... 15-320
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15-84-48 Intercooler Outlet Temperature .................................................................................... 15-323
15-84-51 Nitrogen Oxide (NOx) .................................................................................................. 15-326
15-86 Solenoid
15-86-00 General ......................................................................................................................... 15-331
15-86-09 Cold Start Advance ...................................................................................................... 15-332
15-87 Switch
15-87-00 General ......................................................................................................................... 15-337
15-87-03 Engine Oil Pressure ..................................................................................................... 15-338
15-87-09 Cold Start ..................................................................................................................... 15-341
15-90 Air Intake
15-90-00 General ......................................................................................................................... 15-347
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Acronyms Glossary
CAN Controller Area Network

CCV Crankcase Ventilation
DC Direct Current
DCU Dosing Control Unit
DEF Diesel Exhaust Fluid
DTC Diagnostic Trouble Code
DTI Dial Test Indicator
ECM Engine Control Module
EGR Exhaust Gas Recirculation
ESOS Engine Shut-Off Solenoid
HPV High Pressure Valve
IMV Inlet Metering Valve
LMS Loadall Monitoring System
MAF Mass Air Flow
NOx Nitrogen Oxide
PTO Power Take-Off
SCR Selective Catalytic Reduction
TDC Top Dead Centre
TMAF Temperature and Mass Air Flow
TMAP Temperature Manifold Air Pressure
VGT Variable Geometry Turbocharger
9813/7600-3
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15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
15 - 1 9813/7600-3 15 - 1
Notes:
15 - 2 9813/7600-3 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.
Make sure that the correct engine service tools,
Operation ....................................................... 15-20 consumables and torque figures are used when you
Diagram ......................................................... 15-24 perform service procedures.
Fault-Finding .................................................. 15-25
Drain and Fill ................................................. 15-35 Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or
Clean ............................................................. 15-35 damage is expected as a matter of course.
Check (Condition) .......................................... 15-36
Check (Leaks) ............................................... 15-37 It is expected that components will be cleaned and
Check (Pressure) .......................................... 15-37 lubricated where appropriate, and that any opened
hose or pipe connections will be blanked to prevent
Remove and Install ....................................... 15-39 excessive loss of hydraulic fluid, engine oil and
Store and Recommission .............................. 15-43 ingress of dirt.
Basic Description
The JCB ecoMax engine is a 4 cylinder diesel engine
in which the fuel is ignited by compression ignition.
The engine operates on a four stroke cycle.
The engine is started by an electric starter motor. The

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

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

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

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

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

coolant circulation pump, alternator, radiator cooling
fan and other ancillaries such as an air conditioning
compressor.
15 - 3 9813/7600-3 15 - 3
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00 - Engine
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Figure 175.
8
5
3
1
10
1 Flywheel 2 Crankshaft
3 Camshaft 4 Inlet valves (x8)
5 Exhaust valves (x8) 6 Push rods (x8)
7 High pressure fuel pump drive gear 8 Turbocharger
9 Lubrication oil pump 10 Front end drive belt
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Internal
The following identifies the main internal components
of a typical engine assembly. Some variants may
differ in detail.
Figure 176.
1 Rocker assembly 2 Valve bridge piece (x8)

3 Valve spring (x16) 4 Inlet valve (x8)
5 Exhaust valve (x8) 6 Piston assembly (x4)
6a Piston ring - top compression (x4) 6b Piston ring - 2nd compression (x4)
6c Piston ring - oil control (x4) 6d Gudgeon pin (x4)
7 Connecting rod assembly (x4) 8 Crankshaft
9 Main bearing - crankshaft (x5) 10 Big end bearing - crankshaft / connecting rod
(x4)
11 Front crankshaft oil seal 12 Flywheel
13 High duty PTO (Power Take-Off) idler gear (if
installed)
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Figure 177.
11
10 5
1a
6 7 4 3
1 Flywheel 1A Flywheel - crankshaft fixing bolts (x8)

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

waste disposal sites.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
Turning the Engine
Do not try to turn the engine by pulling the fan or fan
belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
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 9813/7600-3 15 - 7
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Technical Data
For: JCB Tier 4i /T4F <55kW Engine 4 Cyl,

SL Engine ................................... Page 15-8
For: JCB Tier 4F Engine 4 Cyl
..................................................... Page 15-9
(For: JCB Tier 4i /T4F <55kW Engine 4 Cyl, SL Engine)

Table 58.
Description SL Engine SH Engine DH Engine DM Engine
Engine Variants Turbocharged with Turbocharged with Turbocharged with Turbocharged with
intercooler Intercooler Intercooler Intercooler
Emission compli- US-EPA Tier 4 Final, US-EPA Tier 4i, EU US-EPA Tier 4i, EU MAR-1 (Brazil)
ance EU Stage IV Stage IIIB Stage IIIB
Rated speed 2200 RPM (Revolu- 2200 RPM 2200 RPM (108kW), 2200 RPM (108kW),
tions Per Minute) 2050 RPM (129kW) 2050 RPM (129kW)
Weight (Dry) (Dry weight-No cool- (Dry weight-No cool- (Dry weight-No cool- (Dry weight-No cool-
ing fan drive) 496kg ing fan drive) 496kg ing fan drive) 496kg ing fan drive) 496kg
Number of cylinders 4 4 4 4
Nominal bore size 103mm 103mm 106mm 106mm
Stroke 132mm 132mm 135mm 135mm
Cylinder arrange- In line In line In line In line
ment
Combustion Cycle 4-stroke 4-stroke 4-stroke 4-stroke
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Displacement 4.399L 4.399L 4.765L 4.765L
Compression ratio 16.7: 1 16.7: 1 16.7: 1 16.7: 1
Engine Compres- Compression vari- Compression vari- Compression vari- Compression vari-
sion ance between each ance between each ance between each ance between each
cylinder should be cylinder should be cylinder should be cylinder should be
no greater than no greater than no greater than no greater than
3.5bar (50.7psi) 3.5bar (50.7psi) 3.5bar (50.7psi) 3.5bar (50.7psi)
Direction of rotation Clockwise Clockwise Clockwise Clockwise
(viewed from front
{crankshaft pulley}
end)
Valves 4 per cylinder 4 per cylinder 4 per cylinder 4 per cylinder
Valve clearances
measured at the
tappet end of the
rockers (measured
cold)
- Inlet 0.23–0.04mm 0.23–0.04mm 0.23–0.04mm 0.23–0.04mm
- Exhaust 0.6–0.04mm 0.6–0.04mm 0.6–0.04mm 0.6–0.04mm
Lubricating oil pres- 1.6–6.5bar (23.2– 1.6–6.5bar (23.2– 1.6–6.5bar (23.2– 1.6–6.5bar (23.2–
sure (Dependent on 94.2psi) 94.2psi) 94.2psi) 94.2psi)
engine temperature
and speed)
Filter type Screw-on canister Screw-on canister Screw-on canister Screw-on canister
(with drain facility) (with drain facility) (with drain facility) (with drain facility)
(2) (2) (2) (2)
Pressure to open - 1.6bar (23.2psi) 1.6bar (23.2psi) 1.6bar (23.2psi)

by-pass valve
Oil pressure relief 6bar (87.0psi) 6bar (87.0psi) 6bar (87.0psi) 6bar (87.0psi)
valve setting
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15 - Engine
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Description SL Engine SH Engine DH Engine DM Engine

Oil pressure switch0.6bar (8.7psi) 0.6bar (8.7psi) 0.6bar (8.7psi) 0.6bar (8.7psi)
setting falling falling falling falling
Oil pump
(1)
Integral unit with re- Integral unit with re- Integral unit with re- Integral unit with re-
lief valve lief valve lief valve lief valve
Combustion system Common rail direct Common rail direct Common rail direct Common rail direct
Injection Injection Injection Injection
High pressure fuel High pressure with High pressure with High pressure with High pressure with
pump electronically con- electronically con- electronically con- electronically con-
trolled fuel metering trolled fuel metering trolled fuel metering trolled fuel metering
(1) The oil pump is a non-serviceable part
(2) Some variants have ports for connection of a remote filter assembly.
(For: JCB Tier 4F Engine 4 Cyl)
Table 59.
Description SJ Engine DJ Engine
Engine Variants Turbocharged with intercooler and Turbocharged with intercooler and
exhaust after treatment system exhaust after treatment system
Emission compliance US-EPA Tier 4 Final, EU Stage IV US-EPA Tier 4 Final, EU Stage IV
Rated speed 2200 rpm 2200 rpm (108kW), 2050 rpm
(129kW)
Weight (Dry) (Dry weight-No cooling fan drive) (Dry weight-No cooling fan drive)
496kg 496kg
Number of cylinders 4 4
Nominal bore size 103mm 106mm
Stroke 132mm 135mm
Cylinder arrangement In line In line
Combustion Cycle 4-stroke 4-stroke
Firing order 1-3-4-2 1-3-4-2
Displacement 4.399L 4.765L
Compression ratio 16.7: 1 16.7: 1
Engine Compression Compression variance between Compression variance between
each cylinder should be no greater each cylinder should be no greater
than 3.5bar (50.7psi) than 3.5bar (50.7psi)
Direction of rotation (viewed from Clockwise Clockwise
front {crankshaft pulley} end)
Valves 4 per cylinder 4 per cylinder
Valve clearances measured at the
tappet end of the rockers (mea-
sured cold)
- Inlet 0.15–0.21mm 0.15–0.21mm
- Exhaust 0.43–0.49mm 0.43–0.49mm
Lubricating oil pressure (Depen- 1.6–6.5bar (23.2–94.2psi) 1.6–6.5bar (23.2–94.2psi)
dent on engine temperature and
speed)
Fuel filter type Screw-on canister (with drain facil- Screw-on canister (with drain facil-
ity) ity)
Oil pressure relief valve setting 6bar (87.0psi) 6bar (87.0psi)
Oil pressure switch setting 0.6bar (8.7psi) falling 0.6bar (8.7psi) falling
Oil pump
(1)
Integral unit with relief valve Integral unit with relief valve
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Description SJ Engine DJ Engine

Combustion system Common rail direct Injection Common rail direct Injection
High pressure fuel pump High pressure with electronically High pressure with electronically
controlled fuel metering controlled fuel metering
(1) The oil pump is a non-serviceable part
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For: JCB Tier 4i /T4F <55kW Engine 4 Cyl (For: JCB Tier 4i /T4F <55kW Engine 4
................................................... Page 15-11 Cyl)
For: JCB Tier 4F Engine 4 Cyl
................................................... Page 15-15
External
The following identifies the main components of a
typical engine assembly visible from the exterior.
Some variants may differ in detail.
Figure 178. Left hand Side
2 23 9
1
8
15
10
4
20
14 17
5
13
16
19
12
11
21
7
18
22 6
1 Rocker cover 2 Fuel injectors and high pressure fuel pipes

3 Lubrication oil filler cap 4 Timing gear case
5 Flywheel housing 6 Bedplate
7 Lubrication oil sump 8 EGR (Exhaust Gas Recirculation) cooler
9 Air inlet manifold 10 High pressure fuel pump
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11 Fuel filter 12 Lubrication oil filler cap

13 Lubrication oil filter 14 Lubrication oil cooler housing
15 Lubrication oil dipstick 16 Low duty PTO (Power Take-Off) (blanking
cover if no device is installed)
17 Low pressure fuel pipe (to tank) 18 Oil drain plug (sump)
19 Oil filter housing drain plug 20 IMV (Inlet Metering Valve)
21 ECM (Engine Control Module) 22 Crankcase ventilation filter assembly
23 Inlet manifold induction heater
Figure 179. Right Hand Side

6
11 14
8
2
16
3
10
9
4
12 15 13
1 EGR valve heatshield 2 Timing gear case
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00 - Engine
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5 Lubrication oil sump 6 VGT (Variable Geometry Turbocharger)
7 Exhaust manifold 8 Alternator
9 Coolant pump housing (crankcase) 10 Coolant inlet/radiator hose connector
11 Heavy duty PTO (blanking cover if no device 12 Starter motor assembly
is installed)
13 Turbocharger oil drain pipe 14 Turbocharger oil feed pipe
15 Oil drain plug (sump) 16 Cab heater connections
Figure 180. Front End

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

3 Crankcase 4 Bedplate
5 Lubrication oil sump 6 Crankshaft pulley
7 FEAD tensioner 8 Coolant pump and drive pulley assembly
9 Alternator and drive pulley assembly 10 Coolant thermostat housing/radiator hose
connector
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11 VGT 12 Coolant temperature sensor
Figure 181. Rear End

3 Flywheel 4 High pressure fuel pump drive gear cover
5 Flywheel housing 6 Engine electrical harness
7 VGT linkage 8 VGT actuator
9 Turbocharger 10 EGR valve
11 EGR co-axial cooler 12 EGR plate cooler
13 EGR water cooler pipe 14 Low pressure return pipe to tank
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External
The following identifies the main components of a
typical engine assembly visible from the exterior.
Some variants may differ in detail.
Figure 182. Left hand Side
24
23 9
2
8
1
15
10
4
20
17
14 5
13 16
19
12
11
21
7
18
22 6
1 Rocker cover 2 Fuel injectors and high pressure fuel pipes

3 Lubrication oil filler cap 4 Timing gear case
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00 - Engine
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7 Lubrication oil sump 8 EGR cooler
9 Air inlet manifold 10 High pressure fuel pump
11 Fuel filter 12 Lubrication oil filler cap
13 Lubrication oil filter 14 Lubrication oil cooler housing
15 Lubrication oil dipstick 16 Low duty PTO (blanking cover if no device is
installed)
17 Low pressure fuel line (to tank) 18 Oil drain plug (sump)
19 Oil filter housing drain plug 20 IMV
21 ECM 22 Crankcase ventilation filter assembly
23 Inlet manifold induction heater (if installed) 24 Intake throttle
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Figure 183. Right Hand Side

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

Reduction) system (not installed on <55kW
Engines)
Figure 184. Front End

12
11
2
10
9
7
6 5

3 Crankcase 4 Bedplate
5 Lubrication oil sump 6 Crankshaft pulley
7 FEAD (Front End Accessory Drive) tensioner 8 Coolant pump and drive pulley assembly
9 Alternator and drive pulley assembly 10 Coolant thermostat housing/radiator hose
connector
11 VGT (not installed on <55kW Engines) 12 Coolant temperature sensor
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Figure 185. Rear End

3 Flywheel 4 High pressure fuel pump drive gear cover
5 Flywheel housing 6 Engine electrical harness
7 VGT linkage (not installed on <55kW Engines) 8 VGT actuator (not installed on <55kW
Engines)
9 Turbocharger 10 EGR valve
11 EGR co-axial cooler 12 EGR plate cooler
13 EGR water cooler pipe 14 Low pressure return pipe to tank
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Operation
It is important to note that number 1 cylinder is firing

The Four Stroke Cycle - 4 Cylinder and about to start its power stroke. Rotating the
Engine crankshaft a further full rotation would position the
pistons as described but the engine would be at a
This section describes the cycle sequence, for the 4 different stage in its four stroke cycle, with number 1
cylinder engine. cylinder about to start its Induction stroke.
With the crankshaft positioned as shown, the pistons The stages in the four stroke cycle for each cylinder
in numbers 1 and 4 cylinders are at top dead centre are as follows:
and pistons in numbers 2 and 3 cylinders are at
bottom dead centre.
Table 60. The Four Stroke Cycle

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

number 1 cylinder will be next to fire. Number 3
A cylinder is said to be firing, when the fuel / air cylinder is starting its compression stroke and is next
mixture ignites and the piston is about to start its in the cycle, followed by cylinders 4 and 2.
power stroke.
The firing order is therefore; 1, 3, 4, 2.
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Figure 186.
CYL1 CYL2 CYL3 CYL4
1 2
C B C B C B C B
G H J K
4
3
745620
745620
G H J K
C B
B C
A A A A
C B
B C
CYL1 Cylinder number 1 CYL2 Cylinder number 2

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

four stroke engine, the crankshaft revolves twice.
Induction
Figure 187.
As the piston travels down the cylinder, it draws
filtered air through inlet valves into the cylinder.
Compression
When the piston reaches the bottom of its stroke the 3

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

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

both temperature and pressure. The high pressure 746030
generated propels the piston downward turning the 1 Induction stroke
crankshaft and producing work. 2 Compression stroke
3 Power stroke
Exhaust 4 Exhaust stroke
A Camshaft
Once the piston has reached the bottom of its travel, B Camshaft lobe - Inlet valve operation
the exhaust valves open and momentum stored C Camshaft lobe - Exhaust valve operation
in the flywheel forces the piston up the cylinder BDC Bottom dead centre
expelling the exhaust gases. TDC TDC
In a running engine these four phases are
continuously repeated. Each stroke is half a
15 - 22 9813/7600-3 15 - 22
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00 - Engine
00 - General
Figure 188.
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
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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 189.
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
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Fault-Finding
Fault
Engine - Will Not Start or Difficult to Start (No Exhaust Smoke) Table 61. Page 15-25
Engine - Will Not Start or Difficult to Start (Exhaust Smoke) Table 62. Page 15-26
Engine - Will Not Crank or Cranks Slowly Table 63. Page 15-27
Engine - Starts Then Stops Table 64. Page 15-27
Engine - Poor Running Table 65. Page 15-28
Engine - Poor Running at Idle Table 66. Page 15-28
Engine - Noise Excessive Table 67. Page 15-29
Engine - Compression Knocks Table 68. Page 15-30
Engine - Reduced Power Output Table 69. Page 15-30
Engine - Will Not Reach Maximum RPM Table 70. Page 15-31
Engine - RPM Surges Table 71. Page 15-31
Engine - Vibration Excessive Table 72. Page 15-32
Engine - Exhaust Smoke Excessive (Black Smoke) Table 73. Page 15-32
Engine - Exhaust Smoke Excessive (White/Blue Smoke) Table 74. Page 15-33
Engine - Will Not Shut Off Table 75. Page 15-33
Lubricating Oil - Consumption Excessive Table 76. Page 15-33
Lubricating Oil - Contaminated Table 77. Page 15-34
Lubricating Oil - Pressure Low Table 78. Page 15-34
Lubricating Oil - Pressure High Table 79. Page 15-34
Table 61. 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 switch or starter electrical system failure. Check the operation of the ignition switch. Check the
correct electrical wires for open or short circuits.
Improper starting procedure. Verify proper starting procedure.
Fuel Filter blocked with water or other contamination. Drain fuel/water separator or replace fuel filter.
Defective fuel lift pump (fuel supply inadequate). Check that the lift pump operates and delivers fuel
to the high pressure fuel pump. Check the correct
electrical wires for open or short circuits. Check
fuses.
Fuel is aerated. Check the fuel system for loose connections and
possible air ingress points. Rectify and bleed the fuel
system.
Fuel inlet restriction. Maximum inlet restriction to fuel lift pump must not
exceed 100mm Hg.
Air intake or exhaust system blocked. Visually check the air intake and exhaust system for
blockage or obstruction. Remove as required. Check
the air filter elements for signs of blocking. Replace
as required.
Fuel drain return line blocked, not connected Verify that the fuel return line is not obstructed and
properly. connected to the top of the fuel tank.
One or more fuel injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
connections at the injectors.
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Cause Remedy
ECM (Engine Control Module) or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
Worn or malfunctioning high pressure fuel pump. Check the electronic fault codes. Do all the
necessary fault finding checks before removal of the
high pressure fuel pump.
Injectors Contaminated. Check the injectors. Use the Servicemaster test
procedure in Servicemaster Tools Actuator Test. Test
and replace as required.
Table 62. 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 specified amount:
Pressure: 0.133bar (1.9psi)
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 63. Engine - Will Not Crank or
Cranks Slowly
ECM or electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at the ECM and sensors.
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Table 63. Engine - Will Not Crank or Cranks Slowly

Cause Remedy
Starting electrical circuit connections loose or Clean and tighten connections.
corroded.
Battery charge low. Check battery voltage, charge the battery or
replace as required. Make sure that the alternator is
functioning correctly and charging the battery.
No electrical connection to starter solenoid. Check voltage to solenoid.
Crankshaft rotation restricted. Use special tool 892/01147 (crankshaft turning tool)
to manually turn the engine and check for any severe
rotational resistance.
Solenoid or starter motor fault. Replace starter motor.
Starter motor operating but not cranking. Remove the starter motor and check for broken teeth
on the ring gear or broken starter motor spring.
Table 64. 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
ECM or Electrical sensor fault. Check the electronic fault codes. Check the electrical
connections at theECM and sensors.
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Table 65. Engine - Poor Running

Cause Remedy
Condition only occurs at idle. For possible poor running at idle faults.
See Also: Table 66. Engine - Poor Running at Idle
Engine is cold, coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
Check the correct electrical wires for open or short
circuits.
Fuel injection lines leaking. Replace defective high pressure fuel lines. Do not
repair defective fuel lines. If there is a fuel leak
remove and discard the necessary components and
install new ones.
system
Fuel lift pump not operating correctly (fuel supply Check that the lift pump operates and delivers fuel
inadequate). to the high pressure fuel pump. Check the correct
fuses.
restriction.
pump and injectors.
Engine is cold - Thermostat fault. Drain Coolant, Remove and replace Thermostat.
Low Power (particularly at high speed) Exhaust back pressure high, Catalyst problem,
Check Servicemaster Diagnostics.
clearances.
Camshaft damaged. Inspect camshaft.
Tappets damaged. Inspect tappets.
Table 66. Engine - Poor Running at Idle

Cause Remedy
Coolant temperature sensor fault. Check the electrical connection at the coolant sensor.
circuits.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
install new ones.
system.
inadequate). fuel to the injection pump.
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Cause Remedy
restriction.
pump and injectors.
clearances.
Table 67. 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 73. Engine - Exhaust Smoke
Excessive (Black Smoke)
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 service master to disable pilot injections to
identify audibly if they are still present.
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Table 68. 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 69. Engine - Reduced Power Output

Cause Remedy
Oil level incorrect. Check oil level.
Engine overload. Check for added loading from malfunctioning
hydraulic controls.
Throttle position sensor (TPS) system defective. Check the throttle assembly. Check the electronic
fault codes.
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.
install new ones.
restriction.
system.
inadequate). fuel to the injection pump. Check fuses.
as required.
Exhaust leak at the manifold or turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Extra injector sealing washer installed under injector. Remove extra injector sealing washer.
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Cause Remedy
clearances.
high pressure fuel pump
Engine in reduced torque or limp home mode. Check the electronic fault codes.
Excessive exhaust back pressure Inspect Catalyst. Check Exhaust pressure readings
using Servicemaster.
Low DEF (Diesel Exhaust Fluid) Level. Fill the DEF Tank with clean DEF
Table 70. Engine - Will Not Reach Maximum RPM

Cause Remedy
Tachometer faulty. Verify engine speed with hand tachometer. Repair as
required.
Engine overloaded. Verify high idle speed without load. Investigate
operation to be sure correct gear is being used.
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
system.
inadequate). fuel to the injection pump. Check fuses.
pump and injectors.
restriction.
Turbocharger wastegate actuator diaphragm Repair or replace turbocharger.
ruptured.
Table 71. Engine - RPM Surges

Cause Remedy
Fuel level low. Check the level in the fuel tank, use sight gauge or
Pedal/ Hand Throttle position sensor (TPS) system Check the throttle assembly. Check the electronic
defective. fault codes.
install new ones.
Fuel tank cap vent/breather blocked. Inspect and rectify as required. Replace cap if
necessary.
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Cause Remedy
system.
Table 72. Engine - Vibration Excessive

Cause Remedy
Engine not running smoothly/misfiring. See Also: Table 66. Engine - Poor Running at Idle
Fan damaged or accessories faulty. Check/replace the vibrating component. Refer to the
machine's service manual for correct installation and
torque figures.
Fan hub faulty. Inspect/replace the fan hub. Refer to the machine's
service manual for correct installation and torque
figures.
Engine mounts over-tightened, damaged or loose. Check/replace engine mounts.
clearances.
Alternator bearing worn or damaged. Check/replace the alternator.
Flywheel housing misaligned. Check/repair flywheel alignment.
Drive line components worn or unbalanced. Check and inspect drive line components such as
propshafts. Refer to the machine's service manual for
correct installation and torque figures.
Table 73. Engine - Exhaust Smoke Excessive (Black Smoke)

Cause Remedy
Engine being lugged down. Check for added loading from malfunctioning
hydraulic controls.
as required.
Air leak between the turbocharger and the intake Check/repair leaks in the air crossover tube, hoses,
manifold. or manifold cover. Visually inspect MAF (Mass Air
Flow) sensor tube
Intercooler faulty. Check for blocked cooler matrix.
Exhaust leak at the manifold or turbocharger Check/repair leaks in the manifold or turbocharger
gaskets. Look for a cracked manifold.
Turbocharger wastegate faulty. Repair or replace turbocharger.
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Cause Remedy
Turbocharger malfunction. Replace turbocharger.
connections at the ECM and sensors
Smokes under load at all speeds, but mainly low to
mid speed range.
Table 74. 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 electronic fault codes. Check the electrical
- white/ blue smoke at operating temperature. connections at the injectors.
Coolant leaking into combustion chamber. Check the EGR (Exhaust Gas Recirculation) Cooler
for leaks. Replace Cylinder head gasket if necessary.
Leaking valve stem seals - evident after long idle Replace valve seals.
period and then acceleration.
Piston rings not sealing - evident with persistent blue Check the engine compression.
smoke at all speeds/load.
Table 75. Engine - Will Not Shut Off

Cause Remedy
Stop switch or stop switch electrical system failure. Check the operation of the stop switch. Check the
correct electrical wires for open or short circuits.
Table 76. Lubricating Oil - Consumption Excessive

Cause Remedy
Oil leaks. Inspect the engine for visible signs of leaks. Pay
particular attentions to seals, gaskets oil cooler and
external connections.
Oil level over-full. Check oil level.
Incorrect lubricating oil (specification of viscosity). Make sure the correct lubricating oil is being used.
Tier 4 Final Engines require a special oil grade. Refer Check for reduced viscosity from dilution with fuel.
to (PIL 75-03). Fuel dilution in lubricating oil can originate from a
defective high pressure fuel pump driveshaft seal.
Review/reduce the lubricating oil change intervals.
Crankcase ventilation (CCV) system blocked. Check the breather tube area for signs of lubricating
oil loss. Check and if necessary replace the CCV
filter.
Lubricating oil cooler leak. Check for lubricating oil in the coolant.
Turbocharger leaking lubricating oil to the air intake Inspect the air crossover tube for evidence of
or exhaust. lubricating oil transfer.
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Cause Remedy
Valve guide seals are leaking. Replace valve guide stem seals as required.
Piston rings not sealing - lubricating oil being Check the engine compression
consumed by the engine (blue smoke from exhaust).
Worn cylinder bores - lubricating oil being consumed Check the engine compression.
by the engine (blue smoke from exhaust).
Glazed cylinder bores. De-glaze bores as required.
Table 77. 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 78. 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 79. 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 connectors and
electronic components such as ECU (Electronic
Control Unit)'s, alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine or exhaust
system.
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9. When the pressure washing is complete move Check (Condition)

the machine away from the wash area, or
alternatively, clean away the material washed
from the machine. Start the engine and check for:
10. Before working on specific areas of the engine • Excessive smoke

use a compressed air jet to dry off any moisture. • Excessive vibration
When the area is dry use a soft clean brush to • Excessive noise
remove any sand or grit particles that remain. • Overheating
• Performance
11. When removing components be aware of any • Unusual smells.
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 (Leaks) Check (Pressure)

Special Tools
Before you start the machine, do a check for oil leaks: Description Part No. Qty.
Pressure Gauge (0-40 892/00278 1
Bar)
2. Get access to the engine compartment (if Digital Hydraulic 998/11051 1
applicable) Pressure Test Kit
3. Check the engine and the area below for oil This test is used to diagnose suspected poor
leaks. compression in one or more of the engine cylinders.
Use ServiceMaster to control the test.
4. Close the engine cover (if applicable).
5. If necessary, contact your JCB dealer. Engine Compression Test
1. Connect the Servicemaster tool to the machine.
2. Access the engine compression test and follow
the on screen commands.
3. There is a 5 second delay before the test starts.
4. The test disables the injectors and requests the
tester to crank the engine.
5. Crank the engine for at least 5 seconds, but no
longer than 10 seconds.
6. The engine ECU measures the variation in
engine cranking speed to determine if one
or more cylinders have lower than expected
compression values.
7. Turn off the ignition after the test.
Note: The engine cranking speed must be greater

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

Use the following procedures to measure the engine
oil pressure. Refer to Oil Sump (PIL 15-45) for a
full explanation of the lubricating oil circuit. Several
factors can influence the engine oil pressure, the
following conditions are assumed:
• The correct engine oil has been used. Refer to

Consumable Products (PIL 75-00).
• The engine oil level is correct. Refer to Oil Filter,
Check Level (PIL 15-21).
1. Make sure that the engine is safe to work on. If
the engine has been running, let it cool before
you start the service work.
2. Get access to the engine.
3. Disconnect the electrical connector to the oil
pressure switch, remove the switch from the oil
cooler housing.
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4. Install a suitable adaptor into the vacant pressure 5. Start the engine and allow a few seconds to
switch port (M10 x 1.5mm thread) and a pressure gain oil pressure, increase the engine revs to
test gauge. Make sure that the gauge has a the rated speed. Record the pressure gauge
sealing washer as shown. reading, refer to Technical Data (PIL 15-00), for
the recommended circuit pressure.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
Special Tool: Digital Hydraulic Pressure Test Kit 6. Remove the pressure gauge and install the
(Qty.: 1) pressure switch.
Figure 190.
High Lubrication Oil Pressure
High oil pressure will be evident when starting in cold
conditions. Typically the pressure will be 1 to 2 bar
and higher in cold operation, the pressure should
drop when the engine reaches normal operating
temperature.
If the pressure remains high when operating

temperature is achieved, check the oil level, if this is
correct, suspect the oil pump relief valve is at fault.
Low Lubrication Oil Pressure

A Several factors can be the cause of low lubricating
oil pressure:
• Low oil level - typically evident as a loss of

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

B Sealing washer
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Remove and Install
Special Tools recommended lifting equipment is shown. Use a

Description Part No. Qty. spreader bar when lifting the engine. Never attempt
Lifting Bracket Front 320/09062 1 to manually lift heavy components on your own.
Always use lifting equipment, or obtain the help of
Lifting Bracket Rear 320/09063 1 an assistant. Inspect the lifting brackets for signs
Engine Lifting Spreader 892/01382 1 of damage. The brackets must be correctly torqued
Bar to the crankcase. Make sure the lifting equipment
does not damage any of the engine dressing and the
Lifting Equipment rocker cover.
equipment. You must identify the weight of the item to Component Identification
enough and suitable for the job. Make sure that lifting The following component identification is for a typical
equipment is in good condition and complies with all engine installation. There will be some component
local regulations. differences depending on the machine variant.
Before attempting to remove the engine ensure that
The lifting equipment used must be an approved all the necessary components have either been
type and capable of lifting the engine safely. The removed, or safely disconnected from the engine.
Figure 191.
14 25 22 15
6
7
8
10 23
17
16
18
21
24
12 19
11
20
6 Engine mounting bolts 7 Lifting bracket- front

8 Lifting bracket fixing bolts 10 Fuel line connector- return to tank line
11 Fuel line connector at fuel filter- feed line from 12 Electrical connector- engine ECU machine
fuel pump side connector (grey)
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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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Before Removal 16. Disconnect and plug the hoses at the hydraulic
pump.
the engine has been running, let it cool before 17. Disconnect the wiring to the hydraulic pump.
18. Remove the gearbox to engine retaining bolts,
2. Position the machine on firm level ground. Make pull the transmission and converter clear of
the machine safe, refer to (PIL 01-03). the engine, make sure that the converter stays
mounted on the gearbox shaft.
19. Attach slings to the engine lifting eyes.
Remove Special Tool: Lifting Bracket Front (Qty.: 1)
Special Tool: Lifting Bracket Rear (Qty.: 1)
1. Disconnect and remove the battery. Refer to (PIL Special Tool: Engine Lifting Spreader Bar (Qty.:
33-03). 1)
2. Drain the engine oil. Refer to (PIL 15-21). 20. Take the weight of the engine on the hoist and
remove the engine mounting bolts.
3. Drain the engine coolant, remove the cooling
pack. Refer to (PIL 21-03). 21. Withdraw the engine in a level attitude until the
hydraulic pump is clear of the chassis. Raise the
4. Discharge the hydraulic pressure. Refer to (PIL engine to lift it clear of the machine.
30-00).
22. Lower the engine into a suitable stand that is
5. Drain the hydraulic tank. Disconnect and plug capable of supporting the weight of the engine.
the hydraulic suction and delivery lines at the
transmission pump and gear pump. Label the
hoses to ensure correct reassembly. Refer to
(PIL 30-00).
6. Disconnect and plug the hydraulic cooler hoses.
Label the hoses to ensure correct reassembly.
7. Disconnect the exhaust system.
8. Label the cab heater hoses at the engine block
connectors. Release the hose clips and remove
the hoses.
9. Disconnect the wiring connections from the
starter motor. Refer to (PIL 15-75).
alternator. Refer to (PIL 15-72).
engine sensors and actuators. Refer to (PIL
15-84).
12. Disconnect the fuel supply line at the fuel lift
pump and the spill line at the fuel injection pump.
Cap all hoses and ports to prevent ingress of dirt.
13. Disconnect the electrical harness at the engine
harness.
14. Uncouple the electrical harness at the
ECM (Engine Control Module) machine side
connector. Important: Do not touch the connector
pins on the ECM or harness connectors. Cover
the connectors to prevent contamination.
15. Ensure that all relevant harnesses and hoses are
unclipped from the engine and tied out of the way.
15 - 41 9813/7600-3 15 - 41
15 - Engine
00 - Engine
00 - General
Figure 192. 3. Fill the cooling system with the correct mix of
coolant fluid. Refer to (PIL 21-00).
4. Fill and Check the hydraulic fluid level. Refer to
B (PIL 30-00).
5. Fill and Check the engine oil level. Make sure the
correct oil is used. Refer to (PIL 75-03).
6. On completion, check the hydraulic and cooling
system for leakage and levels.
7. Check the function of the drive and loader
services.

C Item Nm
A 47
A Lifting bracket mounting bolts

B Lifting equipment
C Spreader bar
Install
1. Replacement is a reversal of the removal
procedure. Note the following:
2. Important: It is vitally important that the torque
converter is installed at the gearbox and engine
flywheel correctly. Failure to locate the converter
correctly will result in damage to the gearbox oil
pump on engine start up.
15 - 42 9813/7600-3 15 - 42
15 - Engine
00 - Engine
00 - General
Store and Recommission
For: JCB Tier 4i /T4F <55kW Engine 4 Cyl All floor stock engines should be stored under cover
................................................... Page 15-43 in dry conditions and not subjected to extreme
For: JCB Tier 4F Engine 4 Cyl variations in temperature or humidity.
................................................... Page 15-45
If an engine is to be placed into storage, all external
signs of surface coating damage or corrosion should
(For: JCB Tier 4i /T4F <55kW Engine 4 be cleaned and re-coated. Electrical connectors and
Cyl) components should be coated with a protective
spray.
Engines should be stored in the original shipping
packaging. Damaged or disturbed packaging should
be made weatherproof immediately.
Capping Engine Openings
All openings on the engine must be suitably capped
If an engine is shipped with oil, it should be stored in
to prevent ingress of water and contamination by
the correct (upright) position.
foreign particles.
If an engine is shipped dry of oil, after 6 months it
Some engine configurations may differ in detail to the
should be filled with oil to the correct level and re-
illustrations shown. Make sure you identify and cap
inhibited, refer to hot test description.
all openings.
15 - 43 9813/7600-3 15 - 43
15 - Engine
00 - Engine
00 - General
Figure 193. Typical engine
13
5
3
4
6
14
17
16
12
11
10 2
15
1 Top hose cap 2 Bottom hose cap

3 Turbocharger intake cap 4 Turbocharger compressor outlet cap
5 Turbocharger exhaust outlet cap 6 Inlet manifold cap
7 Dipstick plug 8 ECM (Engine Control Module) machine
harness connector cap
9 Fuel spill back line cap 10 Low duty PTO (Power Take-Off) (if installed)
cap
11 Heavy duty PTO (if installed) cap 12 Cab heater feed and return spigots
13 Coolant circuit de-gas spigot 14 CCV canister outlet on the closed loop
breathing circuit (55kW)
15 Low pressure fuel filter inlet spigot (engines 16 SCR (Selective Catalytic Reduction) coolant
with fuel filter attached) feed spigot (if installed)
17 Fuel pump low pressure inlet spigot (engines
with no fuel filter attached)
12 Month Revalidation Procedure 1.1. Inspect packaging for signs of damage.
1. Pre-inspection: 1.2. Inspect the caps for signs of damage.
15 - 44 9813/7600-3 15 - 44
15 - Engine
00 - Engine
00 - General
1.3. Inspect openings for signs of water or dirt 5. Refill with the correct oil and inhibit the cooling
ingress. system using the correct product.
1.4. Inspect the engine for signs of external 6. Record details of work as required.
corrosion.
1.5. Inspect the engine for signs of fluid leaks. Hot Test Description
2. From storage: WARNING When using cleaning agents, solvents
or other chemicals, you must adhere to
2.1. Remove the air intake caps. the manufacturer's instructions and safety
precautions.
2.2. Make sure the engine oil level is correct.
2.3. Using a suitable power supply at the correct All engines despatched from JCB will have been
voltage, crank the engine over. subjected to a hot test (checking items such as oil
2.4. During cranking, check that the oil pressure pressure, engines speeds, torque values etc.) and
switch opens using a multimeter. The switch therefore the interior surfaces will have been coated
is closed when there is no or low oil with engine oil.
pressure and opens when oil pressure
All coolant galleries are coated with CRODAFLUID
reaches a set point. After three separate 20
PA75 corrosion inhibitor.
second cranking periods, If the oil pressure
switch does not open (indicating no, or Stored engines will require re-inhibiting every 12
low oil pressure), contact your JCB engine months, this will include hot testing the engine using
dealer. a dynamometer. The hot test profile is:
2.5. Recap all engine openings.
Table 82. Hot Test Profile
2.6. Coat any exposed bare metal with a
suitable product. Stage Mode Speed Torque Time
(rpm) (Nm) (secs)
2.7. Electrical connectors and components
1 Speed/ 830 0 50
should be coated with a protective spray if
Torque
exposed.
2 Speed/ 1300 50 60
2.8. Cover in weatherproof packaging. Torque
2.9. Place in storage, under cover on level 3 Speed/ 2500 0 60
ground or shelving. Torque
2.10. Record details of work as required. 4 Speed/ 1300 0 25
Torque
2.11. Do not expose to extremes of temperature 5 Speed/ 800 0 35
or humidity. Torque
Notice: Do not operate the starter motor for more
than 20s at one time. Let the starter motor cool for
at least 2min.
Table 81. Oil Pressure Switch Set Points
Engines should be stored in the original shipping
Oil pressure switch >0.6bar (8.7psi) packaging. Damaged or disturbed packaging should
closed be made weatherproof immediately.
Oil pressure switch open <0.6bar (8.7psi)
If an engine is shipped with oil, it should be stored in
the correct (upright) position.
OEM Commissioning Check on Engine
Installation After More Than 12 Months If an engine is shipped dry of oil, after 6 months it
should be filled with oil to the correct level and re-
1. Flush the coolant system with proprietary
inhibited, refer to hot test description.
flushing solution.
2. Refill the coolant system with 50/50 mix of long All floor stock engines should be stored under cover
life antifreeze mixture. in dry conditions and not subjected to extreme
variations in temperature or humidity.
3. Hot test engine according to the hot test profile.
Refer to Table 82. If an engine is to be placed into storage, all external
signs of surface coating damage or corrosion should
4. Drain engine oil and replace engine oil filter. be cleaned and re-coated. Electrical connectors and
15 - 45 9813/7600-3 15 - 45
15 - Engine
00 - Engine
00 - General
components should be coated with a protective Capping Engine Openings

spray.
All openings on the engine must be suitably capped
The DEF (Diesel Exhaust Fluid) tank should be at to prevent ingress of water and contamination by
least 20% full before being placed in to storage. foreign particles.
Figure 194.
13
5
3
4
6
14
17
16
12
11
10 2
15
1 Top hose cap 2 Bottom hose cap

3 Turbocharger intake cap 4 Turbocharger compressor outlet cap
5 Turbocharger exhaust outlet cap 6 Inlet manifold cap
7 Dipstick plug 8 ECM machine harness connector cap
9 Fuel spill back line cap 10 Low duty PTO (if installed) cap
11 Heavy duty PTO (if installed) cap 12 Cab heater feed and return spigots
13 Coolant circuit de-gas spigot 14 CCV canister outlet on the closed loop
breathing circuit (55kW)
15 Low pressure fuel filter inlet spigot 16 SCR coolant feed spigot (if installed)
12 Month Revalidation Procedure 1.1. Inspect packaging for signs of damage.
1. Pre-inspection: 1.2. Inspect the caps for signs of damage.
15 - 46 9813/7600-3 15 - 46
15 - Engine
00 - Engine
00 - General
1.3. Inspect openings for signs of water or dirt 3. Hot test engine according to the hot test profile.
ingress. Refer to Table 84.
1.4. Inspect the engine for signs of external 4. Drain engine oil and replace engine oil filter.
corrosion.
5. Refill with the correct oil and inhibit the cooling
1.5. Inspect the engine for signs of fluid leaks.
system using the correct product.
1.6. Check that the DEF tank level is above the
specified level. 6. Drain the DEF tank.
Percentage: 20% 7. Fill the DEF tank with clean good quality DEF.
Leave to stand for the specified time period.
2. From storage:
Duration: 72h
2.1. Remove the air intake caps.
8. Record details of work as required.
2.2. Make sure the engine oil level is correct.
2.3. Using a suitable power supply at the correct Hot Test Description
voltage, crank the engine over. WARNING When using cleaning agents, solvents
2.4. During cranking, check that the oil pressure or other chemicals, you must adhere to
switch opens using a multimeter. The switch the manufacturer's instructions and safety
is closed when there is no or low oil precautions.
pressure and opens when oil pressure
reaches a set point. After three separate 20 All engines despatched from JCB will have been
second cranking periods, If the oil pressure subjected to a hot test (checking items such as oil
switch does not open (indicating no, or pressure, engines speeds, torque values etc.) and
low oil pressure), contact your JCB engine therefore the interior surfaces will have been coated
dealer. with engine oil.
2.5. Recap all engine openings.
All coolant galleries are coated with CRODAFLUID
2.6. Coat any exposed bare metal with a PA75 corrosion inhibitor.
suitable product.
Stored engines will require re-inhibiting every 12
2.7. Electrical connectors and components
months, this will include hot testing the engine using
should be coated with a protective spray if
a dynamometer. The hot test profile is:
exposed.
2.8. Cover in weatherproof packaging. Table 84. Hot Test Profile
2.9. Place in storage, under cover on level Stage Mode Speed Torque Time
ground or shelving. (rpm) (Nm) (secs)
1 Speed/ 830 0 50
2.10. Record details of work as required.
Torque
2.11. Do not expose to extremes of temperature 2 Speed/ 1300 50 60
or humidity. Torque
Notice: Do not operate the starter motor for more 3 Speed/ 2500 0 60
than 20s at one time. Let the starter motor cool for Torque
at least 2min. 4 Speed/ 1300 0 25
Torque
Table 83. Oil Pressure Switch Set Points 5 Speed/ 800 0 35
Torque
Oil pressure switch >0.6bar (8.7psi)
closed
Oil pressure switch open <0.6bar (8.7psi)
OEM Commissioning Check on Engine

Installation After More Than 12 Months
1. Flush the coolant system with proprietary
flushing solution.
2. Refill the coolant system with 50/50 mix of long
life antifreeze mixture.
15 - 47 9813/7600-3 15 - 47
15 - Engine
03 - Crankcase
03 - Crankcase
Contents Page No.
15-03-00 General ........................................................................................................................... 15-49
15 - 48 9813/7600-3 15 - 48
15 - Engine
03 - Crankcase
00 - General
Introduction .................................................... 15-49 The crankcase is the housing for the crankshaft.
Technical Data ............................................... 15-50 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 195.
A
A Crankcase
B Crankshaft
15 - 49 9813/7600-3 15 - 49
15 - Engine
03 - Crankcase
00 - General
Technical Data
Table 85. Crankcase and Bedplate Data

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

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

Diameter of second oversize bore 104–104.02mm
Main bearing bore (without bear-
ings)
Numbers 1 to 4 92–92.02mm 92–92.02mm
Number 5 105–105.02mm 105–105.02mm
Main bearing bore (with bearings)
Numbers 1 to 4 88.047–88.09mm 88.047–88.09mm
Number 5 100.047–100.09mm 100.047–100.09mm
Camshaft bore
Numbers 1 to 4 60.04–60.07mm 60.04–60.07mm
Number 5 (bush) 60.29–60.32mm 60.29–60.32mm
Permissible wave profile wt < 10m (2.5 distance) wt < 10m (2.5 distance)
(1) Nominal diameter to be measured 63mm below the cylinder head face.
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures
may result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
(3) The crankcase to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
15 - 50 9813/7600-3 15 - 50
15 - Engine
06 - Cylinder Head
06 - Cylinder Head
Contents Page No.
15-06-00 General ........................................................................................................................... 15-53
15 - 51 9813/7600-3 15 - 51
Notes:
15 - 52 9813/7600-3 15 - 52
15 - Engine
06 - Cylinder Head
00 - General
Introduction .................................................... 15-53 For: JCB T4F 4.4 over 55kw Electronic
Technical Data ............................................... 15-54 Engine, JCB Tier 4F Engine 4 Cyl, JCB Tier
Component Identification ............................... 15-55 4i /T4F <55kW Engine 4 Cyl ...... Page 15-53
Remove and Install ....................................... 15-56 Otherwise .................................. Page 15-53
(For: JCB T4F 4.4 over 55kw Electronic

Engine, JCB Tier 4F Engine 4 Cyl, JCB
Tier 4i /T4F <55kW Engine 4 Cyl)
The cylinder head is located above the cylinders
on top of the crankcase. It closes in the top of the
cylinder, forming the combustion chamber. This joint
is sealed by a cylinder head gasket.
The cylinder head also provides the space for the

passages that feed air and fuel to the cylinder and
allow the exhaust to escape. The cylinder head is
also used to mount the valves and fuel injectors.
(Otherwise)
The cylinder head is located above the cylinders
on top of the crankcase. It closes in the top of the
cylinder, forming the combustion chamber. This joint
is sealed by a cylinder head gasket.
The cylinder head also provides the space for the

passages that feed air and fuel to the cylinder and
allow the exhaust to escape. The cylinder head is
also used to mount the valves and fuel injectors.
15 - 53 9813/7600-3 15 - 53
15 - Engine
06 - Cylinder Head
00 - General
Technical Data
Table 86. Cylinder Head Data

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

- Side to side 0.03mm
Valve recess depth
- Inlet 0.85mm
- Exhaust 0.85mm
Valve seat angle
- Inlet 120(inclusive)
- Exhaust 90(inclusive)
Cylinder head bolts tourque
(2)
- First stage 40
- Second stage 75
- Third stage Repeat75
- Fourth stage Torque angle + 90
- Final stage Torque angle + 180
Surface finish for cylinder head joint Rz < 15 Rmax < 20
Permissible wave profile wt < 10m 2.5 distance
(1) The block to cylinder head surface may be skimmed and restored using the oversize gaskets (0.25mm
and 0.5mm).
(2) Torque information MUST be used in conjunction with the recommended procedures contained in this
manual. Failure to use the appropriate and correct remove, install, disassemble and assemble procedure may
result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
15 - 54 9813/7600-3 15 - 54
15 - Engine
06 - Cylinder Head
00 - General
Figure 196.
C
A Cylinder head
B Cylinder head gasket
C Cylinder head bolts
15 - 55 9813/7600-3 15 - 55
15 - Engine
06 - Cylinder Head
00 - General
Remove and Install
Special Tools 2. Make sure that the engine is safe to work on. If
Description Part No. Qty. the engine has been running, let it cool before
Torque Wrench 993/70111 1 you start the service work.
(10-100Nm) 3. Get access to the engine.
Consumables 4. Remove the thermostat, refer to (PIL 21-12).
Cleaner/Degreaser 4104/1557 0.4L 5. Remove the fuel pipes, refer to (PIL 18-96).
- General purpose 6. Remove the rocker cover, refer to (PIL 15-42).
solvent based parts
cleaner 7. Remove the fuel injectors, refer to (PIL 18-18).
Before Removal 8. Remove the rocker assembly, refer to (PIL

15-42).
1. This procedure requires service parts. Make sure
9. Remove the exhaust manifold, refer to (PIL
you have obtained the correct parts before you
18-24).
start, refer to Parts Catalogue.
10. Remove the inlet manifold, refer to (PIL 18-24).
15 - 56 9813/7600-3 15 - 56
15 - Engine
06 - Cylinder Head
00 - General
Figure 197.
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 - 57 9813/7600-3 15 - 57
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 87.
1. Obtain the correct new cylinder head bolts. Note
that the original bolts MUST NOT be re-used. Description Torque Value
Cylinder head to
2. Obtain the correct replacement head gasket. crankcase bolts 1-18
Note the number of identification holes as shown - first stage torque 40N·m
at X.
- second stage torque 75N·m
3. Make sure that all items are clean and free from - third stage torque 75N·m
damage and corrosion. - fourth stage torque 90°
- final stage torque 180°
Assemble
The cylinder head bolts are tightened using a torque
and angle method, refer to Fasteners and Fixings,
General, Introduction (PIL 72-00).
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 - 58 9813/7600-3 15 - 58
15 - Engine
09 - Bedplate
09 - Bedplate
Contents Page No.
15-09-00 General ........................................................................................................................... 15-61
15 - 59 9813/7600-3 15 - 59
Notes:
15 - 60 9813/7600-3 15 - 60
15 - Engine
09 - Bedplate
00 - General
Introduction .................................................... 15-61 The bedplate acts as the main strength component
Remove and Install ....................................... 15-62 of the engine. it maintains the correct alignment and
supports the weight of the internal components.
Figure 198.
1
1 Bedplate
2 Crankcase
15 - 61 9813/7600-3 15 - 61
15 - Engine
09 - Bedplate
00 - General
Remove and Install
Special Tools 10. Remove the rocker assembly including the push
Description Part No. Qty. rods, refer to (PIL 15-42).
Template for Sealant 892/12356 1 11. It is not necessary to remove the cylinder head
Bedplate to Crankcase assembly to remove the crankshaft. If however
(4 Cyl) the cylinder head needs to be removed for other
Torque Wrench 993/70111 1 reasons (for piston and connecting rod removal
(10-100Nm) for example) remove it now, refer to (PIL 15-06).
Consumables 12. Remove the fuel injection pump, refer to (PIL
Description Part No. Size 18-18).
Cleaner/Degreaser 4104/1557 0.4L 13. Remove the starter motor, refer to (PIL 15-75).
- General purpose
solvent based parts 14. Remove the high duty PTO (Power Take-Off)
cleaner device (if installed).
CAUTION This component is heavy. It must only 15. Position the engine upside down in a suitable jig
be removed or handled using a suitable lifting or fixture, supported at the front of the cylinder
method and device. block.
16. Remove the flywheel, refer to (PIL 15-54).
Before Removal
17. Remove the flywheel housing, refer to (PIL
1. This procedure requires service parts. Make 15-54).
sure you have obtained the correct service parts
before you start, refer to Parts Catalogue. 18. Remove the fuel injection pump drive gear, refer
to (PIL 15-51).
the engine has been running, let it cool before 19. Remove the oil pump, refer to (PIL 15-60).
20. Remove the high duty PTO idler drive gear (if
3. Remove the engine, refer to (PIL 15-00). installed), refer to (PIL 15-51).
4. Remove the drive belt, refer to (PIL 15-18). 21. Remove the crankshaft drive gear, refer to (PIL
15-51).
5. Remove the crankshaft pulley, refer to (PIL
15-12). 22. Remove the camshaft, refer to (PIL 15-15).
6. Remove the oil sump, refer to (PIL 15-45). 23. Remove the rear timing case, refer to (PIL
15-51).
7. Disconnect and remove the fuel pipes from the
injectors, refer to (PIL 18-96). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
8. Remove the rocker cover, refer to (PIL 15-42). caps, refer to (PIL 15-12).
9. Remove the fuel injectors, refer to (PIL 18-18).
15 - 62 9813/7600-3 15 - 62
15 - Engine
09 - Bedplate
00 - General
Figure 199.
4 1 5
11
8 9
7 10
3 P3 2 6
X
12 18
18
18
18
18
13
18
1-10 Main bearing bolts (x10) 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Upper bearing shell (x5) P3 O-ring (if installed)
T1 Lifting bolts (obtain locally)
15 - 63 9813/7600-3 15 - 63
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 200.
Y P2 Y A (T5) T4
T4
P2
P3
B (T5)
Y Y P2 T6
18
18 18
X
18
T6 18
4 1 5 T6
11
8 9
W
18
12
T6
7 10
3 2 6
13
1-10 Main bearing bolts 11 Bedplate peripheral bolts (x16)

12 Bedplate 13 Crankcase
18 Lower bearing shells (x5) A Left side template
B Right side template T3 Angle Gauge (obtain locally)
15 - 64 9813/7600-3 15 - 64
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 - 65 9813/7600-3 15 - 65
15 - Engine
09 - Bedplate
00 - General
Before Installation as a guide apply beads of sealant P2 around the

crankcase/bedplate mating face as shown to the
1. Clean off all traces of the old sealant compound dimension specified.
from the crankcase and bedplate mating faces.
Length/Dimension/Distance: 1.5mm
2. Use a suitable degreasing agent to carefully
9. Remove the four fixing bolts at positions Y.
clean the main bearing saddles in the bedplate
Remove the templates A and B, make sure
and crankcase. Take care not to block the oil
you do not smudge the sealant. Discard the
ways or the piston cooling jets.
templates.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner 10. Add beads of sealant P2 around the four bolt
holes at positions Y, so as to join the sealant
Important: Anaerobic sealant will not start to cure beads as shown at X.
whilst it is open to the atmosphere, however when
air is excluded (for instance when the two parts are 11. Make sure that the location guide pins T4 are in
put together) it will immediately start to harden. Make position in the crankcase. Assemble the bedplate
sure that all the necessary tools, bolts etc. are readily to the crankcase use the alignment guide pins.
available prior to assembling the components. The 12. Note: The bedplate is heavy. Two people will
parts must be installed and tightened to the correct be required to lift and rotate the bedplate safely
torque value within 5 minutes (with a maximum on to the crankcase. Install new main bearing
permissible time of 15 minutes). bolts 1-10. Tighten the bolts to the correct torque
value in pairs, starting in the centre and working
Important: BEFORE installing the bedplate: DO NOT
outwards (in sequence 1-10) to the 1st stage pre-
rotate the crankshaft. Make sure that the upper main
torque.
bearing shells are flush with the bottom face of the
crankcase. Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
Install 13. Install the bedplate peripheral bolts. Tighten the
1. The installation procedure is the opposite of the bolts to the correct torque value.
14. After installation and tightening the bedplate
steps.
peripheral bolts, further tighten the main bearing
2. Make sure that all items are clean and free from bolts in pairs, starting in the centre and working
damage and corrosion. outwards (in sequence 1-10) to the 2nd stage
pre-torque.
3. Install the two guide pins T4 to the crankcase
bedplate fixing holes as shown. 15. Finally, angle tighten the main bearing bolts in
pairs, starting in the centre and working outwards
4. Install the four lifting bolts T6 to the bedplate as (in sequence 1-10) for the final stage torque. Use
shown. the torque and angle method, refer to Fasteners
and Fixings, General, Introduction (PIL 72-00).
5. Install a new O-ring at the bedplate.
Important: If the parts have not been tightened to the
6. Use a suitable degreasing agent to clean both correct torque value within the maximum 15 minute
sides of the lower bearing shells. Assemble the time period, then the parts must be separated,
lower bearing shells into the bedplate. Lubricate thoroughly cleaned and fresh sealant applied.
the lower bearing shells with clean engine oil.
Note: Make sure that the location tab W engages
in the slot as shown.
After Installation
Consumable: Cleaner/Degreaser - General 1. Check that the crankshaft can be freely rotated
purpose solvent based parts cleaner by hand. Remove the bedplate lifting bolts T6.
7. Note: The sealant template T5 is used on 2. Carry out the procedures listed, Before removal
the crankcase, NOT the bedplate. The sealant in reverse order.
template T5 comprises of two pieces, A and B.
Modify the template A by removing portion V.
Table 88. Torque Table
Special Tool: Template for Sealant Bedplate to
Crankcase (4 Cyl) (Qty.: 1) Item Torque Value
1-10 (1st Stage) 50N·m
8. Locate the holes in the templates A and B using 1-10 (2nd Stage) 115N·m
four fixing bolts at positions Y. Use the templates
15 - 66 9813/7600-3 15 - 66
15 - Engine
09 - Bedplate
00 - General
Item Torque Value

1-10 (Final Stage) 180°
11 24N·m
15 - 67 9813/7600-3 15 - 67
15 - Engine
12 - Crankshaft
12 - Crankshaft
Contents Page No.
15-12-00 General ........................................................................................................................... 15-69

15-12-03 Main Bearing .................................................................................................................. 15-78
15-12-06 Front Oil Seal ................................................................................................................. 15-80
15-12-09 Rear Oil Seal ................................................................................................................. 15-83
15-12-12 Pulley .............................................................................................................................. 15-87
15 - 68 9813/7600-3 15 - 68
15 - Engine
12 - Crankshaft
00 - General
Operation ....................................................... 15-72 Otherwise .................................. Page 15-69
Check (Condition) .......................................... 15-73
Remove and Install ....................................... 15-74 (For: JCB T4F 4.4 over 55kw Electronic
Figure 201.
A
A Crankcase
B Crankshaft
(Otherwise)
The crankshaft is housed inside the crankcase. It is
connected to the piston via a connecting rod, they
form a simple mechanism that converts reciprocating
motion into rotating motion. Refer to: PIL 15-00-00.
15 - 69 9813/7600-3 15 - 69
15 - Engine
12 - Crankshaft
00 - General
Technical Data
Table 89.
Main bearing journal diameter (x4)
- min 87.98mm
- max 88mm
Main rear bearing journal diameter (x1)
- min 99.98mm
- max 100mm
Connecting rod bearing journal diameter
- min 72.98mm
- max 73mm
Maximum wear and ovality on journals
(1)
Crankshaft induction hardness 55 HRc min on surface

Thrust washer width
- min 2.44mm
- max 2.5mm
Crankshaft end float
- min 0.05mm
- max 0.28mm
(1) No visible damage/wear or marks
15 - 70 9813/7600-3 15 - 70
15 - Engine
12 - Crankshaft
00 - General
Figure 202.
A
A Crankcase
B Crankshaft
15 - 71 9813/7600-3 15 - 71
15 - Engine
12 - Crankshaft
00 - General
Operation
diameter of the upper main bearing shell allows oil

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
engine.
Figure 203.
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 - 72 9813/7600-3 15 - 72
15 - Engine
12 - Crankshaft
00 - General
1. Check the main bearing surfaces for damage and

excessive wear.
Figure 204.
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 205.
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 - 73 9813/7600-3 15 - 73
15 - Engine
12 - Crankshaft
00 - General
Remove and Install
Consumables reasons (for piston and connecting rod removal

Description Part No. Size for example) remove it now, refer to (PIL 15-06).
Cleaner/Degreaser 4104/1557 0.4L 12. Remove the fuel injection pump, refer to (PIL
- General purpose 18-18).
solvent based parts
cleaner 13. Remove the starter motor, refer to (PIL 15-75).
CAUTION This component is heavy. It must only 14. Remove the high duty PTO device (if installed).
method and device. 15. Position the engine upside down in a suitable jig
or fixture, supported at the front of the cylinder
block.
Before Removal
16. Remove the flywheel, refer to (PIL 15-54).
1. This procedure requires service parts. Make
sure you have obtained the correct service parts 17. Remove the flywheel housing, refer to (PIL
before you start, refer to Parts Catalogue. 15-54).
2. Make sure that the engine is safe to work on. If 18. Remove the fuel injection pump drive gear, refer
the engine has been running, let it cool before to (PIL 15-51).
19. Remove the oil pump, refer to (PIL 15-60).
3. Remove the engine, refer to (PIL 15-00).
20. Remove the high duty PTO idler drive gear (if
4. Remove the drive belt, refer to (PIL 15-18). installed), refer to (PIL 15-51).
5. Remove the crankshaft pulley, refer to (PIL 21. Remove the crankshaft drive gear, refer to (PIL
15-12). 15-51).
6. Remove the oil sump, refer to (PIL 15-45). 22. Remove the camshaft, refer to (PIL 15-15).
7. Disconnect and remove the fuel pipes from the 23. Remove the rear timing case, refer to (PIL
injectors, refer to (PIL 18-96). 15-51).
8. Remove the rocker cover, refer to (PIL 15-42). 24. If the pistons and connecting rods have not been
removed, undo and remove the main bearing
9. Remove the fuel injectors, refer to (PIL 18-18). caps, refer to (PIL 15-12).
10. Remove the rocker assembly including the push 25. Remove the bedplate, refer to (PIL 15-09).
rods, refer to (PIL 15-42).
Remove
11. It is not necessary to remove the cylinder head
assembly to remove the crankshaft. If however 1. Remove the thrust washers between the
the cylinder head needs to be removed for other crankshaft and crankcase rear main bearing.
15 - 74 9813/7600-3 15 - 74
15 - Engine
12 - Crankshaft
00 - General
Figure 207.
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 208. 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 - 75 9813/7600-3 15 - 75
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 - 76 9813/7600-3 15 - 76
15 - Engine
12 - Crankshaft
00 - General
Figure 211.
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 - 77 9813/7600-3 15 - 77
15 - Engine
12 - Crankshaft
03 - Main Bearing
03 - Main Bearing Introduction

Introduction .................................................... 15-78 In a piston engine, the main bearings are the
Check (Condition) .......................................... 15-79 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 212.
A Main bearing
B Crankshaft
15 - 78 9813/7600-3 15 - 78
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 - 79 9813/7600-3 15 - 79
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
06 - Front Oil Seal
Remove and Install
Special Tools Figure 213.

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 214.
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
214.
15 - 80 9813/7600-3 15 - 80
15 - Engine
12 - Crankshaft
06 - Front Oil Seal
Figure 214.
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 215.
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
215. G
Dimension: -0.5 -0/+0.5mm
C
A Crankshaft oil seal
B Crankcase
C Crankshaft hub
F Centre body
G Outer sleeve
5. Remove the seal installation tool.
15 - 81 9813/7600-3 15 - 81
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 - 82 9813/7600-3 15 - 82
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
09 - Rear Oil Seal
Remove and Install
Special Tools Figure 217. 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 216. 24mm Hub
C B
A Crankshaft rear oil seal
B Flywheel housing
C Flywheel hub
15 - 83 9813/7600-3 15 - 83
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 218.
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 219.
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 - 84 9813/7600-3 15 - 84
15 - Engine
12 - Crankshaft
09 - Rear Oil Seal
Figure 220.
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 221.
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 - 85 9813/7600-3 15 - 85
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 - 86 9813/7600-3 15 - 86
15 - Engine
12 - Crankshaft
12 - Pulley
12 - Pulley Install
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 223.

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 222.
C Angle gauge (obtain locally)
After Replacement
1. Install the drive belt. Refer to (PIL 15-18).
A
Table 92.
Item Torque Value Torque Angle
(Nm) (Degrees)
2 (1st stage) 30N·m
2 (2nd stage) 75N·m
2 (Final stage) 180°
A
B
A Crankshaft pulley
B Fixing bolts (x3)
2. The bolts must not be reused. Discard the bolts.
15 - 87 9813/7600-3 15 - 87
15 - Engine
15 - Camshaft
15 - Camshaft
Contents Page No.
15-15-00 General ........................................................................................................................... 15-89
15 - 88 9813/7600-3 15 - 88
15 - Engine
15 - Camshaft
00 - General
Operation ....................................................... 15-94 Otherwise .................................. Page 15-91
Check (Condition) .......................................... 15-95
15 - 89 9813/7600-3 15 - 89
15 - Engine
15 - Camshaft
00 - General
(For: JCB T4F 4.4 over 55kw Electronic Dieselmax Turbocharged Aftercooled Engine, JCB
Tier 4F Engine 4 Cyl, JCB Tier 4i /T4F <55kW Engine 4 Cyl)
Figure 224.
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 - 90 9813/7600-3 15 - 90
15 - Engine
15 - Camshaft
00 - General
(Otherwise)
When the engine runs the crankshaft drives the
camshaft via gears. The camshaft opens and closes
the inlet and exhaust valves via push rods in time with
the four stroke cycle. Refer to: PIL 15-00-00.
The relationship between the rotation of the camshaft

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 - 91 9813/7600-3 15 - 91
15 - Engine
15 - Camshaft
00 - General
Technical Data
Table 93. Camshaft Data

Camshaft journal diame-
ter
- 4 off 59.99–59.97mm
- 1 off 60.25–60.22mm
Camshaft lobe wear lim-
its
Inlet lift 7.161–7.271mm
Exhaust lift 7.2–7.31mm
Camshaft bore diameter
- 4 off 60.07–60.04mm
- 1 off 60.32–60.29mm
Camshaft gear
(1)
104 teeth
(1) The camshaft gear is not available as a separate
item. The gear must be heated on to the camshaft
in the correct timed position. Specialist fixtures are
used during the production process to achieve the
correct timing.
15 - 92 9813/7600-3 15 - 92
15 - Engine
15 - Camshaft
00 - General
Figure 225.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700

3 Camshaft 3a Camshaft lobes
4 Tappets 5 Push rods
15 Inlet valves 16 Exhaust valves
15 - 93 9813/7600-3 15 - 93
15 - Engine
15 - Camshaft
00 - General
Operation
during the cycle it follows that the camshaft is driven

As the crankshaft rotates the camshaft also rotates, at half crankshaft (engine) speed.
driven by a gear on the crankshaft. The inlet and
exhaust valves are opened by lobes on the camshaft Lubrication
in time with the cycle.
Oil is fed from the main gallery via a drilling to the
The diagrams show the position of the camshaft at camshaft bearing. A groove around the diameter of
each part of the four stroke cycle, refer to Engine- the bearing and connecting the cross drilling ensures
General, Operation. Refer to: PIL 15-00-00. that oil is always fed to the centre drilling. Oil is then
transferred to the remaining camshaft bearings by
It can be seen that for a complete cycle the camshaft
further cross drillings in the shaft. The cam lobes and
revolves once. Since the crankshaft revolves twice
tappets are 'splash' lubricated.
Figure 226.
1 Main gallery 2 Camshaft bearing

3 Groove 4 Centre drilling
15 - 94 9813/7600-3 15 - 94
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 227.
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 - 95 9813/7600-3 15 - 95
15 - Engine
15 - Camshaft
00 - General
Figure 228. 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 230.
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 229. 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 - 96 9813/7600-3 15 - 96
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 - 97 9813/7600-3 15 - 97
15 - Engine
18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-99

15-18-03 Drive Belt ..................................................................................................................... 15-102
15-18-21 Tensioner ...................................................................................................................... 15-106
15 - 98 9813/7600-3 15 - 98
15 - Engine
18 - Engine Belt
00 - General
Introduction .................................................... 15-99 A crankshaft pulley is used to drive a FEAD
Health and Safety ........................................ 15-100 (Front End Accessory Drive) belt. The belt drives
Component Identification ............................. 15-100 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 - 99 9813/7600-3 15 - 99
15 - Engine
18 - Engine Belt
00 - General
Health and Safety Component Identification

Turning the Engine Figure 231. A - With air condition-
Do not try to turn the engine by pulling the fan or fan ing compressor, no cooling fan
belt. This could cause injury or premature component
failure. A
4
Switch off the engine before working in the engine 5
engine cover open.
3
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts. 7
Figure 232. B - Without air condi-

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

2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
7 Air conditioning compressor drive pulley
15 - 100 9813/7600-3 15 - 100

15 - Engine
18 - Engine Belt
00 - General
Figure 233. C - With air conditioning com-

pressor, cooling fan pulley installed
C
6
4
5
3
7
Figure 234. D - Without air conditioning

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

2 Coolant pump drive pulley
3 Alternator drive pulley
4 Idler pulley
5 Tensioner pulley
6 Cooling fan drive pulley
7 Air conditioning compressor drive pulley
15 - 101 9813/7600-3 15 - 101

15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Introduction

Introduction .................................................. 15-102 The crankshaft pulley is used to drive the coolant
Health and Safety ........................................ 15-103 pump via a FEAD (Front End Accessory Drive) belt.
Check (Condition) ........................................ 15-103 In addition to the coolant pump the drive belt can
Adjust .......................................................... 15-104 also be configured to drive the engine mounted
accessories.
Remove and Install ..................................... 15-104
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 - 102 9813/7600-3 15 - 102

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 235.
B
A
C
A Crack in belt
B Missing piece of belt
C Frayed belt
15 - 103 9813/7600-3 15 - 103

15 - Engine
18 - Engine Belt
03 - Drive Belt
Adjust Remove and Install
Adjustment is not possible with this drive belt. A Remove

spring loaded tensioning unit ensures that the FEAD
(Front End Accessory Drive) belt is kept at the correct 1. Make the machine safe. Refer to (PIL 01-03).
tension.
3. Use a socket of the specified size to locate
on to the hexagon spigot nut, carefully rotate
the tensioner against the spring force in the
direction shown. Do not use excessive force or
the tensioner will be damaged.
Dimension: 16mm
4. Keep holding the tensioner against the spring
force and lift the belt off the drive tensioner pulley.
5. Slowly release the spring force by rotating the
tensioner unit in the opposite direction.
15 - 104 9813/7600-3 15 - 104

15 - Engine
18 - Engine Belt
03 - Drive Belt
Figure 236.
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 - 105 9813/7600-3 15 - 105

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 94. Torque Values

4. Remove the drive belt, refer to (PIL 15-18). Item Nm
2 24
Figure 237.
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 - 106 9813/7600-3 15 - 106

15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ......................................................................................................................... 15-109
15 - 107 9813/7600-3 15 - 107

Notes:
15 - 108 9813/7600-3 15 - 108

15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................. 15-109 The oil filter is a spin on type which screws on and
Health and Safety ........................................ 15-110 off the oil filter head.
Component Identification ............................. 15-111
Operation ..................................................... 15-113
Check (Level) .............................................. 15-113
15 - 109 9813/7600-3 15 - 109

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 - 110 9813/7600-3 15 - 110

15 - Engine
21 - Oil Filter
00 - General
Figure 238.
1
13
A
16
5 6
14
4
19
15
18 8
10
10
3 9 9
11
13
B
16 11 1
14
19
15
18
12 17
3 3 8
1 Oil cooler and filter housing 2 Oil filler cap (not shown)
3 Oil filter head 4 Oil gallery - from pump to cooler
5 Oil cooler matrix 6 Sealing gasket - housing to crankcase
7 Coolant gallery 8 Oil filter drain down plug
9 Oil gallery - from cooler to filter head 10 Oil gallery - from filter head to main oil gallery
15 - 111 9813/7600-3 15 - 111

15 - Engine
21 - Oil Filter
00 - General
11 Oil filler port 12 Oil pressure switch

13 Oil filter 14 Filter element
15 Anti-drain seal 16 Spring
17 Oil Temperature Sensor 18 O-ring
19 Anti-drain pipe A Oil filter state - engine running
B Oil filter state - engine stopped
15 - 112 9813/7600-3 15 - 112

15 - Engine
21 - Oil Filter
00 - General
Operation Check (Level)

For: JCB T4F 4.4 over 55kw Electronic
Dieselmax Turbocharged Aftercooled Engine oil and oil filter replacement must be
Engine, JCB Tier 4F Engine 4 Cyl, JCB Tier completed in accordance with the service schedules.
4i /T4F <55kW Engine 4 Cyl .... Page 15-113 Failure to replace the oil and filter at the
Otherwise ................................ Page 15-113 recommended interval could cause serious engine
failure.
(For: JCB T4F 4.4 over 55kw Electronic 1. Make the machine safe, refer to (PIL 01-03).
Engine, JCB Tier 4F Engine 4 Cyl, JCB 2. Get access to the engine.
Tier 4i /T4F <55kW Engine 4 Cyl) 3. Check that the oil level is between the two marks
on the dipstick.
At Engine Running
4. If necessary, add recommended oil through one
The oil pump delivers oil at pressure to the oil filter of the filler points.
via a port. The anti-drain seal is forced off its seat and
Figure 239.
oil flows through a large area paper element. Filtered
oil enters the inner part filter before leaving the filter B
head via a port.
At Engine Stopped
With the engine stopped oil pressure in the galleries
and filter decays. The anti-drain seal falls on
its seat and oil is prevented from draining from
the filter assembly. The anti-drain pipe prevents
approximately half the filters oil capacity from A
draining. These features help protect the engine from
oil starvation on start up.
(Otherwise)
At Engine Running B
The oil pump delivers oil at pressure to the oil filter

via a port. The anti-drain seal is forced off its seat and
oil flows through a large area paper element. Filtered
oil enters the inner part filter before leaving the filter
head via a port.
A Dipstick
At Engine Stopped B Oil filler point
With the engine stopped oil pressure in the galleries

and filter decays. The anti-drain seal falls on
its seat and oil is prevented from draining from
the filter assembly. The anti-drain pipe prevents
approximately half the filters oil capacity from
draining. These features help protect the engine from
oil starvation on start up.
15 - 113 9813/7600-3 15 - 113

15 - Engine
21 - Oil Filter
00 - General
Remove and Install
Special Tools 9. If the engine has a dead crank feature, carry out
Description Part No. Qty. the following procedure.
Oil Filter Removal Tool 892/00292 1 9.1. Turn the ignition key to the on position.
Data Link Adaptor 892/01174 1
(DLA) Kit 9.2. Turn the ignition key to the off position.
9.3. Repeat steps 9.1 and 9.2 5 times.
Drain the oil when the engine is warm as
contaminants held in suspension will then be drained 9.4. Wait for the ECU (Electronic Control Unit) to
with the oil. shutdown.
Duration: 30s
CAUTION! Oil will gush from the hole when the drain
plug is removed. Keep to one side when you remove 9.5. Turn the ignition key to the start position.
the plug. The engine will crank for an extended time
period before starting.
1. Place a container of suitable size beneath the
Duration: 10s
drain plug.
10. If the engine does not have a dead crank feature,
2. Remove the oil sump drain plug and 'O' ring. Let
carry out the following procedure.
the oil drain out, then clean and install the drain
plug with a new 'O' ring. Tighten the plug to the 10.1. Connect a laptop to the engine with a data
correct torque value. link adaptor and open Servicemaster.
3. Loosen and remove the filter housing drain plug. Special Tool: Data Link Adaptor (DLA) Kit
Let the oil fully drain. Install the plug. Tighten the (Qty.: 1)
plug to the correct torque value. 10.2. Perform the IMV (Inlet Metering Valve)
4. Unscrew the filter canister, use special tool if Override test.
necessary. 10.3. The IMV Override test will allow the engine
Special Tool: Oil Filter Removal Tool (Qty.: 1) to be cranked for a set time period without
starting allowing sufficient time to prime
5. Clean the seal face of the filter head. the oil pressure.
6. Smear the seal on the new filter canister with Duration: 10s
clean engine oil. 11. Operate the engine at idle, make sure that the
7. Screw in the new filter canister (hand tight only). oil pressure low warning light is extinguished
immediately after the engine starts. If it does not
8. Through one of the filler points, fill the engine with extinguish, stop the engine and investigate the
the recommended oil to the MAX mark on the cause.
dipstick. Wipe off any spilt oil, install the filler cap
and make sure it is secure. 12. Check for oil leakage. When the oil has cooled,
check the oil level again, and if necessary top up
with clean engine oil.
15 - 114 9813/7600-3 15 - 114

15 - Engine
21 - Oil Filter
00 - General
Figure 240.
B
A Dipstick B Oil filler points

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

Item Description Nm
C Oil sump drain plug 40
E Filter housing drain plug 40
15 - 115 9813/7600-3 15 - 115

15 - Engine
24 - Air Filter
24 - Air Filter
Contents Page No.
15-24-00 General ......................................................................................................................... 15-117

15-24-09 Dust Valve .................................................................................................................... 15-120
15 - 116 9813/7600-3 15 - 116

15 - Engine
24 - Air Filter
00 - General
Introduction .................................................. 15-117 Engine performance and durability will be severely
Health and Safety ........................................ 15-118 affected if the quality of the air intake is poor.
Check (Condition) ........................................ 15-118
Remove and Install ..................................... 15-119 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 - 117 9813/7600-3 15 - 117

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 - 118 9813/7600-3 15 - 118

15 - Engine
24 - Air Filter
00 - General
Remove and Install Figure 241.
B
Do not attempt to wash or clean the elements, they
must only be renewed.
A new inner element must be installed at least

every other time the outer element is changed. As
a reminder, mark the inner element with marker pen
each time the outer element is changed.
F
Remove E
D
3. Depress the clips and lift off the cover.
4. Remove the outer element. Take care not to tap
or knock the element.
5. If the inner element is to be changed, lift up pulls
and remove the inner element.
G
C
B Clips
C Cover
D Outer element
E Inner element
F Housing
G Air holes
Install
steps.
2. Clean inside the housing, and cover, make sure
that the air holes are clear.
3. Install the cover and fasten the latch. Make sure
that dust valve is at the bottom.
15 - 119 9813/7600-3 15 - 119

15 - Engine
24 - Air Filter
09 - Dust Valve
09 - Dust Valve
Check (Condition)
• Check the dust valve for rips/tears.
• Check there are no obstructions.
• Check that the dust valve is free of dirt and dust.
• Check that the dust valve securely attached to
the air filter housing.
15 - 120 9813/7600-3 15 - 120

15 - Engine
27 - Crankcase Ventilation Filter
Contents Page No.
15-27-00 General ......................................................................................................................... 15-123
15 - 121 9813/7600-3 15 - 121

Notes:
15 - 122 9813/7600-3 15 - 122

15 - Engine
00 - General
Introduction .................................................. 15-123 Depending on the specification, the engine may be
Component Identification ............................. 15-124 installed with open loop, filtered open loop or a closed
Operation ..................................................... 15-125 loop CCV (Crankcase Ventilation) system.
15 - 123 9813/7600-3 15 - 123

15 - Engine
00 - General
Figure 242. Filtered open loop crankcase ventilation (CCV) system

C
H
D
G
A
A Crankcase vapour B Pressure relief valve

C Transfer hose D Filter element - second stage
E Filter element - first stage F Filtered vapour vent to atmosphere
G Oil droplets - return to sump H Crankcase ventilation filter assembly
15 - 124 9813/7600-3 15 - 124

15 - Engine
00 - General
Operation Remove and Install
Filtered open loop crankcase ventilation The filter element must be changed at the
recommended maintenance interval. Refer to (PIL
(CCV) system 78-24).
Crankcase emissions are created during the 1. Make the machine safe. Refer to (PIL 01-03).
combustion process. These emissions include
unburned fuel and 'blow by gases' which contain 2. Get access to the engine. Refer to (PIL 06-06).
hydrocarbon and engine oil contaminates. A large
proportion of these emissions are prevented from 3. Rotate the filter cover anti-clockwise and
entering the atmosphere by the CCV (Crankcase remove.
Ventilation) filter assembly.
4. Lift out the filter element and discard it.
A series of ports in the crankcase, cylinder head
and rocker cover allow pressure to vent from 5. Clean the inside of the filter housing. Remove all
the crankcase. The vapour from the crankcase oil and sludge contamination.
flows from the rocker cover to the filter assembly. 6. Make sure that the oil drain in the bottom of the
Combined two stage filter elements remove around filter housing is not blocked with sludge.
90% of contaminates as the vapour passes from the
inside to the outside of the filter elements. Trapped oil 7. Install a new filter element. Make sure that the
is allowed to drain back to the sump via a non return correct type of filter element is installed.
valve. The filtered vapour vents to the atmosphere.
8. Align the arrows on both parts to install the filter
If the pressure inside the filter assembly rises due cover.
to a blocked filter non return valve in the oil drain
line prevents vapour being forced back into the Figure 243.
crankcase.
A
The ventilation circuit incorporates a pressure relief
valve. If the filter element becomes blocked the valve
opens bypassing the filter and preventing a build up
of pressure in the crankcase. Although this prevents
serious engine damage it must be remembered
that the filtration system does not function when B
bypassed. The filter element must be replaced at the
intervals specified to ensure a bypass condition is
avoided.
A Filter cover
B Filter element
C Filter housing
15 - 125 9813/7600-3 15 - 125

15 - Engine
30 - Valve
30 - Valve
Contents Page No.
15-30-00 General ......................................................................................................................... 15-127

15-30-12 Valve Spring ................................................................................................................. 15-136
15-30-24 Stem Seal .................................................................................................................... 15-137
15 - 126 9813/7600-3 15 - 126

15 - Engine
30 - Valve
00 - General
Introduction .................................................. 15-127 The valve train system opens and closes the
Technical Data ............................................. 15-128 valves with correct timing in relation to the piston
Component Identification ............................. 15-129 movements.
Operation ..................................................... 15-131
Each push rod has one end in a valve tappet and the
Adjust .......................................................... 15-131 other end under a rocker arm, or as applicable. The
Remove and Install ..................................... 15-134 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 - 127 9813/7600-3 15 - 127

15 - Engine
30 - Valve
00 - General
Technical Data
Table 96. Inlet and Exhaust Valve Data

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

valve rockers.
15 - 128 9813/7600-3 15 - 128

15 - Engine
30 - Valve
00 - General
Figure 244.
6c
6b
6a
7
9
10
15
3
5
16
1
4
2
3a
745700

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 - 129 9813/7600-3 15 - 129

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

17 Valve stem
Cross Sectional View
Figure 245.
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 - 130 9813/7600-3 15 - 130

15 - Engine
30 - Valve
00 - General
Operation Adjust
Special Tools
The camshaft drive gear is driven by the crankshaft Description Part No. Qty.
gear at half the speed of the crankshaft. Camshaft Crankshaft Turning Tool 892/01147 1
lobes, two for each cylinder, (operating exhaust and (95.25mm PCD)- JCB
inlet valves) actuate the valve tappets. 4 Cylinder Ecomax and
Dieselmax
When the camshaft rotates the cam lobes act on the
tappets. The push rods act on the rockers which pivot Valve Clearance 892/01380 1
on the camshaft, depressing two valves at the same Service Kit
time via the bridge piece.
Engine Position
The screw is self locking in the rocker by means of
a tapered thread. Wave washers act like springs to The engine needs to be set to two different positions
keep the rockers in their correct positions along the to measure and adjust all of the valves. The graphics
camshaft and prevent them contacting one another. show which valves are applicable at which engine
The rockers incorporate a swivel tip to ensure position.
alignment with the bridge piece. This prevents
excessive wear. 1. Make sure that the engine is safe to work on. If
Each valve has a compression spring. The function you start the service work.
of the spring is to close the valve and at the same
time return the rocker arm and push rod to ensure 2. Get access to the engine.
that the tappets follow the camshaft lobes. The spring
is located on the valve stem by a retainer and split 3. Remove the tappet covers. Refer to (PIL 15-42).
collets.
4. Put the indicator pins into the holes inside the
tappet adjusters for cylinder number 4. Make
sure that the pins do not fall into the engine.
5. Use the crankshaft turning tool to turn the engine
crankshaft clockwise. Stop turning the crankshaft
when one indicator pin starts to move up after the
other pin has moved down. This is the position
where the exhaust valve is almost closed and the
inlet valve is just starting to open.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax
(Qty.: 1)
Special Tool: Valve Clearance Service Kit (Qty.:
1)
6. Put a mark on the crankshaft pulley at the 12
o'clock position.
15 - 131 9813/7600-3 15 - 131

15 - Engine
30 - Valve
00 - General
Figure 246. Figure 248. 360 Degree Position

A
360
T7
2B 4B
1A 2A
1A Exhaust valve-Cylinder 1
2A Exhaust valve-Cylinder 2
2B Inlet valve-Cylinder 2
T8 T8 Valve Clearances
The procedure describes how to measure and,
if necessary, adjust one valve clearance. The
procedure for all the valves is the same. Do the
A 12 o'clock position procedure for the correct valves at each of the two
T7 Crankshaft turning tool engine positions. Remember you must remove the
T8 Indicator pins (obtain locally) valve clearance service tools before you turn the
engine crankshaft.
7. Turn the engine crankshaft 90 degrees
clockwise. Important: The engine must be cold before you
8. Measure and, if necessary, adjust the clearances measure or adjust the valve clearances.
for the correct valves.
1. Install the adaptor plate in the correct position on
Figure 247. 90 Degree Position the rocker cover using the screws A.
2. Make sure that the crankshaft is in the correct
position.
3. Put the adaptor sleeve on the correct valve
tappet adjuster screw.
90 4. Push the lock bar into the correct valve tappet
adjuster screw.
1B 3B 5. Tighten the lock bar by turning it with your hand.
3A 4A
6. Assemble the DTI support and DTI.
3A Exhaust valve-Cylinder 3 7. Push and then pull the lock bar in the direction of
3B Inlet valve-Cylinder 3 the arrows X and Y. Do this until you are sure that
4A Exhaust valve-Cylinder 4 the lock bar is correctly installed and oil is moved
away from the cam follower and push rod.
9. Remove the valve clearance service tools. Turn
the engine crankshaft 360 degrees clockwise. 8. Important: Apply a side force on the lock bar
Use the mark on the crankshaft pulley as a at the same time as pushing and pulling. This
reference. prevents the rocker moving along the rocker
shaft and giving a false reading on the DTI. Apply
10. Measure and, if necessary, adjust the clearances a force to the left on the exhaust valve tappets
for the correct valves. and to the right on the inlet valve tappets.
15 - 132 9813/7600-3 15 - 132

15 - Engine
30 - Valve
00 - General
T1
C
T5
X A
T4 Y B
A
T3
T2
T6
A Screws B Tappet adjusters
T1 Dial Test Indicator (DTI)(obtain locally) C Rockers
T2 Adaptor plate (part of valve clearance service T6 Spanner open ended (obtain locally)
kit)
T3 Adaptor sleeve (part of valve clearance service
kit)
T4 Lock bar (part of valve clearance service kit)
T5 DTI Support (obtain locally)
9. Pull the lock bar in the direction of arrow Y and
turn the DTI to zero.
10. Push the lock bar in the direction of arrow X and
record the DTI indication.
11. Compare the valve clearance measurement with
the correct clearances. If an adjustment is
necessary:
11.1. Turn the tappet adjuster using an open
ended spanner on the adaptor sleeve.
Turn the sleeve clockwise to reduce
the clearance and counterclockwise to
increase the clearance.
11.2. Important: The tappet adjusters are set in
position by thread friction with the rockers.
Make sure that the torque to turn the
tappet adjusters is more than the minimum
necessary. If any of the adjusters show a
lower torque value then the adjuster and
its related rocker must be replaced.
15 - 133 9813/7600-3 15 - 133

15 - Engine
30 - Valve
00 - General
Remove and Install Figure 251. Valve Stand
Special Tools
Valve Stem Seal 892/01152 1
Installation Tool
(444/448/672 Engine)
EXHAUST
EXHAUST
EXHAUST
INLET
INLET
INLET
Before Removal
1. This procedure requires service parts. Make CYL. 1 CYL. 2 CYL. 3

2. Make sure that the engine is safe to work on. If Remove
you start the service work. 1. Use a spring compressor tool to compress each
valve spring and remove the collets. Make sure
3. Get access to the engine. that the springs are compressed squarely.
4. Remove the thermostat, refer to (PIL 21-12). Figure 252.
5. Remove all of the fuel injector pipes, refer to (PIL
18-96). B
6. Remove the rocker cover, refer to (PIL 15-42).

7. Remove the fuel injectors, refer to (PIL 18-18).
8. Remove the rocker assembly, refer to (PIL
15-42).
9. Remove the exhaust manifold, refer to (PIL A
18-24).
10. Remove the inlet manifold, refer to (PIL 18-24).
11. Remove the cylinder head assembly from the
cylinder block, refer to (PIL 15-06). A Spring compressor tool
12. Measure the valve recession with a suitable DTI B Collets
(Dial Test Indicator). Clean the carbon deposits 2. Remove the spring compressor tool and lift off
from a small area of the valve heads for location the retainer and valve spring.
of the DTI probe. If the valve recession is outside
the serviceable limits, it is advisable to obtain Figure 253.
a new or reconditioned cylinder head assembly,
refer to Technical Data (PIL 15-06). C
13. To aid removal and replacement, use a wooden

valve stand to retain the valves after removal. D
Add labels to make sure that the valves are
correctly replaced.
C Retainer
D Valve spring
3. Turn the cylinder head on its side and withdraw
the inlet valves and exhaust valves as shown.
15 - 134 9813/7600-3 15 - 134

15 - Engine
30 - Valve
00 - General
Figure 254. If there is evidence of wear or damage to the valves,

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

F Inlet valves
G Exhaust valves 1. The installation procedure is the opposite of the
4. When removing, note the respective position of steps.
each valve. Use a suitable valve stand to keep
the valves together and identify them with their 2. Install the new valve stem seals as shown. Use
respective cylinder. Note: The exhaust valves the installation tool to avoid damaging the seals.
have smaller diameter heads. Pre-assemble the seal into the tool. Locate the
tool over the valve guide and gently press the
5. Remove the valve stem seals. Discard the seals. seal into place. Lubricate the seal with P80 fluid.
Figure 255. Special Tool: Valve Stem Seal Installation Tool
(444/448/672 Engine) (Qty.: 1)
3. With the cylinder head on its side, insert the
J H inlet valves and exhaust valves as shown. Make
sure that the valves are installed in the correct
positions. Lubricate the valve stems with clean
engine oil before assembly. Carefully push the
end of the valve stem through the stem seals.
4. Install the valve springs on to the valve
stems, together with a retainer. Use the spring
compressor tool to compress each valve spring
and insert the collets. Make sure that the collets
are correctly seated in the valve stem grooves,
before you remove the spring compressor tool.
H Valve stem seals After Installation

J Punch tool
1. Tap the valve stems in turn using a rubber mallet
top fully seat the valves.
Inspection
1. Carefully clean the carbon deposits from the
valves, take care not to damage the valve seats.
2. Check that the valves and valve seats are not
cracked, burnt or damaged.
3. Check the valve stems and valve guides for wear,
refer to Technical Data (PIL 15-30).
15 - 135 9813/7600-3 15 - 135

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

15 - 136 9813/7600-3 15 - 136

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

15 - 137 9813/7600-3 15 - 137

15 - Engine
33 - Connecting Rod
33 - Connecting Rod
Contents Page No.
15-33-00 General ......................................................................................................................... 15-139

15-33-06 Big-End Bearing ........................................................................................................... 15-143
15 - 138 9813/7600-3 15 - 138

15 - Engine
33 - Connecting Rod
00 - General
Introduction .................................................. 15-139 The connecting rod connects the piston to the
Technical Data ............................................. 15-140 crankshaft. They form a simple mechanism that
Component Identification ............................. 15-140 converts reciprocating motion into rotating motion.
Check (Condition) ........................................ 15-141
Connecting rods are usually made of high strength
Remove and Install ..................................... 15-141 steel. They are not rigidly fixed at either end, so that
Disassemble and Assemble ........................ 15-142 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 - 139 9813/7600-3 15 - 139

15 - Engine
33 - Connecting Rod
00 - General
Technical Data Component Identification
Table 97. Connecting Rods Data Refer to Piston- Component Identification.Refer to:
PIL 15-36-00.
Connecting rod type
(1)
Split fracture
Connecting rod bore di- 77–77.01mm
ameter
Connecting rod side
clearance
min 0.05mm
max 0.4mm
Big end bearings
Width 32.5–33mm
Thickness (at centre) 1.99–1.981mm
Small end bearings
Inside diameter 40.034–40.02mm
(1) Split fracture type connecting rods MUST NOT be
dot punched or etched in anyway during disassembly
- refer to relevant service procedures.
15 - 140 9813/7600-3 15 - 140

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 - 141 9813/7600-3 15 - 141

15 - Engine
33 - Connecting Rod
00 - General

15 - 142 9813/7600-3 15 - 142

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

Introduction .................................................. 15-143 In a piston engine, the big-end bearings are the
Check (Condition) ........................................ 15-144 bearings at the big-end of the connecting rod.
15 - 143 9813/7600-3 15 - 143

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 - 144 9813/7600-3 15 - 144

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 - 145 9813/7600-3 15 - 145

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 258.
0° +90°
Figure 259.
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 - 146 9813/7600-3 15 - 146

15 - Engine
36 - Piston
36 - Piston
Contents Page No.
15-36-00 General ......................................................................................................................... 15-149

15-36-03 Piston Ring ................................................................................................................... 15-161
15 - 147 9813/7600-3 15 - 147

Notes:
15 - 148 9813/7600-3 15 - 148

15 - Engine
36 - Piston
00 - General
Introduction .................................................. 15-149 The piston is acted upon by the pressure of the
Technical Data ............................................. 15-150 expanding combustion gases in the combustion
Component Identification ............................. 15-151 chamber space at the top of the cylinder. This force
Operation ..................................................... 15-152 then acts downwards through the connecting rod and
on to the crankshaft.
Check (Condition) ........................................ 15-153
Calibrate ...................................................... 15-153 The pistons are cast from aluminium alloys for
Remove and Install ..................................... 15-155 increased strength and improved fatigue life.
Disassemble and Assemble ........................ 15-158
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 - 149 9813/7600-3 15 - 149

15 - Engine
36 - Piston
00 - General
Technical Data
Table 99.
Engine 444 448
Gudgeon pin bore diameter
- min. 40.01mm 42.008mm
- max. 40.015mm 42.013mm
Piston ring clearance
- Top ring Full keystone ring Full keystone ring
- Middle ring 0.125–0.08mm 0.125–0.08mm
- Bottom (oil) ring 0.09–0.05mm 0.09–0.05mm
Piston ring gap
- Top ring 0.3–0.4mm 0.3–0.4mm
- Middle ring 0.55–0.8mm 0.55–0.8mm
Piston height above crankcase 0.00025–0.36825mm
(1)
0.00025–0.36825mm
(1)
(cold)
Piston groove width
- Top ring 3.114–3.134mm 3.114–3.134mm
- Middle ring 2.575–2.595mm 2.575–2.595mm
Piston skirt 102.853–102.871mm 105.851–105.869mm
Piston pin 39.994–40mm 41.994–42mm
(1) Nominal measurement is 0.03325mm
15 - 150 9813/7600-3 15 - 150

15 - Engine
36 - Piston
00 - General
Figure 260.
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 - 151 9813/7600-3 15 - 151

15 - Engine
36 - Piston
00 - General
Operation
top of the pistons. Oil spray also enters the small end
The groove around the diameter of the upper main bearing bushes via a feed hole on the top of each
bearing shells allows oil transfer to an oil jet located connecting rod.
in the crankcase bearing saddle. Jets are installed at
the main bearing positions. Note: On turbocharged engines additional J-jets are
installed. Oilways connect the J-shaped jets fixed to
The jets spray oil directly to the under side of the the crankcase at the underside of each cylinder bore.
pistons effectively transferring heat away from the
Figure 261.
1 1
6
2
5
1 Groove 2 Oil jet

3 Pistons 4 Bearing bushes
5 Crankshaft 6 J shaped jets
15 - 152 9813/7600-3 15 - 152

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 - 153 9813/7600-3 15 - 153

15 - Engine
36 - Piston
00 - General
Figure 262. 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 263. 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 - 154 9813/7600-3 15 - 154

15 - Engine
36 - Piston
00 - General
Remove and Install

Before Removal 4. Disconnect and remove the fuel pipes from the
The following procedure is for one piston and injectors. Refer to (PIL 18-96).
connecting rod assembly. Note that each assembly 5. Remove the rocker cover. Refer to (PIL 15-42).
must be replaced in the same cylinder bore. Label
each piston and connecting rod assembly to make 6. Remove the fuel injectors. Refer to (PIL 18-18).
sure it is installed in the correct position on assembly.
7. Remove the cylinder head assembly. Refer to
1. This procedure requires service parts. Make sure (PIL 15-06).
that you have obtained the correct service parts
before you start. Refer to Parts Catalogue. 8. Remove the oil sump. Refer to (PIL 15-45).
2. Make sure that the engine is safe to work on. If 9. Remove the big end bearing caps. Refer to (PIL
the engine has been running, let it cool before 15-33-06).
15 - 155 9813/7600-3 15 - 155

15 - Engine
36 - Piston
00 - General
Figure 264.
X
1
1 Piston 2 Piston ring

3 Connecting rod X Longest side of connecting rod
15 - 156 9813/7600-3 15 - 156

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 - 157 9813/7600-3 15 - 157

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

Dismantle To avoid damage or distortion to the rings, use a
suitable piston ring expander tool. Note that the
1. Clamp the connecting rod in a vice. Take care not oil control ring is installed with a spiral wire. Pull
to damage the connecting rod. the wire apart and remove it.
2. It is recommended that the piston rings are 3. Remove the circlips and push out the piston pin.
renewed. If they are to be reused, label the
rings to ensure they are installed in the correct 4. Use a suitable cleaning agent, clean the carbon
positions and the correct way up on assembly. deposits from the piston.
15 - 158 9813/7600-3 15 - 158

15 - Engine
36 - Piston
00 - General
Figure 265.
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 - 159 9813/7600-3 15 - 159

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 - 160 9813/7600-3 15 - 160

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 - 161 9813/7600-3 15 - 161

15 - Engine
39 - Manifold
39 - Manifold
Contents Page No.
15-39-00 General ......................................................................................................................... 15-163
15 - 162 9813/7600-3 15 - 162

15 - Engine
39 - Manifold
00 - General
00 - General
Introduction
15 - 163 9813/7600-3 15 - 163

15 - Engine
42 - Rocker and Fittings
Contents Page No.
15-42-00 General ......................................................................................................................... 15-165

15-42-06 Rocker Cover ............................................................................................................... 15-174
15-42-09 Push Rod ..................................................................................................................... 15-176
15-42-21 Tappet ........................................................................................................................... 15-178
15-42-24 Tappet Cover ................................................................................................................ 15-180
15 - 164 9813/7600-3 15 - 164

15 - Engine
00 - General
Introduction .................................................. 15-165 The rocker assembly is an indirect valve actuating
Technical Data ............................................. 15-166 system consisting of rocker arms and a shaft.
Operation ..................................................... 15-168 The rocker arm is an oscillating lever that conveys
radial movement from the cam lobe into linear
Check (Condition) ........................................ 15-169 movement at the poppet valve to open it. One end is
Remove and Install ..................................... 15-170 raised and lowered by a rotating lobe of the camshaft
Disassemble and Assemble ........................ 15-172 via a tappet and push rod while the other end acts
on the bridge piece which is connected to the valve
stem.
15 - 165 9813/7600-3 15 - 165

15 - Engine
00 - General
Technical Data
Table 100. Rocker Levers, Rocker Shafts and Tappets Data

Valve clearances measured at the valve bridge piece
tip of the rockers (measured cold):
- Inlet 0.19–0.27mm
Rocker clearances measured at the adjusting screw
tip of the rockers (measured cold):
- Inlet 0.15–0.2mm
Rocker lever bore diameter
- min 26.058mm
- max 26.092mm
Rocker shaft diameter
- min 26.003mm
- max 26.021mm
Tappets stem diameter
- min 19.975mm
- max 19.985mm
Tappet bore diameter
- min 20mm
- max 20.021mm
Tappet height (maximum) 55.25mm
15 - 166 9813/7600-3 15 - 166

15 - Engine
00 - General
Figure 266.
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 - 167 9813/7600-3 15 - 167

15 - Engine
00 - General
Operation
rocker arm is permitted to return due to the camshafts

When the camshaft lobe raises the outside of the rotation, the inside rises to allow the valve spring to
rocker arm, the inside presses down on the valve close the valve.
stem to open the valve. When the outside of the
Figure 267.
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 - 168 9813/7600-3 15 - 168

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 - 169 9813/7600-3 15 - 169

15 - Engine
00 - General
Remove and Install

Before Removal 3. Disconnect and remove the fuel pipes from the
1. Make sure that the engine is safe to work on. If fuel injectors, refer to Fuel pipes (PIL 18-96).
Figure 268.
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 - 170 9813/7600-3 15 - 170

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

Item Nm
2 24
3 24
15 - 171 9813/7600-3 15 - 171

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

Before Disassembly 15-42).
1. Remove the rocker cover. Refer to (PIL 15-42).
Figure 269.
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 - 172 9813/7600-3 15 - 172

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
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 - 173 9813/7600-3 15 - 173

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

Before Removal 15-00).

Figure 270.
D
A Rocker cover B Bolts

C Gasket D Injector seals
15 - 174 9813/7600-3 15 - 174

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

Item Nm
B 24
15 - 175 9813/7600-3 15 - 175

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

Introduction .................................................. 15-176 Push rods are used in a reciprocating engine to open
Remove and Install ..................................... 15-177 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 - 176 9813/7600-3 15 - 176

15 - Engine
09 - Push Rod
Remove and Install

15 - 177 9813/7600-3 15 - 177

15 - Engine
21 - Tappet
21 - Tappet Figure 272.
Remove and Install

B
Before Removal
injectors. Refer to (PIL 18-96). C
B Timing pin - crankshaft
3. Remove the rocker cover. Refer to (PIL 15-42). C Blanking plug
4. Remove the fuel injection pump. Refer to (PIL 12. Remove the fuel injection pump drive gear. Refer
18-18). to (PIL 15-51).
5. Remove the rocker assembly and push rods.
Refer to (PIL 15-42). Removal
6. Remove the starter motor. Refer to (PIL 15-75). The engine must be inverted. DO NOT attempt
to remove the camshaft and its drive gears with
7. Remove the oil sump. Refer to (PIL 15-45). the engine upright. The tappets and push rods will
8. Remove the flywheel. Refer to (PIL 15-54). fall into the engine and further dismantling will be
required to retrieve them.
9. Remove the flywheel housing. Refer to (PIL
15-54). 1. Remove the camshaft timing pin.
10. Rotate the crankshaft until the camshaft timing 2. Carefully withdraw the camshaft and gear
pin can be inserted through the gear and into the assembly from the crankcase. Make sure you
aligning hole in the rear gear case. fully support the camshaft to prevent the lobes
contacting the bearing surfaces in the crankcase.
Figure 271. The bearing surfaces can easily be damaged by
the sharp hard edges on the cam lobes.
Figure 273.
A Timing pin - camshaft

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

D Camshaft and drive gear
15 - 178 9813/7600-3 15 - 178

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

the crankcase bedplate next to the crankshaft.
Lift out the tappets from the crankcase using a 1. Lubricate the tappets and tappet bores inside the
suitable magnetic probe. Label the tappets to crankcase with clean engine oil.
ensure replacement in their original positions.
2. Insert the tappets in their original positions in the
Figure 274. crankcase using a suitable magnetic probe.
3. Lubricate the camshaft bearing journals inside
F the crankcase with clean engine oil.
4. Carefully insert the camshaft assembly into the
crankcase as shown. Support the camshaft
E preventing the lobes contacting the bearing
surfaces in the crankcase. Before meshing the
E camshaft gear with the crankshaft gear, rotate
the camshaft until the timing hole in the gear
aligns with the dowel hole in the gear casing.
Insert the timing pin to lock the camshaft in this
position.
After Installation
1. Note that the fuel injection pump drive gear
fixing nut is torque tightened as part of the fuel
injection pump replacement procedure. Refer to
(PIL 18-18).
2. Do the procedures in Before Removal in reverse
order.
E Tappet (8 off)
F Magnetic probe
Inspection
1. Inspect the camshaft gear teeth for signs of
damage or excessive wear.
2. Inspect the cam lobes for signs of excessive
wear, scoring or pitting.
3. Inspect the cam bearing surfaces for signs
of excessive wear, or scoring. Check that the
dimensions are within service limits.
4. Inspect the cam bearing surfaces inside the
crankcase for signs of excessive wear, or
scoring. Check that the dimensions are within
service limits.
5. Inspect the bearing surfaces of the tappets for
the dimensions are within service limits.
6. Inspect the tappet bores inside the crankcase for
the dimensions are within service limits.
7. If any of the camshaft bearings or lobes are worn
or damaged then the relative oil feed galleries
in the crankcase and camshaft may be blocked.
Make sure all oil ways are clear and free from
debris.
15 - 179 9813/7600-3 15 - 179

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 103. 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 275.
B B D B B
B A
E C
A Screws
B Tappet covers
C Slot
D Rocker cover
E Tappet cover seals
15 - 180 9813/7600-3 15 - 180

15 - Engine
45 - Oil Sump
45 - Oil Sump
Contents Page No.
15-45-00 General ......................................................................................................................... 15-183
15 - 181 9813/7600-3 15 - 181

Notes:
15 - 182 9813/7600-3 15 - 182

15 - Engine
45 - Oil Sump
00 - General
Introduction .................................................. 15-183 The lubrication system distributes oil around the
Component Identification ............................. 15-184 engine by a system of galleries and drillings in the
Remove and Install ..................................... 15-185 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 - 183 9813/7600-3 15 - 183

15 - Engine
45 - Oil Sump
00 - General
Figure 276.
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 - 184 9813/7600-3 15 - 184

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

Template for Sealant 892/01149 1 Removal
Oil Sump - Pressed
1. Remove the fixing bolts and remove the oil sump
Oil Sump Location 892/01150 2
from the engine. The oil sump may be difficult to
Dowel
remove due to adhesion of sealing compound.
Template for Sealant 892/12354 1 If necessary, carefully lever the mating flanges
Oil Sump (Cast) apart. Do not use excessive force, the oil sump
could be damaged. Be sure to retrieve the oil pick
Consumables up seal.
Clear Silicone Sealant 4102/0901 0.31L 2. Use a gasket removal compound, carefully
remove all traces of sealing compound from the
oil sump and engine mating faces. Do not allow
Before Removal the sealing compound to enter the engine.
1. Make sure that the engine is safe to work on. 3. Use a suitable degreasing agent to thoroughly
If the engine has been running, make sure the clean the oil sump.
engine has cooled sufficiently before you start.
Figure 277.
1 Oil sump 1a Integral suction tube

1b Integral baffle plates 2 Oil sump fixing bolts (x20)
3 Oil pick up seal
15 - 185 9813/7600-3 15 - 185

15 - Engine
45 - Oil Sump
00 - General
Installation Figure 279.
1. Lightly smear the new oil pick up seal with oil and X
install into the bedplate as shown.
Figure 278.
3 Oil pick up seal

2. Install the two guide pins at the oil sump screw
holes in the engine.
Special Tool: Oil Sump Location Dowel (Qty.: 2)
S Hole
3. Use the fixing bolts to locate the template to T Hole
the oil sump mating face. Make sure that the T2 Guide pins
template is the correct way round (note that holes X 4mm Bead of sealant
are on different centres).
8. Position the oil sump with the suction tube outlet
Special Tool: Template for Sealant Oil Sump aligned with the oil pump inlet port on the engine.
(Cast) (Qty.: 1) Take care not to damage the oil pick up seal when
Special Tool: Template for Sealant Oil Sump - you install the oil sump. Damage to the seal could
Pressed (Qty.: 1) cause a drop in oil pressure and subsequently
damage to the engine.
4. Apply a bead of sealing compound around the
oil sump flange using the inside edge of the 9. Locate the oil sump on the guide pins on the
template as a guide as shown. Note the beads engine. Avoid smudging the sealant beads. DO
around holes. NOT remove the guide pins until sufficient bolts
Length/Dimension/Distance: 4mm have been installed to secure the oil sump.
Consumable: Clear Silicone Sealant 10. Install the bolts and tighten the bolts to the correct
5. Carefully remove the template without smudging torque value. Note that the bolts are not installed
the sealant beads. at 6 positions.
6. Apply a bead of sealant so as to join the sealant Figure 280.

beads around holes with the bead around the oil
sump flange.
7. After applying the sealing compound, the oil
sump must be installed and the bolts torque
tightened within
Duration: 5min
2 Bolts
Y No bolts to be installed at this position (x6)
15 - 186 9813/7600-3 15 - 186

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

Item Nm
2 24
15 - 187 9813/7600-3 15 - 187

15 - Engine
48 - Grid Heater
48 - Grid Heater
Contents Page No.
15-48-00 General ......................................................................................................................... 15-189
15 - 188 9813/7600-3 15 - 188

15 - Engine
48 - Grid Heater
00 - General
Operation ..................................................... 15-189 The system aids engine starting by heating the air
Diagram ....................................................... 15-191 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 281.
B
A
G
C D
E
F
A Coolant expansion tank B Warning light- grid heater on
15 - 189 9813/7600-3 15 - 189

15 - Engine
48 - Grid Heater
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 - 190 9813/7600-3 15 - 190

15 - Engine
48 - Grid Heater
00 - General
Diagram
Figure 282.
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 - 191 9813/7600-3 15 - 191

15 - Engine
51 - Timing Gear
51 - Timing Gear
Contents Page No.
15-51-00 General ......................................................................................................................... 15-193

15-51-03 Crankshaft Gear ........................................................................................................... 15-196
15-51-06 Camshaft Gear ............................................................................................................. 15-199
15-51-09 Fuel Injection Pump Gear ............................................................................................ 15-200
15-51-15 Heavy Duty PTO Gear ................................................................................................. 15-203
15-51-22 Rear Case .................................................................................................................... 15-206
15 - 192 9813/7600-3 15 - 192

15 - Engine
51 - Timing Gear
00 - General
Introduction .................................................. 15-193 The timing gears are located inside a case at the
Component Identification ............................. 15-194 flywheel end of the engine.
Operation ..................................................... 15-195
Check (Condition) ........................................ 15-195 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 - 193 9813/7600-3 15 - 193

15 - Engine
51 - Timing Gear
00 - General
Figure 283.
B E
A Crankshaft gear B Camshaft gear

C High pressure fuel pump gear D Oil pump gear
E Heavy duty PTO device gear (if installed) F Heavy duty PTO device gear (if installed)
G Low duty PTO device gear (if installed)
15 - 194 9813/7600-3 15 - 194

15 - Engine
51 - Timing Gear
00 - General
Operation Check (Condition)
All the gears are driven via the crankshaft gear as 1. Inspect the gears for wear or damage. If one or
follows. more of the gears are worn or damaged, replace
them.
• Camshaft gear-The camshaft is driven at half
crankshaft speed.
• High pressure fuel pump gear-The high
pressure fuel pump is driven via the camshaft
gear installed to the camshaft.
• Oil pump gear-The lubrication oil pump is driven
directly by the crankshaft gear.
• Power Take-Off (PTO)-driven by the crankshaft
gear via idler gear.
• Low Duty Power Take-Off (PTO) Gear (if
installed)-driven by the camshaft gear.
15 - 195 9813/7600-3 15 - 195

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

Crankshaft / 892/01148 2 15-54).
Camshaft Timing Pin
(444/448/672 Engine) 4. Rotate the crankshaft until the camshaft locking
pin can be inserted through the gear and into the
Note: The illustrations show the engine inverted. If aligning hole in the rear gear case. Note: The
the drive gear components are being removed prior camshaft and crankshaft locking pins must be
to crankshaft or camshaft removal the engine must in position to lock the crankshaft and camshaft
be inverted. If the gear components only are being before removing the crankshaft gear.
removed (for inspection/renewal) then the engine
need not be inverted. Special Tool: Crankshaft / Camshaft Timing Pin
(444/448/672 Engine) (Qty.: 2)
Before Removal 5. Remove the taper blanking plug and insert the
crankshaft locking pin.
1. Remove the starter motor. Refer to (PIL 15-75).
15 - 196 9813/7600-3 15 - 196

15 - Engine
51 - Timing Gear
Figure 284.
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 - 197 9813/7600-3 15 - 197

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 - 198 9813/7600-3 15 - 198

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 - 199 9813/7600-3 15 - 199

15 - Engine
51 - Timing Gear
09 - Fuel Injection Pump Gear
Remove and Install
2. Loosely install the high pressure fuel pump and

Note: The illustrations show the engine inverted. If fixing nut, retain the gear.
the drive gear components are being removed prior
to crankshaft or camshaft removal the engine must 3. Remove the starter motor. Refer to (PIL 15-75).
be inverted. If the gear components only are being
removed (for inspection/renewal) then the engine 4. Remove the flywheel. Refer to (PIL 15-54).
need not be inverted. 5. Remove the flywheel housing. Refer to (PIL
15-54).
Before Removal
1. Remove the high pressure fuel injection pump.
15 - 200 9813/7600-3 15 - 200

15 - Engine
51 - Timing Gear
Figure 285.
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 - 201 9813/7600-3 15 - 201

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

15 - 202 9813/7600-3 15 - 202

15 - Engine
51 - Timing Gear
15 - Heavy Duty PTO Gear
Remove and Install
Before Removal
The illustrations show the engine inverted. If the
drive gear components are being removed prior to 1. This procedure requires service parts. Make
crankshaft or camshaft removal the engine must sure you have obtained the correct service parts
be inverted. If the gear components only are being before you start, refer to Parts Catalogue.
removed (for inspection / renewal) then the engine
need not be inverted. 2. Remove the starter motor. Refer to (PIL 15-75).
3. Remove the flywheel. Refer to (PIL 15-54).
15-54-03).
15 - 203 9813/7600-3 15 - 203

15 - Engine
51 - Timing Gear
Figure 286.
1 Z
6
5 W
4 W
X
2
Y
3
1
2
1 High duty PTO idler gear 2 Idler gear hub

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

screws and lift out the hub.
1. Remove the flywheel hub fixing bolt and remove
the flywheel hub. DO NOT remove the crankshaft Inspect
gear.
1. Check the idler gear teeth and idler gear bearing
2. Lift the High duty PTO (Power Take-Off) idler bush for signs of damage or excessive wear.
gear from the hub.
15 - 204 9813/7600-3 15 - 204

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

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

Item Nm
3 65
5 47
15 - 205 9813/7600-3 15 - 205

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 - 206 9813/7600-3 15 - 206

15 - Engine
51 - Timing Gear
22 - Rear Case
Figure 287.
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 - 207 9813/7600-3 15 - 207

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 107. 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 - 208 9813/7600-3 15 - 208

15 - Engine
54 - Flywheel
54 - Flywheel
Contents Page No.
15-54-00 General ......................................................................................................................... 15-211

15-54-03 Housing ........................................................................................................................ 15-215
15-54-09 Gear Ring ..................................................................................................................... 15-218
15-54-12 Drive Plate .................................................................................................................... 15-219
15 - 209 9813/7600-3 15 - 209

Notes:
15 - 210 9813/7600-3 15 - 210

15 - Engine
54 - Flywheel
00 - General
Introduction .................................................. 15-211 Flywheels are used to provide continuous energy in
Component Identification ............................. 15-212 systems, where the energy source is not continuous.
Remove and Install ..................................... 15-213 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 - 211 9813/7600-3 15 - 211

15 - Engine
54 - Flywheel
00 - General
Figure 288.
1 Flywheel
2 Flywheel gear ring
15 - 212 9813/7600-3 15 - 212

15 - Engine
54 - Flywheel
00 - General
Remove and Install

Before Removal the engine has been running, let it cool before
sure you have obtained the correct service parts 3. Get access to the engine.
before you start. The flywheel is installed with a
crankshaft position sensor target disc. DO NOT Removal
remove the target disc. If the disc is defective the
flywheel must be replaced. 1. Remove the bolts and withdraw the flywheel from
the crankshaft hub. The bolts MUST NOT be
reused. Discard the bolts.
Figure 289.
3 1 2
1
T3
1 Flywheel 2 Flywheel fixing bolts (x8)

3 Flywheel location dowel Y Angle tightening mark
15 - 213 9813/7600-3 15 - 213

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 - 214 9813/7600-3 15 - 214

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

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

before you start.
15 - 215 9813/7600-3 15 - 215

15 - Engine
54 - Flywheel
03 - Housing
Figure 290.
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 - 216 9813/7600-3 15 - 216

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

Anaerobic sealant will not start to cure whilst it 1. Install a new crankshaft rear oil seal.
is open to the atmosphere, however when air is
excluded (for instance when the two parts are 2. Install the flywheel.
put together) it will immediately start to harden. 3. Install the starter motor.
Make sure that all the necessary tools, bolts
etc. are readily available prior to assembling the Table 109. Torque Values
components. The parts must be installed and torque
tightened within5min with a maximum permissible Item Nm
time of 15min 4 47
5 24
removal procedure. Additionally do the following 7 24
steps.
3. Make sure that the dowels are installed to the
mating face of the flywheel housing.
4. Install the sealant template T4 on the housing.
Locate the holes in the template, use the dowel
and three fixing bolts in the fixing points.
Special Tool: Template for Sealant Flywheel
Housing to Gear Case (4 Cyl Elec ) (Qty.: 1)
5. Use the template T4 as a guide, apply a
continuous bead of sealant around the flywheel
housing mating face
5.1. Some engines feature a flywheel housing
with a different fixing hole pattern. Use the
template to apply the sealant but apply
sealant manually in the position shown at Z.
6. Remove the three fixing bolts at positions.
Remove the template T4, make sure not to
smudge the sealant. Discard the template.
7. Locate the flywheel housing on the alignment
pins T3 on the crankcase and install the fixing
bolts. Progressively tighten the bolts to the
7.1. Remove the alignment pins to install the last
two M10 fixing bolts.
7.2. The parts must be separated, thoroughly
cleaned and fresh sealant applied if the
parts have not been torque tightened within
the maximum time period.
Duration: 15min
8. Install the access cover and use the bolts to
secure. Tighten the bolts to the correct torque
value. Refer to Table 109.
15 - 217 9813/7600-3 15 - 217

15 - Engine
54 - Flywheel
09 - Gear Ring
09 - Gear Ring of the gear teeth as shown. Drive a chisel into the
adjacent tooth to spread the gear ring apart. Take
care not to damage the flywheel or the position
Remove and Install sensor target disc.
CAUTION Wear eye protection when you drive
the gear ring off the flywheel. Installation
If the flywheel gear teeth are damaged or excessively damage and corrosion.
worn, the gear ring can be replaced with a new one.
2. Heat up the new gear ring, preferably in an oven
Before Removal to make sure that the heat is applied evenly
around the circumference. Do not heat the gear
1. This procedure requires service parts. Make ring above
sure you have obtained the correct service parts Temperature: 200°C (391.7°F)
before you start.
3. When sufficiently heated, install the gear ring into
2. Remove the flywheel from the crankshaft hub. position over the flywheel. Make sure that the
gear ring is installed the correct way around.
Figure 291.
X After Installation
1. Install the flywheel to the crankshaft hub.
2
1
1 Flywheel
2 Gear ring
x Position of hole
Removal
1. Note that the gear teeth have a lead-in chamfer
on one side to assist the starter motor pinion to
engage. Note which way around the gear ring is
installed to make sure that the new gear ring is
installed the same way on assembly.
2. Place the flywheel flat on a firm surface. Drill a
hole through the gear ring below the root of one
15 - 218 9813/7600-3 15 - 218

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

Introduction .................................................. 15-219 This is a gear type coupling comprising a drive plate
Remove and Install ..................................... 15-220 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 292.
B
A Drive plate
B Coupling (PIL 2731)
15 - 219 9813/7600-3 15 - 219

15 - Engine
54 - Flywheel
12 - Drive Plate
Remove and Install Table 110. 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,
refer to (PIL 27-31).
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 293.
A Drive plate
C Bolts
E Boss
15 - 220 9813/7600-3 15 - 220

15 - Engine
60 - Oil Pump
60 - Oil Pump
Contents Page No.
15-60-00 General ......................................................................................................................... 15-223
15 - 221 9813/7600-3 15 - 221

Notes:
15 - 222 9813/7600-3 15 - 222

15 - Engine
60 - Oil Pump
00 - General
Introduction .................................................. 15-223 The oil pump is a rotor type pump located inside the
Component Identification ............................. 15-224 timing gear case. The pump is driven by gears via
Check (Condition) ........................................ 15-226 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 - 223 9813/7600-3 15 - 223

15 - Engine
60 - Oil Pump
00 - General
Figure 294.
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 - 224 9813/7600-3 15 - 224

15 - Engine
60 - Oil Pump
00 - General
Figure 295.
10
10 CCV Anti drain back valve
15 - 225 9813/7600-3 15 - 225

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 - 226 9813/7600-3 15 - 226

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 296.
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 - 227 9813/7600-3 15 - 227

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 - 228 9813/7600-3 15 - 228

15 - Engine
63 - Mount
63 - Mount
Contents Page No.
15-63-00 General ......................................................................................................................... 15-231
15 - 229 9813/7600-3 15 - 229

Notes:
15 - 230 9813/7600-3 15 - 230

15 - Engine
63 - Mount
00 - General
Introduction .................................................. 15-231 Engine mounts support the engine and in some
Remove and Install ..................................... 15-232 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 - 231 9813/7600-3 15 - 231

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 - 232 9813/7600-3 15 - 232

15 - Engine
69 - Oil Cooler
69 - Oil Cooler
Contents Page No.
15-69-00 General ......................................................................................................................... 15-235
15 - 233 9813/7600-3 15 - 233

Notes:
15 - 234 9813/7600-3 15 - 234

15 - Engine
69 - Oil Cooler
00 - General
Introduction .................................................. 15-235
Oil Cooler Assembly
Operation ..................................................... 15-236 The oil cooler and filter are incorporated in a housing
Check (Condition) ........................................ 15-237 that is bolted to the side of the crankcase. The
Remove and Install ..................................... 15-237 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 - 235 9813/7600-3 15 - 235

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

Figure 297. The oil cooler housing allows transfer of lubricating
oil from the crankcase to the oil cooler and filter head.
The coolant also transfers to the housing and passes
1 over the oil cooler matrix causing heat to exchange
from the oil to the coolant.
The cooled and filtered oil then passes back into the
main oil gallery into the crankcase.
An engine oil filler point is also included via cap and

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

Figure 298.
1 3
2 4
8 5
7 6
1
1 Oil cooler housing

2 Oil cooler matrix
3 Sealing gasket (housing to crankcase)
4 Coolant gallery
5 Oil gallery (from cooler to filter head)
6 Oil fill port
7 Oil gallery (from filter head to main oil gallery)
8 Oil gallery (from pump to cooler)
15 - 236 9813/7600-3 15 - 236

15 - Engine
69 - Oil Cooler
00 - General

1. Inspect the sealing faces on the oil cooler matrix,
oil cooler housing and the crankcase. Make sure
Before Removal
that the faces are clean and free from scale or 1. Make sure that the engine is safe to work on. If
damage. the engine has been running, let it cool before
2. Inspect the sealing gasket and o-rings for signs
of damage. If in doubt, renew the gasket or O- 2. Drain the coolant, refer to (PIL 21-00).
rings.
3. Remove the oil filter, refer to (PIL 15-21).
Figure 299.
A B
C D
E
A Oil cooler housing (integral oil filter head)
B Oil cooler housing fixing bolts (x10)
C Oil filter head
D Oil cooler housing (remote oil filter head)
E Remote oil filter head hose ports
Remove
2. If applicable, disconnect the electrical connectors
at the oil pressure switch and the oil temperature
sensor.
3. If applicable, label and disconnect the electrical
connectors at the ECM (Engine Control Module).
Do not touch the electrical pins on the ECM.
Cap the connectors on the harnesses and the
15 - 237 9813/7600-3 15 - 237

15 - Engine
69 - Oil Cooler
00 - General
ECM to prevent ingress of oil and coolant. Tie the Table 112. Torque Values
harnesses away from the oil cooler housing.
Item Description Nm
4. If applicable disconnect the remote oil filter head B Bolts 24
hoses from the ports on the oil cooler.
5. Remove the bolts and lift the oil cooler housing
away from the crankcase. DO NOT attempt to
remove the oil cooler matrix from the oil cooler
housing.
If there is cross contamination of coolant and

lubricating oil, the oil cooler matrix may be faulty. If a
faulty matrix is suspected renew the matrix and the
seals.
Figure 300.
A
B C
A Oil cooler housing

B Oil cooler matrix
C Sealing gasket
Install
steps.
2. Make sure that sealing gasket is undamaged and
correctly located in its groove. A faulty gasket will
cause cross contamination of the lubricating oil
and coolant. If in doubt install a new gasket.
After Installation
1. If applicable, install the oil filter, refer to (PIL
15-21).
2. Refill the cooling system with the recommended
coolant mixture, refer to (PIL 21-00).
3. If applicable, make sure that the harness
connectors are connected to the correct
connectors on the ECM.
4. Start the engine and check for oil and coolant
leaks.
15 - 238 9813/7600-3 15 - 238

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

1. Locate the new O-rings. Install the oil cooler
Dismantling of the oil cooler and oil filter head matrix. Tighten the bolts to the correct torque
assembly is not necessary unless the oil cooler value.
matrix or the seals are faulty.
2. Install the sealing gasket to the oil cooler
Disassemble housing.
1. Remove the four fixing bolts and lift off the oil Table 113. Torque Values
cooler matrix. Item Nm
2. Remove and discard the two sealing O-rings. A 23
3. Remove the sealing gasket.

Figure 301.
D
C
A
B C
A
A
A
A Fixing bolts
B Oil cooler matrix
C O-rings
D Sealing gasket
E Oil cooler housing
Inspect
1. Refer to Oil Cooler - Check Condition.
15 - 239 9813/7600-3 15 - 239

15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ......................................................................................................................... 15-241

15-72-03 Pulley ............................................................................................................................ 15-247
15-72-06 Voltage Regulator ......................................................................................................... 15-248
15 - 240 9813/7600-3 15 - 240

15 - Engine
72 - Alternator
00 - General
Introduction .................................................. 15-241 The alternator is a three phase generator having a
Health and Safety ........................................ 15-242 rotating field winding and static power windings.
Technical Data ............................................. 15-242
Component Identification ............................. 15-243 When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
Check (Condition) ........................................ 15-243 warning light to the field winding. This creates
Remove and Install ..................................... 15-245 a magnetic field which supplements the residual
Disassemble and Assemble ........................ 15-246 magnetism in the rotor poles. As the engine is
started, the FEAD (Front End Accessory Drive)
belt drives the rotor and the alternating current is
generated in the power windings as they are cut by
the rotating magnetic field. Output is controlled by a
solid state regulator which varies the field current in
accordance with electrical demand.
15 - 241 9813/7600-3 15 - 241

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 - 242 9813/7600-3 15 - 242

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

Figure 302.
Charging Circuit Test
1. Make sure that all the battery and alternator
D connections are in place, secure and making
good metal - to - metal contact, especially the
earth connections to chassis and engine.
2. Adjust the alternator drive belt tension if
necessary and make sure that the battery is well
charged.
3. Turn the ignition switch to the ON position. Oil
pressure and ''No Charge'' warning lights should
glow. If any light fails, re-check the connections.
4. Start the engine; all warning lights should
extinguish rapidly. If the ''No Charge'' warning
light remains ON, re-check the alternator drive
belt tension and that the battery is charged. If
the oil pressure warning remains on stop the
engine Immediately and investigate the engine
A Alternator lubrication system.
B Regulator and brush assembly
C Drive pulley Check 1
D Tie bolts
With the ignition switch ON, check that the heater
motor and screen wiper will operate.
If they operate normally, check the warning light bulb

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

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

withdraw the triple plug from the back of the
alternator. Make a temporary connection between
the small terminal in the plug and earth as shown
below. If the 'No Charge' warning bulb still fails to
light, check the cable for continuity. If the bulb now
lights, check the alternator for a defective regulator.
Figure 303.
Check 2
The following checks should be made using an
analogue (moving pointer) type Multimeter.
15 - 243 9813/7600-3 15 - 243

15 - Engine
72 - Alternator
00 - General
1. Stop the engine and turn the ignition switch to 4. Alternatively, operate the starter for a few
OFF. moments with the ESOS (Engine Shut-Off
Solenoid) fuse removed.
2. Withdraw the alternator plug and connect the
Multimeter between the large terminals and 5. Install an open type shunt between the battery
earth. With the Multimeter set to measure, positive lead and the battery positive terminal.
Voltage: 12V Current: 100A
Figure 304. 6. Connect a Multimeter positive lead to machine
side of the shunt and negative lead to battery side
of the shunt.
7. Connect the leads to the Multimeter and set the
Multimeter to the relevant range as follows.
8. AVO 2002
8.1. Red lead to volts (middle) socket on
Multimeter.
8.2. Black lead to negative on Multimeter.
2.1. The Multimeter should show battery 8.3. Right side slider to DC (Direct Current)
voltage. voltage.
2.2. If the reading is zero, check the cables 8.4. Left side slider,Refer to Figure 305.
for continuity, particularly at the starter
9. AVO 2003
terminals.
9.1. Red lead to amps socket (A) on the
3. If the voltage is correct, check the alternator.
Multimeter.
Alternator Charging Test 9.2. Black lead to negative on Multimeter.
Figure 305. 9.3. Right side slider to DC voltage

9.4. Left side slider to 200 Shunt
10. FLUKE 85
10.1. Red lead to volts socket (V ) on Multimeter.
10.2. Black lead to COM socket on Multimeter.
10.3. Set dial to mV.
11. Start the engine and run at maximum speed
(see Technical Data). Multimeter should show
maximum alternator output in Amps (see
Technical Data). The Multimeter reading should
be taken as soon as possible after starting the
engine, as the charging current will fall rapidly.
12. A zero reading indicates failure of the alternator
and may be caused by one of the following
1. Make sure that all battery and alternator conditions. These are listed in the order of
connections are in place, secure and making probability.
good metal to metal contact, especially the earth
connections to chassis and engine. 12.1. Defective suppression capacitor.
2. Make sure that the alternator drive belt tension is 12.2. Dirty slip rings or worn brushes.
correctly adjusted. 12.3. Defective regulator.
3. If the battery is in a fully charged condition, before 12.4. Defective rectifier.
commencing the test switch on the working lights
for 12.5. Open or short circuited field (rotor)
windings.
Duration: 3min
15 - 244 9813/7600-3 15 - 244

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

windings.
13. To check for a fault, disconnect the capacitor and Figure 306. Alternator location
repeat the charging test. Renew the capacitor if
necessary.
14. To check for faults with the slip rings, bushes or
regulator, remove the regulator and brush box
assembly. Check the condition of the brushes
and, if necessary, clean the slip rings using extra-
fine glass paper. The regulator may only be
renewed.
15. Faults with the rectifier, rotor and stator may be
checked only by removing and dismantling the
alternator for further testing. Remove
1. Disconnect the negative (-) lead followed by the
positive (+) lead from the battery terminals.
2. Remove the alternator (accessory) drive belt.
3. Disconnect the electrical leads from the
alternator terminals. Label the leads to make
sure that they are installed in the correct positions
on assembly.
4. Undo the alternator securing bolts and lift the
alternator away from the cylinder block mounting.
Figure 307.
A
A Alternator
B Securing bolts
Inspect
1. Check the brushes for wear. Renew the brushes
if the length is less than
15 - 245 9813/7600-3 15 - 245

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

removal procedure. Additionally do the following Voltage Regulator and Brushes
steps.
1. The voltage regulator and brush set is a
2. It is not necessary to adjust the position of the combined assembly. Refer to (PIL 15-72-06).
alternator in order to tension the drive belt, as
the accessory drive belt arrangement is self-
tensioning. Drive Pulley
3. Tighten the alternator securing bolts to the 1. Refer to (PIL 15-72-03).
4. Make sure you reconnect the electrical leads to
the alternator in the correct positions and tighten
to the correct torque.
Table 114. Alternator securing bolt torque

Item Torque Value
A 47N·m
B 47N·m
Figure 308.
Table 115. Alternator

electrical connection torque
Item Torque Value
B+ 9–13N·m
L 2.7–3.8N·m
W 2.7–3.8N·m
15 - 246 9813/7600-3 15 - 246

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 - 247 9813/7600-3 15 - 247

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 - 248 9813/7600-3 15 - 248

15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ......................................................................................................................... 15-251

15-75-03 Solenoid ....................................................................................................................... 15-259
15-75-06 Brush Gear ................................................................................................................... 15-260
15 - 249 9813/7600-3 15 - 249

Notes:
15 - 250 9813/7600-3 15 - 250

15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................. 15-251 The electric starter motor is either a permanent-
Health and Safety ........................................ 15-252 magnet or a series-parallel wound direct current
Technical Data ............................................. 15-252 electric motor with a starter solenoid mounted on to
Component Identification ............................. 15-253 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
Check (Condition) ........................................ 15-253 the solenoid engages a lever that pushes out the
Remove and Install ..................................... 15-255 drive pinion on the starter driveshaft and meshes the
Disassemble and Assemble ........................ 15-257 pinion with the starter ring gear on the flywheel of the
engine.
The solenoid also closes high current contacts for the

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

use, the electrical components are designed only
to operate for a time period of 30 seconds before
overheating.
15 - 251 9813/7600-3 15 - 251

15 - Engine
75 - Starter Motor
00 - General

WARNING Make the machine safe before
working on it. Park the machine on level ground Refer to Electrical System- General, Technical Data
and lower the loader arm. Stop the engine and (PIL 33-00).
remove the ignition key. Make sure the park brake
is engaged. Disconnect the battery to prevent the
engine being started. Block all four wheels.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to
protect the circuits and components. The battery
must still be disconnected even if a battery
isolator is installed.
Notice: Do not isolate the machine electrics
when the engine is running, this may cause
damage to the machine electrics.
15 - 252 9813/7600-3 15 - 252

15 - Engine
75 - Starter Motor
00 - General

Figure 309. Before carrying out the multimeter tests, check
the battery condition and make sure that all the
1 applicable electrical connections are clean and tight.
Make sure that the starter motor fixing bolts are
tightened to the correct torque.
To prevent the engine starting during the tests make

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

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

terminals.
Figure 310.
1.1. Reading in start position approximately

Voltage: 10V
Voltage: 20V
1.2. Minimum permissible reading in start
position
Voltage: 9.5V
Voltage: 18V
1.3. A low reading probably indicates a fault in
the starter motor.
2. Connect the multimeter between the starter main
terminal and the commutator end bracket. In the
start position, the reading should not be below
the reading obtained in 1 by any more than
Voltage: 0.5V
Voltage: 1V
15 - 253 9813/7600-3 15 - 253

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

B Commutator end bracket (Starter earth B Starter earth connection
connection) C Solenoid terminal
2.1. Minimum permissible reading in start D Start relay feed
position E Start relay switched output
H Battery positive and solenoid connection
Voltage: 9V
Voltage: 17V 4.1. If the reading is less than specified, connect
the multimeter between the start relay feed
2.2. If the reading is within this limit, continue to
and earth.
3. If the reading is outside the limit, proceed
to 4. 4.2. A faulty start relay or a fault in the feed to
the relay solenoid is indicated if the voltage
3. Connect the multimeter between the solenoid increases to
terminal and a good earth. Minimum permissible
reading in start position Voltage: 8V
Voltage: 16V
Voltage: 8V
Voltage: 16V 4.3. Check also the solenoid earth connection.
The fault must be in either the starter switch
Figure 312. or in the wiring between the solenoid, starter
switch, and the start relay, if the reading
between terminal and earth is less than
Voltage: 8V
Voltage: 16V
5. Connect the multimeter between battery
negative and starter earth connection. The
reading in the start position should be practically
zero, maximum permissible reading
Voltage: 0.25V
Figure 314.
C Solenoid terminal
4. If the reading is less than specified, connect
the multimeter between the start relay switched
output and earth. A fault is indicated with the
wiring from the start relay to the solenoid if the
reading increases to
Voltage: 8V
Voltage: 16V
B Starter earth connection
15 - 254 9813/7600-3 15 - 254

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 317.
6. Connect the voltmeter between battery positive
and the starter main terminal. With the starter A
switch off, the voltmeter should indicate battery E
voltage, but it should fall to practically zero when
the switch is turned to the on position, maximum
permissible reading B
Voltage: 0.25V
Figure 315.
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 316. 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 - 255 9813/7600-3 15 - 255

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 - 256 9813/7600-3 15 - 256

15 - Engine
75 - Starter Motor
00 - General
These parts are non-serviceable if any part fails, sure the wave washer is installed inside the
replace the complete starter motor. For cleaning cover.
and checking purposes only, dismantle the motor as
1.6. Carefully install the commutator end cover,
follows:
then tighten the tie bolts.
Brush Gear Starter Solenoid
1. Check the brush gear as follows:
1. Check the starter solenoid as follows:
1.1. Remove the tie bolts and carefully separate
1.1. Disconnect the starter motor cable from the
the commutator end cover.
solenoid connector post.
1.2. Remove the screws. Remove the brush
1.2. Remove the screws and carefully withdraw
holder and brushes.
the solenoid assembly.
1.3. Check the brushes for wear. Install or
1.3. Make sure that the sealing ring is
renew the brush set as required. Renew the
undamaged and correctly installed.
brushes if they are less than
Length/Dimension/Distance: 8mm 1.4. Before you install the solenoid make sure
you engage the pinion lever arm through
1.4. Clean the commutator. the hole in the solenoid actuator rod, then
tighten the screws.
1.5. Before installing the commutator end
cover, make sure that the sealing ring is 1.5. Reconnect the starter motor cable to the
undamaged and correctly installed. Make solenoid connector post.
15 - 257 9813/7600-3 15 - 257

15 - Engine
75 - Starter Motor
00 - General
Figure 318.
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 - 258 9813/7600-3 15 - 258

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 - 259 9813/7600-3 15 - 259

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 - 260 9813/7600-3 15 - 260

15 - Engine
80 - Glow Plug
80 - Glow Plug
Contents Page No.
15-80-00 General ......................................................................................................................... 15-263
15 - 261 9813/7600-3 15 - 261

Notes:
15 - 262 9813/7600-3 15 - 262

15 - Engine
80 - Glow Plug
00 - General
Introduction .................................................. 15-263 A glow plug is a heating device used to help
Operation ..................................................... 15-264 start diesel engines. In cold weather, diesel engines
Remove and Install ..................................... 15-264 can be difficult to start because the mass of the
crankcase and cylinder head absorb the heat of
compression, preventing ignition due to the higher
surface to volume ratio.
The glow plug is a pencil shaped piece of metal with

a heating element at the tip. The heating element,
when electrified, heats due to its electrical resistance.
15 - 263 9813/7600-3 15 - 263

15 - Engine
80 - Glow Plug
00 - General
The glow plugs are controlled by the ECM (Engine The glow plugs for cylinders 1, 3 and 4 can be
Control Module). The ECM takes signals from engine removed without the need to remove any other
sensors such as the engine coolant temperature components. The glow plug for cylinder 2 requires
sensor to determine whether the glow plugs are the removal of the turbocharger to gain access. Refer
required and for how long. The glow plugs will be to: PIL 18-35-00.
activated when the ambient temperature is below
0°C (32.0°F). The glow plugs will be deactivated by Remove
the ECM after a predetermined time period.
Figure 319.
B
A
A Electrical connector
B Glow plug
4. Remove the glow plug from the cylinder head.
Install
step.
2. Tighten the glow plug to the correct torque value.

Item Nm
B 15 ± 2
15 - 264 9813/7600-3 15 - 264

15 - Engine
84 - Sensor
84 - Sensor
Contents Page No.
15-84-00 General ......................................................................................................................... 15-267

15-84-03 Crankshaft Position ...................................................................................................... 15-278
15-84-06 Camshaft Position ........................................................................................................ 15-282
15-84-09 Knock ........................................................................................................................... 15-286
15-84-14 Exhaust Manifold Temperature .................................................................................... 15-289
15-84-16 Exhaust Manifold Pressure .......................................................................................... 15-292
15-84-17 Temperature and Manifold Air Pressure (TMAP) ......................................................... 15-295
15-84-18 Temperature and Mass Air Flow (TMAF) ..................................................................... 15-298
15-84-19 Exhaust Temperature ................................................................................................... 15-301
15-84-24 Fuel Temperature ......................................................................................................... 15-304
15-84-27 Fuel Rail Pressure ....................................................................................................... 15-307
15-84-29 Foot Throttle Control .................................................................................................... 15-310
15-84-33 Coolant Temperature .................................................................................................... 15-314
15-84-42 Engine Oil Temperature ............................................................................................... 15-317
15-84-43 Engine Oil Level ........................................................................................................... 15-320
15-84-48 Intercooler Outlet Temperature .................................................................................... 15-323
15-84-51 Nitrogen Oxide (NOx) .................................................................................................. 15-326
15 - 265 9813/7600-3 15 - 265

Notes:
15 - 266 9813/7600-3 15 - 266

15 - Engine
84 - Sensor
00 - General
Introduction .................................................. 15-267 The engine sensors continually send signals to the
Technical Data ............................................. 15-268 ECM (Engine Control Module) to help the ECM to
Component Identification ............................. 15-270 control the smooth running of the engine and related
Fault-Finding ................................................ 15-272 components.
Check (Operation) ....................................... 15-277 The ECM processes signals from the sensors
continually and its response will be based on an
evaluation of the combination of sensor signals.
After removal from the engine, protect the sensors

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

be replaced in the event of damage.
15 - 267 9813/7600-3 15 - 267

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

Sensor (TMAP)
Atmospheric Output voltage +/- V
pressure bar V
Table 118.
(psi)
Crankshaft Position Sensor 0.98 -0.025/ 1.84 0.05
Type Hall effect. +0.025
(14.2 -0.4/+0.4)
Table 119. Table 122.

Camshaft Position Sensor Knock Sensor
Type Hall effect. Type Piezo crystal.
Fixing screw tightening 24N·m
torque
Table 120.
Fixing screw thread di- M8
Coolant Temperature Sensor ameter
Type Temperature dependant resis-
tance. Table 123.
Tightening 22N·m max
Throttle Position Sensor (TPS)
(1)
torque
Thread diame- M12 x 1.5. Type Two channel ratio metric
ter voltage output sensor.
Temperature v Resistance Table Supply voltage 5V
Temperature °C Resistance Ω +/- % Rotational range 75°
(°F) Output range Linear output voltage
25 (77.0) 2,062 5.7 over the rotational
range.
50 (121.9) 833 4.3
(1) The throttle position sensor is not supplied as part
100 (211.9) 187 2
of the engine assembly. The technical data given is
110 (229.8) 144 2.4 compatible with the specification required.
Table 124.
Table 121.
Rail Pressure Sensor
Inlet Manifold Air Pressure and Temperature
Sensor (TMAP) Type The rail pressure sensor
is integral with the com-
Fixing screw 22N·m max mon rail.
tightening
torque
Table 125.
Fixing screw M6
thread diameter High Pressure Rail Fuel Valve
Supply voltage 5V Type The HPV (High Pressure
Temperature Sensor Valve) is integral with
the common rail.
Type Temperature dependant resistor.
Temperature v Resistance Table Table 126.
Temperature °C Resistance Ω +/- %
Fuel Temperature Sensor
(°F)
Type The fuel temperature
5 (41.0) 4,707 4.66
sensor is integral with
10 (50.0) 3,791 4.55 the high pressure fuel
15 (59.0) 3,075 4.44 pump.
20 (68.0) 2,510 4.33
25 (77.0) 2,062 4.22 Table 127.
30 (86.0) 1,715 4.12 Oil Pressure Switch
Pressure Sensor Set pressure 0.6bar (8.7psi) falling.
Type Piezo-resistive Switch mode Normally open.
Atmospheric Pressure v Voltage Max pressure 27.5bar (398.5psi)
15 - 268 9813/7600-3 15 - 268

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

Max working pressure 13.8bar (200.0psi)
Tightening torque 23N·m max.
Thread diameter M12 x 1.5.
15 - 269 9813/7600-3 15 - 269

15 - Engine
84 - Sensor
00 - General
Engine Sensors and Actuators
Figure 320.
B
P
F
G
H
J
K
A Coolant temperature sensor (PIL 15-84) B Turbocharger actuator (not installed on 55Kw
engines) (PIL 18-36)
D TMAP (Temperature Manifold Air Pressure) (PIL E Fuel temperature sensor (PIL 15-84)
15-84)
F Fuel inlet metering valve (PIL 18-18) G Camshaft position sensor (PIL 15-84)
H Crankshaft position sensor (PIL 15-84) J Oil temperature sensor (PIL 15-84)
K Oil pressure switch (PIL 15-84) P Inter cooler outlet temperature sensor (PIL
15-84)
15 - 270 9813/7600-3 15 - 270

15 - Engine
84 - Sensor
00 - General
Figure 321.
M
C
C Exhaust manifold pressure sensor (PIL 15-84) L Fuel pressure relief valve (HPV) (PIL 15-84)
M EGR (Exhaust Gas Recirculation) actuator (PIL N Exhaust manifold temperature sensor (PIL
18-27) 15-84)
O Oil level switch (optional) (PIL 15-84)
15 - 271 9813/7600-3 15 - 271

15 - Engine
84 - Sensor
00 - General
Fault-Finding
Fault
General Sensor Fault Table 128. Page 15-272
Water in Fuel Sensor Fault Table 129. Page 15-272
Knock Sensors Table 130. Page 15-273
TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure) Table 131. Page 15-274
Crankshaft Position Sensor Table 132. Page 15-274
Camshaft Position Sensor Table 133. Page 15-275
TMAF (Temperature and Mass Air Flow) Sensor Table 134. Page 15-276
Table 128. General Sensor Fault

Cause Remedy
Sensor supply voltage fault Disconnect the sensor, check sensor voltage supply
at the harness connector (see relevant sensor help
file for pin numbers or refer to engine electrical
schematic). If voltage supply is faulty, disconnect all
other sensors in turn until voltage supply returns.
If sensor supply voltage is OK, proceed to 'Sensor
connection faulty'.
Sensor connection faulty Check the condition of sensor to harness connection,
make sure the seals are in place, check for signs
of corrosion or contamination. Repair/replace as
necessary.
If no fault is found, proceed to 'Sensor failure'.
Sensor failure Check the sensor resistance (see relevant help file
page). If sensor is out of specification replace.
If no faults is found, proceed to ECM (Engine Control
Module) connection fault'.
ECM connection fault Disconnect the harness from engine ECM and
inspect. Check seals are in place, check for signs of
corrosion or contamination.
If ECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing an ECM.
If harness is damaged, repair or replace as
necessary.
If no fault is found proceed to 'Wiring fault'.
Wiring fault Check the harness continuity. Check the machine
and engine earth contacts. Repair/ replace as
necessary.
If no fault is found, raise Techweb Helpdesk call.
Table 129. Water in Fuel Sensor Fault

Cause Remedy
Sensor supply voltage fault Check the presence of electrical supply on water
sensor.
connection faulty'.
necessary.
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15 - Engine
84 - Sensor
00 - General
Cause Remedy
If no faults is found, proceed to ECM connection
fault'.
necessary.
Wiring fault Check the harness continuity and machine and
engine earth contacts. Repair/ replace as necessary.
Table 130. Knock Sensors

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Knock sensors – Water temperature
sensor – Air temperature sensor – Fuel temperature
sensor – Barometric pressure sensor (built inside the
ECM).
Check the knock sensors connection and screw
torque (Check particularly the ground shield
connection). Repair as necessary and re-enter all
injector calibration codes (read then write) in correct
position to reset learned parameters.
If no fault is found proceed to 'Knock sensors ground
fault'.
Knock sensors ground fault Check the grounding of knock sensors, repair as
necessary.
If no fault is found proceed to ECM connection fault'.
ECM connection fault Disconnect ECM and inspect. Check seals are in
place, check for signs of corrosion or contamination.
necessary.
Wiring fault Check the harness continuity and electrical
installation, repair/replace as necessary.
If no fault is found proceed to 'Injector calibration
codes fault'.
Injector calibration codes fault Check the injector calibration codes recorded in
ECM, if found fault re-enter all injector calibration
codes (read then write) in correct position to reset
learned parameters.
If the injector calibration codes are OK, test the
vehicle on road and check the DTC (Diagnostic
Trouble Code) again with the diagnostic tool. If the
problem is still present, replace the knock sensors.
15 - 273 9813/7600-3 15 - 273

15 - Engine
84 - Sensor
00 - General
Table 131. TMAP (Temperature Manifold Air Pressure) Sensor Fault (Boost Pressure)
Cause Remedy
Sensor supply voltage or calibration fault Disconnect the sensor, check sensor voltage supply
schematic). If voltage supply is faulty, disconnect
all other sensor in turn until voltage supply returns.
Replace the faulty sensor. If no sensor is faulty
replace the ECM.
If sensor supply voltage is OK, proceed to 'Air inlet
circuit fault'.
Air inlet circuit fault Check the consistency of barometric pressure
reading. Verify the conformity of air inlet circuit:– VGT
(Variable Geometry Turbocharger) / Turbo – Leakage
before VGT / Turbo – Air filter – Valve position using
ServiceMaster – Vane state.
Check all the hose connections for air leaks, repair
as necessary.
necessary.
fault'.
If ECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing an ECM
necessary.
If no fault found, raise Techweb Helpdesk call.
Table 132. Crankshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to ECM connection fault'.
15 - 274 9813/7600-3 15 - 274

15 - Engine
84 - Sensor
00 - General
Cause Remedy
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the crankshaft position sensor target wheel if
damaged, replace with a new crankshaft.
If no fault is found raise Techweb Helpdesk call.
Table 133. Camshaft Position Sensor

Cause Remedy
schematic). If voltage supply is faulty, replace the
sensor.
connection faulty'.
make sure the seals are in place, check for signs of
corrosion or contamination. Repair as necessary.
If no fault is found, proceed to Step 4.
necessary.
If no fault is found proceed to 'Sensor signals faulty'.
Sensor signals faulty Check the sensor signals. If scope available, display
Cam and crank signals on the scope. Change the
sensor as necessary.
If no fault is found, proceed to 'Sensor target wheel
fault'.
Sensor target wheel fault Check the Cam target wheel if damaged, replace
with new camshaft.
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15 - Engine
84 - Sensor
00 - General
Table 134. TMAF (Temperature and Mass Air Flow) Sensor

Cause Remedy
Sensor supply voltage or calibration fault Disconnect the sensor, check sensor voltage supply
schematic). If voltage supply is faulty, disconnect
all other sensor in turn until voltage supply returns.
Replace the faulty sensor. If no sensor is faulty
replace the ECM
If sensor supply voltage is OK, proceed to 'Air inlet
fault'.
Air inlet fault Check all the hose connections for air leaks, repair
as necessary.
If no fault is found proceed to 'Sensor connection
faulty'.
necessary.
Sensor failure If sensor is out of specification replace.
If no faults is found, proceed to Step 5.
necessary.
If no fault is found proceed to Step 6.
If no fault found, raise Techweb Helpdesk call.
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15 - Engine
84 - Sensor
00 - General
Check (Operation)
1. Check the applicable fuse. Refer to (PIL 33-09).
2. Check the display for related fault codes. Refer
to (PIL 33-57).
3. Using Servicemaster perform the required
diagnostic tests. Refer to (PIL 33-57).
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 resistance. 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
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15 - Engine
84 - Sensor
03 - Crankshaft Position
03 - Crankshaft Position Introduction

Introduction .................................................. 15-278 The crankshaft position sensor is a device used
Operation ..................................................... 15-279 to monitor the position or rotational speed of the
Check (Operation) ....................................... 15-280 crankshaft. This information is used by the ECM
Remove and Install ..................................... 15-280 (Engine Control Module) to control the ignition
system timing and other engine parameters.
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15 - Engine
84 - Sensor
Operation
processed by the ECM (Engine Control Module) to

A signal is generated by the crankshaft mounted determine the timing of fuel injection.
target wheel and crankshaft position sensor. It is
Figure 322.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM 2 Camshaft position sensor

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

1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
Before Removal
2. Inspect the sealing O-ring. If it is defective,
replace the sensor. The O-ring is integral to the
sensor and cannot be replaced.
2. Clean the sensor and the adjacent area of the
flywheel housing.
Figure 323.
A
D
C
A Crankshaft position sensor

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

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

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

Introduction .................................................. 15-282 The camshaft position sensor is a device that detects
Operation ..................................................... 15-283 the passing of a gap on a camshaft target wheel. It
Check (Operation) ....................................... 15-284 sends a signal to the ECM (Engine Control Module)
Remove and Install ..................................... 15-284 which stroke number piston is on so that the ECM
knows which cylinder to inject the fuel into.
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15 - Engine
84 - Sensor
Operation
process the signal to determine the engine phase

A signal is generated by the camshaft mounted target (which cylinder is firing).
wheel and camshaft position sensor. This information
is used by the ECM (Engine Control Module) to The ECM will select the correct cylinder for fuel
injection.
Figure 324.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM 2 Camshaft position sensor

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

1. Carefully inspect the sensor. If it is found to be
defective, replace the sensor.
Before Removal
crankcase.
Figure 325.
A
B
A Camshaft position sensor

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

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

Item Nm
C 8
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15 - Engine
84 - Sensor
09 - Knock
09 - Knock Introduction
Introduction .................................................. 15-286 There are two knock sensors fixed to the side of the
Operation ..................................................... 15-287 crankcase with a centre mounted bolt. One sensor is
Check (Operation) ....................................... 15-287 situated between cylinders 1 and 2, and the second
Remove and Install ..................................... 15-288 is situated between cylinders 3 and 4.
A knock sensor is a device that measures engine

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

the knock sensor detects pinging. At that point the
ECM retards the ignition timing just enough for the
pinging to stop. The knock sensor ensures that you
are getting as much power and fuel economy as
possible from your engine.
Figure 326. Knock sensor locations
A
B
A Knock sensor - cylinders 1 and 2

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

sensor is defective it must be replaced.
Figure 327.
B C
A Knock sensor
C Bolt
Install
steps.
2. Make sure that the sensor mates fully with the
adjacent face on the crankcase.
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15 - Engine
84 - Sensor
14 - Exhaust Manifold Temperature
14 - Exhaust Manifold Temperature Introduction

Introduction .................................................. 15-289 The exhaust manifold temperature sensor is screwed
Operation ..................................................... 15-290 directly into the top of the exhaust manifold between
Check (Operation) ....................................... 15-290 cylinder 3 and 4 exhaust outlet ports.
Figure 328. Exhaust manifold
temperature sensor location
15 - 289 9813/7600-3 15 - 289

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

Special Tools
Deep Socket 892/12351 1
Before Removal
Figure 329.
A
N
A Exhaust manifold temperature sensor
Remove
2. Disconnect the electrical connector at the
exhaust manifold temperature sensor.
3. Use the special tool to remove the sensor from
the exhaust manifold.
Special Tool: Deep Socket (Qty.: 1)
4. Discard the sealing washer.
The exhaust manifold temperature sensor is a non-

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

Item Nm
N 45
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15 - Engine
84 - Sensor
16 - Exhaust Manifold Pressure
16 - Exhaust Manifold Pressure Introduction

Introduction .................................................. 15-292 The exhaust manifold pressure sensor also known
Operation ..................................................... 15-293 as the manifold absolute pressure sensor is a device
Check (Operation) ....................................... 15-293 that is used to calibrate the fuel delivery on an ECM
Remove and Install ..................................... 15-294 (Engine Control Module) Controlled engine.
The sensor is mounted in the rear section of the

rocker cover.
Figure 330.
C Exhaust manifold pressure sensor
15 - 292 9813/7600-3 15 - 292

15 - Engine
84 - Sensor
The exhaust manifold pressure sensor measures For the full inspection and testing procedure, refer to
the exhaust pressure from the engine. To attain an the help files in ServiceMaster.
accurate and stable reading, the take-off point is
piped from the exhaust manifold between cylinders
3 and 4. This is fed to a sample chamber where the
sensor is screwed directly into the pressure path. The
analogue voltage signal is 0.5–4.5V.
15 - 293 9813/7600-3 15 - 293

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

Figure 331.
P1
1 Exhaust manifold pressure sensor

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

it must be renewed.
Install
steps.
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15 - Engine
84 - Sensor
17 - Temperature and Manifold Air Pressure (TMAP)
17 - Temperature and Manifold Air Introduction

Pressure (TMAP)
The TMAP (Temperature Manifold Air Pressure)
Introduction .................................................. 15-295 sensor is mounted in a port on top of the inlet
Operation ..................................................... 15-296 manifold. It measures the inlet manifold boost air
Check (Operation) ....................................... 15-296 pressure and temperature. The sensor incorporates
a piezo-resistive element and resistor.
Figure 332.
D TMAPsensor
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15 - Engine
84 - Sensor
The TMAP (Temperature Manifold Air Pressure) 1. Remove oil and sludge contamination from the
sensor measures the inlet manifold boost air sensor.
pressure and temperature. The sensor produces an
analogue signal voltage proportional to air pressure. 2. Carefully inspect the sensor. If it is defective,
replace it.
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15 - Engine
84 - Sensor
Remove and Install 3. Carefully push the sensor into its location bore in
the inlet manifold. Do not use excessive force.
Before Removal
1. Make sure that the engine is safe to work on. If Table 139. Torque Values
the engine has been running, let it cool before Item Nm
you start the service work. C 3.3
inlet manifold.
Figure 333.
A
C B
D
A TMAP (Temperature Manifold Air Pressure)
C Bolt
D O-ring seal
Remove
3. Remove the bolt.
4. Remove the sensor from the inlet manifold
together with O-ring.
The TMAP sensor is a non-serviceable item. If the

sensor is defective, it must be replaced.
Install
steps.
2. Make sure that the sealing O-ring is correctly
installed.
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15 - Engine
84 - Sensor
18 - Temperature and Mass Air Flow (TMAF)
18 - Temperature and Mass Air Introduction

Flow (TMAF)
The TMAF (Temperature and Mass Air Flow) sensor
Introduction .................................................. 15-298 measures the amount of air coming in to the engine
Operation ..................................................... 15-299 and the air temperature. It is mounted between the
Check (Operation) ....................................... 15-299 air filter and turbo charger.
Remove and Install ..................................... 15-300 Figure 334.
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15 - Engine
84 - Sensor
The TMAF (Temperature and Mass Air Flow) sensor Faults relating to the TMAF (Temperature and Mass
produces a digital signal measuring air flow, and an Air Flow) will normally be reported by the fault codes.
analogue signal measuring inlet air temperature.
1. Remove contamination from the sensor. Do not
touch the air flow sensor area or temperature
sensor area.
2. Carefully inspect the sensor. If it is defective,
replace it.
replace it.
Figure 335.
1 Air flow sensor area

2 Temperature sensor area
15 - 299 9813/7600-3 15 - 299

15 - Engine
84 - Sensor

Do not install a TMAF sensor which has been
Before Removal dropped or damaged. Replace it with a new one.
1. Make sure that the engine is safe to work on. If 1. The installation procedure is the opposite of the
the engine has been running, let it cool before removal procedure. Additionally do the following
you start the service work. step.
2. Get access to the TMAF (Temperature and Mass 2. Tighten the screws to the correct torque value.
Air Flow) sensor
3. Clean the area around the sensor to prevent
Item Nm
contamination entering the engine.
2 5
Remove
Figure 336.
1 2
3
2 Screws (x2)
3 TMAF sensor
1. Disconnect the electrical connector. Do not touch
the connector pins.
2. Remove the screws (x2) which secure the TMAF
sensor to the air intake hose.
3. Remove the TMAF sensor together with the O-
ring from the air intake hose. Do not touch the air
flow sensor area or temperature sensor area.
Figure 337.
1 Air flow temperature sensor area

2 Temperature sensor area
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15 - Engine
84 - Sensor
19 - Exhaust Temperature
19 - Exhaust Temperature Introduction

Introduction .................................................. 15-301
Operation ..................................................... 15-302
(For: DJ Engine, SJ Engine)
Check (Operation) ....................................... 15-302 The exhaust temperature sensor is located in the
Remove and Install ..................................... 15-303 exhaust system just before the SCR (Selective
Catalytic Reduction) catalyst.
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15 - Engine
84 - Sensor
(For: DJ Engine, SJ Engine) (For: DJ Engine, SJ Engine)

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

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

2. Undo the retaining screw.
(For: DJ Engine, SJ Engine) 3. Remove the sensor from the exhaust, take care
Consumables not to damage the sensor probe.
The exhaust temperature sensor is a non-
Graphite/Calcium 4004/7545 - serviceable item. If the sensor is faulty or damaged
Fluoride Based Metal it must be replaced.
Free Anti-Seize
Compound
Install
Before Removal 1. The installation procedure is the opposite of the
1. Make sure that the engine is safe to work on. If steps.
you start the service work. 2. Apply anti-seize compound to the threads of the
retaining nut. Make sure the correct anti-seize
2. Get access to the exhaust temperature sensor. compound is used to prevent damage to the SCR
(Selective Catalytic Reduction) system.
Remove Consumable: Graphite/Calcium Fluoride Based
Metal Free Anti-Seize Compound
Figure 338.
3. Tighten the retaining screw to the correct torque
value.

Item Nm
2 44
2
1
1 Exhaust temperature sensor

2 Retaining nut
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15 - Engine
84 - Sensor
24 - Fuel Temperature
24 - Fuel Temperature Introduction

Introduction .................................................. 15-304 The fuel temperature sensor is an integral part of
Operation ..................................................... 15-305 the fuel injection high pressure pump, refer to (PIL
Check (Operation) ....................................... 15-305 18-18).
Figure 339.
E Fuel temperature sensor
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15 - Engine
84 - Sensor
The fuel temperature sensor detects the fuel For the full inspection and testing procedure, refer to
temperature as it enters the high pressure fuel the help files in ServiceMaster.
injection pump.
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15 - Engine
84 - Sensor
Remove and Install
This part is a non-serviceable component, if it is

defective, replace the fuel injection high pressure
pump. Refer to: PIL 18-18-15.
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15 - Engine
84 - Sensor
27 - Fuel Rail Pressure
27 - Fuel Rail Pressure Introduction

Introduction .................................................. 15-307 The fuel rail pressure sensor measures the fuel
Operation ..................................................... 15-308 pressure in the common rail.
Check (Operation) ....................................... 15-308
A Fuel rail pressure sensor
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15 - Engine
84 - Sensor
The fuel rail pressure sensor measures the fuel For the full inspection and testing procedure, refer to
pressure in the fuel rail. This allows the ECM (Engine the help files in ServiceMaster.
Control Module) to control the IMV (Inlet Metering
Valve) to deliver the correct amount of fuel to the high
pressure fuel pump. This keeps the fuel pressure in
the fuel rail constant at all engine RPM (Revolutions
Per Minute).
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15 - Engine
84 - Sensor
Remove and Install
This part is a non-serviceable component, if it

is defective, replace the complete common rail
assembly. Refer to: PIL 18-18-12.
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15 - Engine
84 - Sensor
29 - Foot Throttle Control
29 - Foot Throttle Control Technical Data

Technical Data ............................................. 15-310
Operation ..................................................... 15-311
Throttle Position Sensor
Remove and Install ..................................... 15-312 Figure 341. Throttle Pedal Movement
A
B
Table 142.
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
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15 - Engine
84 - Sensor
Operation
The throttle pedal sensor (TPS) converts the

movement from the pedal into an electrical signal
for interpretation by the Engine ECU (Electronic
Control Unit), variflow pump ECU hi(if installed) or
the hydraulic control ECU.
The the movement of the throttle pedal is transmitted

from the footplate to the roller and the swing arm
on the throttle position sensor (TPS) unit. A variable
resistor within the TPS unit changes the voltage
output in relation to the position of the pedal.
Two signals are output from the unit, a track 1 signal

and a track 2 signal. One signal varies the voltage by
the angle below the foot pedal pad. The other signal
varies the voltage by the angle above the foot pedal
pad. Both signals will always add up to 5V. Refer to
engine- sensor, refer to (PIL 15-84).
Figure 342.
B
A
C
D
A Throttle position sensor unit

B Throttle pedal
C Swing arm
D Roller
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15 - Engine
84 - Sensor
Remove and Install
Consumables 4. Remove the floor mat from the cab.

JCB Threadlocker 4101/0250 0.01L chassis harness, from below the cab.
Strength) 6. Remove the socket head bolts.
Remove 7. Make sure you keep the spacer plate (if

installed).
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 343.
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 - 312 9813/7600-3 15 - 312

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

Introduction .................................................. 15-314 The coolant temperature sensor is located on the
Operation ..................................................... 15-315 cylinder head at the drive belt end.
Check (Operation) ....................................... 15-315
A
A Coolant temperature sensor
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15 - Engine
84 - Sensor
The coolant temperature sensor detects the 1. For the full inspection and testing procedure,
temperature of the coolant in the cylinder head. refer to the help files in ServiceMaster.
The signal from the sensor is used to drive the

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

injection the ECM (Engine Control Module)
processes the signal to determine the engine
operating temperature. The ECM adjusts the
injection timing and the amount of fuel injected, this
can facilitate cold starting.
15 - 315 9813/7600-3 15 - 315

15 - Engine
84 - Sensor

Item Nm
1 16
Before Removal
2. Drain the coolant, refer to (PIL 21-00).
Figure 345.
1
P1
1 Coolant temperature sensor

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

serviceable item. If the switch is faulty or damaged it
must be renewed.
Install
steps.
3. Tighten the coolant temperature sensor to the
4. Refill the cooling system with the recommended
coolant mixture, refer to Technical Data (PIL
21-00).
5. Start the engine and check for coolant leaks.
15 - 316 9813/7600-3 15 - 316

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

Introduction .................................................. 15-317 The engine oil temperature sensor is mounted in a
Operation ..................................................... 15-318 port on the oil cooler housing adjacent to the engine
Check (Operation) ....................................... 15-318 oil dipstick.
Figure 346. Engine oil tem-
perature sensor location
A Engine oil temperature sensor
15 - 317 9813/7600-3 15 - 317

15 - Engine
84 - Sensor
The oil temperature sensor informs the ECM (Engine 1. For the full inspection and testing procedure,
Control Module) of the engine oil temperature. The refer to the help files in ServiceMaster.
ECM processes the signal to determine the oil
temperature. The ECM adjusts the fuel delivery.
15 - 318 9813/7600-3 15 - 318

15 - Engine
84 - Sensor

Item Nm
Special Tools
Description Part No. Qty. 1 21
Before Removal
Figure 347.
B
A Sealing washer
B Engine oil temperature sensor
Remove
2. Disconnect the electrical connector at the engine
oil temperature sensor.
the oil cooler housing.
4. Discard the sealing washer. Cap the open port
with a blanking cap to prevent loss of fluid and
ingress of dirt.
The engine oil temperature sensor is a non-

it must be renewed.
Install
steps.
3. Use the special tool to tighten the engine oil
temperature sensor to the correct torque value.
15 - 319 9813/7600-3 15 - 319

15 - Engine
84 - Sensor
43 - Engine Oil Level
43 - Engine Oil Level Introduction

Introduction .................................................. 15-320 The engine oil level sensor is used to warn the
Operation ..................................................... 15-321 operator that the engine oil level is low and damage
Check (Operation) ....................................... 15-321 may be caused if it is not topped up immediately. It is
Remove and Install ..................................... 15-322 mounted on the engine oil sump.
15 - 320 9813/7600-3 15 - 320

15 - Engine
84 - Sensor
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 - 321 9813/7600-3 15 - 321

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 348.
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.
4. Remove the oil sump.
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 - 322 9813/7600-3 15 - 322

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

Introduction .................................................. 15-323 The intercooler outlet sensor is located in the air
Operation ..................................................... 15-324 intake on the inlet manifold.
Check (Operation) ....................................... 15-324
P Intercooler outlet sensor
15 - 323 9813/7600-3 15 - 323

15 - Engine
84 - Sensor
The intercooler outlet sensor measures the 1. For the full inspection and testing procedure,
temperature of the air coming from the intercooler refer to the help files in ServiceMaster.
into the inlet manifold. The sensor sends an
analogue voltage signal to the ECM (Engine Control
Module).
15 - 324 9813/7600-3 15 - 324

15 - Engine
84 - Sensor
Remove and Install
Before Removal
Figure 350.
A Intercooler outlet temperature sensor
Remove
3. Remove the sensor from the air intake.
4. Cap the open port with a blanking cap to prevent
dirt ingress.
Install
step.
2. Tighten the sensor to the correct torque value.

Item Nm
A 8.5
15 - 325 9813/7600-3 15 - 325

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

Introduction .................................................. 15-326
Operation ..................................................... 15-327
Introduction
Reaction of nitrogen and oxygen gases in the air
during combustion, especially at high temperatures
causes the NOx (Nitrogen Oxide) emission from the
exhaust system.
To monitor the NOx emission, two NOx sensors are

installed on the exhaust system. One is the upstream
NOx sensor and another is downstream NOx sensor.
The Upstream NOx sensor is installed before the
SCR (Selective Catalytic Reduction) catalyst and it
measures NOx level in the exhaust gases before
the after-treatment system. The downstream NOx
sensor is installed after the SCR catalyst and it
measures NOx level in the exhaust outlet.
Figure 351.
P
B
C
A D
P
F
K E L M N
G H J
A DEF (Diesel Exhaust Fluid) system control unit-
ECM (Engine Control Module) or a separate
ECU (Electronic Control Unit)
B Supply module (SM)- pump, filter and valves
C DEF tank- tank, tank level sensor and heating
device (with or without DEF quality sensor)
D Engine coolant connections – used to defrost
DEF
E Dosing module– DEF injector nozzle
F Engine coolant connections – for nozzle cooling
G Diesel Oxidation Catalyst (DOC) – Not installed
on all systems
H Mixer
J SCR
K NOx sensor - Upstream
L Upstream catalyst temperature sensor
M Downstream catalyst temperature sensor
N NOx sensor - Downstream
P DEF lines (inlet, pressure and return) – usually
heated by electric elements or engine coolant
15 - 326 9813/7600-3 15 - 326

15 - Engine
84 - Sensor
Operation
These two signals are then compared to determine

(For: JCB Tier 4F Engine 4 Cyl) the conversion efficiency of the catalyst.
NOx (Nitrogen Oxide) sensors are similar to The NOx sensors will not work unless they are at
wideband oxygen sensors, but typically have their the correct temperature, so they have an integrated
own control module that communicates with the heater that is also module controlled. The power
SCR (Selective Catalytic Reduction)ECU (Electronic supply to the NOx sensor control module is critical
Control Unit) over a CAN (Controller Area Network) for proper sensor operation.
bus.
During a cold start, moisture in the exhaust system
Two NOx sensors are used: can interfere with the NOx sensor operation. In
this scenario, the ECU will not turn on the NOx
• Upstream sensor at the Turbocharger exhaust sensor heaters until the exhaust temperatures reach
outlet. a certain threshold and condensed moisture is
• Downstream sensor from the SCR catalyst. evaporated. This can result in a delay of up to 5min
before both NOx sensors are fully operational.
Figure 352.
G E
C H
J
F C
K
A O2 B NOx
C O and O2 D N
E NOx sensor body F First chamber
G Nerst cell 1 H Second chamber
J Catalytic element K Nerst cell 2
Diesel NOx sensors are of dual-purpose. They are point, the NOx molecules come into contact with a
used to measure both the oxygen level in the catalytic element, which breaks them into nitrogen
exhaust as well as NOx (NO and NO2) content. and oxygen gases.
The measurements take place in two separate
chambers in the sensor, and the exhaust gases flow A second Nerst cell is then used to pump the newly
sequentially through one and then into the other. generated oxygen out of the chamber, and this
electric current is used to calculate the NOx levels in
Gases flow from the exhaust stream through a the exhaust. The residual nitrogen gases then flow
diffusion barrier to reach the first chamber, which out an exit port in the second measurement chamber.
pumps the free oxygen out using a Nerst cell (simple
oxygen sensor). The electric current for operating When two NOx sensors are in a urea SCR system,
this first Nerst cell is used to measure the exhaust the upstream sensor is used to estimate what
oxygen content. amount of DEF (Diesel Exhaust Fluid) needs to be
injected ahead of the SCR catalyst to achieve optimal
With the free oxygen removed, the NOx is then NOx conversion. The downstream (post-catalyst)
left to pass through another diffusion barrier and sensor is then used to check the results.
into the second measurement chamber. At this
15 - 327 9813/7600-3 15 - 327

15 - Engine
84 - Sensor
Remove and Install Remove

Figure 353.
Consumables
Graphite/Calcium 4004/7545 -
Fluoride Based Metal
Free Anti-Seize 4
Compound
NOx (Nitrogen Oxide) sensors are extremely

delicate. Care must be taken to avoid knocks and
impacts which can damage the sensor. Do not
touch the tip of the sensor, doing so can prevent it
from functioning correctly. The NOx sensor and the
1
sensor control unit are permanently connected, do
not attempt to disconnect the harness as damage will
be caused.
Before Removal 2
2. Get access to the NOx sensor.
3
3. Ensure that the area around the NOx sensor
is clean to prevent contamination of the SCR
1 NOx sensor
2 Harness support bracket
3 NOx sensor retaining nut
4 Cable tie
15 - 328 9813/7600-3 15 - 328

15 - Engine
84 - Sensor
Figure 354. Tighten the retaining nut to the correct torque

value.
7
5. Install the harness support bracket around the
NOx sensor.
6. Install the Sensor control unit.
6
6.1. Install the bolts (x2) finger tight to minimise
the strain on the harness.
6.3. Connect the electrical connector.
7. Install the new cable ties around the harness
support brackets.
8. Install any additional supports and clips.

5
Item Nm
3 70
5 Electrical connector 7 10
6 Sensor control unit
7 Bolts
Sensor control unit.
2. Remove the cable ties from the harness support
brackets.
3. Remove the bolts (x2) that secure the Sensor
control unit to the machine.
4. Remove the harness support bracket.
5. Remove the NOx sensor retaining nut.
6. Remove any additional supports or clips.
7. Remove the NOx sensor and the Sensor control
unit from the machine.
Install
1. Inspect the sensor for signs of damage. Pay
particular attention to the mating faces of the
sensor and exhaust system. Clean off any oil
or corrosion. Make sure that the faces are flat,
smooth and free from damage.
2. Replace the NOx sensor sealing washer.
3. Apply anti-seize compound to the threads of the
retaining nut. Make sure the correct anti-seize
compound is used to prevent damage to the SCR
system.
Consumable: Graphite/Calcium Fluoride Based
Metal Free Anti-Seize Compound
4. Carefully insert the NOx sensor into the exhaust
system. Make sure that it is seated correctly.
15 - 329 9813/7600-3 15 - 329

15 - Engine
86 - Solenoid
86 - Solenoid
Contents Page No.
15-86-00 General ......................................................................................................................... 15-331

15-86-09 Cold Start Advance ...................................................................................................... 15-332
15 - 330 9813/7600-3 15 - 330

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 - 331 9813/7600-3 15 - 331

15 - Engine
86 - Solenoid
09 - Cold Start Advance
09 - Cold Start Advance Introduction

Introduction .................................................. 15-332 The cold start advance solenoid consists of an
Check (Condition) ........................................ 15-333 electrical solenoid and a valve which allows extra
Remove and Install ..................................... 15-334 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 - 332 9813/7600-3 15 - 332

15 - Engine
86 - Solenoid
Check (Condition)
1. If a faulty solenoid is suspected, perform tests to
confirm its serviceability.
15 - 333 9813/7600-3 15 - 333

15 - Engine
86 - Solenoid
Remove and Install
Before Removal 2. Get access to the engine.

Figure 355.
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 148. 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 - 334 9813/7600-3 15 - 334

15 - Engine
87 - Switch
87 - Switch
Contents Page No.
15-87-00 General ......................................................................................................................... 15-337

15-87-03 Engine Oil Pressure ..................................................................................................... 15-338
15-87-09 Cold Start ..................................................................................................................... 15-341
15 - 335 9813/7600-3 15 - 335

Notes:
15 - 336 9813/7600-3 15 - 336

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 - 337 9813/7600-3 15 - 337

15 - Engine
87 - Switch
03 - Engine Oil Pressure
03 - Engine Oil Pressure Introduction

Introduction .................................................. 15-338 The oil pressure switch is mounted in a port on the
Operation ..................................................... 15-339 oil cooler housing.
Check (Operation) ....................................... 15-339
A
A Engine oil pressure switch
15 - 338 9813/7600-3 15 - 338

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 - 339 9813/7600-3 15 - 339

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

item. If the switch is faulty or damaged it must be
renewed.
Install
steps.
2. Replace the sealing washer.
3. Tighten the engine oil pressure switch to the
Torque: 16N·m
15 - 340 9813/7600-3 15 - 340

15 - Engine
87 - Switch
09 - Cold Start
09 - Cold Start Introduction

Introduction .................................................. 15-341 The cold start switch will send a signal to turn on the
Check (Condition) ........................................ 15-342 cold start advance solenoid at specific temperatures
Remove and Install ..................................... 15-343 to help in cold starting conditions.
15 - 341 9813/7600-3 15 - 341

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 - 342 9813/7600-3 15 - 342

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 357.
2
1 Engine cold start switch 2 Crankcase

3 Sealing washer - switch
15 - 343 9813/7600-3 15 - 343

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 - 344 9813/7600-3 15 - 344

15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ......................................................................................................................... 15-347
15 - 345 9813/7600-3 15 - 345

Notes:
15 - 346 9813/7600-3 15 - 346

15 - Engine
90 - Air Intake
00 - General
00 - General
Check (Condition)
15 - 347 9813/7600-3 15 - 347

Notes:
15 - 348 9813/7600-3 15 - 348

Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-03 Tank
18-03-00 General ........................................................................................................................... 18-17
18-06 Level Sender
18-06-00 General ........................................................................................................................... 18-25
18-09 Filter
18-09-00 General ........................................................................................................................... 18-29
18-09-03 Filter Element ................................................................................................................. 18-34
18-09-09 Pre-Filter Element .......................................................................................................... 18-36
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-39
18-12-04 Water in Fuel Sensor ..................................................................................................... 18-42
18-18 Injection
18-18-00 General ........................................................................................................................... 18-45
18-18-03 Injector ............................................................................................................................ 18-60
18-18-07 Injector Seal ................................................................................................................... 18-65
18-18-12 Rail ................................................................................................................................. 18-67
18-18-15 Pump .............................................................................................................................. 18-69
18-18-27 High Pressure Rail Valve ............................................................................................... 18-76
18-21 Fuel Pump
18-21-00 General ........................................................................................................................... 18-81
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-87
18-24-03 Inlet Manifold .................................................................................................................. 18-89
18-24-04 Outlet Manifold ............................................................................................................... 18-93
18-27 Exhaust Gas Recirculation (EGR)
18-27-00 General ........................................................................................................................... 18-99
18-27-03 Actuator ........................................................................................................................ 18-106
18-30 Selective Catalytic Reduction (SCR)
18-30-00 General ......................................................................................................................... 18-109
18-30-03 Tank .............................................................................................................................. 18-116
18-30-06 Filter ............................................................................................................................. 18-122
18-30-09 Tank Sensor ................................................................................................................. 18-126
18-30-12 Pump Supply Module ................................................................................................... 18-131
18-30-15 Dosing Metering Module .............................................................................................. 18-137
18-30-18 Catalyst ........................................................................................................................ 18-140
18-30-24 Coolant Valve ............................................................................................................... 18-143
18-30-30 Intake Throttle .............................................................................................................. 18-146
18-30-36 Mixer Reactor ............................................................................................................... 18-150
18-30-90 Hose ............................................................................................................................. 18-152
18-35 Turbocharger
9813/7600-3
2018-01-31
18-35-00 General ......................................................................................................................... 18-155
18-36 Variable Geometry Turbocharger (VGT)
18-36-00 General ......................................................................................................................... 18-163
18-36-03 Actuator ........................................................................................................................ 18-170
18-39 Fuel Cooler
18-39-00 General ......................................................................................................................... 18-173
18-96 Fuel Pipe
18-96-00 General ......................................................................................................................... 18-177
18-96-03 High Pressure Pipe ...................................................................................................... 18-179
18-96-06 Low Pressure Pipe ....................................................................................................... 18-182
9813/7600-3
2018-01-31
Acronyms Glossary

CPA Connector Position Assurance
EAT Exhaust After Treatment
HPV High Pressure Valve
IMV Inlet Metering Valve
NOx Nitrogen Oxide
PPE Personal Protective Equipment
PWM Pulse Width Modulation
VGT Variable Geometry Turbocharger
WIF Water in Fuel
9813/7600-3
2018-01-31
Notes:
9813/7600-3
2018-01-31
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3
18 - 1 9813/7600-3 18 - 1
Notes:
18 - 2 9813/7600-3 18 - 2
00 - General
Introduction ...................................................... 18-3 USE THE CORRECT FUEL. The potential for
Health and Safety ........................................... 18-4 engine damage due to the use of incorrect or
Technical Data ................................................. 18-4 contaminated fuel is much greater with common
Component Identification ................................. 18-5 rail injection technology than with mechanical
injection systems. For information about fuel types
Operation ......................................................... 18-6 and cleanliness requirements, refer to Consumable
Fault-Finding .................................................... 18-9 Products Refer to: PIL 75-00-00. Technical Data,
Discharge and Pressurise ............................. 18-11 Fuel, Acceptable and Unacceptable Fuels and
Clean ............................................................. 18-11 Cleanliness Requirements.
Check (Pressure) .......................................... 18-13 For information about the fuel injection system. Refer
Bleed ............................................................. 18-15 to: PIL 18-18.
Common Rail Fuel Injection

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

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

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

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

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

more important than with mechanical direct injection
systems. To combat fuel contamination, a water
separator and pre-filter is installed in addition to the
main filter.
18 - 3 9813/7600-3 18 - 3
00 - General

Fuel Table 150. Fuel System Data
Fuel is flammable, keep naked flames away from the
High pressure pump Delphi DFP 4.2
fuel system. Stop the engine immediately if a fuel
type
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the Direction of rotation from Anti-clockwise
engine running. Completely wipe off any spilt fuel drive end
which could cause a fire. There could be a fire and Fuel lift pump type Electrically operated
injury if you do not follow these precautions. Fuel filter micron rating
Fluid Under Pressure Pre-filter 5 micron
Fine jets of fluid at high pressure can penetrate the Main filter 2 micron
skin. Keep face and hands well clear of fluid under Fuel filter restriction - 0.65bar (9.4psi)
pressure and wear personal protective equipment. maximum pressure drop
Hold a piece of cardboard close to suspected Fuel return restriction - 0.22bar (3.2psi)
leaks and then examine the cardboard for signs of maximum
fluid. If fluid penetrates your skin, get medical help Injector information Electronically controlled
immediately. solenoid actuated in-
WARNING! Do not open the high pressure fuel jectors. Each injector is
system with the engine running. Engine operation marked with a unique
causes high fuel pressure. High pressure fuel spray calibration code.
can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow these
instructions will lead to dirt entering the fuel system.
Dirt in the fuel system will seriously damage the fuel
injection equipment and could be expensive to repair.
Notice: The high pressure fuel system is extremely
susceptible to damage if it is contaminated. Always
clean the engine using the correct procedures before
carrying out maintenance. Contamination of the fuel
system can cause catastrophic failure of the engine.
Notice: Running the engine with air in the system
could damage the fuel injection pump. After
maintenance, the system must be bled to remove
any air.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
accordance with local regulations. Use authorised
18 - 4 9813/7600-3 18 - 4
00 - General
Figure 358.
3
2
15
A
6 6 6 6
14
13
1 16
1 ECM (Engine Control Module)(refer to PIL 2 High pressure fuel injection pump (refer to PIL
33-45) 18-18)
3 Common fuel rail (refer to PIL 18-18) 6 Fuel injectors (refer to PIL 18-18)
13 Fuel filter (2 micron) (refer to PIL 18-09) 14 Fuel pre-filter and water separator (5 micron)
(refer to PIL 18-12)
15 Electric feed pump (refer to PIL 18-21) A Electrical sensors (refer to PIL 15-84)
B Fuel tank (refer to PIL 18-03)
18 - 5 9813/7600-3 18 - 5
00 - General
Operation
Some fuel flows through the pump at all times to

The fuel system is central to the performance and provide internal lubrication and cooling. This fuel
efficiency of the engine, distributing an accurate bleeds back to tank via the bleed-off fuel lines.
amount of fuel to each cylinder at exactly the right
time. Pressurised fuel from the high pressure pump
passes into the common fuel rail. The high pressure
Fuel is drawn from the fuel tank by the electric pump is capable of pressurising the fuel in the rail
lift pump integral via the 5 micron pre-filter/water up to 2000 bar. The ECM controlled IMV is used to
separator. (The fuel lift pump is integral with the pre- control the amount, and therefore pressure of the fuel
filter/water separator assembly.) in the common rail.
Fuel is pressurised at low pressure by the electric In some operating conditions the inlet metering valve
lift pump and passes through an engine mounted 2 is not able to reduce the rail pressure quickly enough
micron fuel filter on its way to the inlet on the high (if the operator goes from full throttle to no throttle
pressure pump. suddenly for example). In these circumstances the
rail pressure is dumped to the bleed off line using the
Important: Use of the correct fuel grade, together ECM controlled electric HPV (High Pressure Valve).
with effective filtration and decontamination of the
fuel is essential. The high pressure pump, injectors High pressure fuel pipes connect the injectors to
and engine can be damaged beyond repair by the common fuel rail. The injectors are electrically
contaminated fuel or use of incorrect fuel. controlled and incorporate a small solenoid valve.
The high pressure fuel injection pump is a rotary type Injection timing is determined by the ECM. Electrical
and is gear driven by the engine. The pump consists data from several sensors is continually monitored
of two sections, the transfer pump and high pressure and processed by the ECM to determine when, how
pump. Fuel is first pressurised to about 6 bar by the much and to which cylinder fuel must be injected.
transfer pump. A constant pressure is maintained
regardless of engine speed by the regulating valve. The injectors inject fuel in response to a supply
of electrical current from the ECM. So precise is
Fuel is transferred to the high pressure pump via the control that several injections of fuel occur
the IMV (Inlet Metering Valve). The metering valve during each firing stroke for maximum efficiency and
controls the amount of fuel transferred depending on minimum emissions. During fuel injection some fuel
the engine operating parameters (throttle position, bleeds off the injectors and back to tank via bleed off
coolant temperature etc.). The metering valve is lines.
controlled by the ECM (Engine Control Module).
18 - 6 9813/7600-3 18 - 6
00 - General
Figure 359.
2b
2e 2
2c 2d
3b
3
5 4
15
6 6 6 6
14
16
13
1 ECM 2 Fuel high pressure pump

2b IMV 2c Fuel high pressure pump (transfer section)
18 - 7 9813/7600-3 18 - 7
00 - General
2d Fuel high pressure pump (high pressure 2e Pressure regulating valve (transfer section)
section)
3 Common fuel rail 3b HPV
4 High pressure fuel lines 5 Bleed off fuel lines
6 Fuel injectors 13 Fuel filter
14 Pre-filter/water separator 15 Electric fuel lift pump
16 Fuel tank
Table 151. Colour code key

Colour Component
Green Tank pressure
Blue Transfer pressure
Red Injection rail pressure
Yellow Electrical connections
-ECM - injectors
Light Green Pump internal pressure,
injector bleed-off
18 - 8 9813/7600-3 18 - 8
00 - General
Fault-Finding
Fault
Fuel Consumption Excessive Table 152. Page 18-9
Fuel/Oil- Leaking from Exhaust Manifold Table 153. Page 18-9
General Fuel System Faults Table 154. Page 18-10
Exhaust Gas Recirculation Table 155. Page 18-10
Table 152. Fuel Consumption Excessive

Cause Remedy
Additional load on engine. Check/repair accessories and vehicle components.
Refer to the equipment manufacturer's procedures.
Operator technique. Review operation for correct gear shifts, deceleration
and idling.
Fuel leaks. Check for external leaks at the fuel tank, fuel lines,
filters and lift pump WARNING: Do not repair
defective fuel lines. If there is a fuel leak remove and
discard the necessary components and install new
ones.
Air intake or exhaust leaks.
ECM (Engine Control Module)or electrical sensor Check the electronic fault codes. Check the electrical
fault. connections at the ECM and sensors.
One or more engine injectors worn or malfunctioning. Check the electronic fault codes. Check the electrical
clearances.
Table 153. Fuel/Oil- Leaking from Exhaust Manifold

Cause Remedy
Operating for extended periods under light or no load Review operation for correct gear shifts, deceleration
conditions. and idling.
Air intake or exhaust leaks.
Turbocharger lubricating oil drain line obstructed. Check/clean line.
Exhaust leak at the Manifold or Turbocharger. Check/repair leaks in the manifold or turbocharger
gaskets. Check for a cracked manifold.
Valve guide seals are leaking. Replace valve guide stem seals as required.
One or more engine injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
18 - 9 9813/7600-3 18 - 9
00 - General
Table 154. General Fuel System Faults

Cause Remedy
Fuel supply fault Check the low pressure circuit connections are
secure.
Check the fuel pressure in low circuit/tank level.
Check the fuel type (EN590 Specification).
Check for the external diesel fuel leaks.
Check the filter is not blocked
Check the fuel lift pump operation (Refer to
ServiceMaster help files).
Replace/repair as necessary.
If no faults are found, proceed to "Engine does not
start," or "Engine starts," depending on symptoms
Engine does not start Complete the ‘Static Injector Leak Test’.
If the injector back leak is above the limit, replace
injector(s) as necessary.
If the injector back leak is OK check the rail pressure
is above 300 bar, if not, replace the high pressure
pump.
If the rail pressure is OK and back leak is within
limits, raise Techweb Helpdesk Call.
Engine starts Complete the ‘Dynamic IMV (Inlet Metering Valve)
Test’.
If the IMV is faulty replace the high pressure pump.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
injector(s).
If the back leak is OK complete the ‘Dynamic HPV
(High Pressure Valve) test’
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 155. Exhaust Gas Recirculation

Cause Remedy
Air inlet circuit fault Check the air inlet circuit: – Valve position using
ServiceMaster – Check the EGR (Exhaust Gas
Recirculation) linkage – Vane state
If no fault is found proceed to 'EGR valve connection
fault'.
EGR valve connection fault Check the EGR valve connection. Check that the
supply voltage is correct. Repair as necessary.
Check that the EGR valve position can reach MIN
(0%) to MAX position (100%). Use ServiceMaster to
launch the learning procedure of the EGR position.
18 - 10 9813/7600-3 18 - 10
00 - General
Discharge and Pressurise Clean

Notice: Running the engine with air in the
system could damage the fuel injection pump. Cleanliness Requirements
After maintenance, the system must be bled to
remove any air. Important: Additional cleaning must be carried out
prior to working on the high pressure fuel system.
Obey all fuel system health and safety information. It is extremely important the high pressure fuel
Refer to (PIL 18-00). components and the adjacent parts of the engine
are meticulously cleaned before any components are
The entry of air into the fuel system can cause removed. Refer to: Effects of Contamination.
problems such as difficult engine starting and
unstable engine running. Air can enter the system if Before starting work on the high pressure fuel
the following occurs: system, make sure that the working environment
is suitable. Refer to: Maintenance Environment,
• A fuel system component has been Common Rail Fuel Injection.
disconnected. For example, a fuel filter renewal.
• A leak in the low pressure side of the fuel 1. Obey all fuel system health and safety
system during engine operation, or the low information.
pressure pipes have been disconnected. Refer Refer to: PIL 18-00-00.
to Fuel System - General (PIL 18-00) for a more
detailed description of the fuel circuit. 2. Clean the machine, prior to completing any
• The fuel tank is allowed to drain fully during maintenance work.
normal operation.
3. Clean the engine.
The engine installation features an electrically Refer to: PIL 15-00-00.
operated fuel lift pump. The system is designed to
bleed automatically when the lift pump is operated. 4. Remove the hoses, electrical harnesses and
Make sure that as much air is removed from the fuel ancillaries to improve access and expose any
as possible before you start the engine. Bleed the remaining trapped dirt close to the relevant high
system as follows: pressure components.
Important: DO NOT attempt to bleed the high 5. Wash away any remaining dirt or debris and then
pressure fuel system by loosening the high pressure dry the area using a compressed air jet. When
pipe connections even when the engine is not the area is dry use a soft clean brush to remove
running. To bleed the fuel system follow the correct sand or grit particles that remain.
procedure.
Effects of Contamination
1. Turn on the machine ignition switch to start the
fuel lift pump. DO NOT start the engine. Allow the Whist the requirement for a good level of cleanliness
pump to run for 30 seconds. is well known and common practice, the introduction
of high pressure common rail fuel injection
2. Turn off the machine ignition switch to stop the
necessitates working to new levels of cleanliness.
fuel lift pump. Wait 10 seconds and then turn the
ignition switch to start the pump. DO NOT start Once inside the system, fuel circuit contaminants
the engine. Allow the pump to run for 30 seconds. greatly affect the performance and life of the fuel
3. Repeat step 2 twice more before you start the injection equipment. For example, contaminants in
engine. the fuel pump will develop internal wear to cause
internal leakage and hence lower discharges. Use
4. Start the engine and make sure it runs smoothly. of poor quality fuels and poor maintenance could
also lead to contaminants entering the fuel injectors.
There is a possibility of catastrophic equipment
failure if debris should prevent the injectors from fully
closing. The main contaminants can be classified as
follows:
• Solid Particles - sand, fibres, metallic particles,

welding scale, sealing materials and wear
particles etc.
• Liquid - usually water and incompatible oils and
greases.
18 - 11 9813/7600-3 18 - 11
00 - General
• Gases - Air, sulphur dioxide etc. which can Maintenance Environment, Common
create corrosive compounds if dissolved in the Rail Fuel Injection
fluid.
Depending on circumstances engine maintenance
These contaminants can appear during may be required in various working environments.
manufacture, assembly, operation and maintenance. Obviously procedures are best carried out in a
dedicated workshop equipped with a suitable clean
The main filter is rated at 2 micron = 0.002 mm
room, but in practice this is not always possible.
(0.0007874 in). The pre-filter is rated at 5 micron.
Listed are a few typical comparisons of micron size: Maintenance procedures requiring removal or
replacement of fuel system components, particularly
Figure 360.
high pressure components, require special
precautions to make the working environment
suitable, reducing the risk of contamination to an
absolute minimum.
Use the following guidelines to make sure you reduce

the chances of fuel system contamination when
C working in different environments:
B
Worksite - Open to weather
This repair site is not an acceptable location. Only
A
in extreme circumstances should a machine be
repaired on an open site. Use the guidelines below:
A 8 Microns • Clean the engine, Refer to: PIL 15-00-00. If
B 70 Microns the machine is on hard standing, clean away the
C 100 Microns material washed from the engine.
• Red Blood Cell = 8 microns (0.008 mm, • Place suitable clean boards on the ground
0.000315 in). around the machine.
• Human Hair = 70 microns (0.07 mm, 0.00275 • Erect clean plastic sheeting to shelter the
in). engine from wind and rain.
• Grain of Salt = 100 microns (0.1 mm, 0.00394 • Wear a new disposable environmental type suit
in). when working on the fuel system. If the suit
• The smallest particle visible to the naked eye is becomes contaminated with mud, move away
40 microns (0.00157in) approximately. from the engine and change into a new suit.
• Use clean latex gloves (non-powdered).
The main filter and pre-filter must be changed in • Before you start work make sure that all the
accordance with the applicable service schedule required replacement parts and tools are on
and procedures. The water in fuel sensor must be site. Make sure that the replacement parts are
maintained to ensure correct operation at all times. still sealed inside their packaging.
• Cap all exposed ports and orifices immediately.
The potential for engine damage due to fuel Do not leave them open.
contamination is much greater when using common • High pressure fuel pipes MUST BE REPLACED
rail injection technology than with mechanical if any pipe joint is loosened or disconnected. DO
injection systems. This is because common rail NOT re-use the original pipe.
requires components with smaller manufacturing
tolerances, especially the fuel injectors. In addition, Worksite - Closed to weather from above
common rail operates at much higher fuel pressures,
over five times that of mechanical systems. This repair site is the least acceptable condition,
if possible move the machine to a more suitable
Similar pressures are used by commercial water environment. Use the guidelines below:
jet cutting machines to cut metal. Fortunately clean
diesel fuel has lubricating qualities that prevents • Clean the engine, Refer to: PIL 15-00-00.
erosion of components but it is obvious that Clean the floor of all material washed from the
contaminated fuel will cause serious damage at such engine.
high pressures. • Place suitable clean boards on the ground
around the machine.
18 - 12 9813/7600-3 18 - 12
00 - General
• Erect clean plastic sheeting to shelter the Check (Pressure)

engine from the wind and the possibility of
debris such as dirt and dust falling from above.
• Wear a new disposable environmental type suit When it is necessary to check the fuel rail pressure
when working on the fuel system. If it becomes function on a faulty vehicle, it is often difficult to
contaminated with mud, move away from the decide which component of the system has failed.
engine and change into a new suit. It is essential to keep in mind the principles of the
• Use clean latex gloves (non-powdered). function of the Common Rail Fuel system:
• Before you start work make sure that all the
required replacement parts and tools are on Table 156.
site. Make sure that the replacement parts are Principle Function
still sealed inside their packaging.
• Cap all exposed ports and orifices immediately. Pressure production The pump compresses
Do not leave them open. the fuel at high pressure
• High pressure fuel pipes MUST BE REPLACED Pressure regulation The pressure thus pro-
if any pipe joint is loosened or disconnected. DO duced is accumulated in
NOT re-use the original pipe. a rail and measured and
regulated (the rail pres-
Vehicle Maintenance Workshop sure sensor, the ECU
(Electronic Control Unit)
Unless the workshop has a dedicated `sealable and the IMV (Inlet Me-
clean room' work bay, precautions must still be taken. tering Valve) function in
a closed loop, excess
• Clean the engine, Refer to: PIL 15-00-00. pressure is drained to
Clean the engine in the dedicated area and tank by the HPV (High
then move it to the workshop. Pressure Valve)
• Clean the floor area around the machine. Pressure consumption This pressure is finally
• Erect clean plastic sheeting to shelter the consumed by the injec-
engine from any wind and the possibility of tors (injection into the
debris such as dirt and dust falling from above. engine cylinders and in-
• Ensure that workshop doors to the outside are jector management)
kept closed. A gust of wind through an open
door will easily blow sand particles into the air. This means that a pressure fault may come from
• Make sure your work wear is clean, non-flocking the producer, the regulator or the consumers. Simply
and lint free. If in doubt wear a new disposable studying the physical parameters of the rail pressure
environmental type suit. does not allow the disassociation of the producer and
the consumer.
• Use clean latex gloves (non-powdered).
• Before you start work make sure that all the Symptoms
required replacement parts and tools are on • The engine won’t start or is difficult to start.
site. Make sure that the replacement parts are • The engine stalls while running.
still sealed inside their packaging • Lack of power and dashboard warning lamps
• Cap all exposed ports and orifices immediately. light: the recovery mode may lead to engine
Do not leave them open. stop.
• High pressure fuel pipes MUST BE REPLACED
if any pipe joint is loosened or disconnected. DO Hydraulic System Status Analysis
NOT re-use the original pipe.
Hydraulic flow balance is established as follows:
Injected flow + Back leaks flow (Flow consumed)

= Capacity of the HP pump to supply the flow
requested for a given diesel fuel temperature
Hydraulic flow balance is upset if:

• The Injector back leak flow increases sharply,
exceeding the pump capacity.
• This can happen when particles disturb the
internal injector sealing, increasing the back
leak flow from one/several injectors or HPV
18 - 13 9813/7600-3 18 - 13
00 - General
Examples: • Excessive negative pressure at the pump inlet

(<- 300m Bar, fuel filter blocked).
• Heavy contamination of the fuel wear and tear
• Mechanical wear in the pump.
on the pump leads to the production of metallic
• Excessive pump inlet temperature.
particles that will seriously disturb the injector
function. Figure 362. Reduction in HP Pump Capacity
• Mechanical wear in the injector.
• HPV stuck open.
100 100
The capacity of the pump to supply the required
pressure is reduced due to internal pump wear,
pressure is reduced due to internal pump wear or a
fuel feed problem.
Figure 361. Increased Back Leak Flow
C
F
C
100 100
E D
0 0
B A
A Production
B Consumption
C Reduction in HP pump capacity
D Pressure deficit
E Pump capacity
E F Injected flow
G Back Leak flow
0 0
B A
A Production
B Consumption
C Increased back leak flow
D Pressure deficit
E Pump capacity
F Injected flow
Example
• Presence of air in the low pressure circuit.
18 - 14 9813/7600-3 18 - 14
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: 30s
Figure 363.
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: 30s
4. Do the step 3 for two more times before you start
the engine.
18 - 15 9813/7600-3 18 - 15
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ........................................................................................................................... 18-17
18 - 16 9813/7600-3 18 - 16
03 - Tank
00 - General
Introduction .................................................... 18-17 The fuel tank is a safe container for storing flammable
Clean ............................................................. 18-18 fluids, from here the fuel is pumped into the engine.
There can be condensation in a partially filled fuel
tank. Therefore, you must fill the fuel tank after you
operate the engine.
Drain the water and sediment from any fuel storage

tank at the recommended service intervals.
18 - 17 9813/7600-3 18 - 17
03 - Tank
00 - General
Clean
The diesel tank must be drained if there is a chance

the fuel is contaminated or it has been filled with the
incorrect fuel.

2. Drain the diesel tank.
3. Drain the fuel from the low pressure fuel pipes.
4. Replace the fuel filters.
5. Refill the tank to the specified level with clean
diesel.
Percentage: 25%
6. Start the engine and leave it to run for the
specified time period.
Duration: 10min
7. Stop the engine.
8. Drain the water separator and the main fuel filter.
9. If there was any water or other liquid in the water
separator, repeat 6 to 8.
18 - 18 9813/7600-3 18 - 18
03 - Tank
00 - General
Remove and Install
Figure 364. Fuel Tank Drain Plug

(For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY], JCB Tier 4F Engine 4 Cyl)
Remove
W
Some machines have a DEF (Diesel Exhaust Fluid)
tank installed if the machine has SCR (Selective W Fuel tank drain plug
Catalytic Reduction) system installed. The DEF tank 5. Remove the access panel in the cab floor. Refer
is a separate component but is installed within the to (PIL 06-06-39).
area of the fuel tank. When the fuel tank is removed,
the DEF tank remains in place. The fuel tank must be 6. Remove the side step. Refer to (PIL 06-49).
removed before removing the DEF tank.
7. Remove the batteries. Refer to (PIL 33-03-00).
The fuel tank has to be removed before the DEF tank
can be removed. 8. Remove the cab exterior front and rear panels.
Refer to (PIL 06-06-12) and (PIL 06-06-15).
The removal and installation procedure of all fuel
tanks is similar. Some illustrations may differ from 9. Disconnect the fuel filler neck and breather pipe
your machine. from the fuel tank. Take precautions to prevent
the ingress of debris. Make sure that you do not
1. Make the machine safe. Refer to (PIL 01-03). confuse this with the DEF tank filler.
2. Make sure there is sufficient clearance under the 10. Put a label on the hoses to the fuel sender to help
machine to remove the fuel tank before you begin installation.
work.
3. Remove the fuel tank drain plug and drain the contamination.
fuel tank.
12. Disconnect the fuel sender electrical connector.
4. Install the drain plug and tighten to the correct
torque value. 13. Disconnect the tank breather pipe at the outer
side. Remove the cable tie securing it to the
outrigger. Stow the pipe so that it does not get
damaged during tank removal.
14. Remove the bolt 1 and bolt 2.
18 - 19 9813/7600-3 18 - 19
03 - Tank
00 - General
Figure 365. Fuel Tank T4F

B A A C
E D
F
G
J
K
L
A Fuel pipes (sender unit) B Electrical connection (sender unit)

C Bolt 1 (pipe retaining bracket) D Bolt 2 (primary fuses bracket)
E Cable tie (breather pipe) F Breather pipe connection (outer side)
G Fuel filler neck hose clip H Fuel filler breather hose clip
J Nut 1 (tank support- front side) K Nut 2 (tank support- rear side)
L Fuel tank support bracket M Top view of tank (with cab removed for clarity)
N View of tank from LH side of machine (cut away
to show detail)
15. Make sure that there are no other wires, pipes or 16. Support the tank from below, make sure that the
hoses clipped to the tank that may be damaged load is spread evenly. Remove nut 1 and nut 2
when you lower the tank.
18 - 20 9813/7600-3 18 - 20
03 - Tank
00 - General
and washers from the tank support bracket and Figure 367.
remove it.
17. Tilt the tank and pull it towards you slightly to
allow the protrusion on the rear of the tank to
clear the bracket on the chassis.
Figure 366.
T
P S
P Protrusion on inner side of the tank.

18. Lower the tank carefully. Make sure that any fuel
U
tank or DEF tank connections do not get trapped
or damaged during the tank removal.
19. To remove the DEF tank. Refer to (PIL18-30-03).
Install
steps. L V
1.1. Remove the front side fuel tank support bolt L Tank support bracket
before installing the tank. R Fuel tank support bracket
S Fuel tank support bolt (front side)
T Spacer
U O-ring (spacer retention)
V Locknut and washer
1.2. Set the spacer on the fuel tank support
bolt so there is approximately the specified
clearance between the spacer and the
underside of the head of the bolt. The
spacer is held in position by an O-ring
installed on the bolt.
1.3. Make sure that you do not install the
fuel tank support bolt without the spacer
installed correctly on the bolt.
1.4. Make sure that all foam and rubber mats
and seals on the tank are in good condition.
Install new parts if they are defective.
1.5. Install the front side fuel tank support bolt.
1.6. Install the tank. When you install the tank,
tilt it to allow the protrusion on the rear of the
tank to fit above the bracket on the chassis.
18 - 21 9813/7600-3 18 - 21
03 - Tank
00 - General
1.7. If required, reposition the rear side tank

support bracket bolt so it protrudes
correctly.
1.8. Install the fuel tank support bracket and
locking nuts and washers (use new locking
nuts).
1.9. Make sure that the DEF tank and
connections are not damaged during this
procedure.
1.10. Make sure that hoses or wires are not
twisted or trapped.
1.11. Tighten the fuel tank support bracket nuts
1.12. Reinstall all pipework, electrical
connectors, brackets, cable ties and the
filler neck. Make sure that no hoses are
twisted or trapped.
1.13. Make sure that all connections are tight
and correctly secured.
1.14. Fill the fuel tank with clean fuel.
1.15. Bleed the fuel system. Refer to (PIL
18-00).
1.16. Check for leaks. Refer to (PIL 18-00).
1.17. Install all access panels. Refer to (PIL
06-06).

Item Nm
W 9
TBA
TBA
18 - 22 9813/7600-3 18 - 22
06 - Level Sender
06 - Level Sender
Contents Page No.
18-06-00 General ........................................................................................................................... 18-25
18 - 23 9813/7600-3 18 - 23
Notes:
18 - 24 9813/7600-3 18 - 24
06 - Level Sender
00 - General
00 - General
Remove and Install
2. Make sure that the tank contains no more than

(For: 531-70 [5AA], 531-70 [5TA], 535-95 the specified amount of fuel.
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 Percentage: 75%
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
3. Isolate the battery. Refer to (PIL 33-03-03).
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 4. Remove the cab floor access plate, Refer to (PIL
[5UY], JCB Tier 4F Engine 4 Cyl) 06-06-39).
Notice: Do not allow dirt to enter the fuel system. 5. Make sure that the area around the sender unit
Before disconnecting any part of the fuel system, is clean. Make sure that no debris can enter the
thoroughly clean around the connection. When a fuel tank.
a fuel pipe, always install protective caps and 6. Disconnect the fuel feed and return hoses and
plugs to prevent dirt ingress. Failure to follow plug the ends. Mark each hose before you
these instructions will lead to dirt entering the disconnect them to make sure they are correctly
fuel system. Dirt in the fuel system will seriously replaced.
damage the fuel injection equipment and could be
7. Disconnect the fuel sender electrical connector.
expensive to repair.
Remove
Figure 368. Diesel Fuel Tank (Cab removed for clarity)

D A C B
A Diesel fuel sender unit B Diesel fuel pipes

C Sender electrical connector D Diesel fuel tank
18 - 25 9813/7600-3 18 - 25
06 - Level Sender
00 - General
8. Remove the screws from the annular ring that

secures the sender unit to the fuel tank.
Figure 369. Sender Unit
E
D
D Diesel Fuel Tank
E Screw (x6)
9. Manoeuvre the fuel sender to remove it from the
tank.
Install
steps.
1.1. Make sure that no debris enters the fuel
tank or fuel system.
1.2. Tighten all fasteners to the correct torque
value.
1.3. Renew the sender unit O-ring seal.
1.4. Bleed the fuel system. Refer to (PIL
18-00-00).
1.5. Make sure there are no leaks. Refer to (PIL
18-00-00).

Item Nm
E 5
18 - 26 9813/7600-3 18 - 26
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-29

18-09-03 Filter Element ................................................................................................................. 18-34
18-09-09 Pre-Filter Element .......................................................................................................... 18-36
18 - 27 9813/7600-3 18 - 27
Notes:
18 - 28 9813/7600-3 18 - 28
09 - Filter
00 - General
Introduction .................................................... 18-29 The fuel filter consists of a paper element folded in
Component Identification ............................... 18-30 such a way as to give a very large surface area. It is
Operation ....................................................... 18-31 most important that the fuel filter is changed regularly
Drain and Fill ................................................. 18-31 in accordance with the machine maintenance
schedule. Use only the correct specification filters.
18 - 29 9813/7600-3 18 - 29
09 - Filter
00 - General
Figure 370.
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 - 30 9813/7600-3 18 - 30
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 - 31 9813/7600-3 18 - 31
09 - Filter
00 - General
Remove and Install Remove - Disposable Type

Special Tools Figure 372.
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 371. 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: 24N·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 - 32 9813/7600-3 18 - 32
09 - Filter
00 - General
Remove - Element Type

Figure 373.
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: 35N·m
Special Tool: Fuel Filter Removal Tool (4
cyl) (Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.:
1)
18 - 33 9813/7600-3 18 - 33
09 - Filter
03 - Filter Element
03 - Filter Element Remove - Disposable Type

Figure 375.
Remove and Install E
Special Tools C
Spanner - HP Fuel 334/G5933 1
Filter
Fuel Filter Removal 892/01383 1 D
Tool (4 cyl)
Before Removal
you start the service work. A
2. Get access to the filter.
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 B
information for details. A Filter
B Drain tap
2.2. There are different types of filters. Refer to
C Low pressure fuel line
the correct procedure.
D Screw
3. Thoroughly clean the outside of the filter housing E Low pressure fuel line
and around the filter head.
1. Remove the low pressure fuel lines.
4. Loosen the drain tap and allow the water / fuel to
1.1. Put a label on the hoses to help installation.
drain into a suitable container.
5. On machines with a fuel shut-off valve, set the contamination.
valve to isolate the fuel supply.
2. Release the filter strap retaining screw and lift the
Figure 374. filter upward.
A
Install - Disposable Type
1. Make sure that the filter is in the correct position
to enable connection of the fuel lines.
2. Install the filter strap.
B
2.1. Tighten the filter strap to the correct torque
value.
Torque: 24N·m
A Fuel filter element 3. Install the low pressure fuel lines.

B Drain tap
3.1. Make sure they are installed at the correct
ports.
18 - 34 9813/7600-3 18 - 34
09 - Filter
03 - Filter Element
Remove - Element Type

Figure 376.
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
Torque: 35N·m
Special Tool: Fuel Filter Removal Tool (4
cyl) (Qty.: 1)
Special Tool: Spanner - HP Fuel Filter (Qty.:
1)
18 - 35 9813/7600-3 18 - 35
09 - Filter
09 - Pre-Filter Element
09 - Pre-Filter Element Introduction

Introduction .................................................... 18-36 The fuel pre-filter with water separator is installed on
Remove and Install ....................................... 18-37 to the fuel lift pump. The fuel lift pump is a sealed
integral electrical unit.
18 - 36 9813/7600-3 18 - 36
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 377.
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 - 37 9813/7600-3 18 - 37
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-39

18-12-04 Water in Fuel Sensor ..................................................................................................... 18-42
18 - 38 9813/7600-3 18 - 38
00 - General
Introduction .................................................... 18-39 The water separator with fuel pre-filter and the fuel
Drain and Fill ................................................. 18-40 lift pump is a sealed integral electrical unit. The
Clean ............................................................. 18-40 assembly is a non-serviceable component. If any
Remove and Install ....................................... 18-41 part is defective, replace the complete pump, filter
and separator assembly.
Figure 378.
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 - 39 9813/7600-3 18 - 39
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 380.
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 379. Typical Engine
A
B
B
A Tap
B Bowl
A Fuel filter
B Drain tap
18 - 40 9813/7600-3 18 - 40
00 - General
Remove and Install
Refer to Fuel and Exhaust system - Filter - Pre-Filter

Element. Refer to: PIL 18-09.
18 - 41 9813/7600-3 18 - 41
04 - Water in Fuel Sensor
04 - Water in Fuel Sensor Introduction

Introduction .................................................... 18-42 The water in fuel sensor is installed in the fuel
Remove and Install ....................................... 18-43 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 - 42 9813/7600-3 18 - 42
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 381.
A 1
1 Fixing screw
2 Electrical connections
A Water in fuel sensor
Install
removal procedure.
18 - 43 9813/7600-3 18 - 43
18 - Injection
18 - Injection
Contents Page No.
18-18-00 General ........................................................................................................................... 18-45

18-18-03 Injector ............................................................................................................................ 18-60
18-18-07 Injector Seal ................................................................................................................... 18-65
18-18-12 Rail ................................................................................................................................. 18-67
18-18-15 Pump .............................................................................................................................. 18-69
18-18-27 High Pressure Rail Valve ............................................................................................... 18-76
18 - 44 9813/7600-3 18 - 44
18 - Injection
00 - General
Introduction .................................................... 18-45 Fuel at rail pressure is continuously supplied to the
Component Identification ............................... 18-46 injectors via high pressure fuel pipes.
Operation ....................................................... 18-47
Fault-Finding .................................................. 18-50 The high pressure fuel injector fuel pipes consist
of thick walled, seamless steel tubing. The ends of
Check (Operation) ......................................... 18-57 the tubes are formed with conical nipples for sealing
Calibrate ........................................................ 18-59 in the sealing cones on the common rail and on
the injector at port. It is essential that the tubes
are maintained and installed correctly for safe and
effective engine operation.
Important: If the high pressure fuel pipes are

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

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

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

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

initiates several separate injections of fuel during the
compression stroke. The timing of the fuel injections
is also varied by the ECM depending on engine
operating parameters.
18 - 45 9813/7600-3 18 - 45
18 - Injection
00 - General
Figure 382.
3
2
15
A
6 6 6 6
14
13
1 16
1 ECM (Engine Control Module)(refer to PIL 2 High pressure fuel injection pump (refer to PIL
33-45) 18-18)
3 Common fuel rail (refer to PIL 18-18) 6 Fuel injectors (refer to PIL 18-18)
13 Fuel filter (2 micron) (refer to PIL 18-09) 14 Fuel pre-filter and water separator (5 micron)
(refer to PIL 18-12)
15 Electric feed pump (refer to PIL 18-21) A Electrical sensors (refer to PIL 15-84)
B Fuel tank (refer to PIL 18-03)
18 - 46 9813/7600-3 18 - 46
18 - Injection
00 - General
Operation
Fuel Injection Cycle
Figure 383.
TDC 2 3
5
4
C1 C2
D1 D2 6
1 ECM (Engine Control Module) 2 Camshaft position sensor

3 Camshaft target disc 4 Crankshaft position sensor
5 Crankshaft mounted target disc 6 Fuel injector
A Camshaft sensor signal - Signal is B Crank position sensor signal - Signal is
generated by camshaft target disc 3 and generated by crankshaft mounted target
sensor 2. Processed by the ECM 1 to disc 5 and sensor 4. Processed by the
determine which cylinder to inject. ECM 1 to determine timing of injection.
C1-C2 Current pulse - injector solenoid coil - D1-D2 Fuel Injection - Start and duration of
Sent to the injector (6) solenoid coil by actual injection. It can be seen that
the ECM 1 to initiate injection. Time of there is a time shift between the current
pulse calculated by the ECM to control pulse and actual injection. This is
the amount of fuel injected. Pulse C1 due to electrical resistance and the
controls pilot injection. Pulse C2 controls individual characteristics on the fuel
the main injection. injector assembly 6. D1 indicates the
pilot injection and D2 the main injection.
Total fuel injected for one cycle = D1 +
D2.
TDC Top dead centre - Shows when piston
is at top dead centre in relation to the
injection sequence.
18 - 47 9813/7600-3 18 - 47
18 - Injection
00 - General
Injection Cycle to bleed from the control chamber and ultimately

back to the fuel tank via the bleed off lines.
It is important to remember that the injector solenoid
coil does not directly lift the injector needle. Instead Although the control chamber is still connected to the
it operates a tiny valve which causes a fuel pressure rail pressure different sized metering orifices K and
imbalance inside the injector. In this way the needle L cause the pressure in the chamber to fall below
is lifted hydraulically. The method of operation is as the rail pressure. The metering orifice ensures full rail
follows: pressure is maintained in the chamber around the
needle.
State 1 - No fuel injection
When the pressure imbalance in the chambers is
The solenoid coil is not energised. Fuel at rail sufficient to overcome spring the needle lifts and
pressure fills the small chamber around the needle. injection begins.
Fuel at rail pressure also fills the control chamber.
Since the surface area of the needle inside the Figure 385.
control chamber is greater than the area inside
chamber the needle is held on its seat by hydraulic
(fuel) pressure. Spring holds the needle on its seat
when the engine is stopped (when the rail pressure
is low or zero).
Figure 384. F
E
L R
K
F
J
M
J
Q
B
B Needle
E Spool valve
Q F Solenoid coil
J Spring
B K Metering orifice
L Metering orifice
M Metering orifice
B Needle Q Small chamber
F Solenoid coil R Control chamber
J Spring
Q Small chamber State 3 - Fuel injection
R Control chamber
When the flow of fuel to the injection nozzle is
State 2 - Fuel injection start established the metering orifice causes a pressure
drop in the small chamber. Since the needle is now
At the commencement of fuel injection the solenoid lifted its surface area subjected to the pressure in the
coil is energised by the ECM.The solenoid coil lifts small chamber is increased. The force is sufficient to
spool valve off its seat. Fuel at rail pressure is allowed keep the needle lifted.
18 - 48 9813/7600-3 18 - 48
18 - Injection
00 - General
H
G
M M
Q Q
B B
B Needle B Needle
M Metering orifice E Spool valve
Q Small chamber F Solenoid coil
G Spring
State 4 - Fuel injection stop H Calibration dowel
J Spring
To stop fuel injection the ECM de-energises the M Metering orifice
solenoid coil. The spool valve is pushed on to its seat Q Small chamber
by the force of the spring. Fuel no longer bleeds from R Control chamber
the control chamber.
A calibration dowel, selected during manufacture, is

used to finely set the force from the spring.
Fuel pressure inside the control chamber reaches

the rail pressure. Since the needle is lifted its
surface area under pressure from the fuel in the
small chamber is increased. Force from the fuel in
the control chamber is now insufficient to push the
needle on to its seat.
The only way to push the needle on to its seat is

to reduce the fuel pressure in the small chamber.
This is achieved by the metering orifice. As fuel flows
through the metering orifice a pressure drop in the
small chamber is produced. The needle is forced on
to its seat by pressure in the control chamber. Fuel
injection stops.
18 - 49 9813/7600-3 18 - 49
18 - Injection
00 - General
Fault-Finding
Fault
Injector Calibration Table 159. Page 18-50
Injector Trim Codes Table 160. Page 18-50
Open Circuit Injector Table 161. Page 18-51
Injection Bank Table 162. Page 18-51
Short Circuit Injector Table 163. Page 18-52
Engine Low on Power Table 164. Page 18-52
Injector Calibration Table 165. Page 18-53
Open Circuit Injector Table 166. Page 18-53
High Pressure Injection Diagnostics Table 167. Page 18-54
Fuel Rail Pressure Calibration Table 168. Page 18-54
IMV Table 169. Page 18-55
HPV Table 170. Page 18-55
Table 159. Injector Calibration

Cause Remedy
Old/incorrect software version Check if the software is up to date or new software
that will solve this problem is available. Upgrade as
necessary. Re-flash the injector calibration codes,
respecting power down and up delay and taking care
of injector position; erase all the faults.
If no fault is found proceed to 'Injector cylinder
position and value fault'
Injector cylinder position and value fault Check that ‘individual injector corrections’ are
correctly entered in ECM (Engine Control Module).
Check the cylinder position and value.
If no faults is found, proceed to 'Injector program
fault'.
Injector program fault Re-flash the injector calibration codes, respecting
power down and up delay and taking care of injector
position; erase all the faults.
Electrical connection faulty Check the knock sensor connection and screw
torque, repair as necessary. Note: Check the ground
shield connection of knock sensor.
If no knock sensor is installed, raise Techweb
Helpdesk call.
Table 160. Injector Trim Codes

Cause Remedy
Sensor connection fault Check the following sensors and make sure they
work correctly. – Knock sensors – Water temperature
sensor – Air temperature sensor – Fuel temperature
sensor – Barometric pressure sensor (built inside the
ECM.
Check the knock sensors connection and screwing
torque (Check particularly the ground shield
connection). Repair as necessary and re-enter all
injector calibration codes (read then write) in correct
position to reset learned parameters.
If no fault is found proceed to 'Knock sensors ground
fault'.
Knock sensors ground fault Check the grounding of knock sensors, repair as
necessary.
If no fault is found proceed to ECM connection fault'.
18 - 50 9813/7600-3 18 - 50
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
If ECMpins are damaged, replace ECM and re-flash
necessary.
insulation, repair/replace as necessary.
If no fault is found proceed to 'Injector calibration
codes faulty'.
Injector calibration codes faulty Check the injector calibration codes recorded inECM,
if found fault re-enter all injector calibration codes
(read then write) in correct position to reset learned
parameters.
If the injector calibration codes are OK, test the
vehicle on road and check the Defect Trouble Code
(DTC) again with the diagnostic tool. If the problem is
still present change the knock sensor.
Table 161. Open Circuit Injector

Cause Remedy
Fuel injector fault Perform the injector buzz test, if the injector is faulty
it will not produce a buzzing sound. In such instances
raise Techweb Helpdesk call.
If no fault is found proceed to 'Injector connection
fault'.
Injector connection fault Check the resistance of injector – For solenoid, it
should be less than 1 ohm.
If the resistance is incorrect, change the injector and
calibrate it.
If no fault is found proceed to 'Electrical/ECM
connection fault'.
ElectricalECM connection fault Disconnect the harness from engine ECM and
necessary.
Table 162. Injection Bank

Cause Remedy
Injector connection fault Check the injector connections corresponding to
faulty bank, repair as necessary.
If no fault is found proceed to 'Injector faulty'.
Injector faulty Check all the injectors individually. Replace the
injector and re-calibrate the ECM with the trim file of
the new injector.
If no fault is found proceed to
'Electrical/ECMconnection fault'.
18 - 51 9813/7600-3 18 - 51
18 - Injection
00 - General
Cause Remedy
Electrical/ECM connection fault Disconnect the harness from engineECM and
If ECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing anECM).
necessary.
Table 163. Short Circuit Injector

Cause Remedy
it not will produce a buzzing sound. In such instances
fault'.
Injector connection fault Disconnect the injector (one by one) to see if the fault
disappeared. Repair/ replace as necessary.
Disconnect the engine harness inter connect plug
it to see if the fault disappears. Repair/replace as
necessary.
connection fault'.
ElectricalECM connection fault Disconnect the harness from engine ECM and
IfECM pins are damaged, replaceECM and re-flash
appropriate calibration (see Re-flashing an ECM).
Table 164. Engine Low on Power

Cause Remedy
Injector fault - electrical If an electrical injector fault is present raise Techweb
Helpdesk call.
fault'.
Injector connection fault Check the Individual Injector Corrections and injector
connections. If the problem with C3I or injector
connection is evident,replace/repair as necessary.
If no fault is found proceed to 'Fuel rail pressure'.
Fuel rail pressure Check the fuel rail pressure.
If no fault is found proceed to 'Engine Cylinder
compression fault'.
Engine Cylinder compression fault Run the compression test (automatic or manual),
if any of the engine cylinder pressure is not in the
limits, repair/replace as necessary.
If no fault is found proceed to 'Blocked inlet tubes'.
18 - 52 9813/7600-3 18 - 52
18 - Injection
00 - General
Cause Remedy
Blocked inlet tubes Check the fuel lines for any blockage and
contamination. Clean the fuel lines as necessary.
If no fault is found proceed to 'Injector faulty'.
Injector faulty Swap the injectors with another. Re-write the trim
codes. Replace/repair as necessary and re-flash the
injector calibration codes.
Table 165. Injector Calibration

Cause Remedy
Injector calibration fault Re-write the injector calibration codes allowing the
power down and up delay and taking care of injector
position, erase the faults.
If no fault is found proceed to 'Power relay operation
fault'.
Power relay operation fault Check the power relay operation, repair the relay or
wiring as necessary.
If no fault is found proceed to 'ECM connection fault'.
Check the harness continuity and electrical
necessary.
Table 166. Open Circuit Injector

Cause Remedy
it will not produce a buzzing sound. In such instances
fault'.
Injector connection fault Check the resistance of injector. – For solenoid, it
should be less than 1 Ohm.
If the resistance is incorrect, change the injector and
calibrate it.
connection fault'.
ElectricalECM connection fault Disconnect the harness from engineECM and
IfECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing anECM).
necessary.
18 - 53 9813/7600-3 18 - 53
18 - Injection
00 - General
Table 167. High Pressure Injection Diagnostics

Cause Remedy
Pressure diagnostics fault Check the fault of type IMV (Inlet Metering Valve)
or HPV (High Pressure Valve) (if applicable) or rail
pressure sensor, repair the corresponding fault.
If no fault is found proceed to 'High pressure system
fault'.
High pressure system fault Read the Diagnostic Trouble Code (DTC).
Connect the battery booster.
If the DTC links to high pressure control: – Check
the fuel feed circuit is in good condition – Check the
diesel fuel is present in the system – Check there is
no air bubbles or emulsion in the pipes – Check there
is enough fuel pressure in the inlet pump – Check
there are no high pressure circuit leaks – Check the
quality and type of the diesel fuel.
If the low pressure circuit is faulty, repair the low
pressure circuit.
If no faults are found, proceed to 'Engine does not
start' or 'Engine starts' depending on symptoms,
replace the corresponding injectors.
Engine does not start Perform the ‘Dynamic IMV Test’.
If the IMV is faulty replace the IMV.
If the IMV is OK complete the ‘Dynamic Injector Back
leak Test’
If the back leak is above the limit, replace the
corresponding injector(s).
If the back leak is OK complete the ‘Pump Pressure
Build Capacity Test’
If the pump capacity is below the limit, replace the
high pressure pump.
If the pump capacity is OK, raise Techweb Helpdesk
Call.
Table 168. Fuel Rail Pressure Calibration

Cause Remedy
repair/replace as necessary.
If no fault is found, proceed to 'ECM connection fault'.
necessary.
If no fault is found proceed to 'Sensor failure'.
page). If sensor is out of specification replace, the
sensor.
fault'.
18 - 54 9813/7600-3 18 - 54
18 - Injection
00 - General
Cause Remedy
ECM connection fault Disconnect the harness from engine ECU (Electronic
Control Unit) and inspect. Check seals are in place,
check for signs of corrosion or contamination.
necessary.
If no fault is found proceed to 'Rail pressure sensor
and rail fault'.
Rail pressure sensor and rail fault Replace the rail pressure sensor and rail.
If the problem still not solved, raise Techweb
Helpdesk call.
Table 169. IMV

Cause Remedy
IMV (Inlet Metering Valve) connection fault Check the connection to IMV
If the IMV connection is faulty, replace the high
Pressure fuel injection pump.
If no fault is found proceed to 'ECM connection fault'.
ECMconnection fault Disconnect the harness from engine ECM and
If ECM pins are damaged, replace ECMand re-flash
necessary.
If no fault is found proceed to 'Electrical resistance
fault'.
Electrical resistance fault Measure the IMV electrical resistance around 5.3
ohms at 20 degrees C.
replace the high Pressure fuel injection pump if the
resistance fault occurs.
If no fault is found proceed to IMV buzz fault'.
IMV buzz fault Perform the IMV buzz test. If the IMV is not buzzing
replace the high Pressure fuel injection pump.
If the IMV buzzes, raise Techweb Helpdesk call.
Table 170. HPV

Cause Remedy
HPV (High Pressure Fuel Valve) connection fault Check the connection of HPV
If the HPV connection is faulty, repair or replace as
necessary.
If no fault is found proceed to ECMconnection fault'.
ECM connection fault Disconnect the harness from engineECM and
IfECM pins are damaged, replace ECM and re-flash
necessary.
18 - 55 9813/7600-3 18 - 55
18 - Injection
00 - General
Cause Remedy
If no fault is found proceed to 'Electrical resistance
fault'.
Electrical resistance fault Measure the HPVelectrical resistance, it should be
around 2.2 ohms at 25 degrees C.
If the electrical resistance is OK, replace the rail and
HPV.
If no fault is found proceed to 'HPV buzzing fault'.
HPV buzzing fault Perform the HPV buzz test. If theHPV is not buzzing
replace the rail and HPV.
If the HPV buzzes, raise Techweb Helpdesk call.
18 - 56 9813/7600-3 18 - 56
18 - Injection
00 - General
Check (Operation) Figure 388. Injector leak off test kit
Special Tools
Servicemaster 721/10855 1
Electronic Test Cable
Servicemaster 892/01033 1*
Electronic Test Kit 892/01174
Data Link Adaptor
(DLA) Kit
Injector Leak-off Test 892/12350 1
Kit ((Electronic Engine))
Injector Cap Kit 892/12359 1
*Unless otherwise stated, you can use any of the
tools shown.
To test the fuel injection system, there are two test

options available. Actuator tests, which supply a
voltage signal to the actuators and diagnostic tests Fuel System Diagnostic Test (Cranking only)
which require the engine to be cranked or started.
This test can be found in the fuel system diagnostic
Static Actuator Tests test (cranking) tab in the EcoMax engine test section
on the engine diagnostic tool within Servicemaster.
The IMV (Inlet Metering Valve), HPV (High Pressure This test closes the injectors, opens the IMV and
Valve) and the injectors can each be tested using the controls the rail pressure using the HPV.
engine diagnostic tool within Servicemaster.
1. Connect the fuel leak off test kit, ensure all open
The IMV test can be found under the fuel system tab fuel pipes are capped.
in EcoMax actuators section. The test sends a signal
to theIMV, normally the IMV can be heard operating Special Tool: Injector Leak-off Test Kit
and the test results will be displayed. ((Electronic Engine)) (Qty.: 1)
Special Tool: Injector Cap Kit (Qty.: 1)
The HPV test can be found under the fuel system
2. Use Servicemaster to control the tests and follow
tab in EcoMax actuators section. The test sends a
the on screen instructions in Servicemaster.
signal to the HPV, normally the HPV can be heard
operating. Special Tool: Servicemaster Electronic Test Kit /
Data Link Adaptor (DLA) Kit (Qty.: 1)
The injector test can be found under the injector test Special Tool: Servicemaster Electronic Test
tab in EcoMax actuators section. The test sends a Cable (Qty.: 1)
signal to each individual injector, normally the injector
can be heard operating. 3. Measure the quantity of diesel fuel obtained in
the leak off kit.
Diagnostic Tests 4. Replace the injectors whose back leak exceeds
the value given in the Servicemaster reference
To diagnose fuel system faults the return flow from table.
the fuel system must be measured using the fuel
Injector leak off test kit. Refer to Injector-Check 5. Replace the fuel rail if the HPV return volume
Operation (PIL 18-18). exceeds the value given in the Servicemaster
help file. Note: The HPV is a non-serviceable
There are two sets of dynamic tests, one for when part.
the engine does not start (Cranking only) and one for
when the engine does start (Engine running). 6. After each replacement confirm the results by re-
testing.
7. If the leak off volumes are within limits and the
maximum rail pressure during the test is below
500 bar this indicates the high pressure pump
capacity may be low.
18 - 57 9813/7600-3 18 - 57
18 - Injection
00 - General
Fuel System Diagnostic Tests (Engine 1. Warm the engine to over 60°C (depending on
Running) the application) and the fuel temperature to over
20°C to be able to start the cycle.
These tests can be found in the fuel system
diagnostic test (engine running) tab in the ecomax 2. Connect the HPV leak off bottle, make sure all
engine test section on the engine diagnostic tool open fuel pipes are capped.
within Servicemaster. 3. Use Servicemaster to control the tests and follow
IMV Dynamic test
4. Measure the quantity of diesel fuel obtained in
1. Warm the engine to over 60°C (depending on
the HPV leak off bottle.
the application) and the fuel temperature to over
20°C to be able to start the cycle. 5. Replace the fuel rail if the HPV return volume
exceeds the value given in the Servicemaster
part.
3. Check status. If test OK, it should report
6. After each replacement confirm the results by re-
Diagnosis finished and no problem detected.
testing.
If the test indicates it is not OK (status
report Diagnosis finished and problem detected).
Replace the High pressure pump. Note: The IMV
is a non-serviceable part.
High Pressure IMV Diagnostic test
This test is designed to check the fuel system by

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

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

by opening the IMV fully and controlling the rail
pressure using the HPV. Leak off flow from the HPV
indicates the high pressure pump capacity.
18 - 58 9813/7600-3 18 - 58
18 - Injection
00 - General
Calibrate
recorded in code form and attached to the injector

Since the injector operating components are by body.
necessity very small, even the most advanced
manufacturing techniques do not ensure consistent The codes for each injector installed to the engine are
injection cycle characteristics between injectors. programmed into the ECM (Engine Control Module).
The operating software in the ECM uses the data
For example, small variations in the metering orifice to adjust the control of the injector solenoid coil
sizes will alter the time durations for the start and accordingly. The injector is therefore effectively re-
stop of fuel injection. The small dimensions involved calibrated by the ECM.
mean that only a tiny variation will alter the orifice
area by a relatively large percentage. It follows that if injectors are removed they must
always be installed in their original positions. If
For this reason it is necessary to individually test and new injectors are installed the ECM must be
record the operating characteristics of each injector reprogrammed with the new injector codes.
assembly at the factory. The results of the test are
Figure 389.
18 - 59 9813/7600-3 18 - 59
18 - Injection
03 - Injector
03 - Injector Introduction
Introduction .................................................... 18-60 The fuel Injectors are electronically controlled and
Component Identification ............................... 18-61 incorporate a small solenoid valve. The injectors are
Check (Operation) ......................................... 18-61 supplied with pressurised fuel by the high pressure
Remove and Install ....................................... 18-62 fuel injection pump and when energised, the injector
atomizes the fuel into a fine mist so that it can burn
easily by the vehicle’s engine.
The fuel injectors are mounted in the inlet manifold

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

chambers, so effective cooling is essential. A special
thin walled sleeve is screwed into the cylinder head
which allows a coolant jacket close to the injector.
The coolant jacket is sealed at the bottom by sealant
on the sleeve thread and at the top by O-ring.
Figure 390.
52 5 1 4
1 Injector
2 Sleeve
3 Cylinder head
4 Coolant jacket
5 Sleeve thread
6 O-ring
18 - 60 9813/7600-3 18 - 60
18 - Injection
03 - Injector
Component Identification Check (Operation)

Special Tools
Figure 391. Description Part No. Qty.
Injector Leak-off Test 892/12350 1
N Kit ((Electronic Engine))
H
Injector Cap Kit 892/12359 1
G
The injectors can be tested using Servicemaster
D F diagnostics and by means of a leak off test. To test
M for a defective injector first use Servicemaster to
diagnose the problems with the high pressure fuel
E injection equipment, specifically when the engine
does not start.
C
Leak Off Test
J
The leak off test kit must be installed on the engine
and the ServiceMaster must be used to test the
engine.
1. Operate the engine until it reaches its normal

operating temperature.
2. Stop the engine. Remove the bleed off pipe at
B each injector. Refer to (PIL 18-96). Cap the open
connectors on the pipes with the caps in the
A injector leak off test kit.
Special Tool: Injector Leak-off Test Kit
((Electronic Engine)) (Qty.: 1)
Special Tool: Injector Cap Kit (Qty.: 1)
3. Connect the test pipes to the leak off ports on the
L four injectors.
4. Position the four plastic bottles as upright as
possible. Keep the test equipment clear of
A Multi-point injector nozzle components that get hot when the engine is
B Needle operated.
C Spacer
5. Connect a test pipe to the leak off ports on the
D Nut
High Pressure valve outlet. Cap the open pipe.
E Valve
F Solenoid coil 6. Make sure it is safe to start the engine.
G Valve spring
H Calibration dowel 7. Use ServiceMaster to control the tests. Refer to
J Injector spring Fuel Injection - Check Operation (PIL 18-18).
L Electrical connector
M Return port (bleed off) 7.1. Fuel System Diagnostic Test (Cranking
N High pressure port and filter element Only).
7.2. Fuel System Diagnostic Tests (Engine
Running).
8. Examine the fuel levels in the test bottles. If the
difference between any of the levels is more than
10 ml. this indicates that there are one or more
defective injectors.
9. Remove the test equipment and replace the
bleed off pipes. Refer to (PIL 18-96).
18 - 61 9813/7600-3 18 - 61
18 - Injection
03 - Injector
Figure 392. Remove and Install

B
The following procedure is for one injector, the
A procedures are identical for all injectors.
Note: The original injector calibration codes are

located on a label on the rocker cover.
A
Before Removal
A
A 4. Remove the fuel bleed off fuel pipes. Refer to

6. Record which injector is for which cylinder. The
injectors must be installed in the same positions.
Note: If a fuel injector is defective, it must be

replaced.
Remove
1. Remove the injector clamp retaining bolt and lift
the clamp away.
A Injectors (x4)
B HP valve
18 - 62 9813/7600-3 18 - 62
18 - Injection
03 - Injector
4 X 1 5
2
1 Injector
2 Injector clamp
3 Retaining bolt
4 Injector sleeve
X Injector bleed-off port 6
2. Remove and discard the sealing washer. Label
the injector to make sure it is installed in its
original cylinder. Put a clean protective cap over
the nozzle of the injector. 7
3. Remove and discard the O-ring.
5 Protective cap
6 Protective cap
7 Sealing washer
Install
Important: The fuel injectors are not interchangeable
between cylinders or other engines. Make sure you
install the injectors in the same positions. If a new
or different injector is installed, the engine electronic
control unit (ECU) must be re-programmed. Refer to
(PIL 33-45), Engine Electronic Control Unit, Vehicle
Set Up Data.
When new or different injectors are installed, record

the calibration code. Record which cylinder the
injector is installed into. Refer to (PIL 33-45), Engine
Electronic Control Unit, Vehicle Set Up Data.
18 - 63 9813/7600-3 18 - 63
18 - Injection
03 - Injector
Figure 395. Table 171. Torque Values

Item Nm
A 3 28
4 39
D
C
A Correction factor (20 characters)

B Manufacturers reference
C JCB part number
D Injector serial number
steps.
2. Clean off any sludge or oil from the inner bore
of the injector sleeve. Make sure you do not
damage the surface of the bore. Any damage
or surface contamination will cause the injector
sealing O-ring to fail.
3. Install a new O-ring.
4. Install a new sealing washer.
5. Make sure that the injector is installed in the
correct orientation, with the bleed-off port facing
the right hand side (exhaust manifold) of the
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, refer to (PIL 15-42).
2. Renew the high pressure fuel pipes, Refer to Fuel
Pipes (PIL 18-96).
3. Replace the low pressure fuel pipes, Refer to
4. Start the engine and check for fuel leaks.
18 - 64 9813/7600-3 18 - 64
18 - Injection
07 - Injector Seal
07 - Injector Seal
Remove and Install
Special Tools Before Removal

Injector Seal 892/12346 1 1. Make sure that the engine is safe to work on. If
Installation Tool the engine has been running, let it cool before
(Electronic Engine) you start the service work.
Injector Sleeve 892/12348 1 2. Clean the engine. Refer to Engine- Clean (PIL
Installation/Removal 15-00).
Tool
Figure 396.
D
A Rocker cover B Bolts

C Gasket D Injector seals
18 - 65 9813/7600-3 18 - 65
18 - Injection
07 - Injector Seal
Remove Figure 398.
1. Get access to the engine. E

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

4. Put wooden supports under the rocker cover and
tap out the injector seals using the special tool.
Discard the seals. G
Special Tool: Injector Seal Installation Tool E Injector seal installation tool
(Electronic Engine) (Qty.: 1) F Injector seals
G Wooden supports
Figure 397.
4. Renew the rocker cover gasket.
F E
5. Prevent damage to the seals. Put sleeves/covers
on the injectors. Apply a rubber lubricant to the
seals.
Special Tool: Injector Sleeve Installation/
Removal Tool (Qty.: 1)
6. Install the rocker cover. Refer to (PIL 15-42).
G
After Installation
E Injector seal installation tool
F Injector seals 1. The high pressure fuel pipes must be replaced
G Wooden supports with new parts. Refer to Fuel Pipes (PIL 18-96).
Install 2. Start the engine and check for oil and fuel leaks.

steps.
2. Remove all oil and sludge contamination from
inside the valve chamber.
3. Renew the injector seals. Put supports under the
rocker cover and tap in the new seals using the
special tool.
Special Tool: Injector Seal Installation Tool
(Electronic Engine) (Qty.: 1)
18 - 66 9813/7600-3 18 - 66
18 - Injection
12 - Rail
12 - Rail Introduction
Introduction .................................................... 18-67 The fuel rail also known as a common rail, is a
Remove and Install ....................................... 18-68 pipe resembling a rail that is used to deliver fuel
to individual fuel injectors on internal combustion
engines. It is designed to have an outlet for each
injector, an inlet for a fuel supply and an outlet for a
fuel bleed off.
The fuel rail also incorporates an attached fuel

pressure sensor and a fuel valve. DO NOT
remove the high pressure fuel valve or the fuel
pressure sensor from the rail. If these components
are defective replace the complete common rail
assembly.
Figure 399.
A B
F
E
D
A Fuel pressure sensor

B Outlet
C Bleed off
D High pressure fuel valve
E Inlet
F Rail assembly
18 - 67 9813/7600-3 18 - 67
18 - Injection
12 - Rail

A B
Before Removal
C
1. Obey all fuel system health and safety
information. Refer to (PIL 18-00).
E F
2. Make sure that the engine is safe to work on. The
engine must cool and pressure in the fuel system
must decay before you start work. If the engine E
has been running, wait at least one hour before D
you start work.
A Fuel pressure sensor
3. Clean the engine. Refer to Engine-Clean (PIL B High pressure fuel pipe
15-00). C Fuel bleed off pipe
4. Remove the high pressure fuel pipes. Refer to D High pressure fuel valve
Fuel Pipes (high pressure) - Remove and Install E Bolts
(PIL 18-96). F Rail assembly
5. Remove the fuel bleed off pipe at the rail. Refer to Table 172. Torque Values
Fuel Pipes (low pressure) - Remove and Install Item Nm
(PIL 18-96). C 24
Remove
1. Disconnect the electrical connector at the high
pressure fuel valve.
2. Disconnect the electrical connector at the fuel
pressure sensor.
3. Remove the bolts and lift off the common rail
assembly.
Seal the common rail assembly inside a clean plastic

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

replace all of the high pressure fuel pipes. Refer to
(PIL 18-96).
18 - 68 9813/7600-3 18 - 68
18 - Injection
15 - Pump
15 - Pump Introduction
Introduction .................................................... 18-69 The high pressure fuel injection pump is a rotary
Component Identification ............................... 18-70 type device that pumps fuel into the cylinders of
Operation ....................................................... 18-70 the engine. The pump is driven indirectly from the
Remove and Install ....................................... 18-72 crankshaft by gears.
18 - 69 9813/7600-3 18 - 69
18 - Injection
15 - Pump

Figure 401. The high pressure fuel injection pump is driven via a
7 8 2 10 gear on the engine and rotates at half engine speed.
The pump comprises of two sections, the transfer
pump and the high pressure pump.
1
9 Although the pump does not control fuel injection
timing, it is still timed in relation to engine phasing.
12 3 By timing the pump pressure pulses, the load on the
engine timing gears is reduced together with reduced
mechanical noise.
Transfer Pump Operation

The integral transfer pump is a vane type. An
engine driven rotor houses four vanes in slots.
13 The rotor rotates inside an eccentric liner. The
6 vanes are held in contact with the liner by springs.
5 Fuel is drawn into the pump chamber at port X,
pressurised by the decreasing volume inside the
chamber and expelled at port Y. Fuel pressure
4 2 11 generated by the transfer pump is limited to a
1 Fuel injection pump specified pressure by an integral pressure regulating
2 Pump fixing nuts (x3) valve. This pressure is maintained regardless of
3 Injection pump gear cover engine speed.6bar (87.0psi)
4 Inlet metering valve electrical connector
5 Fuel temperature sensor electrical connector Figure 402.
6 Fuel pipe connector (inlet)
7 Fuel bleed-off connector
8 Fuel bleed-off connector, injector bleed off
9 Drive shaft nut E
10 Drive gear A
11 Injection pump O-ring oil seal
12 High pressure fuel outlet port B
13 Gear cover O-ring oil seal
D
X Y
A Rotor
B Vanes (x4)
C Eccentric liner
D Springs
E Regulating valve
X Port X
Y Port Y
High Pressure Pump Operation

Fuel passes to the high pressure pump via the IMV
(Inlet Metering Valve). The ECM (Engine Control
18 - 70 9813/7600-3 18 - 70
18 - Injection
15 - Pump
Module) controlled IMV determines the amount of Fuel pressure in the chamber rises and forces the
fuel transferred to the high pressure pump. The inlet valve on to its seat. As the plunger is pushed
plunger actuator block is located on the engine driven further up its chamber the fuel pressure exceeds that
eccentric shaft. When the shaft rotates the actuator of the rail pressure and the delivery valve is forced off
block operates the two plungers. As one plunger is its seat. Fuel is forced into the rail at high pressure.
pushed up its chamber the other is pushed down by
its spring. Figure 404.
State 1 - Charging E
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries. D
When the eccentric shaft is in the position shown
force from spring moves the plunger down its C
chamber. Pressure in the chamber falls below the
rail pressure and the delivery valve closes. Transfer
pressure is now sufficient to force inlet valve off its
seat and allow the fuel to fill the chamber.
Figure 403.
E B
D
A Eccentric shaft
C B Actuator block
C Plunger
D Inlet valve
E Delivery valve
F
A Eccentric shaft
B Actuator block
C Plunger
D Inlet valve
E Delivery valve
F Spring
State 2 - Pumping
Note: The description is for one plunger. The
opposite plunger operates in an identical way. The
inlet and delivery ports from each plunger are
connected by internal galleries.
When the eccentric shaft is in the position shown the

actuator block moves the plunger up its chamber.
18 - 71 9813/7600-3 18 - 71
18 - Injection
15 - Pump

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

debris may become exposed or dislodged. Stop the
removal procedures and clean away the exposed
deposits. Refer to Engine- Clean (PIL 15-00).
18 - 72 9813/7600-3 18 - 72
18 - Injection
15 - Pump
11
3
B
A
1
F G
1 Bedplate plug H
A Crankshaft / Camshaft timing pin
C Crankshaft turning tool
4. Use the crankshaft turning tool to turn the E
crankshaft until the timing pin engages in the
crankshaft timing hole.
Special Tool: Crankshaft Turning Tool (95.25mm
PCD)- JCB 4 Cylinder Ecomax and Dieselmax 3 Gear cover
(Qty.: 1) 11 Drive shaft nut
Special Tool: Crankshaft / Camshaft Timing Pin B Gear removal tool
(444/448/672 Engine) (Qty.: 1) E Pump gear removal tool, comprises:
F Pump gear removal tool (Reaction cap)
5. Use the gear removal tool and a suitable ratchet G Pump gear removal tool (Body)
drive to remove the fuel injection pump gear H Pump gear removal tool (Bolt)
cover.
Special Tool: Pump Gear Removal Tool (Qty.: 1) 7. Remove the nuts. Use the special C shaped
ring spanner to remove the nut closest to the
6. Remove the drive shaft nut. crankcase. Make sure you remove all nuts (X3).
8. Install the reaction cap over the pump shaft.
Screw the body to the housing. Use a suitable
ratchet drive and socket to screw the bolt in until
you feel a slight resistance.
Special Tool: C-Shaped Ring Spanner (Qty.: 1)
Special Tool: Pump Gear Removal Tool (Qty.: 1)
18 - 73 9813/7600-3 18 - 73
18 - Injection
15 - Pump

2 10
2 10
9
F
G
2 12
2 Fixing nuts
9 Gear pump nut
2 Fixing nuts
10 Drive gear
10 Injection pump drive gear
12 Drive shaft
F Pump gear removal tool (Reaction cap)
G Pump gear removal tool (Body) 2. Make sure that the oil seal is correctly located on
H Pump gear removal tool (Bolt) the pump mounting face.
9. The injection pump drive gear is located on a Figure 410.
taper on the pump drive shaft. To remove the
pump the taper lock must be broken. Support
the fuel pump. Tap the end of the bolt H with a
soft faced hammer. When the taper breaks there
will be an audible sound. Note: The pump drive 16
gear connects to the injection pump drive shaft by
means of taper lock alone, there is no mechanical
locking key.
10. Remove the service tools. Withdraw the pump
from the flywheel housing.
Install
1. Make sure that the taper surfaces on the injection 16 Oil seal
pump drive shaft and gear are clean and free 3. Locate the pump on to the mounting studs.
from oil and damage. Locate the drive gear over the pump drive shaft.
4. Install the fixing nuts and tighten to the correct
torque value.
5. Install the gear pump nut and tighten to the
correct torque value. Note: If a washer is supplied
with a replacement pump, Do not install the
washer. Secure the gear with the gear pump nut
only.
6. Use the tamperproof cover removal tool to install
the gear cover. Make sure its sealing O-ring is
correctly installed. Tighten the gear cover to the
1)
Special Tool: Tamper proof Cover Removal Tool
(Qty.: 1)
18 - 74 9813/7600-3 18 - 74
18 - Injection
15 - Pump
7 8
12
3
B
6
3 Gear cover 5
B Tamperproof cover removal tool
4
After Installation 4 IMV electrical connector
1. Remove the crankshaft turning tool. 5 Fuel temperature sensor electrical connector
2. Remove the crankshaft timing pin and install the 7 Fuel pump bleed-off connection
bedplate plug. 8 Fuel pump bleed-off connection
12 High pressure fuel outlet port
3. Reconnect the fuel pipe couplings at the inlet
connection, reconnect the bleed-off connections Table 173. Torque Values
on the pump.
Item Nm
4. Install a new high pressure fuel pipe, remove 2 24
the protective caps from the ports, refer to Fuel 3 70
Pipes- Remove and Install, refer to (PIL 18-96). 9 65
5. Connect the electrical connectors at the IMV and
the fuel temperature sensor.
6. Replace the fuel filter, refer to (PIL 18-09).
18 - 75 9813/7600-3 18 - 75
18 - Injection
27 - High Pressure Rail Valve
27 - High Pressure Rail Valve Introduction

Introduction .................................................... 18-76 The HPV (High Pressure Valve) is an integral part
Operation ....................................................... 18-77 of the common fuel rail assembly, If the valve
Check (Operation) ......................................... 18-77 is defective replace the complete common rail
Remove and Install ....................................... 18-78 assembly. (Refer to PIL 18-18).
Figure 413. High pressure valve location
Figure 414.
A HPV
B Solenoid coil
18 - 76 9813/7600-3 18 - 76
18 - Injection
In certain operating conditions, the HPV (High For the full inspection and testing procedure, refer to
Pressure Valve) controls the fuel pressure inside the the help files in ServiceMaster.
common rail.
When the valve opens, fuel is bled from the rail back
to the fuel tank, reducing the fuel pressure inside the
fuel rail. The valve is actuated by a solenoid coil and
features proportional control. The fuel flow through
the valve is proportional to the current supplied to
the coil. The current value is controlled by the ECM
(Engine Control Module) using PWM (Pulse Width
Modulation).
During normal engine operation, the fuel pressure is

controlled solely by the IMV (Inlet Metering Valve),
In some operating circumstances, the IMV is unable

to alter the fuel pressure in the common rail quickly
enough. At these times, the ECM activates the HPV.
Typically the valve is used in the following conditions:
• Extreme transients, for example if the operator

goes from full throttle to no throttle quickly.
• When the fuel is cold.
In the event of an IMV failure, the ECM compensates

by altering the control of the HPV to ensure the
engine performance is sufficient to limp home.
18 - 77 9813/7600-3 18 - 77
18 - Injection
Remove and Install
This part is a non-serviceable component, if it

is defective, replace the complete common rail
assembly. Refer to: PIL 18-18-12.
18 - 78 9813/7600-3 18 - 78
21 - Fuel Pump
21 - Fuel Pump
Contents Page No.
18-21-00 General ........................................................................................................................... 18-81
18 - 79 9813/7600-3 18 - 79
Notes:
18 - 80 9813/7600-3 18 - 80
21 - Fuel Pump
00 - General
Introduction .................................................... 18-81 The fuel lift pump is a sealed electrical unit integral
Technical Data ............................................... 18-83 with the fuel pre-filter and water separator.
Operation ....................................................... 18-84
Check (Operation) ......................................... 18-84 The fuel lift pump is a non-serviceable component.
If any part is defective, replace the complete pump,
Remove and Install ....................................... 18-85 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 24V supply by means of an in-line voltage
reducer.
18 - 81 9813/7600-3 18 - 81
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 - 82 9813/7600-3 18 - 82
21 - Fuel Pump
00 - General
Technical Data
Table 174.
Component Value
Operating pressure 0.8bar (11.6psi)
Expected minimum free 2.5L/min
flow delivery
Table 175. 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 - 83 9813/7600-3 18 - 83
21 - Fuel Pump
00 - General
The pump draws fuel from the tank, through the water If the fuel lift pump is suspect, measure the delivery
separator, pumping it through the fuel filter and into flow rate.
the fuel injection pump. The pump has a built in
protection against running dry and will shut down Flow Test
after 2min if no fuel is present.
2. Disconnect the fuel hose from the outlet of the
pump/ filter assembly.
3. Connect a length of fuel hose from the pump
outlet to a suitable fuel container.
Volume: 5L
4. Activate the fuel pump. Do not attempt to start
the engine.
5. Run the pump. The fuel flow must be equal to or
greater than the value shown.
Duration: 1min
Flowrate: 2.5L/min
Machines with Electronic Control Fuel

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

within Servicemaster to energise the fuel pump (fuel
lift pump test). After a 5s delay the pump runs for a
period of 24s.
18 - 84 9813/7600-3 18 - 84
21 - Fuel Pump
00 - General
Remove and Install
4. Disconnect the WIF (Water in Fuel) sensor

Remove harness connector.
Refer to Figure 417. 5. Make sure to mark label on the fuel pipes to aid
in the installation.
The fuel lift pump is installed on the loader tower. 6. Disconnect the fuel pipes at the fuel lift pump by
This procedure is also similar for the machines with means of the quick release connectors.
lift pumps installed on the side of the fuel tank.
7. Disconnect the drain hose at drain tube.
8. Support the fuel lift pump and remove the bolts.
2. Disconnect the battery.
9. Remove the fuel lift pump together with its pre-
3. Disconnect the fuel lift pump harness connector. filter/separator from the machine.
Figure 417.
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 176. Colour code

Fuel pipe Colour
E Blue
J Red
18 - 85 9813/7600-3 18 - 85
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-87

18-24-03 Inlet Manifold .................................................................................................................. 18-89
18-24-04 Outlet Manifold ............................................................................................................... 18-93
18 - 86 9813/7600-3 18 - 86
24 - Exhaust
00 - General
Introduction .................................................... 18-87 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-88 away from the controlled combustion inside the
Check (Condition) .......................................... 18-88 engine by means of an exhaust pipe. Depending
on the machine design, the exhaust gas may flow
through the following components:
• Cylinder head and exhaust manifold.

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

away from the users of the machine. Note machines
or generators that work indoors can quickly fill an
enclosed space with carbon monoxide or other
poisonous exhaust gases if they are not properly
vented to the outdoors.
18 - 87 9813/7600-3 18 - 87
24 - Exhaust
00 - General

Exhaust Gases Excessive smoke from the exhaust stack combined
Machine exhaust gases can harm and possibly kill with a complaint of low power could be as a result of:
you or bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure • Dirt or dust (unfiltered air) ingested directly into
there is good ventilation. If possible, install an the engine, resulting in damage to the cylinder
exhaust extractor. If you begin to feel drowsy, stop bores, there will also be a possible increase in
the machine at once and get into fresh air. oil consumption.
• Air leaks from the air hose connections.
Sparks • Exhaust manifold leaks.
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
Switch off the engine before working in the engine
engine cover open.
18 - 88 9813/7600-3 18 - 88
24 - Exhaust
03 - Inlet Manifold
03 - Inlet Manifold Introduction

Introduction .................................................... 18-89 The inlet manifold (or intake manifold) supplies
Component Identification ............................... 18-90 combustion air to the cylinders in compression
Check (Condition) .......................................... 18-90 ignition engines or the air/fuel mixture for spark
Remove and Install ....................................... 18-91 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 - 89 9813/7600-3 18 - 89
24 - Exhaust
03 - Inlet Manifold

Figure 418. 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 - 90 9813/7600-3 18 - 90
24 - Exhaust
03 - Inlet Manifold
Remove and Install

4. Remove the fuel rail assembly. Refer to (PIL
18-18).
Figure 419.
6
12 11 10
8
13
9
3
4
5
1 Inlet manifold 2 Manifold gasket

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

ingress of dirt.
1. Disconnect the TMAP (Temperature Manifold Air
Pressure) sensor electrical connector. 5. Inspect the manifold, refer to Check Condition
(PIL 18-24).
2. Disconnect the air inlet hose.
3. Remove the bolts 3 and lift the inlet manifold from
the cylinder head. Discard the gasket.
18 - 91 9813/7600-3 18 - 91
24 - Exhaust
03 - Inlet Manifold
Install
steps.
2. Renew the manifold gasket.
3. Loosely assemble the manifold, together with the
new inlet gasket to the cylinder head, use the two
bolts (one at each end).
4. With the manifold and gasket in position, install
the remaining six bolts.

Item Nm
3 43
18 - 92 9813/7600-3 18 - 92
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold Introduction

Component Identification ............................... 18-94 Engine, JCB Tier 4F Engine 4 Cyl, JCB Tier
Check (Condition) .......................................... 18-94 4i /T4F <55kW Engine 4 Cyl ...... Page 18-93
Remove and Install ....................................... 18-95 Otherwise .................................. Page 18-93

Figure 420.
A B
A Exhaust manifold
B Manifold gasket and heat shield
(Otherwise)
The exhaust outlet manifold collects the exhaust
gases from the multiple cylinders and delivers it to
the turbocharger or the exhaust pipe.
18 - 93 9813/7600-3 18 - 93
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 - 94 9813/7600-3 18 - 94
24 - Exhaust
Remove and Install

4. Disconnect the oil pipes to the turbocharger, refer
to (PIL 18-36).
Figure 422.
1 Exhaust manifold 2 Fixing bolts M10 x 57mm (x8)

3 Manifold gasket
Remove 2. Renew the manifold gasket.
1. Remove the upper four bolts. 3. Install the lower four bolts, together with the new
exhaust gasket to the cylinder head (screw in the
2. Loosen the lower four bolts and lift the exhaust bolts approximately to a length of 8 mm).
manifold from the cylinder head. Remove the
bolts and discard the gasket. 4. Rest the manifold in position on the row of
lower bolts by locating the slots, then install the
3. Cap the exhaust ports to prevent ingress of dirt. remaining four upper bolts.
4. Inspect the manifold, refer to Check Condition 5. Tighten the bolts to the correct torque value.
(PIL 18-24). Refer to Torque and Angle Tightening procedure
(PIL 72-00 ).
Install
After Installation
removal procedure. Additionally do the following 1. Reconnect the oil pipes to the turbocharger (if
steps. installed).
18 - 95 9813/7600-3 18 - 95
24 - Exhaust
2. Install the exhaust pipe and the silencer box.

3. Start the engine and check for exhaust leaks.

Item Torque Value Torque Angle
(Nm) (Degrees)
2 (First Stage) 25
2 (Final Stage) +90
18 - 96 9813/7600-3 18 - 96
27 - Exhaust Gas Recirculation (EGR)
Contents Page No.
18-27-00 General ........................................................................................................................... 18-99

18-27-03 Actuator ........................................................................................................................ 18-106
18 - 97 9813/7600-3 18 - 97
Notes:
18 - 98 9813/7600-3 18 - 98
00 - General
Introduction .................................................... 18-99 The EGR (Exhaust Gas Recirculation) system is
Component Identification ............................. 18-100 a technique that re-circulates a portion of the
Operation ..................................................... 18-101 exhaust gases back into the combustion chamber.
Check (Condition) ........................................ 18-102 The system cools and controls the quantity of re-
circulated exhaust gas.
The EGR valve is controlled by the CAN (Controller
Area Network)bus system (PIL 33-45), the valve
opens and closes to allow the exhaust gases to
flow back into the intake system via the EGR cooler.
This has the effect of lowering the combustion
temperature and reducing the formation of NOx
(Nitrogen Oxide).
In order to ensure full power is always available when

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

a feedback position sensor, linkage and a valve
mechanism. The valve actuator, which is controlled
by the CANbus system, position sensor and linkage,
drives the valve to the demanded position.
18 - 99 9813/7600-3 18 - 99
00 - General
Figure 423.
B
C
D
A E
F
G
A VGT (Variable Geometry Turbocharger) actuator B VGT

C EGR (Exhaust Gas Recirculation) valve D EGR actuator
E EGR intermediate cooler F Main plate cooler
G Mixer tube
Table 179. Colour Code Key

Colour System
Blue Coolant Flow 1
Red Recirculated Gas Flow
Green Air Flow
Yellow Coolant flow 2
18 - 100 9813/7600-3 18 - 100

00 - General
Operation Figure 426.
1. Exhaust gases enter the exhaust manifold.

Figure 424.
4. Exhaust gases enter the mixer tube.

Figure 427.
2. The exhaust gases travel through the
intermediate EGR (Exhaust Gas Recirculation)
cooler.
Figure 425.
5. The exhaust gases are mixed with new air and

re-enter the engine.
Figure 428.
3. The exhaust gases enter the main cooler which
reduces the heat.
18 - 101 9813/7600-3 18 - 101

00 - General
Check (Condition)
1. Check that the EGR (Exhaust Gas Recirculation)
for excessive carbon build up. Visually inspect for
leaks at the EGR. Make sure all gaskets are in
good condition, replace as required.
18 - 102 9813/7600-3 18 - 102

00 - General
Remove and Install

Before Removal
Figure 429.
C
B D
E
A
F
G

C EGR (Exhaust Gas Recirculation) actuator D EGR valve
E EGR Intermediate Cooler F Main Plate Cooler
G Mixer Tube
18 - 103 9813/7600-3 18 - 103

00 - General
Remove 8. Remove the bolts (x4) that retain the heat shield
to the EGR control module.
1. Remove the EGR cooler hose (Left side viewed
from the rear of the engine). 9. Remove the bolt from the cooler pipe.
2. Remove the EGR cooler bracket assembly bolts 10. Remove the cooler connections (banjo fittings
(x2). (x4) and copper washers) from the EGR control
module and electrical harness connector.
3. Carefully remove the main EGR cooler.
11. Remove the small bolts (x3) that fix the control
4. Remove the EGR cooler hose (Right side viewed module to the EGR valve.
from the rear of the engine).
12. Remove the bolts (x2) that fix the EGR bracket
5. Remove the nuts (x4) fixing the EGR tube in tube to the W-clip that clamp the cooler pipes together
cooler pipe assembly to the EGR valve. (captive nuts).
6. Remove the EGR actuator control rod pivot pin 13. Remove the EGR valve body from the mounting
fixing clips and the EGR control rod. studs fixed to the manifold with a steel gasket
both sides.
7. Remove the bolt fixing the EGR tube in tube
cooler to the rear of the cylinder head.
Figure 430.
19
22
41
42 41
45
5 41 35
25 20
17 41
10
29
38
32
19 41
3 20
22 15
7
37
4 13
20 20 6
42
12
27 8 40
1
26 39
20 42
42 14
43
23 16
9 21
34
2 28
23
24 31
1 Main EGR cooler 2 Intermediate EGR cooler

3 EGR valve 5 Pipe (Coolant return to header)
6 Pipe (Under actuator to coolant return) 7 Pipe (EGR actuator feed)
18 - 104 9813/7600-3 18 - 104

00 - General
8 Pipe (EGR cooler out) 9 Pipe (rear of head feed)

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

Network) driven device and can only be
1. The installation procedure is the opposite of the evaluated with the use of Servicemaster. Refer
removal procedure. Additionally do the following to EGR Actuator (PIL 18-27).
steps.
4. All conditions of the EGR are reported by the fault
2. Renew all O-rings, sealing washers and gaskets. codes. Test the turbocharger boost pressure,
refer to Check Operation (PIL 18-36).
3. Tighten the fixings to the correct torque value.
Note: Tighten the EGR cross over tube bolts in Table 180. Torque Values
the correct order, 1 to 4 as shown in 2 stages.
Item Nm
Figure 431. 31 50
32 27
2
33 16
39 24
40 24
4
41 10.5
42 24
43 24
44 24
3
1
After Installation
1. Complete the actuator learn procedure, Refer to
Servicemaster, JCB Engine > Diagnostic Tool >
Ecomax Actuators > Actuator Learn > EGR Valve
Position Learn.
2. Start the engine and check for exhaust leaks and
coolant leaks.
18 - 105 9813/7600-3 18 - 105

03 - Actuator
03 - Actuator Introduction
Introduction .................................................. 18-106 The EGR (Exhaust Gas Recirculation) actuator is a
Remove and Install ..................................... 18-107 smart electronic CAN driven device and can only be
evaluated with the use of Servicemaster.
The device does a self check on the operating range

to check the adaption window every time the ignition
is switched off and on. The unit is extremely sensitive
and constantly monitors the conditions it is operating
under. If it detects over voltage, under voltage, high
or low current, movement, temperature etc, if it is
working outside of it's desired limits in any way at all,
it will shut down until the fault is rectified.
18 - 106 9813/7600-3 18 - 106

03 - Actuator
Remove and Install
The EGR (Exhaust Gas Recirculation) electronic

actuator is not a serviceable component, if it fails
replace the EGR valve assembly.
18 - 107 9813/7600-3 18 - 107

30 - Selective Catalytic Reduction (SCR)
Contents Page No.
18-30-00 General ......................................................................................................................... 18-109

18-30-03 Tank .............................................................................................................................. 18-116
18-30-06 Filter ............................................................................................................................. 18-122
18-30-09 Tank Sensor ................................................................................................................. 18-126
18-30-12 Pump Supply Module ................................................................................................... 18-131
18-30-15 Dosing Metering Module .............................................................................................. 18-137
18-30-18 Catalyst ........................................................................................................................ 18-140
18-30-24 Coolant Valve ............................................................................................................... 18-143
18-30-30 Intake Throttle .............................................................................................................. 18-146
18-30-36 Mixer Reactor ............................................................................................................... 18-150
18-30-90 Hose ............................................................................................................................. 18-152
18 - 108 9813/7600-3 18 - 108

00 - General
Introduction .................................................. 18-109 To meet Tier 4 emission standards, this machine has
Health and Safety ........................................ 18-110 EAT (Exhaust After Treatment) using SCR (Selective
Technical Data ............................................. 18-111 Catalytic Reduction) technology. In SCR technology
Component Identification ............................. 18-112 a liquid called DEF (Diesel Exhaust Fluid) is injected
into the exhaust gases.
Check (Condition) ........................................ 18-113
DEF is specified in standards DIN 70070 and ISO
22241. Most commonly known trademarks of DEF
are:
• AdBlue
• Air1
• Greenox
The SCR system consists of the engine control

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

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

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

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

ISO 22241 certified). Do not dilute DEF or mix it with
other substances, it may damage the catalyst.
When filling the DEF tank, make sure that you use
the DEF filler and not the fuel filler. Even small
amounts of DEF in the fuel tank may damage the
system. If there is any possibility that fuel has been
contaminated with DEF, the engine must not be
started before emptying and cleaning the fuel tank.
Make sure that no other substances can get in to
the DEF tank. If there is any possibility that the DEF
tank could have been misfiled or contaminated do
not start the engine. Drain and clean the tank before
refilling with clean, good quality DEF. Refer to (PIL
18-30-03).
Supplementary admixtures or additives are not

allowed. Do not dilute DEF or mix it with other
substances as it may damage the catalyst. If the DEF
18 - 109 9813/7600-3 18 - 109

00 - General
quality sensor detects a problem, it will cause the Health and Safety
engine to run at reduced power.
Be careful when handling DEF. It is aggressive to Diesel Exhaust Fluid (DEF)

some materials and corrosive to some metals. DEF If large quantities of DEF have been swallowed
becomes crystalline when in contact with air. In case a doctor should be called immediately. Do not
of a spillage, rinse with plenty of water and dry with induce vomiting unless directed to do so by medical
a clean cloth. personnel. Never give anything by mouth to an
unconscious person. Avoid prolonged or repeated
skin contact. After contact with skin wash thoroughly
with plenty of soap and water. If irritation develops
seek medical advice. Avoid contact with eyes,
skin and clothing. Wear chemical resistant gloves,
overalls and safety goggles complying with an
approved standard. If in contact with eyes, rinse
immediately with plenty of clean water. If irritation
occurs seek medical attention. Always wash hands
and arms thoroughly after handling before eating,
drinking, smoking or using the lavatory. DEF is
corrosive to some metals such as copper and
its alloys. Use only recommended storage and
dispensing systems. DEF solution is very polluting
to surface water and groundwater. DEF may not
be removed by oil separators so it is important to
isolate drainage from the dispensing area to prevent
pollution in the event of a spill. Store below 30
degrees C in a segregated, approved and labelled
area. Keep container closed.
Notice: No warranty liability whatsoever will be
accepted for failure of the emissions control system
where the failure is attributed to the quality and grade
of the diesel exhaust fluid (DEF) used.
Notice: No warranty liability whatsoever will be
accepted for failure of the emissions control system
where the failure is attributed to contamination of the
diesel exhaust fluid (DEF).
18 - 110 9813/7600-3 18 - 110

00 - General
Technical Data
Table 181.
Description Data
Recommended DEF (Diesel Exhaust Fluid) 32.5% Urea, 67.5% Water (Must meet Standards
ISO 22241 and DIN70070)
18 - 111 9813/7600-3 18 - 111

00 - General
Figure 432.
G
E
F
L
D
L L
C J
A
K
O
A
M
P
B
A NOx (Nitrogen Oxide) sensor upstream B NOx sensor downstream

C Dosing metering module D SCR (Selective Catalytic Reduction) dosing
control module
E Pump supply module F Coolant valve
G Tank sensor H Heated DEF (Diesel Exhaust Fluid) hoses
I SCR catalyst J DEF tank
K Harness to ECM (Engine Control Module) L Engine coolant hoses
M Exhaust gas in (dirty) N Exhaust gas out (clean)
O Mixer reactor P Exhaust temperature sensor
18 - 112 9813/7600-3 18 - 112

00 - General

Engine, JCB Tier 4F Engine 4 Cyl)
A
Special Tools
Meter (hydrometer) 333/H5664 1
Kit Vacuum Pump 998/10424 1
It may be necessary to obtain a sample of DEF

(Diesel Exhaust Fluid) if contamination is suspected
or to check the operation of the DEF quality sensor.
This procedure must be carried out in clean

conditions, make sure that no contamination of any A DEF Filler cap
kind is allowed to enter the DEF tank. Figure 434.
Make sure that all test equipment is scrupulously
clean. Any contamination can make test results B
inaccurate.
This procedure does not apply to T4F machines

installed with engines under 55kW.

3. Make sure that you wear the correct
PPE (Personal Protective Equipment) for the
procedure. Refer to (PIL 01-03).
B Hexagonal key
4. Make sure that the area around the DEF filler
cap is scrupulously clean. The location of the Figure 435.
DEF filler may vary according to your machine.
Consult the operators manual.
5. For 506, 507, 509, 510, 512 and 514 machines,
do the following:
5.1. Use the correct hexagonal key to remove
the screws (x3) that attach the cap and
strainer to the machine.
5.2. Remove the blue cap and strainer assembly
by rotating counterclockwise and remove it
from the tank.
18 - 113 9813/7600-3 18 - 113

00 - General
C DEF Cap and strainer assembly

6. For all other machines, unlock and remove the
DEF tank cap.
6.1. Remove the strainer by rotating it
counterclockwise and remove from the tank Figure 439. DEF Strainer (Other machines)
filler neck.
6.2. Make sure that any contamination retained D
in the strainer does not enter the tank.
Figure 437. DEF Filler location (Other machines)
D DEF Strainer
7. Assemble the JCB sampling kit and feed the
hose in to the DEF tank through the filler neck.
Special Tool: Kit Vacuum Pump (Qty.: 1)
8. Make sure the hose is fully inserted in to the
bottom of the DEF tank.
9. Pump and fill the sample bottle with the required
amount of DEF.
A DEF Cap
18 - 114 9813/7600-3 18 - 114

00 - General
Figure 440. DEF Sampling Kit Special Tool: Meter (hydrometer) (Qty.: 1)
13. The float should rise so that the DEF level is
within the green area on the scale. If the DEF
level is not within the green area it suggests that
the DEF is of poor quality or is contaminated.
F Figure 442.
J
K
E
J Hydrometer
K Hydrometer reading
14. DEF should have a urea concentration of the
specified range.
E Sample bottle
F Vacuum pump Percentage: 31.8–33.2%
10. Install the strainer and filler cap and make sure 15. Further DEF quality tests are available. Refer to
that the cap is locked. JCB Technical service.
11. Examine the DEF sample: 16. Dispose of the DEF sample correctly. Do not pour
it back in the tank.
11.1. Contaminated DEF will appear cloudy.
11.2. Clean DEF should be clear and colourless.
Figure 441.
E
G H
E DEF Test bottle

G Contaminated DEF sample
H Clean DEF sample
12. Carefully place the sample into the JCB
hydrometer to test the quality of the DEF.
18 - 115 9813/7600-3 18 - 115

03 - Tank
03 - Tank Introduction
Introduction .................................................. 18-116 The DEF (Diesel Exhaust Fluid) tank stores the
Drain and Fill ............................................... 18-117 DEF. It is very important that only clean DEF is
Clean ........................................................... 18-118 used. Use of any other fluid will contaminate and
Remove and Install ..................................... 18-120 potentially cause damage to the SCR (Selective
Catalytic Reduction) system.
18 - 116 9813/7600-3 18 - 116

03 - Tank
Drain and Fill Drain

Figure 443.
(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
A
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
Special Tools
DEF Tank Drain Tool 334/E9120 1
CAUTION Make sure you do not over tighten the

DEF tank drain plug. Use the correct tools and
tighten carefully to the correct torque. Do not use
any thread sealants of any kind. Make sure the
drain plug is clean before installation.
The SCR (Selective Catalytic Reduction) tank level

must be checked and filled every time the main diesel
tank is filled. The machine must not be run with the
tank empty.
H
The tank must never be filled with anything other than
the DEF (Diesel Exhaust Fluid) specified in Technical A DEF Tank
Data. Refer to (PIL 18-30). H DEF Drain plug
The DEF tank is a separate tank located within 1. Make the machine safe. Refer to (PIL 01-03).
the area of the diesel tank. The drain plug can be 2. Follow the general health and safety procedures.
accessed from underneath the machine in the area Refer to (PIL 01-03).
of the diesel tank. Make sure you identify the correct
drain plug. 3. Position a container of suitable size under the
drain plug.
4. Use the special tool to remove the drain plug and
let the DEF drain out.
Special Tool: DEF Tank Drain Tool (Qty.: 1)
5. Make sure the drain plug is kept scrupulously
clean.
6. Dispose of any unused DEF according to local
regulations.
7. Make sure that the drain plug is clean before you
install it. Do not use any thread sealants of any
kind.
8. Tighten the drain plug to the correct torque value.
Do not over tighten the drain plug.
Fill
1. Make sure that the area around the filler is clean
to prevent SCR system contamination. Make
sure the drain plug is correctly installed.
2. Remove the DEF tank filler cap.
18 - 117 9813/7600-3 18 - 117

03 - Tank
3. Fill the tank with clean DEF. Clean

4. Install the DEF tank filler cap. Special Tools
DEF Tank Drain Tool 334/E9120 1
Item Description Nm Data Link Adaptor 892/01174 1
A Drain plug 9 (DLA) Kit
DEF Diagnostic Test Kit 892/12461 1
Consumables
Traffic Film Remover 4006/2120 20L
993/99174 200L
If the DEF (Diesel Exhaust Fluid) tank requires

cleaning, for example due to filling with diesel fuel by
mistake, it may be possible to clean the tank without
removing the tank or tank sensor from the machine.
Do not use a high pressure washer, jet or steam

cleaning equipment with the tank sensor installed as
this may cause damage to the internal components.
Make sure that any unused or contaminated DEF is
disposed of in accordance with the local authority
regulations.
Flushing the DEF tank

The DEF tank should be flushed when there is a
chance that dirt may have entered the system or
there is an insufficient DEF flow rate with no other
symptoms.
1. Drain the DEF tank.

Special Tool: DEF Tank Drain Tool (Qty.: 1)
Figure 444.
A Drain plug
18 - 118 9813/7600-3 18 - 118

03 - Tank
2. Fill the DEF tank with clean water from an open 11. Clean the DEF filler cap with water and traffic film
ended low pressure hose pipe. remover solution. Rinse thoroughly afterwards
with clean water.
4. Repeat steps 2 and 3.
13. With the DEF tank drain plug removed,
5. Fill the DEF tank with clean good quality DEF. thoroughly rinse the DEF tank through the filler
cap with clean water from an open ended low
Cleaning the DEF tank pressure hose pipe.
The DEF tank should be cleaned when there is 14. Install the DEF tank drain plug. Tighten to the
a chance that the system has been contaminated correct torque value.
or there is DEF contamination or quality warnings
present. 15. Fill the DEF tank with clean water from an open
ended low pressure hose pipe.
1. Disconnect the DEF pressure hose from the 16. Drain the DEF tank.
dosing metering module. Install a cap to the
dosing metering module to prevent dirt ingress. 17. Install the DEF tank drain plug. Tighten to the
2. Connect the extension tube to the DEF pressure
hose. 18. Fill the DEF tank with clean good quality DEF.
Special Tool: DEF Diagnostic Test Kit (Qty.: 1)
19. Place the dosing metering module pressure line
3. Insert the end of the DEF extension hose into a extension tube end into a clean container and
clean container with enough traffic film remover perform the maximum pump flow DEF dosing
solution DEF to completely cover the end of quantity test routine within Service Master.
the extension hose. Traffic film remover solution
20. Replace the DEF filter and the DEF pre-filter
should be made with a ratio of 1L of traffic film
located in the pump supply module. Refer to (PIL
remover for every 5L of clean water.
18-30-06).
Consumable: Traffic Film Remover
21. Perform the maximum pump flow DEF dosing
4. Connect Servicemaster and perform the DEF quantity test routine within Service Master.
emptying routine. This will draw traffic film
remover from the container through the DEF 22. Disconnect the test equipment.
return hose and into the contaminated DEF tank.
Make sure that the traffic film remover in the 23. Install the dosing metering module. Make sure
container remains above the end of the extension the metal gasket is replaced.
pipe at all times. 24. Start the engine.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
1) 25. Switch off the engine.
Duration: 1min
Special Tool: DEF Tank Drain Tool (Qty.: 1) 26. Start the engine. All faults and warnings should
be cleared.
6. Install the DEF tank drain plug. Tighten to the
correct torque value. 27. If contamination warnings remain further
cleaning will be required. Carry out 28 to 32.
7. Add the required amount of traffic film remover
into the tank through the filler cap to the ratio of 1L 28. Remove the tank sensor. Refer to (PIL 18-30-09).
of traffic film remover for every 5L of clean water.
29. With the DEF tank drain plug removed, use a
Consumable: Traffic Film Remover pressure washer to rinse the inside of the DEF
tank.
8. Fill the DEF tank with clean water from an open
ended low pressure hose pipe. 30. Clean the tank sensor unit with water and traffic
film remover solution.
9. Leave the solution to stand.
Duration: 20min 31. Carefully wipe the DEF quality sensor lens and
mirror with a clean, disposable soft wipe. Make
10. Where possible, agitate the solution to make sure sure that you do not to scratch or damage the
all internal surfaces of the tank are cleaned. quality sensor.
18 - 119 9813/7600-3 18 - 119

03 - Tank
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
Before Removal
3. Remove the fuel tank. Refer to (PIL 18-03).
4. Drain the DEF (Diesel Exhaust Fluid) tank,
removal must only be done when the tank is
A empty. Refer to (PIL 18-30-03).
A DEF quality sensor
5. The DEF tank must be kept free of contaminants.
32. Install the tank sensor unit. Do not re-use the drained DEF.
If contamination warnings remain, the DEF tank and 6. Any unused DEF should be disposed of
tank sensor unit may have to be replaced. according to local regulations.
Table 183. Torque Values 7. Do not allow contaminants to enter the DEF tank.
Make sure that contamination does not enter the
Item Nm pipes or fittings.
2 9
18 - 120 9813/7600-3 18 - 120

03 - Tank
Remove 8. Remove the DEF tank.
Figure 446. Install

F G 1. The installation procedure is the opposite of the
steps.
1.1. Tighten the tank strap securing bolts to the
D correct torque value.
1.2. Make sure that the check valve is installed
E correctly.

Item Nm
C 21
C
B
A DEF tank
B Tank securing strap bolts (x3)
C Check valve
D Breather pipe
E Filler pipe
F Hose connections
G Electrical connector
1. Remove the fuel tank. Refer to (PIL 18-03).
2. Disconnect the tank sensor. Prevent
contamination entering the fittings and hoses.
3. Disconnect the tank filler neck.
4. Disconnect the tank breather.
5. Disconnect any additional fittings or pipe work.
6. Cap all open ports to prevent contamination.
7. Remove the securing strap on top of the tank.
18 - 121 9813/7600-3 18 - 121

06 - Filter
06 - Filter Introduction
Introduction .................................................. 18-122 The DEF (Diesel Exhaust Fluid) filter is located in the
Remove and Install ..................................... 18-123 pump supply module. It is designed to filter all the
contamination that is generated through use to the
required level of cleanliness.
It is important that the filter is changed in accordance

with the machine maintenance schedule. Use only
the correct specification filters.
18 - 122 9813/7600-3 18 - 122

06 - Filter
Remove and Install
Remove 4. Remove and discard the pressure equalising

element.
1. Perform the DEF (Diesel Exhaust Fluid)
emptying routine using ServiceMaster. Figure 448.
2. Get access to the DEF supply module.

3. Remove the filter cover.
Figure 447.
D B
B Pressure equalising element

A 5. Use the filter extraction tool to remove the filter
from the supply module. The filter extraction tool
is supplied with each new filter.
5.1. Insert the split end into the filter element.
Gently rotate the tool to position it in the
A Filter cover correct position. Then rotate the tool in a
D Supply module clockwise motion to engage the tool with the
filter.
18 - 123 9813/7600-3 18 - 123

06 - Filter
Figure 449.
D
C
E C
E
C
F
E
E
G
C Filter element D Supply module

E Filter extraction tool F Extraction tool- not engaged with filter
G Extraction tool- engaged with filter ready for
removal
6. Place a suitable tool through the slot in the end of

the filter extraction tool and pull hard to remove
the filter element.
7. Discard the filter element.
18 - 124 9813/7600-3 18 - 124

06 - Filter
Figure 450.
C Filter element
Install
1. Lubricate the 0-rings with distilled water or DEF.
2. Install a new filter element into the supply
module.
3. Install a new pressure equalising element.
4. Install the filter cover, tighten to the correct torque
value.

Item Nm
3 22.5
18 - 125 9813/7600-3 18 - 125

09 - Tank Sensor
09 - Tank Sensor Introduction

Introduction .................................................. 18-126 The tank sensor is mounted in the DEF (Diesel
Operation ..................................................... 18-127 Exhaust Fluid) tank.
Clean ........................................................... 18-127
18 - 126 9813/7600-3 18 - 126

09 - Tank Sensor
Operation Clean
The tank sensor has a number of functions: Refer to (PIL 18-30-03).
• To measure the level of DEF (Diesel Exhaust

Fluid) inside the tank.
• To confirm the DEF quality meets the
requirements of the SCR (Selective Catalytic
Reduction) system.
• To defrost the DEF inside the tank.
• To measure the temperature of the DEF inside
the tank to inform when heating is required.
The tank sensor uses the CAN (Controller Area

Network)bus system to communicate with the DCU
(Dosing Control Unit).
18 - 127 9813/7600-3 18 - 127

09 - Tank Sensor
Remove and Install 12. Clamp the coolant hoses within the specified
distance of the quick connectors.
For: 531-70 [5AA], 531-70 [5TA], 535-95 Length/Dimension/Distance: 152mm
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 13. Remove the coolant hoses from the head unit.
[5AD], 541-70 [5TD], 550-80 [5AW], Make sure the hoses are capped correctly.
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................. Page 18-128 14. Remove the electrical harness connector from
Otherwise ................................ Page 18-129 the bracket and then separate the female and
male part.
(For: 531-70 [5AA], 531-70 [5TA], 535-95 15. Remove the jubilee clip.
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 16. Remove the head unit and place it in a clean
plastic bag to prevent contamination whilst it
[5AD], 541-70 [5TD], 550-80 [5AW], is removed from the tank. Depending on the
550-80 [5UW], 560-80 [5AY], 560-80 machine and its application you may need to
[5UY]) rotate the head unit as it is removed from the tank
to prevent it fouling. Do not use excessive force.
Make sure you have read and fully understand this Do not put force the pipe on to the spigots.
procedure before you begin.
17. The DEF quality sensor works by measuring the
The actual appearance of the component may differ DEF opacity. Make sure the lens is kept clean
from the illustration shown below. and is not touched.
Remove 18. Make sure you cap the DEF tank to prevent the
ingress of debris.
Figure 451.
2. Follow the general health and safety procedures. 3
Refer to (PIL 01-03). 2 1
3. Isolate the battery. Refer to (PIL 33-03).
4. Remove the ignition key to make sure that no
one attempts to start the machine during this
4
procedure.
5
6. Make sure there is no pressure in the engine
cooling system. Carefully loosen the cap on the
expansion tank and let the pressure release from
the system.
7. Open the cab door and remove the kick strip.
8. Remove the floor mat and access panel. Refer
to (PIL 06-06-39).
9. Locate the head unit. Make sure the area around
the head unit and the lens are clean to prevent 6
contamination of the SCR (Selective Catalytic
Reduction) system.
10. Record the angular position of the sensor relative 1 Pipe spigots- engine coolant hoses
to the DEF (Diesel Exhaust Fluid) tank. 2 Pipe spigots- DEF hoses
11. Remove the DEF hoses and the silver DEF line 4 Worm drive clip
from the retaining guide. Make sure that the 5 Tank level sensor
hoses are capped correctly. 6 DEF quality sensor
18 - 128 9813/7600-3 18 - 128

09 - Tank Sensor
Install Remove
1. The installation procedure is the opposite of the Figure 452. Typical installation
removal procedure. Additionally do the following 3
steps. 2 1
1.1. Do not put force on the pipe spigots when
installing.
1.2. Align the sensor at the correct angular 4
position relative to the DEF tank, as
recorded in Removal.
5
1.3. Make sure that the tank sensor is seated
correctly and not touching the sides of the
tank.
1.4. Make sure that any spilt DEF is removed.
1.5. Make sure the coolant level is correct. Refer
to (PIL 21-00-00).
1.6. Run the machine for the specified time with
the throttle fully engaged to ensure that the
head unit is working correctly and that there
are no error codes present in the right hand
instrument panel.
Duration: 2min
6
(Otherwise)
CAUTION Antifreeze can be harmful. Obey the
manufacturer's instructions when handling full 1 Pipe spigots - engine coolant hoses
strength or diluted antifreeze. 2 Pipe spigots - DEF hoses
4 Worm drive clip
Your machine/components may differ from those 5 Tank level sensor
shown below. This section is only provided for 6 DEF quality sensor
general information on this system.
1. Drain the engine coolant.
Before Removal
2. Disconnect and cap the coolant hoses to prevent
1. Make the machine safe. Obey general safety dirt ingress. Make sure that any spills or residual
precautions. Refer to (PIL 01-03). coolant is cleaned up immediately.
2. Disconnect the battery. Remove the ignition key. 3. Disconnect the DEF hoses and cap to prevent
Refer to (PIL 33-03). dirt ingress. Make sure any spills or residual DEF
is cleaned up immediately.
the engine has been running, let it cool before 4. Disconnect the electrical connector and cap to
you start the service work. prevent dirt ingress.
4. Get access to the tank sensor. 5. Loosen the worm drive clip.
5. Record the angular position of the sensor relative 6. Carefully remove the tank sensor from the tank.
to the DEF tank. Place the tank sensor in a clean plastic bag
to prevent contamination whilst it is removed
6. Ensure that the area around the tank sensor from the tank. Depending on the machine and
is clean to prevent contamination of the SCR its application you may need to rotate the tank
system. sensor as it is removed from the tank to prevent
it fouling. Do not use excessive force. Do not put
7. The DEF quality sensor works by measuring the force on the pipe spigots.
DEF opacity. Make sure the lens is kept clean
and is not touched. 7. Cap the tank to prevent dirt ingress.
18 - 129 9813/7600-3 18 - 129

09 - Tank Sensor
Install
steps.
2. Do not put force on the pipe spigots when
installing.
3. Align the sensor at the correct angular position
relative to the DEF tank, as recorded in Removal.
4. Make sure that the tank sensor is seated
correctly and not touching the sides of the tank.
5. Fill the engine cooling system.
18 - 130 9813/7600-3 18 - 130

12 - Pump Supply Module
12 - Pump Supply Module Introduction

Introduction .................................................. 18-131 The SCR (Selective Catalytic Reduction) pump
Operation ..................................................... 18-132 supply module has a number of functions:
Clean ........................................................... 18-134
Remove and Install ..................................... 18-135 • Provide the stable DEF (Diesel Exhaust Fluid)
system pressure.
• Provide clean DEF to the dosing metering
module.
• Emptying (purging) of the pressure line to
protect the dosing metering module against
damage due to ice expansion or crystallization.
• Thawing of the DEF inside the pump supply
module.
• Diagnosis of motor speed and temperature
inside the pump supply module.
• Prevention of dosing metering module flooding.
18 - 131 9813/7600-3 18 - 131

Operation
The supply module pumps DEF (Diesel Exhaust • Inlet: DEF enters the pump supply module from
Fluid) from the tank into the dosing metering module the tank.
at a stable pressure of 5bar (72.5psi). There are three • Outlet: DEF is pumped into the dosing metering
spigots which the DEF hoses are connected to: module.
• Backflow: DEF returns to the tank.
Figure 453.
1
7
2
1 Pump supply module 2 DEF inlet spigot

3 DEF outlet spigot 4 DEF backflow spigot
5 Bolts (x3) 6 DEF filter
18 - 132 9813/7600-3 18 - 132

The pump supply module contains the DEF filter.

There is also a course mesh filter within the DEF inlet
spigot. A heater is integrated into the pump supply
module to defrost the DEF in freezing conditions.
After a machine shutdown, the pump supply module

will recover DEF from the system and return it to
the tank. This helps to prevent DEF crystallising
when the machine is not in use. This function can
also be activated using ServiceMaster to purge the
system of DEF before carrying out service work.
This is controlled by the SCR (Selective Catalytic
Reduction)ECU (Electronic Control Unit) and takes
approximately 30s to complete. During this time it is
important that the battery isolator is not removed /
disconnected otherwise damage to the SCR system
can result.
18 - 133 9813/7600-3 18 - 133

Clean
The pump supply module has a mesh filter to prevent

any large particles or contaminants entering the
module. This is located within the inlet spigot.
Remove
Figure 454.
A Inlet spigot
B Clip
C Pump supply module
1. Get access to the pump supply module.
2. Disconnect the inlet DEF (Diesel Exhaust Fluid)
hose. Make sure that you clean up any spilled
DEF immediately.
3. Remove the clip.
4. Carefully pull the inlet spigot to remove it from the
pump supply module.
Clean
1. Rinse the spigot with clean water to remove any
debris in the filter.
2. If rinsing is not sufficient, the inlet spigot must be
replaced. Do not attempt to force debris out of
the filter as this may cause damage.
Install
1. Installation is the reverse of the removal
procedure.
18 - 134 9813/7600-3 18 - 134

Remove and Install
This component is not serviceable, if the component 2. Get access to the pump supply module.
fails replace the complete module.
3. Ensure that the area around the pump supply
module is clean to prevent contamination of the
Before Removal SCR (Selective Catalytic Reduction) system.
Remove
Figure 455.
1
7
2
1 Pump supply module 2 DEF (Diesel Exhaust Fluid) inlet spigot
18 - 135 9813/7600-3 18 - 135

3 DEF outlet spigot 4 DEF backflow spigot

5 Bolts (x3) 6 DEF filter
1. Perform the DEF emptying routine using

ServiceMaster.
2. Disconnect the DEF hoses from the spigots (x3).
3. Install caps to all open ports to prevent dirt
ingress and contamination of the SCR system.
5. Install a cap on to the electrical connector to
prevent dirt ingress and corrosion.
6. Undo the bolts (x3).
7. Remove the pump supply module from the
machine.
Install
1. Installation is the reversal of the removal
procedure.

Item Nm
5 19
18 - 136 9813/7600-3 18 - 136

15 - Dosing Metering Module
15 - Dosing Metering Module Introduction

Introduction .................................................. 18-137 The dosing metering module injects the required
Operation ..................................................... 18-138 amount of DEF (Diesel Exhaust Fluid) into the
Remove and Install ..................................... 18-138 exhaust gas. It is mounted on the mixer before the
SCR (Selective Catalytic Reduction) catalyst.
18 - 137 9813/7600-3 18 - 137

The dosing metering module is controlled by the Before Removal

SCR (Selective Catalytic Reduction) control module.
The SCR control module uses information from the 1. Make sure that the engine is safe to work on. If
upstream and downstream NOx (Nitrogen Oxide) the engine has been running, let it cool before
sensors to determine the quantity of DEF (Diesel you start the service work.
Exhaust Fluid) needed to reduce the nitrogen
emissions to the required level. The SCR control 2. Get access to the dosing metering module.
module will then send a signal to the dosing metering
module which will inject DEF in to the exhaust gases. 3. Ensure that the area around the dosing metering
module sensor is clean to prevent contamination
The dosing metering module has engine coolant of the SCR (Selective Catalytic Reduction)
flowing through it so that the DEF is prevented from system.
freezing when the machine is used in cold conditions.
Remove
Figure 456.
1 Coolant hoses
2 DEF (Diesel Exhaust Fluid) hose
3 Bolts (x3)
ServiceMaster.
3. Disconnect and cap the coolant hoses.
4. Disconnect and cap the DEF hose.
18 - 138 9813/7600-3 18 - 138

5. Disconnect and cap the electrical connector.

6. Undo the bolts (x3).
7. Remove the dosing metering module from the
mixer. Discard the metal gasket.
8. Install the caps on the mixer and the dosing
metering module.
The dosing metering module is a non-serviceable

item. If it is damaged or faulty it must be replaced.
Do not attempt to disassemble the dosing metering
module, any evidence of tampering will result in
warranty claims being rejected.
Install
Figure 457.
A Dosing metering module

B Metal gasket
1. Installation is the reversal of the removal
procedure.
2. Replace the metal gasket.
4. Fill the engine cooling system.

Item Nm
3 8
18 - 139 9813/7600-3 18 - 139

18 - Catalyst
18 - Catalyst Introduction
Introduction .................................................. 18-140 The SCR (Selective Catalytic Reduction) catalyst is
Remove and Install ..................................... 18-141 the location where the DEF (Diesel Exhaust Fluid)
reacts with the exhaust gases to reduce the amount
of NOx (Nitrogen Oxide) emissions.
DEF consists of water and urea. When injected into

the exhaust gases, the heat converts the DEF into
ammonia and carbon dioxide. The ammonia reacts
with the NOx in the exhaust gases to convert them
into nitrogen and water.
It is the catalytic surfaces within the catalyst that

allow the reaction to take place. In order for optimum
conversion, the SCR catalyst temperature needs to
be greater than 200°C (391.7°F).
The SCR catalyst is located in the exhaust system.
18 - 140 9813/7600-3 18 - 140

18 - Catalyst
Remove and Install Remove

CAUTION The exhaust pipe becomes extremely Figure 458. Typical Catalyst without Insulation
hot when the engine is running and will remain so
for some time after the engine is stopped. If you 2
touch the hot pipe you could be severely burned.
This component is not serviceable, if the component

fails replace the catalyst.
The actual appearance may differ from the illustration

shown below. This section is provided for general
information.
Some machines may have an insulation jacket

installed on the SCR (Selective Catalytic Reduction)
catalyst. If the insulation is installed, it must not be
removed. If the insulation becomes damaged it must
be replaced.
Before Removal
2. Get access to the SCR catalyst. 3
3. Ensure that the area around the head unit
system.
1
1 Exhaust clamp
2 Catalyst straps
3 Catalyst
18 - 141 9813/7600-3 18 - 141

18 - Catalyst
Figure 459. Typical Catalyst with Insulation
1
3
1 Exhaust clamp
2 Catalyst straps
3 Catalyst with insulation jacket
1. Remove the exhaust clamps. There is one at
each end of the catalyst.
2. Loosen the catalyst straps.
3. Remove the catalyst from the machine.
Install
removal procedure.
2. Tighten the exhaust clamps to the correct torque
value. Check whether the clamp is a standard
joint (1a) or a sealing ring joint (1b).

Item Nm
1a 10
1b 14
18 - 142 9813/7600-3 18 - 142

24 - Coolant Valve
24 - Coolant Valve Introduction

Introduction .................................................. 18-143 The coolant valve (or coolant solenoid) controls the
Operation ..................................................... 18-144 flow of engine coolant into the heat exchanger in the
Remove and Install ..................................... 18-144 head unit.
It is used to defrost DEF (Diesel Exhaust Fluid) in

the DEF tank. It is a normally closed solenoid valve
that will open when the temperature drops below a
calibrated level.
The coolant is taken directly from a port on the

crankcase. The coolant valve will close once the
temperature rises above the calibrated level.
The coolant valve is machine mounted, the location

will depend on the machine and its application.
Figure 460.
18 - 143 9813/7600-3 18 - 143

24 - Coolant Valve

Special Tools
The coolant valve is controlled by the DCU (Dosing Description Part No. Qty.
Control Unit). When the head unit in the DEF (Diesel Data Link Adaptor 892/01174 1
Exhaust Fluid) tank detects that the temperature (DLA) Kit
is below the calibrated level, the coolant valve will
open to allow engine coolant to flow through a heat CAUTION Antifreeze can be harmful. Obey the
exchanger on the heat unit. This warms the DEF manufacturer's instructions when handling full
to defrost and prevent it from freezing. Once the strength or diluted antifreeze.
temperature has reached the calibrated level the
coolant valve will close to prevent the DEF from
overheating. Before removal
2. Get access to the coolant valve.
Remove
Figure 461.
4 2
1 3 3 1
1 Coolant hose connections

3 Bolts (x4)
4 Coolant valve
2. Disconnect the coolant hoses from the hose
connections. Make sure that you clean up any
spilled coolant.
3. Cap all open ports.
5. Remove the bolts (x4).
6. Remove the coolant valve from the machine.
Install
steps.
2. Make sure that the coolant valve is in the correct
orientation. The coolant hoses have different
18 - 144 9813/7600-3 18 - 144

24 - Coolant Valve
sized connectors so that it cannot be installed

incorrectly.
3. Tighten the bolts (x4) to the correct torque figure.
4. Fill the engine cooling system with the specified
engine coolant. Refer to (PIL 75-09-03).
5. Connect the Servicemaster diagnostic tool.
1)
6. Check for active fault codes. Make sure any
existing fault codes are erased and do not return.
6.1. Diagnose and repair any faults that return
before continuing.
7. Select the aftertreatment system in the service
master diagnostic tool and identify the coolant
valve image and the status indicator next to it.
Refer to the helpfiles.
8. Start the engine.
9. Check that the status indicator of the coolant
valve changes from red to green. If the ambient
temperature is above the specified limit, the
indicator will return to red after a short period of
time.
10. Continue to run the engine and allow it to reach
operating temperature and for the after treatment
system to start dosing.
11. Check for active fault codes. Make sure any
existing fault codes are erased and do not return.
11.1. Diagnose and repair any faults that return
before continuing.
12. Disconnect the Servicemaster diagnostic tool.

Item Nm
3 10
18 - 145 9813/7600-3 18 - 145

30 - Intake Throttle
30 - Intake Throttle Introduction

Introduction .................................................. 18-146 The intake throttle is used to aid engine warm up
Operation ..................................................... 18-147 so that the SCR (Selective Catalytic Reduction)
Remove and Install ..................................... 18-148 system can reach operating temperature as quickly
as possible. It can also be used to aid SCR
regeneration.
The intake throttle is mounted on the intake manifold

after the grid heater (if installed).
Figure 462.
18 - 146 9813/7600-3 18 - 146

Operation
The intake throttle is controlled by the ECM (Engine

Control Module) It works by restricting the amount
of air entering the engine so that there is a
higher fuel to air ratio. This causes the engine
temperatures to rise quickly and therefore enables
the SCR (Selective Catalytic Reduction) system to
reach optimum operating temperature as quickly as
possible.
Once the SCR system has reached the operating

temperature, the throttle returns to the fully open
position and airflow in to the engine will return to
normal.
The Intake throttle can also be used to aid SCR

catalyst regeneration by restricting the air into the
engine during running to raise the temperature in the
engine and exhaust system.
The intake throttle is controlled automatically by the

ECM with no need for operator intervention.
18 - 147 9813/7600-3 18 - 147

Remove and Install
Before Removal 2. Get access to the intake throttle.
1. Make sure that the engine is safe to work on. If 3. Ensure that the area around the intake throttle
the engine has been running, let it cool before is clean to prevent contamination of the SCR
you start the service work. (Selective Catalytic Reduction) system.
Remove
Figure 463.
6
4
1
2 3
1 Temperature sensor connector 2 Throttle valve connector

3 Intake throttle 4 Throttle adaptor
5 O-rings (x2) 6 Bolts (x4)

A B
A
A CPA (Connector Position Assurance) tab A CPA tab

B connector latch
18 - 148 9813/7600-3 18 - 148

1. Disconnect the temperature sensor.

2. Disconnect the throttle valve.
2.1. Carefully pull back the CPA tab.
2.2. Depress the connector latch and pull
the connector whilst supporting the wiring
harness.
3. Disconnect the air intake hose.
4. Remove the bolts (x4) and remove the intake
throttle from the engine.
5. Separate the intake throttle from the throttle
adaptor.
Install
Do not use any grease or lubricants on the O-
rings, doing so can cause contamination of the SCR
system.
1. Make sure that all the sealing surfaces are clean

and flat.
2. Replace the O-rings (x2).
3. Install the intake throttle and adaptor plate on to
the engine.
4. Install the screws (x4), tighten to the correct
torque value.
5. Connect the temperature sensor.
6. Connect the throttle valve.
6.1. Push the connector until it is firmly seated
and an audible click is heard.
6.2. Carefully push the CPA tab in.

Item Nm
5 8
18 - 149 9813/7600-3 18 - 149

36 - Mixer Reactor
36 - Mixer Reactor Introduction

Introduction .................................................. 18-150 The mixer reactor is where the DEF (Diesel
Operation ..................................................... 18-151 Exhaust Fluid) is injected and mixed with the
exhaust gases. The mixer is mounted between the
exhaust manifold and the SCR (Selective Catalytic
Reduction) catalyst. The mixer is shaped to create
a vortex which helps to mix the DEF evenly with the
exhaust gases for optimum NOx (Nitrogen Oxide)
conversion in the SCR catalyst.
18 - 150 9813/7600-3 18 - 150

36 - Mixer Reactor
Operation
The atomizer is integrated into the mixer reactor

and aids the thermolytic process to convert the DEF
(Diesel Exhaust Fluid) to NH3. The 90° bend in the
mixer reactor optimizes the mass flow within the
reactor and thereby assists the NH3 conversion.
18 - 151 9813/7600-3 18 - 151

90 - Hose
90 - Hose Introduction
Introduction .................................................. 18-152 The DEF (Diesel Exhaust Fluid) hoses carry the
Remove and Install ..................................... 18-153 supply of DEF from the tank to the supply module and
on to the dosing module, and back to the DEF tank.
The DEF hoses are insulated and contain heating

elements in order to defrost DEF when machines
are used in temperatures below -8°C (17.6°F). The
heating elements are controlled by the DCU (Dosing
Control Unit) through 3 relays for individual heater
control, and a single master relay for diagnostic
purposes.
Figure 466.
18 - 152 9813/7600-3 18 - 152

90 - Hose
Remove and Install 5. Press the tabs on the quick connector and at the
same time pull the connector to disconnect the
hose.
Before Removal 6. Install caps to all open ports to prevent dirt
1. Make sure that the engine is safe to work on. If ingress and contamination of the SCR system.
you start the service work. Install
2. Get access to the DEF (Diesel Exhaust Fluid) 1. The installation procedure is the opposite of the
hose. removal procedure.
3. Ensure that the area around the DEF hose
Remove
Figure 467.
3
1 Quick connector
3 DEF hose
Servicemaster. Refer to (PIL 33-57).
3. Remove any clamps or supports securing the
DEF hose to the machine.
4. Locate the quick connectors at the ends of the
DEF hose.
Figure 468.
1 Quick connector
3 DEF hose
18 - 153 9813/7600-3 18 - 153

35 - Turbocharger
35 - Turbocharger
Contents Page No.
18-35-00 General ......................................................................................................................... 18-155
18 - 154 9813/7600-3 18 - 154

35 - Turbocharger
00 - General
Introduction .................................................. 18-155 The turbocharger (turbo) is a turbine driven forced
Component Identification ............................. 18-156 induction device that makes an engine more efficient
Check (Condition) ........................................ 18-157 and helps to produce more power for its size.
Check (Operation) ....................................... 18-158
Engine exhaust gasses drive a turbine, which in turn
Remove and Install ..................................... 18-159 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 - 155 9813/7600-3 18 - 155

35 - Turbocharger
00 - General
Figure 469.
7.5
7 7.4 7.3,4 1 9
12
7.2
8
11
7.3,13
3
6
8.8 5
1 Turbocharger 2 Exhaust manifold

3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
18 - 156 9813/7600-3 18 - 156

35 - Turbocharger
00 - General
1. Visually inspect for leaks at the turbocharger.

Make sure that all gaskets are in good condition,
replace as required.
2. Check the turbine and compressor blades inside
the turbocharger rotate freely and smoothly by
hand. If the blades are stiff to turn, or damaged
the turbocharger must be replaced.
3. Make sure that the oil feed pipe and oil drain pipe
are clear and free from debris and sludge.
4. Check the turbine shaft running clearance.
4.1. Place the stylus of a DTI (Dial Test Indicator)
against the shaft.
4.2. Move the shaft sideways. 5.2. Move the shaft axially.
Figure 470. 5.3. Make sure that the shaft end float is within
the specified limits.
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 - 157 9813/7600-3 18 - 157

35 - Turbocharger
00 - General
Check (Operation)
To maximise the duration of the turbocharger follow

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

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

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 158 9813/7600-3 18 - 158

35 - Turbocharger
00 - General
Remove and Install
Figure 472.
7.5
7 7.4 7.3,4 1 9
12
7.2
8
11
7.3,13
3
6
8.8 5
1 Turbocharger 2 Exhaust manifold

3 Oil feed pipe (turbo bearing) 4 Banjo bolts M12
5 Oil drain pipe (turbo bearing) 6 Fixing bolts (x2)
7 Pipe adaptor (oil drain connection) 8 Retaining nuts (x4)
11 Pipe clip 12 Bolt - pipe adaptor ( oil drain connection)
13 Banjo bolts M16
Before Removal 4. Get access to the engine.
1. This procedure requires service parts. Make sure 5. Drain the cooling system.
start, refer to Parts Catalogue. Remove
2. Make sure that the engine is safe to work on. 1. Disconnect the air induction hose at the inlet
If the engine has been running, make sure the manifold and turbocharger. Remove the hose.
engine has cooled sufficiently before you start.
2. Remove the pipe clip. Undo fixing bolts and
3. Remove the ignition key. remove the oil drain pipe. Note that the pipe pulls
18 - 159 9813/7600-3 18 - 159

35 - Turbocharger
00 - General
off the pipe adaptor, leaving the adaptor in place.

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

Item Nm
4 21
6 24
8 24
13 36
18 - 160 9813/7600-3 18 - 160

36 - Variable Geometry Turbocharger (VGT)
Contents Page No.
18-36-00 General ......................................................................................................................... 18-163

18-36-03 Actuator ........................................................................................................................ 18-170
18 - 161 9813/7600-3 18 - 161

Notes:
18 - 162 9813/7600-3 18 - 162

00 - General
Introduction .................................................. 18-163 The VGT (Variable Geometry Turbocharger) is
Component Identification ............................. 18-165 the next generation in turbocharger technology.
Operation ..................................................... 18-166 The turbocharger uses variable vanes to control
Check (Condition) ........................................ 18-167 exhaust flow and to introduce EGR (Exhaust Gas
Recirculation) to reduce emission in diesel engines.
Check (Operation) ....................................... 18-167 The turbocharger is bolted to the outlet port of the
Remove and Install ..................................... 18-168 exhaust manifold.
The turbo uses heat and energy from the waste

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

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

1 bar (14.5 lb/in2) depending upon engine speed
and load. The turbocharger spins at up to 100,000
rpm and reaches temperatures approaching 700 ºC
(1292 ºF); it is essential, therefore, that a good supply
of oil reaches it at all times. The oil not only lubricates
the turbocharger but also carries away excess heat.
External oil feed pipe connected to a port on the
crankcase supplies oil to the turbocharger bearing.
Oil returns to the engine oil sump via an external
drain pipe. Integral oil seals prevent oil escaping to
the compressor and turbine ends of the turbocharger.
18 - 163 9813/7600-3 18 - 163

00 - General
Figure 473.
B
A VGT
B VGT actuator
18 - 164 9813/7600-3 18 - 164

00 - General
Figure 474.
B
C
D
A E
F
G

C EGR (Exhaust Gas Recirculation) valve D EGR actuator
E EGR intermediate cooler F Main plate cooler
G Mixer tube
18 - 165 9813/7600-3 18 - 165

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

spread across a slot and over the louvres turning
the turbine and out of the outlet.
Figure 475.
4. The angle of the airflow can be adjusted as it

strikes the adjustable louvres to change the turbo
performance.
Figure 478.
2. The louvre ring sits inside the turbine housing

with the turbine spinning in the centre.
Figure 476.
3. The outer ring is adjusted by the actuator.
18 - 166 9813/7600-3 18 - 166

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

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

Avoid running the engine at idle speed for long
periods (above 20-30 minutes). Idle operation leads
to low pressure values in the turbocharger, which
may cause oil leaks from the seals at the ends of
the turbo bearing shaft. Even if this does not cause
damage, it can cause blue smoke from the exhaust
when the engine speed and load are increased.
18 - 167 9813/7600-3 18 - 167

00 - General
Remove and Install
Before Removal 3. Remove the ignition key.
1. This procedure requires service parts. Make sure 4. Get access to the engine.
start, refer to Parts Catalogue. 5. Drain the cooling system. Refer to (PIL 21-00).
2. Make sure that the engine is safe to work on. If 6. Remove the EGR (Exhaust Gas Recirculation)
the engine has been running, let it cool before valve. Refer to (PIL 18-27).
Figure 479.
10
7
6
2
8
9 9
3
4
14
17
16 19 11
20
15 12
18
13
1 Turbocharger 2 Gasket
3 Studs M8 4 Lock nut
18 - 168 9813/7600-3 18 - 168

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

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

boost pressure.
1. Disconnect the air induction hose at the inlet
manifold and turbocharger. Remove the hose. Table 192. Torque Values
2. Undo the bolts and remove the oil drain pipe. Item Nm
Note that the pipe pulls off the pipe adaptor, 4 24
leaving the adaptor in place. Cap the open ports 9 10
to prevent ingress of dirt. Discard the O-ring and 13 24
the gasket.
16 36
3. Remove the pipe clips. Undo the banjo bolts at 19 21
each end of the oil feed pipe, remove the pipe.
Cap the open ports to prevent ingress of dirt.
Discard the sealing washers.
4. Remove the exhaust manifold from the cylinder
head complete with the turbocharger still
installed, refer to Exhaust Manifold- Removal
and Replacement. Discard the exhaust manifold
gasket.
5. With the exhaust manifold removed from the
engine, undo the nuts and separate the
turbocharger from the manifold. Discard the
gasket
6. If the turbocharger is to be replaced remove the
bolts and pipe adaptor. Discard gasket.
Install
steps.
2. Check the condition of the turbocharger. Refer to
(PIL 18-35).
3. Prime the top of the turbo with 200ml of fresh
clean engine oil. It is Important: not to run the new
turbo dry.
4. Renew all O-rings, sealing washers and gaskets.
5. Note that the exhaust manifold gasket also
functions as a heat-shield.
6. Tighten the nuts, bolts and banjo bolts to the
After Installation
1. Start the engine and check for exhaust leaks.
18 - 169 9813/7600-3 18 - 169

03 - Actuator
03 - Actuator Install
steps.
Special Tools
Description Part No. Qty. 2. Perform the VGT (Variable Geometry
Data Link Adaptor 892/01174 1 Turbocharger) position learn routine using
(DLA) Kit Servicemaster. Refer to the engine Helpfiles.
Before Removal 1)
1. Make the machine safe. Refer to (PIL 01-03). Table 193. Torque Values
2. Make sure that the engine is safe to work on. If Item Nm
the engine has been running, let it cool before B 10
you start the service work. C 13
Remove
Figure 480.
D A
A Actuator
B Actuator linkage
C Nuts (x4)
D Electrical connector
2. Disconnect the actuator linkage from the
actuator.
3. Disconnect the coolant hoses. Plug all the open
ports and hoses to prevent contamination. Make
sure that any spills or residual coolant is cleaned
up immediately.
4. Remove the nuts (x4) and remove the actuator
from the turbocharger housing.
18 - 170 9813/7600-3 18 - 170

39 - Fuel Cooler
39 - Fuel Cooler
Contents Page No.
18-39-00 General ......................................................................................................................... 18-173
18 - 171 9813/7600-3 18 - 171

Notes:
18 - 172 9813/7600-3 18 - 172

39 - Fuel Cooler
00 - General
00 - General
Remove and Install
4. If the engine is hot let it cool for one hour.

(For: JCB Tier 4F Engine 4 Cyl) 5. Open the engine compartment cover. Refer to
(PIL 06-06).
Remove
6. Disconnect the fuel hoses from the matrix at the
1. Make the machine safe. Refer to (PIL 01-03). quick release couplings.
2. Follow the general health and safety procedures. 7. Support the matrix.
8. Remove the nuts.
3. Switch off the engine before working in the
engine compartment. Remove ignition key or 9. Remove the fuel cooler matrix from the machine.
isolate battery to prevent the engine from being
started. Refer to (PIL 33-03).
Figure 481.
B
B C
A Quick release couplings B Nuts

C Matrix
18 - 173 9813/7600-3 18 - 173

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 - 174 9813/7600-3 18 - 174

96 - Fuel Pipe
96 - Fuel Pipe
Contents Page No.
18-96-00 General ......................................................................................................................... 18-177

18-96-03 High Pressure Pipe ...................................................................................................... 18-179
18-96-06 Low Pressure Pipe ....................................................................................................... 18-182
18 - 175 9813/7600-3 18 - 175

Notes:
18 - 176 9813/7600-3 18 - 176

96 - Fuel Pipe
00 - General
Introduction .................................................. 18-177 Fuel at rail pressure is continuously supplied to
Health and Safety ........................................ 18-178 the injectors via high pressure fuel pipes. The high
Component Identification ............................. 18-178 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 common rail and on the injector at port.
It is essential that the pipes are maintained and

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

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

removed for any reason they must be renewed.
Installing the original fuel pipes will cause fuel leaks
at the pipe connections.
18 - 177 9813/7600-3 18 - 177

96 - Fuel Pipe
00 - General

WARNING Do not open the high pressure fuel
system with the engine running. Engine operation Figure 482.
causes high fuel pressure. High pressure fuel A
spray can cause serious injury or death. A A A
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system, B
thoroughly clean around the connection. When a
a fuel pipe, always install protective caps and H
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously C
damage the fuel injection equipment and could be
expensive to repair. G
E
D
A Pipe assembly high pressure - fuel rail to

injector (x4)
B Injector
C Pipe assembly high pressure - injection pump to
fuel rail
D Pipe low pressure - return to tank
E Injection pump
F Pipe assembly low pressure - Fuel injectors to
tank
G Pipe assembly low pressure - fuel rail to tank
H Fuel rail
18 - 178 9813/7600-3 18 - 178

96 - Fuel Pipe
03 - High Pressure Pipe
03 - High Pressure Pipe 5.3. Remove any dirt or debris that is exposed.
Refer to Engine, Clean (PIL 15-00-00).
Remove and Install 6. Always use a spanner at the top of the fuel pipe
nut (this will prevent damage to the nut).
Special Tools
Description Part No. Qty. Figure 484.
Socket 17MM Offset - 331/27987 1
(HP Fuel pipes)
(10-100Nm)
Important. Before disconnecting or removing fuel

pipes proceed as follows.
1. Make sure that you have the correct new parts.

1.1. The high pressure fuel pipes MUST BE
REPLACED with new ones.
1.2. The new fuel pipes must remain sealed
inside their bags before use. If a bag is open
DO NOT USE the fuel pipe, get a new one.
2. Obey all fuel system health and safety Injector Fuel Pipes
information. Refer to (PIL 18-00).
Remove
3. Make sure that the engine is safe to work on.
The procedure describes how to remove one fuel
3.1. The engine must cool and pressure in the pipe.
fuel system must decay before you start
work. Figure 485.
3.2. If the engine has been running, wait at least B
one hour before you start work.
A
4. Clean the engine. Refer to Engine, Clean (PIL C
15-00-00).
5. Remove the protective cover as follows.
E
Figure 483.
B
A Fuel pipe
A B Nut 1
C Fuel injector
D Fuel rail
E Nut 2
C
1. Remove the fuel pipes one at a time as follows.
A Screw
B Plastic segment 1.1. Loosen the nut 2 at the fuel rail. Do not
C Protective cover remove the nut at this step.
1.2. Use the 17mm deep socket special tool at
5.1. Push out the plastic segments. the top of nut. This will prevent damage to
5.2. Remove the screws and lift off the cover. the nut.
18 - 179 9813/7600-3 18 - 179

96 - Fuel Pipe
Special Tool: Socket 17MM Offset - (HP Injection Pump to Rail Fuel Pipe
Fuel pipes) (Qty.: 1)
Special Tool: Torque Wrench (10-100Nm) Remove
(Qty.: 1)
Figure 486.
1.3. Push the fuel pipe against the injector cone
and at the same time remove the nut 1. A
B
1.4. Push the fuel pipe against the fuel rail cone
and at the same time remove the nut 2.
1.5. Make sure that there is no dirt or debris on
the fuel pipe or the connectors.
1.6. Remove the fuel pipe.
1.7. Seal all the open ports, use the correct parts
from the service kit.
2. Repeat step 1 to remove the other fuel pipes.
3. Discard the old fuel pipes.
Install
Important: The high pressure fuel pipes must be E
replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a bag
is open do not use the fuel pipe, get a new one. Do
not open the bag until you are ready to assemble the D
fuel pipe.
1. Make sure that the bleed-off adaptors are C

assembled on the injectors before you install the A Nut 1
high pressure pipes. B Fuel rail
C Injection pump
2. Assemble the fuel pipes one at a time. The D Nut 2
procedure describes how to assemble one fuel E Fuel pipe
pipe.
1. Remove the fuel pipe as follows.
2.1. Put the correct end of the fuel pipe against
the correct injector cone. 1.1. Loosen the nut 2. Do not remove the nut at
this step.
2.2. Tighten the nut 1 with your hand.
1.2. Use the 17mm deep socket special tool at
2.3. Put the other end of the fuel pipe against the
the top of nut. This will prevent damage to
correct fuel rail cone.
the nut.
2.4. Tighten the nut 2 with your hand. Special Tool: Socket 17MM Offset - (HP
2.5. Nuts must be tightened in the correct Fuel pipes) (Qty.: 1)
sequence. Tighten nut 1 and then nut 2. Special Tool: Torque Wrench (10-100Nm)
(Qty.: 1)
2.6. Use the special tool at the top of nut 1 and
tighten it to the correct torque value. 1.3. Push the fuel pipe against the injector cone
and at the same time remove the nut 1.
Torque: 27N·m
Special Tool: Socket 17MM Offset - (HP 1.4. Push the fuel pipe against the rail cone and
Fuel pipes) (Qty.: 1) at the same time remove the nut 2.
2.7. Put the spanner at the top of nut 2 and 1.5. Make sure that there is no dirt or debris on
tighten it to the correct torque value. the fuel pipe or the connectors.
Torque: 27N·m 1.6. Remove the fuel pipe.
1.7. Seal all the open ports, use the correct parts
from the service kit.
2. Discard the old fuel pipe.
18 - 180 9813/7600-3 18 - 180

96 - Fuel Pipe
Install
Important: The high pressure fuel pipes must be

replaced with new ones. The new fuel pipes must
remain sealed inside their bags before use. If a bag
is open do not use the fuel pipe, get a new one. Do
not open the bag until you are ready to assemble the
fuel pipe.
1. To assemble the fuel pipe.

1.1. Put the correct end of the fuel pipe against
the correct pump cone at the injection
pump.
1.3. Put the other end of the fuel pipe against the
correct fuel rail cone.
1.5. Nuts must be tightened in the correct
sequence. Tighten nut 2 and then nut 1.
1.6. Use the special tool at the top of nut 2 and
tighten it to the correct torque value.
Torque: 27N·m
Special Tool: Socket 17MM Offset - (HP
Fuel pipes) (Qty.: 1)
1.7. Put the spanner at the top of nut 1 and
tighten it to the correct torque value.
Torque: 27N·m
After Installation
1. Ensure that all pipes are correctly installed
and located in retaining clips as applicable. If
retaining clips are missing or damaged they must
be replaced or renewed
18 - 181 9813/7600-3 18 - 181

96 - Fuel Pipe
06 - Low Pressure Pipe
06 - Low Pressure Pipe Figure 487.

B
Remove and Install
A
Before Removal A
Obey all fuel system health and safety information.
Refer to Fuel System, Health and Safety (PIL 18-00). C
Low Pressure Fuel Pipes

Remove
The low pressure fuel pipes have a nylon fitting
attached to the pipe that replaces the nut and olive.
The fittings are part of the pipe and not a separate
item.
1. To release the fuel pipe, first press and hold the

release buttons (one each side of the coupler).
Push the coupler towards the connector spigot
and then withdraw.
2. Cap all open ports to prevent ingress of dirt and
debris.
Assemble
1. To install the fuel pipe, press and hold the release
buttons. Push the coupler over the connector A Release Buttons
spigot and release the button. The connector will B Coupler
be heard to click when it is fully home and locked C Spigot
in place.
After Assembly
2. To check that the connection has been fully
made, attempt to pull the connector from the 1. Make sure that all the fuel pipes are correctly
connector spigot without releasing the lock installed and located in the retaining clips as
mechanism. (A gentle pull is all that is required, applicable. If retaining clips are missing or
if the connection is not correct the connector will damaged, they must be replaced or renewed.
release very easily.)
Injector Bleed-off Pipes

Before Removal
Obey all fuel system health and safety information.
1. Make sure that the engine is safe to work on. The

engine must cool and pressure in the fuel system
must decay before you start work. If the engine
has been running, wait at least one hour before
you start work.
2. Clean the engine. Refer to Engine, Clean (PIL
15-00).
3. Remove the protective cover as follows.
18 - 182 9813/7600-3 18 - 182

96 - Fuel Pipe
06 - Low Pressure Pipe
3.1. Push out the plastic segments. Figure 489.

3.2. Remove the screws and lift off the cover.
Figure 488.
D
C
B
A B
C
A Screw A Location tabs
B Plastic segment B Bleed pipe connector
C Protective cover C Bleed pipe clip
D High pressure fuel pipe
3.3. Remove any dirt or debris that is exposed.
Refer to Engine, Clean (PIL 15-00). After Assembly
4. To remove the bleed pipe clips, remove the high 1. Make sure that all pipes are correctly installed
pressure fuel pipes first. Refer to (PIL 18-96-03). and located in retaining clips as applicable. If the
retaining clips are missing or damaged they must
5. DO NOT try to repair fuel pipes or connectors. be replaced or renewed.
Defective fuel pipe assemblies must be replaced.
Remove
3. Install the protective cover. Refer to Figure 488.
The following details the removal and replacement
of one bleed-off connector. The procedure for the
remaining connectors is identical.
1. Gently spring the location tabs apart and pull out

the bleed pipe connector. DO NOT use excessive
force on the tabs.
2. Remove and discard the O-ring.
3. If it is necessary to remove the bleed off pipe
assembly, remove the nylon fitting at the high
pressure pump.
4. Cap all open ports to prevent ingress of dirt and
debris.
Install
1. Install a new O-ring.
2. Push in the bleed pipe connector until the
location tabs snap over the connector.
3. If applicable, replace the high pressure fuel pipes
with new ones. DO NOT use a high pressure fuel
pipe that was removed. Refer to (PIL 18-96-03)
18 - 183 9813/7600-3 18 - 183

Notes:
18 - 184 9813/7600-3 18 - 184

21 - Cooling System
Contents Page No.
21-00 Cooling System

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ........................................................................................................................... 21-15
21-03-03 Radiator .......................................................................................................................... 21-23
21-03-09 Transmission Oil Cooler ................................................................................................. 21-24
21-05 Fan Motor
21-05-00 General ........................................................................................................................... 21-27
21-06 Expansion Tank
21-06-00 General ........................................................................................................................... 21-41
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 ........................................................................................................................... 21-57
21-93 Hose
21-93-00 General ........................................................................................................................... 21-61
9813/7600-3
2018-02-01
Acronyms Glossary
CAC Charge Air Cooler

9813/7600-3
2018-02-01
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9813/7600-3 21 - 1
Notes:
21 - 2 9813/7600-3 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 ................................................. 21-12
Check (Condition) .......................................... 21-12
Check (Leaks) ............................................... 21-13
Check (Level) ................................................ 21-13
21 - 3 9813/7600-3 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 194.
cap, hot coolant can spray out and burn you. Radiator cap pressure 1bar (14.5psi)
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
strength or diluted antifreeze. temperature:
- Nominal temperature 96°C (204.7°F)
- Start to open tempera-94–98°C (201.1–
ture 208.3°F)
- Full open temperature 110°C (229.8°F)
- Travel (fully open) 9mm
Fan drive type FEAD (Front End Acces-
sory Drive) belt
Fan belt (FEAD) adjust- Automatic belt tensioner
ment
Fan belt (FEAD) type Multigroove belt
Coolant Temperature Refer to PIL 15-84
Switch/Sender range
Coolant pump (non-ser- Bolt on, belt driven unit
viceable part)
21 - 4 9813/7600-3 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Figure 490.
11
14
10
8
9
7
16 7
17
15
12
13 7
6
4 5
1 Coolant pump 2 Drive belt

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 Cab heater coolant supply 16 Cab heater coolant return
21 - 5 9813/7600-3 21 - 5
21 - Cooling System
00 - Cooling System
00 - General
17 Port for coolant supply to SCR (Selective

Catalytic Reduction) dosing system and DEF
(Diesel Exhaust Fluid) tank (if applicable)
21 - 6 9813/7600-3 21 - 6
21 - Cooling System
00 - Cooling System
00 - General
Operation (For: JCB Tier 4F Engine 4 Cyl)

For: JCB Tier 4i /T4F <55kW Engine 4 Cyl The coolant pump is driven via a pulley and front end
..................................................... Page 21-7 accessory drive belt, the pump draws coolant from
For: JCB Tier 4F Engine 4 Cyl the pump cavity.
..................................................... Page 21-7
The coolant is pumped through the outlet gallery
to the oil cooler cavity in the left-hand side of the
(For: JCB Tier 4i /T4F <55kW Engine 4 crankcase. As the coolant flows past the oil cooler
Cyl) matrix, heat is exchanged from the oil to the coolant.
This enables the oil to function as a coolant as well
The coolant pump is driven via a pulley and front end as a lubricant. Refer to Oil Cooler (PIL 15-69) and Oil
accessory drive belt, the pump draws coolant from Filter (PIL 15-21).
the pump cavity.
The coolant leaves the oil cooler cavity and passes
The coolant is pumped through the outlet gallery into the main crankcase gallery. The gallery is
to the oil cooler cavity in the left-hand side of the connected to the cylinder water jackets. Coolant
crankcase. As the coolant flows past the oil cooler flows around and up the jackets and then passes into
matrix, heat is exchanged from the oil to the coolant. the cylinder head via the link galleries. The coolant
This enables the oil to function as a coolant as well circulates around the cylinder head where it conducts
as a lubricant. Refer to Oil Cooler (PIL 15-69) and Oil heat away from the combustion chambers and also
Filter (PIL 15-21). the fuel injector tips, refer to (PIL 18-18). The coolant
then passes to the thermostat housing.
The coolant leaves the oil cooler cavity and passes
into the main crankcase gallery. The gallery is When the engine is below normal operating
connected to the cylinder water jackets. Coolant temperature the thermostat is closed, preventing
flows around and up the jackets and then passes into coolant flowing to the machine radiator via the top
the cylinder head via the link galleries. The coolant hose connection port. Instead coolant is directed
circulates around the cylinder head where it conducts through the by-pass gallery back to the pump
heat away from the combustion chambers and also cavity and is again drawn into the pump. Refer to
the fuel injector tips, refer to (PIL 18-18). The coolant Thermostat (PIL 21-12).
then passes to the thermostat housing.
When the engine is at operating temperature the
When the engine is below normal operating thermostat opens, closing the by-pass gallery to the
temperature the thermostat is closed, preventing pump and opening the top hose connection port to
coolant flowing to the machine radiator via the top the machine radiator. The coolant passes through
hose connection port. Instead coolant is directed the radiator matrix and is cooled. The coolant flows
through the by-pass gallery back to the pump back to the engine via the bottom hose connection
cavity and is again drawn into the pump. Refer to port and is again drawn into the pump. Refer to
Thermostat (PIL 21-12). Thermostat (PIL 21-12).
When the engine is at operating temperature the A coolant temperature gauge and warning light
thermostat opens, closing the by-pass gallery to the sender unit is installed at port 14. Refer to Engine
pump and opening the top hose connection port to Sensors (PIL 15-84).
the machine radiator. The coolant passes through
the radiator matrix and is cooled. The coolant flows A cab heater hose can be installed at port 15. This
back to the engine via the bottom hose connection enables coolant to circulate through a heater matrix
port and is again drawn into the pump. Refer to when the thermostat is open or closed, ensuring fast
Thermostat (PIL 21-12). heater warm up. The coolant returns to the engine
through port 16.
A coolant temperature gauge and warning light
sender unit is installed at port 14. Refer to Engine Engine coolant is delivered to the SCR (Selective
Sensors (PIL 15-84). Catalytic Reduction) system and DEF (Diesel
Exhaust Fluid) tank through port 17 irrespective of
A cab heater hose can be installed at port 15. This the thermostat position. This defrosts the DEF as
enables coolant to circulate through a heater matrix quickly as possible in cold conditions so that the
when the thermostat is open or closed, ensuring fast emissions control system can work effectively. The
heater warm up. supply comes direct from the coolant pump outlet.
21 - 7 9813/7600-3 21 - 7
21 - Cooling System
00 - Cooling System
00 - General
Fault-Finding
For: JCB Tier 4F Engine 4 Cyl (For: JCB Tier 4F Engine 4 Cyl)
..................................................... Page 21-8
For: JCB Tier 4i /T4F <55kW Engine 4 Cyl
..................................................... Page 21-9
Fault
Coolant - Loss. Table 195. Page 21-8
Coolant - Over Temperature. Table 196. Page 21-8
Coolant - Under Temperature. Table 197. Page 21-9
Coolant - Contaminated. Table 198. Page 21-9
Table 195. Coolant - Loss.

Cause Remedy
Incorrect coolant level. Check the level.
DEF (Diesel Exhaust Fluid) tank heater circuit The coolant to DEF tank heater circuit has not bled
bleeding. correctly after work has been carried out. When this
(1)
circuit bleeds, the coolant level will drop until the

circuit has bled fully. Check the level until it stabilises.
Coolant leaking from engine radiator or cab heater. Visually inspect the radiator heater, hoses and
connection to locate the leak. If oil is present in the
coolant, check for a transmission or engine oil cooler
leak.
External engine coolant leak. Visually inspect the engine and components for
seal, gasket hose connection leaks. Make sure all
hose clips are in good condition and torqued to the
recommended figure. Make sure all spring band
clamps are in good condition and apply sufficient
pressure to the hoses.
Overheating or compression gases leaking, resulting See Also: Table 196. Coolant - Over Temperature.
in loss through the radiator overflow.
If installed, transmission cooler leak. Check/replace the transmission cooler. Check for
coolant in the inlet manifold and in the oil.
Lubricating oil cooler leak. Check/replace the oil cooler. Check for coolant in the
oil.
EGR (Exhaust Gas Recirculation) cooler leak. Check/replace the EGR cooler. Check for signs of
(1)
coolant leaking into combustion chamber.

SCR (Selective Catalytic Reduction) system leak. Check for signs of engine coolant in the DEF and
(1)
DEF in the engine coolant. Check the dosing

metering module and the head unit for leaks.
Cylinder head gasket leak. Check/replace the head gasket.
Cylinder head cracked or porous. Check/replace the cylinder head.
Crankcase coolant passages leaking. Check/replace the crankcase.
(1) If installed
Table 196. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 195. 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.
21 - 8 9813/7600-3 21 - 8
21 - Cooling System
00 - Cooling System
00 - General
Cause Remedy
Radiator hose collapsed, restricted or leaking. Check/replace hose.
Oil level over filled. Check oil level.
Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system.
Over concentration of antifreeze. Remove part of the coolant from cooling system and
replace with water.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, incorrect or missing. Check/replace the thermostat.
Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the
correct vented thermostat is installed. If aeration
continued, check for a compression leak through the
head gasket.
Coolant pump faulty. Check/replace the coolant pump.
Vent line from engine and/or radiator blocked or Check routing and operation or vent line.
incorrectly routed (sudden overheating).
Leak between the top tank and the auxiliary tank Check for coolant leakage between radiator auxiliary
(sudden overheating). tank and radiator top tank.
Cooling passages in radiator, cylinder head, head Flush the system and fill with clean coolant.
gasket or block blocked.
ECM (Engine Control Module) (if installed) or Check the electronic fault codes. Check the electrical
electrical sensor fault. connections at the ECM and sensors.
Table 197. Coolant - Under Temperature.

Cause Remedy
Air flow across the radiator excessive. Check/repair fan shroud, anti-recirculation sealing,
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 198. 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 195. Coolant - Loss.
gasket, cylinder head and crankcase.
SCR system leak.
(2)
(2) If installed
(For: JCB Tier 4i /T4F <55kW Engine 4

Cyl)
21 - 9 9813/7600-3 21 - 9
21 - Cooling System
00 - Cooling System
00 - General
Fault
Coolant - Loss. Table 199. Page 21-10
Coolant - Over Temperature. Table 200. Page 21-10
Coolant - Under Temperature. Table 201. Page 21-11
Coolant - Contaminated. Table 202. Page 21-11
Table 199. 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 200. 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 cooler leak (if applicable). Check/replace the EGR cooler. Check for signs of
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 200. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
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,
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.
Thermostat faulty, incorrect or missing. Check/replace the thermostat.
Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the
correct vented thermostat is installed. If aeration
continued, check for a compression leak through the
head gasket.
Coolant pump faulty. Check/replace the coolant pump.
Vent line from engine and/or radiator blocked or Check routing and operation or vent line.
incorrectly routed (sudden overheating).
21 - 10 9813/7600-3 21 - 10
21 - Cooling System
00 - Cooling System
00 - General
Cause Remedy
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 or electrical sensor fault (if applicable). Check the electronic fault codes. Check the electrical
Table 201. Coolant - Under Temperature.

Cause Remedy
Air flow across the radiator excessive. Check/repair fan shroud, anti-recirculation sealing,
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 202. 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 199. Coolant - Loss.
gasket, head and crankcase.
21 - 11 9813/7600-3 21 - 11
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 20L 1.1. Leaks.
Concentrate 4006/1103 200L 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 491.
A
B
A Cap
B Bottom radiator hose
C Expansion tank
21 - 12 9813/7600-3 21 - 12
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 - 13 9813/7600-3 21 - 13
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ........................................................................................................................... 21-15

21-03-03 Radiator .......................................................................................................................... 21-23
21-03-09 Transmission Oil Cooler ................................................................................................. 21-24
21 - 14 9813/7600-3 21 - 14
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction .................................................... 21-15 The cooling pack contains the following major
Component Identification ............................... 21-16 components:
Clean ............................................................. 21-18
Check (Condition) .......................................... 21-18 • Radiator.
• Cooling fan.
Remove and Install ....................................... 21-19 • CAC (Charge Air Cooler).
Disassemble and Assemble .......................... 21-22 • Condenser for air-conditioning (if installed).
• Oil cooler (if installed).
21 - 15 9813/7600-3 21 - 15
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 492.
A
A
E
A
E
D
F
B
E
L F
C
G H K
Q
P J
21 - 16 9813/7600-3 21 - 16
21 - Cooling System
03 - Cooling Pack
00 - General
Table 203.
Item Description
A Air cleaner / fuse box
support bolts
B Fuel sedimentor and
pump
C Air to air inter cooler ma-
trix
D Hydraulic oil cooler ma-
trix (if installed)
E Fixing points
F Hydraulic hoses- Fan
Motor/Oil Cooler
G Solenoid valve- re-
versible fan (if installed)
H Fan speed sensor
J Proportional fan speed
control solenoid
K Engine coolant radiator
matrix
L Radiator top hose con-
nection
M Inter cooler inlet hose
connection
N Fixed Speed Cooling fan
and hydraulic motor as-
sembly (55KW engines)
P Variable Speed Cooling
fan and hydraulic motor
assembly (81, 93 and
108 KW engines)
Q Inter cooler outlet hose
connection
R Radiator bottom hose
connection
21 - 17 9813/7600-3 21 - 17
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 - 18 9813/7600-3 21 - 18
21 - Cooling System
03 - Cooling Pack
00 - General
Remove and Install
10. Disconnect the transmission cooler hoses from

(For: JCB Tier 4F Engine 4 Cyl) the chassis.
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 12. Disconnect the hydraulic hoses from the chassis.
is necessary for engine overhaul or removal and
replacement for example. 13. Plug all the open ports and hoses to prevent
contamination.
Disassembly
14. On 527-56 machines, the fan motor hydraulic
1. Make the machine safe. Refer to (PIL 01-03). hoses are connected to the bulkhead plate.
2. Make sure that the engine and hydraulic system Figure 493.
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.
21 - 19 9813/7600-3 21 - 19
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 494.
A
A
E
A
E
D
F
B
E
L F
C
G H K
Q
P J
Table 204.
Item Description
A Fusebox support bolts
B Fuel separator and pump
C Air to air intercooler matrix
(1)
D Hydraulic oil cooler matrix (if installed)

(1)
E Fixing points
21 - 20 9813/7600-3 21 - 20
21 - Cooling System
03 - Cooling Pack
00 - General
Item Description
F Hydraulic hoses- Fan Motor/Oil Cooler
G Solenoid valve- reversible fan (if installed)
H Fan speed sensor
J Proportional fan speed control solenoid
K Engine coolant radiator matrix
(1)
L Radiator top hose connection

M Intercooler inlet hose connection
N Fixed Speed Cooling fan and hydraulic motor assem-
bly (55KW engines)
P Variable Speed Cooling fan and hydraulic motor as-
sembly (81, 93 and 108 KW engines)
Q Intercooler outlet hose connection
R Radiator bottom hose connection
(1) The engine coolant radiator, transmission oil cooler and air to air inter cooler matrix are all integral part. If
any part of the assembly has failed the complete unit must be replaced.
Install 1.1. Tighten the clamps to the correct torque

value.
steps.
Figure 495.
U
U
U Clamp
1.2. Fill the engine cooling system with the Table 205. Torque Values
correct type of coolant. Refer to (PIL 21-00).
Item Description Nm
1.3. Operate the engine and check the fan motor U Clamp 5.5
speed.
1.4. Check the hydraulic fluid level. Refer to (PIL
30-00-00).
1.5. Check the transmission oil level and top up
as necessary.
21 - 21 9813/7600-3 21 - 21
21 - Cooling System
03 - Cooling Pack
00 - General
With the cooling pack removed from the machine

disassemble the components as necessary.
• Remove the transmission oil cooler. Refer to

(PIL 21-03-09).
• Remove the cooling fan motor. Refer to (PIL
21-05).
• Remove the hydraulic oil cooler. Refer to (PIL
21-03-12).
• Remove the fuel cooler. Refer to (PIL 18-39-00).
• Remove the air conditioning condenser. Refer
to (PIL 12-15-00).
21 - 22 9813/7600-3 21 - 22
21 - Cooling System
03 - Cooling Pack
03 - Radiator
03 - Radiator
Introduction
The radiator is a device in the cooling system that

removes heat from the coolant passing through it,
allowing the coolant to remove heat from the engine.
21 - 23 9813/7600-3 21 - 23
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
09 - Transmission Oil Cooler Component Identification

Diagram ......................................................... 21-25
Figure 496. DTVT Oil Cooler
B
D
F
H
C
A Cooled oil (to the mechanical gearbox part of B Hot oil (from the mechanical gearbox part of the
the transmission) (IN port) transmission) (OUT port)
C Hydraulic system oil from fan return D Hydraulic oil return to tank
E Check valve- (installed on the underside of the F Heat exchanger- (transmission mechanical
front chassis torsion box). gearbox oil to hydraulic oil system)
G Mounting plate H Hydraulic oil from air blast cooler (not
transmission oil)
J Hydraulic oil to air blast cooler (not transmission
oil)
21 - 24 9813/7600-3 21 - 24
21 - Cooling System
03 - Cooling Pack
09 - Transmission Oil Cooler
Diagram
Figure 497. DTVT Oil Cooler (Mechanical gearbox oil to hydraulic oil cooler)
A
2
3
6
7
8
D
B C
A DTVT Mechanical gearbox oil (Not hydrostatic B To hydraulic oil tank

oil)
C Fan return D To air blast cooler
E From air blast cooler 1 End fitting code table
2 Straight female fitting 3 90° Female fitting
4 135° Female fitting 5 Straight male fitting
6 Pipe code table 7 Steel tube
8 Hose
21 - 25 9813/7600-3 21 - 25
21 - Cooling System
05 - Fan Motor
05 - Fan Motor
Contents Page No.
21-05-00 General ........................................................................................................................... 21-27
21 - 26 9813/7600-3 21 - 26
21 - Cooling System
05 - Fan Motor
00 - General
Introduction .................................................... 21-27 The product is equipped with a hydraulically driven
Technical Data ............................................... 21-28 fan motor to provide air flow though the cooling pack.
Operation ....................................................... 21-30 Some products may have either a fixed speed fan or
a variable speed hydraulic fan.
Disassemble and Assemble .......................... 21-39 On some products, the fan may be reversible to
assist with the removal of debris from the cooling
pack.
21 - 27 9813/7600-3 21 - 27
21 - Cooling System
05 - Fan Motor
00 - General
Technical Data
(For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY], JCB Tier 4F Engine 4 Cyl)
Fixed Speed Fan Motor (55 KW Engines)

Table 206.
Type: Gear motor
Direction of rotation: Clockwise
Motor Displacement: 19 cc/rev
Fan speed (at maximum engine RPM (Revolutions TBA
Per Minute)):
Maximum pressure setting: 55bar (797.1psi)
Colour code (see sticker): Red
Variable Speed fan Motor (75 KW

Engines)
For information about fan motor control system, refer
to cooling system- fan motor, refer to (PIL 21-05).
Table 207.
Type: Gear motor
Direction of rotation: Bi-directional. Oil flow from port 'A' to port 'B' will ro-
tate the shaft in a clockwise direction when viewed
on the end of the shaft. Oil flow from port 'B' to port
'A' will rotate the shaft in an anti-clockwise direction
when viewed on the end of the shaft.
Motor displacement: 15 cc/rev
Fan speed (at maximum RPM): 3500 RPM
Maximum pressure setting: 210bar (3,043.5psi)
Colour code (see sticker): Black
Variable Speed fan Motor (81, 93 and 108

KW Engines)
For information about fan motor control system, refer
to cooling system- fan motor, refer to (PIL 21-05).
Table 208.
Type: Gear motor
Direction of rotation: Bi-directional (When reversing solenoid is energised
= anticlockwise. When reversing solenoid is de-ener-
gised = clockwise)
Motor displacement: 11 cc/rev
Fan speed (at maximum RPM): Variable
Maximum pressure setting: 230bar (3,333.3psi)
Colour code (see sticker): Green
21 - 28 9813/7600-3 21 - 28
21 - Cooling System
05 - Fan Motor
00 - General
(For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], JCB Tier 4F Engine 4 Cyl)
Figure 498.
E
G
A Cooling pack B Fan supply hydraulic pump section (Variflow

pump shown for illustration purposes, the fan
system operation is identical for gearpump
machines).
C Right hand cluster ECU (Electronic Control Unit) D Fan speed sensor
E Hydraulic cooling fan motor F Fan direction solenoid (if installed)
G Fan speed proportional solenoid
21 - 29 9813/7600-3 21 - 29
21 - Cooling System
05 - Fan Motor
00 - General
Operation
Schematic diagram
Figure 499.
Fixed speed D F
C
The schematic diagram shows an general overview
of the system. Your machine may have a triple pump
installed but the system will be similar. E
The cooling fan motor is hydraulically driven. The

motor turns the cooling fan and air is drawn through
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 - 30 9813/7600-3 21 - 30
21 - Cooling System
05 - Fan Motor
00 - General
Table 209. 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 - 31 9813/7600-3 21 - 31
21 - Cooling System
05 - Fan Motor
00 - General
Schematic diagram
Figure 500.
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 - 32 9813/7600-3 21 - 32
21 - Cooling System
05 - Fan Motor
00 - General
Table 210. Colour key-Oil flow and pressure

Full pressure
Exhaust
Neutral
21 - 33 9813/7600-3 21 - 33
21 - Cooling System
05 - Fan Motor
00 - General
Remove and Install
Before you remove the fan motor, check its

(For: JCB Tier 4F Engine 4 Cyl) performance.
If the performance is below that specified, the

Fixed Speed Fan (If Installed) motor should be renewed. Renewal of individual
components such as gears, bearings and housings
Your machine may be installed with a fixed or will not result in a permanent cure. If the motor
variable speed fan. Removal and installation of both performance is satisfactory, but there is external
types of fan are shown. leakage, it should be dismantled for re-sealing
purposes only.
21 - 34 9813/7600-3 21 - 34
21 - Cooling System
05 - Fan Motor
00 - General
Figure 501.
A Fan retaining nut B Motor retaining bolts

C Fan bracket securing bolts D Feed and return hoses
E Case drain hose
Remove 4. Mark the hydraulic feed and return hoses to help

identification when you install.
1. Make the machine safe. Refer to (PIL 01-06)
5. Disconnect and plug the feed and return hoses.
2. Install the safety strut. Refer to (PIL 06-69).
6. Disconnect and plug the case drain hose.
30-00). 7. Remove the fan guard.
21 - 35 9813/7600-3 21 - 35
21 - Cooling System
05 - Fan Motor
00 - General
8. Undo the fan bracket securing bolts (x4) and lift 2. Follow the general health and safety procedures.
the fan and motor assembly from the machine. Refer to (PIL 01-03).
9. Prevent the fan from turning, release the tab 3. Install the safety strut. Refer to (PIL 06-69).
washer and then undo the fan retaining nut.
10. Withdraw the fan from the motor shaft. Retain the 30-00).
drive key (not shown).
5. Mark the electrical connectors to help in
11. Undo the motor retaining bolts and remove the identification when you install.
motor.
6. Disconnect the harness from the solenoid
Install electrical connector.
1. The installation procedure is the opposite of the 7. Disconnect the harness from the speed sensor
removal procedure. Additionally do the following electrical connector.
steps. 8. If installed, disconnect the harness from the
1.1. Tighten all the fastening nuts and bolts to direction solenoid.
the correct torque value. 9. Mark the hydraulic hoses to help in identification
1.2. Make sure all hoses are attached to the when you install.
correct ports. The case drain hose (if
installed) must be fed in to a tank line 10. Disconnect and plug the feed hose and return
otherwise damage to the motor will occur. hose.
1.3. Check and adjust the hydraulic fluid level. 11. If installed, disconnect and plug the case drain
hose.
Table 211. Torque Settings 12. Support the motor and the fan.
Item Value 13. Remove the bolts.
A 36N·m
14. Remove the fan bracket, the fan and then the
B 28N·m
motor from the machine.
C 47N·m
15. Stop the fan from turning.
Variable Speed Fan (If Installed) 16. Remove the tab washer and then remove the nut.
Before you remove the fan motor, check its 17. Remove the fan from the motor shaft. Keep the
performance. drive key.
If the performance is below that specified, the motor 18. Remove the motor/ control pack retaining nuts.
should be renewed.
19. Remove the motor from the bracket.
Remove
21 - 36 9813/7600-3 21 - 36
21 - Cooling System
05 - Fan Motor
00 - General
Figure 502.
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 - 37 9813/7600-3 21 - 37
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 212. Torque settings

Item Value
B 27N·m
C 48N·m
D 48N·m
K 36N·m
21 - 38 9813/7600-3 21 - 38
21 - Cooling System
05 - Fan Motor
00 - General
Do not attempt to dismantle the motor. If it is

defective, it must be renewed.
21 - 39 9813/7600-3 21 - 39
21 - Cooling System
06 - Expansion Tank
06 - Expansion Tank
Contents Page No.
21-06-00 General ........................................................................................................................... 21-41
21 - 40 9813/7600-3 21 - 40
21 - Cooling System
06 - Expansion Tank
00 - General
Introduction .................................................... 21-41 The expansion tank retains coolant that has been
Remove and Install ....................................... 21-42 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 - 41 9813/7600-3 21 - 41
21 - Cooling System
06 - Expansion Tank
00 - General

B
(For: 526-56 [T4F])
Remove
A
3. Switch off the engine before working in the
engine compartment. Remove the ignition key
or isolate the battery to prevent the engine from
being started. Refer to (PIL 33-03).
4. If the engine is hot, let it cool for one hour.
5. Open the engine compartment cover. Refer to
(PIL 06-06).
6. Drain the engine coolant. Refer to (PIL 21-00).
7. Remove the bolt.
8. Disconnect the coolant level sensor electrical
connector (if installed). D D
9. Loosen the hose clips and disconnect the hoses C
from the expansion tank.
A Expansion tank
10. Support the expansion tank. B Tank securing bolt
C Support bracket
11. Remove the expansion tank from the bracket. D Support bracket bolts
12. If required, remove the bolts from the support
bracket and remove it. Install
steps.
1.1. If removed, tighten the expansion tank
support bracket bolts to the correct torque
value.
1.2. Tighten the expansion tank securing bolt to
the specified torque value.
1.3. Fill the engine cooling system with the
correct type of coolant and bleed. Refer to
(PIL 21-00).
1.4. When the installation procedure is complete
start the engine and check for coolant leaks.

Item Description Nm
B Bolts 25
21 - 42 9813/7600-3 21 - 42
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-45
21 - 43 9813/7600-3 21 - 43
Notes:
21 - 44 9813/7600-3 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 9813/7600-3 21 - 45
21 - Cooling System
09 - Pump
00 - General

Figure 504. 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 9813/7600-3 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 9813/7600-3 21 - 47
21 - Cooling System
09 - Pump
00 - General
Figure 506.
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 9813/7600-3 21 - 48
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-51
21 - 49 9813/7600-3 21 - 49
Notes:
21 - 50 9813/7600-3 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 ....................................... 21-54 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 9813/7600-3 21 - 51
21 - Cooling System
12 - Thermostat
00 - General

Figure 507. 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 508.
7 3
8 11
6
10
5
A Thermostat
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
5 Wax pellet
6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1mm diameter orifice
State B - Open (Engine Hot)

When the engine is hot, the wax pellet melts,
as it does so it expands and pushes against
the diaphragm. The diaphragm reacts against
the actuating rod and both the top and bottom
valve plates move down into the thermostat body,
compressing spring. The outlet port to the radiator
is now open and the bypass port is closed. A 1mm
21 - 52 9813/7600-3 21 - 52
21 - Cooling System
12 - Thermostat
00 - General
diameter orifice allows trapped air to be expelled Check (Condition)

from the system.
Figure 509. 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 1mm diameter orifice
21 - 53 9813/7600-3 21 - 53
21 - Cooling System
12 - Thermostat
00 - General
A period of 3–5min before the thermostat valve starts Before Removal

to operate is normal because of the time required to
heat soak the thermostat. 1. Make sure that the engine is safe to work on. If
1. Make sure that the engine is safe to work on. If you start the service work.
you start the service work. 2. Get access to the engine.
2. Remove the thermostat housing and the 3. Drain the coolant. Refer to (PIL 21-03-03).
thermostat. Refer to (PIL 21-12).
Figure 511.
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 510.
1
Figure 510.
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.
1 Radiator hose
6. Record the start to open temperature, the fully 2 Fixing bolts
open temperature and the amount of valve lift
travel when fully open. Compare this with the Remove
data in Technical Data (PIL 21-00).
1. Disconnect the radiator hose at the thermostat
housing.
2. Remove the fixing bolts and lift off the housing.
3. Lift out the thermostat.
21 - 54 9813/7600-3 21 - 54
21 - Cooling System
12 - Thermostat
00 - General
Figure 512.
3 4
3 Thermostat
4 Seal
4. If the thermostat is suspected of being faulty,
perform tests to confirm its serviceability.
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
renew the seal. Locate the seal correctly as
shown.
3. Make sure you install the thermostat the right way
up.
5. Reconnect the radiator hose at the housing.
After Installation
1. Fill the cooling system with the recommended
coolant mixture.

Item Nm
2 24
21 - 55 9813/7600-3 21 - 55
21 - Cooling System
21 - Inlet
21 - Inlet
Contents Page No.
21-21-00 General ........................................................................................................................... 21-57
21 - 56 9813/7600-3 21 - 56
21 - Cooling System
21 - Inlet
00 - General
00 - General Figure 513.
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 - 57 9813/7600-3 21 - 57
21 - Cooling System
21 - Inlet
00 - General

Item Nm
2 24
21 - 58 9813/7600-3 21 - 58
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-61
21 - 59 9813/7600-3 21 - 59
Notes:
21 - 60 9813/7600-3 21 - 60
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-61 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-62 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-62 between the engine and the radiator/cooling pack.
21 - 61 9813/7600-3 21 - 61
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 - 62 9813/7600-3 21 - 62
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 .............................................................................................................. 24-42
24-03-06 Priority Charge Valve ..................................................................................................... 24-45
24-03-09 Brake Valve .................................................................................................................... 24-49
24-03-39 Piston ............................................................................................................................. 24-53
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-59
24-03-46 Vacuum Pump ................................................................................................................ 24-62
24-03-50 Light Switch .................................................................................................................... 24-66
24-03-57 Pressure Sensor ............................................................................................................ 24-70
24-18 Park Brake
24-18-00 General ........................................................................................................................... 24-81
24-18-03 Switch ............................................................................................................................. 24-96
24-18-06 Cable .............................................................................................................................. 24-97
24-18-15 Pad ............................................................................................................................... 24-107
24-18-18 Caliper .......................................................................................................................... 24-108
24-18-21 Disc .............................................................................................................................. 24-115
24-18-48 Actuator ........................................................................................................................ 24-125
24-36 Trailer Brake
24-36-00 General ......................................................................................................................... 24-129
9813/7600-3
2018-01-31
Acronyms Glossary
2WD Two Wheel Drive

4WD Four Wheel Drive
ISO International Organization for
Standardization
SAHR Spring Applied Hydraulic Release
SRS Smooth Ride System
TBV Trailer Brake Valve
9813/7600-3
2018-01-31
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9813/7600-3 24 - 1
Notes:
24 - 2 9813/7600-3 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
Fault-Finding .................................................... 24-8 result in brake failure.
Discharge and Pressurise ............................. 24-10 Accumulators
Check (Level) ................................................ 24-12 The accumulators contain hydraulic fluid and gas at
high pressure. Prior to any work being carried out
on systems incorporating accumulators, the system
pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
cause serious injury or death.
Service Brake Bleeding
Before bleeding the service brake system, park on
level ground and set the park brake to on. Put blocks
on both sides of the wheels on one axle to prevent
the machine rolling. Stop the engine and disconnect
the battery so that the engine cannot be started. If
you do not take these precautions the machine could
run over you.
Park Brake Maintenance
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels
to prevent the machine rolling. Stop the engine and
disconnect the battery so that the engine cannot be
started. If you do not take these precautions the
machine could run over you.
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 9813/7600-3 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 tank 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 9813/7600-3 24 - 4
24 - Brake System
00 - Brake System
00 - General
Technical Data
For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
..................................................... Page 24-5
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................... Page 24-6
..................................................... Page 24-6
(For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD])
Single axle service brakes system

Table 217. 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 218. Master cylinder

Type Master cylinder.
Master cylinder with remote servo unit.
(1)
No. of Cylinders 1
Diameter 31.75mm
Stroke 39mm
Displacement Minimum- 2835 cc.
(1) Machines with turbo inter-cooled engines.
Table 219. Servo unit

Type Vacuum assisted hydraulic valve.
Vacuum cylinder diameter 175mm
Hydraulic cylinder diameter 22.2mm
Brake vacuum pressure 0.8–1bar (11.6–14.5psi)
Minimum oil displacement 23.6 cc
Stroke 61mm
Table 220. 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 279.4mm
24 - 5 9813/7600-3 24 - 5
24 - Brake System
00 - Brake System
00 - General
(For: 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY])

Table 221. Service Brakes- Power Brake System
Type Single circuit, oil-immersed multi-plate disc.
Actuation Hydraulic
Location Front and Rear Axle, centre mounted (2 brake packs
per axle).
Charge valve cut in pressure 80bar (1,159.4psi)
Charge valve cut out pressure 115bar (1,666.7psi)
Friction plates (6 per brake pack):
Outside diameter 254mm
Inside diameter 176mm
Facing area (per plate) 0.02634m²
Annular Brake piston Area 0.006597m²
Table 222. Park Brake

Type Oil-immersed multi-plate brake pack.
Actuation Cable
Location Gearbox (acts through drive to front axle)

Table 223. Service Brakes- Power Brake System (JCB Axle)
Type Single circuit, oil-immersed multi-plate disc.
Actuation Hydraulic
Location Front axle, centre mounted.
Friction plates (per side) 5
Outside diameter 222mm
Inside diameter 160mm
Friction plate thickness (new) 3.76–3.92mm
Counter plate thickness (new) 3.8–3.9mm

Type Oil-immersed multi-plate brake pack.
Actuation Cable
Location Gearbox (acts through drive to front axle)
24 - 6 9813/7600-3 24 - 6
24 - Brake System
00 - Brake System
00 - General
(For: 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY])
Figure 514.
E
D
F
A Brake friction plates in centre case B Foot brake pedal

C Parking brake lever D Power brake valve
E Handbrake F Brake accumulator
24 - 7 9813/7600-3 24 - 7
24 - Brake System
00 - Brake System
00 - General
Fault-Finding
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY], HM560 Variable
Transmission)
Fault
Pedal travel excessive. Table 225. Page 24-8
Poor braking (not pulling to one side) Table 226. Page 24-8
Pedal hard to operate Table 227. Page 24-8
Pedal touches floor under constant pressure Table 228. Page 24-9
Brakes not releasing. Table 229. Page 24-9
Excessive brake noise from brake packs in operation (Due to the metal to Table 230. Page 24-9
metal contact of oil immersed brakes, limited noise can be heard which is
consistent with this type of design- this is normal).
Fluid escaping from axle breather (Noise is similar to the sound made by an Table 231. Page 24-9
air horn. Noise is possible after hydraulic oil change).
Table 225. Pedal travel excessive.

Cause Remedy
Air in the brake circuit. Bleed the brakes. Refer to (PIL 24-03-00)
Fluid leaks. Check the brake pipes and hoses for leaks, rectify as
required.
Friction and counter plates in poor condition, or worn Check the axle brake pack plates for wear, distortion
beyond limits. Brake piston binding. or damage. Check the axle brake piston operation.
Refer to (PIL 27-20/21)
Table 226. Poor braking (not pulling to one side)

Cause Remedy
Axle oil level low, or incorrect oil type. Check the axle for leaks. Fill the axle with clean oil of
the correct type. Refer to (PIL 75-03).
Brake valve faulty. Check the brake pressure. Refer to (PIL 24-03). If
necessary, install a new brake valve.
Charge valve faulty. Check the charge pressure. If necessary, install a
new charge valve.
Table 227. Pedal hard to operate

Cause Remedy
Tightness at pedal pivot. Inspect pedal pivot. Free-off/lubricate.
Fluid contamination/seal damage. Flush system and renew all hydraulic seals. Bleed
the brake system. Refer to (PIL 24-03).
Misaligned push rod/pedal. Check and rectify as required.
Kinked or crushed brake pipes. Check/renew brake pipework.
Brake valve faulty. Check the brake pressure. If necessary, install a new
charge valve.
Charge valve faulty. Check the charge pressure. If necessary, install a
new charge valve.
24 - 8 9813/7600-3 24 - 8
24 - Brake System
00 - Brake System
00 - General
Table 228. Pedal touches floor under constant pressure

Cause Remedy
Fluid leaks. Check the brake pipes and hoses for leaks, rectify as
required.
Internal fluid leaks Brake piston seal leakage.
Damage to brake valve. Check brake valve condition/operation. Refer to the
Power Brake Valve topic
Table 229. Brakes not releasing.

Cause Remedy
Brake pedal(s) does not return properly. (1) Check the area around the brake pedal is free of
obstructions. (2) Check the operation of the pedal
return spring. Check for tightness of pedal pivot,
lubricate pivot if required. (3) Check the pedal stop
bolt is adjusted correctly.
Brake valve faulty. (1) Check the brake pressure. (2) Check tank line
pressure after brake actuation. (3) If necessary,
renew the brake valve.
Kinked or crushed brake pipes or hoses. Inspect the brake pipes and hoses for damage.
Renew as required.
Refer to (PIL 24-03) and (PIL 24-39).
Friction and counter plates are not free on splines or Check the friction and counter plates for free
dowels. movement. Renew if required - BOTH sides of axle.
Table 230. Excessive brake noise from brake packs in operation (Due to the metal to metal contact of
oil immersed brakes, limited noise can be heard which is consistent with this type of design- this is
normal).
Cause Remedy
Axle oil level low, or incorrect oil type. Check the axle for leaks. Fill the axle with clean oil of
the correct type.
Table 231. Fluid escaping from axle breather (Noise is similar to the sound made by an air horn. Noise
is possible after hydraulic oil change).
Cause Remedy
Brake piston seals in poor condition, or damaged. Renew the piston seals- Both sides of axle. Refer to
(PIL 24-39).
Air in the system. Pump the pedals several times. Bleed the system.
24 - 9 9813/7600-3 24 - 9
24 - Brake System
00 - Brake System
00 - General
Discharge and Pressurise
On machines with SAHR (Spring Applied Hydraulic

(For: 550-80 [5AW], 550-80 [5UW], 560-80 Release) brakes there are two accumulators in the
[5AY], 560-80 [5UY], HM560 Variable braking circuit. The service brakes have the largest
accumulator, the SAHR park brake system having
Transmission) the smaller accumulator.
WARNING Before proceeding with the bleed
procedure it is important to make sure that the To make sure that the pressure in the braking system
park brake is engaged and that one pair of wheels is discharged, carry out the following procedure.
is chocked on both sides.
WARNING You must vent all the hydraulic
pressure from the accumulators before Refer to: PIL 01-03-27.
disconnecting them from the hydraulic system. 2. Make sure the battery is not disconnected during
this operation.
Machines installed with power assisted brakes have
an accumulator installed in the braking circuit. The 3. Make sure the ignition key is set to the on position
accumulator stores enough energy for a limited but with the engine stopped.
number of assisted brake operations when the
4. Prepare the instrument panel by clearing any
engine is not running.
alarm messages to show the brake system
pressure gauge (if installed).
Figure 515.
A Brake system pressure gauge
5. On machines with instrument panel brake 6. On machines without an instrument panel brake
system pressure gauge: system pressure gauge:
5.1. Apply and release the service brakes 6.1. Operate the brake pedal for the specified
repeatedly until the pressure reading number of cycles. Number of cycles = 50.
reduces to zero. This will require a
significant number of presses depending on 7. Discharge the park brake system pressure on
the initial state of charge. machines with SAHR park brake (if installed).
5.2. If the brake system pressure displayed is 7.1. Operate the park brake lever 5 times.
greater than zero, keep pressing the brake
pedal until zero pressure is displayed. 7.2. Make sure the park brake warning light
stays illuminated - this shows there is low
pressure in the park brake circuit.
24 - 10 9813/7600-3 24 - 10
24 - Brake System
00 - Brake System
00 - General
7.3. Operate the park brake lever 5 more times

to fully discharge the pressure.
8. Set the ignition key to the off position and remove
the ignition key. Make sure you do not start
the engine as the brake system will be re-
pressurised and the process will need to be
repeated.
9. Further venting is recommended - especially if
the instrument panel display is not working or not
present.
9.1. Get an assistant to help.
9.2. Do not start the engine during this process.
9.3. Prepare a bleed tube and vessel to catch
any lost oil.
9.4. Attach the bleed tube to one of the front
axle brake bleed points. The bleed points
are shown in the Bleed Procedure.
9.5. With one operator in the cab and one under
the machine, open the bleed nipple and
then slowly press the service brake pedal
up to full stroke.
9.6. Hold the pedal in the fully applied position.
9.7. Do not pump the pedal.
9.8. Only a small amount of residual oil should
come from the bleed nipple, but if the
discharging process (listed above) wasn’t
completed properly, a significant quantity of
oil could flow from the bleed nipple. The
operator must be prepared for this.
9.9. Leave the bleed nipple open until the oil
stops running.
9.10. Close the bleed nipple and tighten.
9.11. Release the brake pedal.
9.12. It will be necessary to bleed the brakes
when the work is complete.
10. Isolate the battery before carrying out additional
service work on the machine.
24 - 11 9813/7600-3 24 - 11
24 - Brake System
00 - Brake System
00 - General
Check (Level) Figure 517.

A
(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD])
WARNING Faulty brakes can kill. If you have to B
top up the brake tank frequently, get the brake
system checked by your JCB Dealer. Do not use
the machine until the fault has been put right.
the correct fluid. The fluid can harm your skin.
Wear rubber gloves. Cover cuts or grazes.
A Tank cap
B Tank
The brake fluid tank is in the panel in front of the cab.
Pull the release knob to open the panel. 3.1. Remove the tank cap.
Figure 516. 3.2. Add the recommended fluid slowly.
3.3. Replace the tank cap.
3.4. Clean any spilt fluid.
A Knob
2. Check the brake fluid level. The correct fluid level
is marked on the tank.
3. If necessary, add more fluid:
24 - 12 9813/7600-3 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 .............................................................................................................. 24-42
24-03-06 Priority Charge Valve ..................................................................................................... 24-45
24-03-09 Brake Valve .................................................................................................................... 24-49
24-03-39 Piston ............................................................................................................................. 24-53
24-03-45 Vacuum Servo Unit ........................................................................................................ 24-59
24-03-46 Vacuum Pump ................................................................................................................ 24-62
24-03-50 Light Switch .................................................................................................................... 24-66
24-03-57 Pressure Sensor ............................................................................................................ 24-70
24 - 13 9813/7600-3 24 - 13
Notes:
24 - 14 9813/7600-3 24 - 14
24 - Brake System
03 - Service Brake
00 - General
Introduction .................................................... 24-15 The service brake is used to stop the machine when
Component Identification ............................... 24-16 it is in motion.
Operation ....................................................... 24-22
Operation (Hydraulic) .................................... 24-23 The service brake is a hydraulic system. The
machine operator applies pressure to the brake
Operation (Electrical) ..................................... 24-25 pedal in the cab.
Diagram ......................................................... 24-26
Check (Pressure) .......................................... 24-29 The pedal is connected to the master cylinder which
Bleed ............................................................. 24-31 supplies hydraulic pressure to the applicable brake
units to apply the brakes.
The brake packs are located in the axle- some
machines have front and rear brakes whilst some
machines only have front axle brakes.
24 - 15 9813/7600-3 24 - 15
24 - Brake System
03 - Service Brake
00 - General
For: Dana 223 Series ................ Page 24-16

For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................... Page 24-17
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 24-18
................................................... Page 24-19
(For: Dana 223 Series)
Figure 518. Dana 223 Axle Service Brakes

6
2 5 7
8
4
9
10
11
23 12
13
14
15
24 16
17
18
19
20
27 22 21
28
2 O-ring 1 4 O-ring 2
5 Bleed screw 6 Cap
7 Adaptor 8 Seal
9 Piston seal and anti-extrusion ring 1 10 Piston seal and anti-extrusion ring 2
11 Piston 12 Spring
13 Adjusting screw 14 Steel disc 1
15 Friction disc 1 16 Steel disc 2
17 Flange- brake disc pack 18 Friction disc 2
19 Steel disc 3 20 Friction disc 3
21 Pin screw 22 Stroke regulation bush
23 Intermediate disc 24 Cylinder
27 Distance piece 28 Shims
24 - 16 9813/7600-3 24 - 16
24 - Brake System
03 - Service Brake
00 - General
(For: 526-56 [T4F], 531-70 [5AA], 531-70 The brake hydraulic fluid tank is situated outside the
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 cab, below the front windscreen.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 An electrical switch is fitted to the pedal assembly for
[5TE], 541-70 [5AD], 541-70 [5TD]) operation of the rear facing brake lights.
Single axle service brakes system Auto 4-wheel braking
The front axle integral brake packs are multi-disc To achieve 4-wheel braking, engage the 4WD (Four
plates that are immersed in oil. The brake packs Wheel Drive). In this way all 4 wheels are effectively
are actuated hydraulically by a single foot pedal and braked via the machine transmission.
master cylinder.
When 2WD (Two Wheel Drive) is selected, operating
On machines with servo assisted brakes, the the brake pedal will automatically select 4-wheel
assistance is provided by means of an engine driven drive. This gives increased braking effect. The
vacuum pump and remotely mounted servo unit transmission will switch back to 2- wheel drive when
which is located on the front of the cab. the brake pedal is released.
Figure 519.
G
E
B
A
C
C A
A Front axle integral brake pack B Foot pedal

C Master cylinder D Exhauster (vacuum) pump (the location of
the pump will differ depending on the engine
installed)
E Servo unit F Brake fluid tank
G Brake light electrical switch
24 - 17 9813/7600-3 24 - 17
24 - Brake System
03 - Service Brake
00 - General
(For: 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY])
Figure 520. Power Brake System
C
B
E F
D
A Front Axle B Charge Valve

C Accumulator D Brake Valve
E Brake Pedal F Rear Axle
24 - 18 9813/7600-3 24 - 18
24 - Brake System
03 - Service Brake
00 - General
Figure 521. Power Brake System- Dual Tech Variable Transmission Machines
A
B
A B
C
F
333/D7974-4
A Direction of view B Direction of view

C Direction of view D Brake accumulator
E Connections to power brake valve (power brake F Connection to front axle
valve not shown)
24 - 19 9813/7600-3 24 - 19
24 - Brake System
03 - Service Brake
00 - General
F
G
F Connection to front axle G Front axle (with integral disc brakes)

H Pedal lever and brake valve assembly
A
C D
F
H
E
J
333/D7974-4
24 - 20 9813/7600-3 24 - 20
24 - Brake System
03 - Service Brake
00 - General
A Power brake valve B Port N

C Port B D Port D
E Front steering ram F SRS (Smooth Ride System) Pressure
transducer
G Tee adaptor H To trailer brake valve
J Blanking cap K To CPV
L Brake Accumulator
Other pipes are shown for reference only.
24 - 21 9813/7600-3 24 - 21
24 - Brake System
03 - Service Brake
00 - General
Operation

The front axle integral brake packs are an oil
immersed, multi disc type. The hydraulic supply to
operate the service brakes is supplied by the engine
driven hydraulic cooling fan gearpump. The pressure
from the hydraulic pump is regulated by the charge
valve. The charge valve provides a constant supply
of oil at a preset charge pressure to the brake valve
and brake accumulator. When the brake pedal is
pressed, the brake valve directs the oil in the charge
circuit to the brake piston housings in the front axle.
The resulting brake pressure is proportional to the

pedal movement. The brake accumulator stores
pressure in the charge circuit, so that there is a
limited supply for the brakes when the engine is
stopped. A pressure sensor located on the charge
valve senses the stored pressure and sends a signal
to the centre warning display.
Before any work is done to the front axle or

braking system, the brake hydraulic system must be
discharged. Refer to discharge and pressurise, (PIL
24-00-00).
24 - 22 9813/7600-3 24 - 22
24 - Brake System
03 - Service Brake
00 - General
Operation (Hydraulic)
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY])
Overview
Refer to Diagram, (PIL 24-03-00)
Figure 524.
D
A
F
C
G
A Rear axle B Brake accumulator

C Charge valve D Sensor
E Brake valve F Front axle
G Centre warning display
1. The hydraulic supply to operate the service The resulting brake pressure is proportional to
brakes is supplied by the engine-driven hydraulic the pedal movement.
cooling fan gearpump.
4. The brake accumulator stores pressure in the
2. The pressure from the hydraulic pump is charge circuit, so that there is a limited supply
regulated by the charge valve. The charge valve for the brakes when the engine is stopped.
provides a constant supply of oil at a preset The brake hydraulic system must be discharged
charge pressure to the brake valve and brake before the braking system is worked on. Refer to
accumulator. discharge and pressurise, (PIL 24-00-00).
3. When the brake pedal is pressed, the brake valve 5. A pressure sensor located on the charge valve
directs the oil in the charge circuit to the brake senses the stored pressure and sends a signal
piston housings in the front axle and rear axle. to the centre warning display.
24 - 23 9813/7600-3 24 - 23
24 - Brake System
03 - Service Brake
00 - General
6. A sensor is shown which is used in the

transmission disconnect system. Refer to (PIL
33-33-15).
24 - 24 9813/7600-3 24 - 24
24 - Brake System
03 - Service Brake
00 - General
Operation (Electrical)
The schematic shown is for illustration purposes

(For: 550-80 [5AW], 550-80 [5UW], 560-80 only. For electrical details of individual devices refer
[5AY], 560-80 [5UY]) to the Harness Drawings (PIL 33-12) or Electrical
Schematics (PIL 33-00-50).
Brake Pressure Display
Refer to (PIL 33-00-50), (PIL 33-12), (PIL 33-00-90),
(PIL 33-09) and (PIL 33-59).
Figure 525.
B - J1
ECU
ECU
IGN +VE
A Centre Warning Display B Hydraulic control ECU (Electronic Control Unit)-

connector J1
C Brake pressure charge sensor
1. The brake pressure charge sensor is located

on the charge valve. The output voltage varies
according to the pressure in the brake charging
system. The output voltage is transmitted to the
centre warning display. The brake pressure is
displayed on screen.
2. The hydraulic control ECU provides the supply
and earth for the sensor.
3. A pressure sensor located on the charge valve
senses the stored pressure and sends a signal
to the centre warning display.
24 - 25 9813/7600-3 24 - 25
24 - Brake System
03 - Service Brake
00 - General
Diagram
For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................... Page 24-26
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 24-28
(For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD])
Single axle service brakes system

Hose and pipework- Machines with trailer brakes
Figure 526.
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 - 26 9813/7600-3 24 - 26
24 - Brake System
03 - Service Brake
00 - General
Hose and pipework- Machines without trailer brakes
Figure 527.
D
C
A Servo exhauster unit B Master cylinder

C Servo unit D Front axle
24 - 27 9813/7600-3 24 - 27
24 - Brake System
03 - Service Brake
00 - General
(For: 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY])
Figure 528.
C
D
A B
F E
H
G
A Front axle B Rear axle

C Trailer brake valve (optional) D Variable displacement pump + gear pump
E Pressure sender F Brake valve
G Charge valve H Hydraulic tank
24 - 28 9813/7600-3 24 - 28
24 - Brake System
03 - Service Brake
00 - General
Check (Pressure) Figure 529.
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY], HM560 Variable
Transmission)
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.
Checking the Brake Charge Pressure

The maximum stored pressure achieveable is as
stated in technical data, Refer to Technical Data, (PIL
24-03-06). 1 Loadall Diagnostic Program
This is factory set inside the charge valve and cannot 6. Open the Loadall Diagnostics program.
be adjusted.
7. Enable the connection between the PC/Laptop
There is no test point in the circuit. To measure by pressing the Start Diagnostics button or select
the charge pressure it will be necessary to connect Start Diagnostics from the File Menu.
the machine to a computer/laptop with the current
Servicemaster software. Refer to (PIL 33-57). Figure 530.
The brake system charge valve cycles the charge

pressure between pre-set limits to ensure the brake
accumulator is filled with pressure.
1. Make sure that the hydraulic fluid is at working Figure 531.

temperature.
3. Follow the health and safety procedures. Refer
to (PIL 01-03).
4. Discharge the braking system pressure. Refer to
(PIL 30-00-00).
5. Connect the machine to a computer/laptop with
up to date Servicemaster software. Open the
Loadall tool set.
8. When the program is open select the Hydraulics

ECU (Electronic Control Unit) tab at the top of the
page.
9. On the left hand side click the box to open
the “brake system”. For details of Servicemaster
display icons/keys refer to (PIL 33-57).
10. Operate the engine for a minimum of two minutes
and occasionally press the brake pedals. This
makes sure that the brake system charge valve
has filled the accumulator.
24 - 29 9813/7600-3 24 - 29
24 - Brake System
03 - Service Brake
00 - General
11. With the engine running, check the reading on Figure 533.
the Servicemaster screen pressure gauge. The
charge pressure will be between the Cut-in and
Cut-out values stated. Refer to (PIL 24-03-06).
12. Press the brake pedal repeatedly and check
that the charge pressure is maintained within Figure 534.
the minimum and maximum limits. Refer to (PIL
24-03-09).
Checking the Brake Supply Pressure

The brake to axle supply pressure is as stated
in technical data, Refer to Technical Data, (PIL
24-03-09).
There is no test point in the circuit. To measure the

brake supply pressure, it will be necessary to connect
the machine to a computer/laptop with the current
Servicemaster software.
For details of connection and use of Servicemaster

software. Refer to (PIL 33-57).
1. Make sure the hydraulic fluid is at working

8. When the program is open select the Hydraulics
temperature.
ECU tab at the top of the page.
9. On the left hand side click the box to open
3. Follow the general care and safety procedures. the “brake system”. For details of Servicemaster
Refer to (PIL 01-03). display icons/keys refer to (PIL 33-57).
4. Discharge the braking system pressure. Refer to 10. Operate the engine for a minimum of two minutes
(PIL 30-00-00). and occasionally press the brake pedals. This
makes sure that the brake system charge valve
5. Connect the machine to a computer/laptop with has filled the accumulator.
up to date Servicemaster software. Open the
Loadall tool set. 11. With the engine running, check the reading on
the Servicemaster screen pressure gauge.
Figure 532.
1 Loadall Diagnostic Program

6. Open the Loadall Diagnostics program.
7. Enable the connection between the PC/Laptop
by pressing the Start Diagnostics button or select
Start Diagnostics from the File Menu.
24 - 30 9813/7600-3 24 - 30
24 - Brake System
03 - Service Brake
00 - General
Bleed Figure 536. Servo unit
For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................... Page 24-31
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 24-31
................................................... Page 24-33
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
B
Single axle service brake system
WARNING Use of incorrect fluid will cause
serious damage to the seals which could in turn
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.
B Bleed point on servo unit
4. Make sure that the fluid level does not fall under
the Minimum mark when you do the bleeding 6. Attach a tube to the applicable bleed screw.
procedure.
7. Make sure that the free end of the tube is put fully
5. Bleed the brake system in the applicable into the fluid in a suitable container.
sequence as follows:
8. Open the bleed screw and apply one rapid full
5.1. Machines without servo brakes- Bleed at stroke of the brake pedal followed by three rapid
the point on the front axle. short strokes from the halfway pedal position.
After the third short stroke, allow the pedal to
Figure 535. Front axle 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.
A
(For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY])
WARNING Before proceeding with this procedure
make sure that the park brake is engaged and that
one pair of wheels is blocked on both sides.
A Bleed point on front axle
The procedures are the same for the front and rear
5.2. Machines with servo brakes- Bleed at the axle.
point on the servo unit and the point on the
front axle. 1. Make the machine safe. Refer to (PIL 01-03).
24 - 31 9813/7600-3 24 - 31
24 - Brake System
03 - Service Brake
00 - General
2. Follow the general health and safety procedures. Figure 537. Front Axle
A A
3. Operate the engine for the specified time and
occasionally press the brake pedal. This makes
sure that the brake system charge valve has filled
the accumulator and removed any air from the
charge circuit.
Duration: 2min
4. Make sure you keep the engine running while
bleeding the system.
5. Bleed each brake in turn:
5.1. Attach a tube to the relevant bleed screw on
the axle centre casing. Put the free end of
the tube into a suitable container to collect A Bleed screw
the hydraulic fluid.
Figure 538. Rear Axle
5.2. Get an assistant to gradually press the
brake pedal, then carefully open the bleed
screw. When the bleed screw is open, oil will
flow through the bleed tube at a high rate A
and pressure. Make sure the tube is secure.
5.3. Continue bleeding until all air is expelled.
Close the bleed screw then release the
brake pedal. As the brake system uses the
hydraulic system fluid, there may be small
traces of air suspended in the fluid which
can be discounted.
6. Repeat step 5 for the opposite brake.
7. Make sure that all bleed screws are correctly
tightened.
8. Repeat steps 3 to 7 for the other axle.
9. On completion, check the brake circuit for leaks
and correct operation.
10. Check the hydraulic system fluid level. Refer to
(PIL 30-00).
11. Check the brake pressure. Make sure that when
the brake pedals are at rest (fully back against
their stops) the brake pressure to the brake packs
is zero.
A Bleed screw
24 - 32 9813/7600-3 24 - 32
24 - Brake System
03 - Service Brake
00 - General
(For: HM560 Variable Transmission) Figure 539. Front Axle

WARNING Before proceeding with this procedure
make sure that the park brake is engaged and that
one pair of wheels is blocked on both sides.

2. Follow the health and safety procedures. Refer A
to (PIL 01-03).
3. Operate the engine for the specified time and
occasionally press the brake pedal. This makes
sure that the brake system charge valve has filled
the accumulator and removed any air from the
charge circuit.
A Bleed screw
Duration: 2min
4. Make sure you keep the engine running while
bleeding the system.
5. Bleed each brake in turn.
5.1. Attach a tube to the relevant bleed screw on
the axle centre casing. Put the free end of
the tube into a suitable container to collect
the hydraulic fluid.
5.2. Get an assistant to gradually press the
brake pedal, then carefully open the bleed
screw. When the bleed screw is open oil will
flow through the bleed tube at a high rate
and pressure. Make sure the tube is secure.
5.3. Continue bleeding until all air is expelled.
Close the bleed screw then release the
brake pedal. As the brake system uses the
machines hydraulic system fluid, there may
be small traces of air suspended in the fluid
which can be discounted.
6. Repeat step 5 for the opposite brake.
7. Make sure that all bleed screws are correctly
tightened.
8. On completion, check the brake circuit for leaks
and correct operation.
9. Check the hydraulic system fluid level. Refer to
(PIL 30-00).
10. Check the brake pressure. Make sure that when
the brake pedals are at rest (fully back against
their stops) the brake pressure to the brake packs
is zero.
24 - 33 9813/7600-3 24 - 33
24 - Brake System
03 - Service Brake
00 - General
Disassemble and Assemble Figure 541.
For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................... Page 24-34
For: Dana 223 Series ................ Page 24-34
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
Refer to driveline, axle, general, dissasemble and
assemble, (PIL 27-20-00).
4. Remove the screws from the counter plate. Refer
to Figure 542.
(For: Dana 223 Series) Figure 542.
Consumables
JCB High Strength 4102/0551 0.05L
Threadlocker
JCB Hydraulic Fluid OP 4002/2001 5L
46 4002/2005 20L
4002/2003 200L
Strength)
1. Sling the axle arm to be removed and connect it

to a hoist. Loosen and remove the screws. Refer 12 Spring
to Figure 540. 13 Counter plate screws
Figure 540. 5. Remove the pin screws. Refer to Figure 543.
Figure 543.
31 Screws
2. Remove the arm together with brakes and axle
21 Pin screws
shafts; lay down the arm vertically.
6. Note down their order of assembly and remove
3. Release pressure. Refer to Figure 541.
the counter plate. Refer to Figure 544.
24 - 34 9813/7600-3 24 - 34
24 - Brake System
03 - Service Brake
00 - General
23 Counter plate 2 O-ring
7. Loosen the studs in an alternate manner and 10. Slowly introduce low-pressure compressed air
remove them. Refer to Figure 545. through the connection port for the service brake,
in order to extract the piston. Refer to Figure 548.
Figure 545.
Figure 548.
11 Piston
8. Remove the cylinder. Refer to Figure 546.
11. Make sure you hold the piston back, as it may be
Figure 546. suddenly ejected and damaged. Refer to Figure
548.
12. Note down the order of assembly. Refer to Figure
549.
Figure 549.
24 Cylinder
9. The O-rings must be replaced each time the unit
is disassembled. Refer to Figure 547.
24 - 35 9813/7600-3 24 - 35
24 - Brake System
03 - Service Brake
00 - General
13. Remove braking discs noting down the order and Figure 552.
direction of assembly. Refer to Figure 550.
Figure 550.
16 Braking disc (x3) 14 Friction disc

15 Friction disc
14. If discs are not to be replaced, make sure you 16 Friction disc
avoid changing their position. Refer to Figure 17 Flange
550. 18 Disc
19 Disc
15. Remove the flange complete with the discs. 20 Disc
Refer to Figure 551. Refer to Figure 552.
16. Remove distance piece, braking discs and
Figure 551. shims, noting down direction of assembly. Refer
to Figure 553.
Figure 553.
27 Braking discs
28 Shim stack
17. Measure the thickness of the friction discs. If one
or more discs measure less than the minimum
value replace the complete brake disc pack,
including the metal discs.
Assemble
1. Replace the O-rings and anti-extrusion rings
on all pistons. The O-rings always have to be
assembled from the pressure facing side.
2. Install O-ring and anti-extrusion ring onto the
piston.
24 - 36 9813/7600-3 24 - 36
24 - Brake System
03 - Service Brake
00 - General
3. Lubricate the piston and the O-rings with the Figure 556.
correct lubricant and install the unit into the
cylinder. Refer to Figure 554.
Consumable: JCB Hydraulic Fluid OP 46
Figure 554.
2 O-ring
6. Engage the cylinder with the drive head. Refer to
Figure 557.
7. Insert the screws and tighten them alternately.
11 Piston
24 Cylinder 8. Lock the cylinder.
4. Using a plastic hammer, ram the piston into the Figure 557.
cylinder. Lightly hammer all around the edge in
an alternate sequence. Refer to Figure 555.
Figure 555.
9. Tighten the studs to the specified torque. Refer

to Figure 558.
11 Piston
24 Cylinder Torque: 30–35N·m
5. Check the condition and position of the cylinder’s Figure 558.

O-ring.Refer to Figure 556.
24 - 37 9813/7600-3 24 - 37
24 - Brake System
03 - Service Brake
00 - General
10. Insert the stroke automatic regulation springs 13. Apply locking fluid to the thread of the adjustment
and place them in line with the intermediate disc. screw. Refer to Figure 562.
Refer to Figure 559. Consumable: JCB Threadlocker and Sealer
Figure 559. (Medium Strength)
14. Tighten with torque wrench to the specified
setting.
Torque: 10–15N·m
Figure 562.
22 Stroke automatic regulation springs

23 Intermediate disc
11. Insert the intermediate disc. Refer to Figure 560.
Figure 560.
15. Fit the pin screws. Apply threadlocker to the

thread. Tighten to the specified torque.
Torque: 5–7N·m
Consumable: JCB High Strength Threadlocker
Figure 563.
12. Fit the reversal springs and the intermediate disc.
Figure 561.
16. Take the dimension from the surface of the

intermediate disc to the cover sealing surface
with the specified pressure introduced. Refer to
Figure 564.
Pressure: 30bar (434.8psi)
12 Reversal spring
13 Pin screw
24 - 38 9813/7600-3 24 - 38
24 - Brake System
03 - Service Brake
00 - General
X Dimension measurement- piston under pressure 28 Shim stack

17. Put the brake disc pack including the distance 20. Install the friction disc on the flange from arm
piece under a press. Apply the specified load and side. Refer to Figure 567. Refer to Figure 552.
measure the dimension. Refer to Figure 565.
Weight/Force: 1,000kg Figure 567.
Figure 565.
18 Friction disc
V Dimension measurement- brake pack under 21. Install the metal disc on the flange from the arm
load side.
18. Calculate the thickness of shim required to set Figure 568.

the disc pack gap to the specified gap. Refer to
Table 232.
19. Insert the measured shim stack under the
distance piece.
19 Metal disc
22. Install the friction disc on the flange from arm side
and insert the group on the u-joint.
24 - 39 9813/7600-3 24 - 39
24 - Brake System
03 - Service Brake
00 - General
Figure 569. 26. Tighten to the specified torque.

Torque: 30–35N·m
Figure 572.
17 Flange
18 Friction disc
19 Metal disc
20 Friction disc
23. Insert the flange and the remaining discs. 27. Check the condition and position of the cylinder’s
O-ring. Refer to Figure 573.
Figure 570.
Figure 573.
1
24. Check the alignment of the last disc and the 28. Check the condition and position of the arm’s O-
flange. ring; install the complete arm. Refer to Figure
Figure 571. 574.
Figure 574.
25. Apply JCB Locking Fluid to the studs.

Consumable: JCB Threadlocker and Sealer 29. Cross tighten the nuts in two stages.
(Medium Strength) Torque: 200–221N·m
24 - 40 9813/7600-3 24 - 40
24 - Brake System
03 - Service Brake
00 - General
Figure 575.
Shim Calculation (Example)

Table 232.
Axle arm brake housing 74mm
(1)
reference depth
Intermediate disc depth 29mm
(1)
measurement X
Disc pack thickness 42.33mm
(1)
measurement V
Disc pack gap measure- 1.25mm
(1)
ment required
Shim stack thickness re- 1.42mm
(1)
quired (74 - (29 + 42.33

+ 1.25)) = 1.42
(1) All dimensions for illustration purposes only.
24 - 41 9813/7600-3 24 - 41
24 - Brake System
03 - Service Brake
01 - Master Cylinder
01 - Master Cylinder Remove and Install

(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
The master cylinder is a non-serviceable part. If it is
defective, it must be replaced with a new one.
Remove
30-00).
4. For machines with power brake system,
Discharge the brake system pressure. Refer to
(PIL 24-00).
5. Remove the retaining clip.
Figure 576. Single axle brak-
ing system- Master cylinder
A C
B
E
F G E
A Retaining clip
B Clevis pin
C Brake pedal lever bracket
D Operating rod
E Nut
F Bolt
G Master cylinder
6. Remove the clevis pin to disconnect the master
cylinder operating rod from the brake pedal lever
bracket.
24 - 42 9813/7600-3 24 - 42
24 - Brake System
03 - Service Brake
Figure 577. Twin axle brak- Figure 578.

ing system- Master cylinder
A C
D F
H
F
E
G
J
K
A Retaining clip
B Clevis pin
C Brake pedal lever bracket
D Operating rod
E Nut H Cab front cover
F Bolt J Plastic feed pipe
G Master cylinder K Master cylinder output hose
7. Get access to the master cylinder hydraulic 10. Plug the cylinder port and blank off the hose (or
connections which are located behind the cab pipe) to prevent ingress of dirt.
front cover.
11. Machines with twin axle service brakes have
8. Disconnect the plastic feed pipe from the brake three master cylinder securing bolts. Machines
fluid tank and then either blank off the pipe or with single axle service brakes have two securing
drain the tank. bolts.
9. Disconnect the master cylinder output hose (or 12. Support the master cylinder.
pipe as applicable).
13. Remove the nuts and the bolts.
14. 'Remove the master cylinder from the machine.
Install
steps.
1.1. Once the master cylinder is installed and
the pipework connected make sure the
brake fluid tank level is correct. Refer to (PIL
24-00).
1.2. Bleed the brake system. Refer to (PIL
24-00).
1.3. Check the operation of the brake light
switch and adjust if necessary. Refer to (PIL
24-03-50).
24 - 43 9813/7600-3 24 - 43
24 - Brake System
03 - Service Brake
The master cylinder is not serviceable and must be

renewed if faulty.
24 - 44 9813/7600-3 24 - 44
24 - Brake System
03 - Service Brake
06 - Priority Charge Valve
06 - Priority Charge Valve Technical Data

Technical Data ............................................... 24-45 For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 24-45
Diagram ......................................................... 24-48 ................................................... Page 24-45
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY])
Table 233. Charge Valve
Charge pressure
(brakes)
(1)
Cut-in 85bar (1,231.9psi)

Cut-out 115bar (1,666.7psi)
(1) The charge pressure may briefly peak at 120bar
(1,739.1psi)

Table 234. Charge Valve
Charge pressure
(brakes)
Cut-in 120bar (1,739.1psi)
Cut-out 155bar (2,246.4psi)
24 - 45 9813/7600-3 24 - 45
24 - Brake System
03 - Service Brake
For: 550-80 [5AW], 550-80 [5UW], 560-80 (For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 24-46 [5AY], 560-80 [5UY])
................................................... Page 24-47 Figure 579. Charge Valve
N
R
F B
P
B Tank port
F Pressure sensor port
N Tank return port
P Inlet port
R Outlet port to brake valve/accumulator
24 - 46 9813/7600-3 24 - 46
24 - Brake System
03 - Service Brake
Figure 580. Priority Valve
A D E
B
F
C
G
A Port R (Accumulator) B Port P (From pump)

C Port N (Tank) D Port A (Priority flow)
E Port F (Accumulator pressure switch) F Port LS (Load sense signal)
G Port B (Fan motor)
24 - 47 9813/7600-3 24 - 47
24 - Brake System
03 - Service Brake
Diagram
Figure 581. DTVT Priority Valve

B A C
A Port A (Priority flow) B Port B (Exceeding flow)

C Port LS (Load sense signal) D Port N (Tank)
E Port R (Accumulator) F Port F (Accumulator pressure switch)
G Port P (Pump)
24 - 48 9813/7600-3 24 - 48
24 - Brake System
03 - Service Brake
09 - Brake Valve
09 - Brake Valve Technical Data

Technical Data ............................................... 24-49
(For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY])
Diagram ......................................................... 24-52
Table 235. Brake Valve Operating Pressure
Input (charge pressure) 80–115bar (1,159.4–
1,666.7psi)
Output (brake pressure) 0.46bar (6.7psi)
Accumulator pre-charge 70bar (1,014.5psi)
(nitrogen gas) at 20ºC
Weight 2.2kg
24 - 49 9813/7600-3 24 - 49
24 - Brake System
03 - Service Brake
09 - Brake Valve
For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY] .................. Page 24-50
................................................... Page 24-51
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY])
Figure 582. Brake Valve
R
B Outlet port to brake packs
N Tank return port
R Inlet port (charge pressure)
24 - 50 9813/7600-3 24 - 50
24 - Brake System
03 - Service Brake
09 - Brake Valve
Figure 583. Dual Tech Variable Transmission Machines- Brake Valve
A C
N
B
334/F5148-1
A Brake valve B Outlet port to brake packs

C Spool position sensor N Tank return port
R Inlet port (charge pressure)
24 - 51 9813/7600-3 24 - 51
24 - Brake System
03 - Service Brake
09 - Brake Valve
Diagram
Figure 584. Dual Tech Variable Transmission- Brake Valve
1
2
3
4
5
6
B Outlet port to brake packs N Tank return port

R Inlet port (charge pressure) 1 Electrical connection
2 Electrical connection 3 Electrical connection
4 Electrical connection 5 Electrical connection
6 Electrical connection
24 - 52 9813/7600-3 24 - 52
24 - Brake System
03 - Service Brake
39 - Piston
39 - Piston Introduction
Introduction .................................................... 24-53
Technical Data ............................................... 24-54
Brake Piston Seal Leakage
Check (Leaks) ............................................... 24-54 The most common reason for internal piston seal
Disassemble and Assemble .......................... 24-58 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 - 53 9813/7600-3 24 - 53
24 - Brake System
03 - Service Brake
39 - Piston
Technical Data Check (Leaks)

For: 526-56 [T4F], 531-70 [5AA], 531-70
Refer to brakes- general, refer to (PIL 24-00). [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................... Page 24-54
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 24-56
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
Special Tools
Bar)
Consumables
JCB Hydraulic Fluid HP 4002/0501 1L
15 4002/0503 5L

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.
The most common reason for internal piston seal

leakage is a build-up of axle contamination as a result
of excessive brake wear caused by extended service
periods.
Two types of internal leakage can occur within the

axle or hub:
1. Low Pressure Leaks- Seal damage, or scoring to

seal component surfaces, caused by a build-up
of metal particles.
2. High Pressure Leaks- Mechanical leakage past
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.
24 - 54 9813/7600-3 24 - 54
24 - Brake System
03 - Service Brake
39 - Piston
1. Make the machine safe. Refer to (PIL 01-03). Figure 586.

2. Disconnect the brake piston feed pipe (or hose,
as applicable) at port 1.
3. Plug all the open ports and hoses to prevent X
contamination.
4. Completely remove the pipe and install a plug at
port 2.
5. Fill both brake piston housings with JCB Light
Hydraulic Fluid through the port 1 and port 3.
Consumable: JCB Hydraulic Fluid HP 15 E
Figure 585.
F
D
A E Port 4
F Brake piston port
B C X Brake fluid level line
7. Test for a high pressure leak as follows:
7.1. Install a hand pump installed with a
pressure gauge of the specified value to the
brake piston port.
A Port 1
Special Tool: Pressure Gauge (0-70 Bar)
B Pipe
(Qty.: 1)
C Port 2
D Port 3 7.2. Fill the hand pump with the correct
Hydraulic Fluid.
6. Test for a low pressure leak as follows:
7.3. Use the hand pump to generate a pressure
6.1. Install an adaptor with a piece of clear tube in the brake piston housing. Do not exceed
to the brake piston port. the specified value.
6.2. Make sure you keep the tube vertical during Pressure: 69bar (1,000.0psi)
the test. Use tape to attach the tube to the 7.4. If the pressure falls off rapidly, or if no
side of the machine. pressure reading can be obtained, the
6.3. Fill the tube until approximately three piston seal is severely damaged. Install a
quarters full with the correct Hydraulic Fluid. new seal.
6.4. Use a suitable pen to mark the level line of 7.5. Repeat the 7.1 to step 7.4 at port 4.
the brake fluid on the tube.
6.5. After approximately 30 minutes, check if
the level has dropped below the original
marked line. If it has, check the brake piston
seal for slight nicks, cuts or generally for
wear.
6.6. Repeat the step 6.1 to step 6.5 at port 4.
24 - 55 9813/7600-3 24 - 55
24 - Brake System
03 - Service Brake
39 - Piston
Figure 587. Two types of internal leakage can occur within the
axle or hub:
1. Low Pressure Leaks- Seal damage, or scoring to

seal component surfaces, caused by a build-up
X of metal particles.
2. High Pressure Leaks- Mechanical leakage past
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
E distort and form a seal under pressure.
The following procedures explain how to check for

F low or high pressure leaks without the need to
dismantle the axle first. The test must only be done
when the axle is COLD.
E Port 4
The procedures are the same for the front and rear
F Brake piston port
axle. Refer to the applicable illustration.
X Brake fluid level line
8. Put the brake system back to the original 1. Make the machine safe. Refer to (PIL 01-03).
condition as follows: 2. Make sure that the axle is cold.
8.1. Connect all the brake pipes and bleed 3. Disconnect the brake piston feed pipe (or hose,
the brake system. Refer to brakes- service as applicable) at port 1.
brake. Refer to (PIL 24-03).
For twin axle brake systems, do this procedure on contamination.
the other axle, if applicable.
5. Fill brake piston housing with the correct fluid
through port 1.
(For: 550-80 [5AW], 550-80 [5UW], 560-80
6. Test for a Low Pressure Leak:
[5AY], 560-80 [5UY])
Special Tools
Hand Pump Pressure 892/00223 1
Test
Bar)

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.
Brake Piston Seal Leakage

The most common reason for internal piston seal
leakage is a build-up of axle contamination as a result
of excessive brake wear caused by extended service
periods.
24 - 56 9813/7600-3 24 - 56
24 - Brake System
03 - Service Brake
39 - Piston
Figure 588. Front Axle Figure 589. Rear Axle
A B
A C
A Piston port 1
B Clear tube
C Piston port 2
X Level marking on tube
6.1. Install an adaptor installed with a piece of
clear tube to the brake piston port 1. The
tube must be kept vertical during the test,
use tape to attach the tube to the side of the
machine.
6.2. Fill the tube until approximately three
quarters full with JCB Light Hydraulic Fluid.
6.3. Using a suitable pen, mark the level line of
the brake fluid X on the tube.
6.4. After approximately 30 minutes, check if
the level has dropped below the original
marked line. If it has, check the brake piston
seal for slight nicks, cuts or generally for
wear.
6.5. Repeat the steps above for port 2.
7. Test for a high pressure leak:
24 - 57 9813/7600-3 24 - 57
24 - Brake System
03 - Service Brake
39 - Piston
Figure 590. Disassemble and Assemble
Refer to driveline- front axle, refer to (PIL 27-20).
D Hand pump
A Port 1
7.1. Install a hand pump D with the specified
pressure gauge to brake piston port 1.
Special Tool: Pressure Gauge (0-70 Bar)
(Qty.: 1)
Special Tool: Hand Pump Pressure Test
(Qty.: 1)
7.2. The hand pump must be filled with the
correct fluid. Make sure you do not exceed
the specified pressure.
7.3. Use the hand pump to generate a pressure
in the brake piston housing.
7.4. If the pressure falls off rapidly, or if no
pressure reading can be obtained, the
piston seal is severely damaged and needs
replacing with a new one.
7.5. Repeat the steps above for port 2.
8. Re-instate the brake system.
8.1. Reconnect all brake pipes and bleed the
brake system. Refer to (PIL 24-03).
24 - 58 9813/7600-3 24 - 58
24 - Brake System
03 - Service Brake
45 - Vacuum Servo Unit
45 - Vacuum Servo Unit Check (Leaks)

Check (Leaks) ............................................... 24-59 Refer to (PIL 24-03-46).
24 - 59 9813/7600-3 24 - 59
24 - Brake System
03 - Service Brake
Remove and Install
3. Disconnect the servo vacuum hose.

(For: 526-56 [T4F], 531-70 [5AA], 531-70 4. Disconnect and install a plug on the master
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 cylinder output pipe. Install a plug on the cylinder
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 port.
[5TE], 541-70 [5AD], 541-70 [5TD])
5. Disconnect and install a plug on the cylinder
output hose. Install a plug on the cylinder port.
Servo unit- Single axle brakes
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
installed).
Figure 591.
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 - 60 9813/7600-3 24 - 60
24 - Brake System
03 - Service Brake
Install
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).
24 - 61 9813/7600-3 24 - 61
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
46 - Vacuum Pump Introduction

Introduction .................................................... 24-62 The service brake system requires vacuum
Check (Leaks) ............................................... 24-63 assistance to operate.
On machines with standard hydraulic service brakes
the vacuum assistance is provided by a vacuum
pump mounted on the engine.
24 - 62 9813/7600-3 24 - 62
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Check (Leaks) 7. Switch OFF the engine and monitor the vacuum
gauge reading:
7.1. Make sure that the mercury (Hg) level stays
(For: 526-56 [T4F], 531-70 [5AA], 531-70 above the specified value after 60 seconds.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 Length/Dimension/Distance: 500mm
[5TE], 541-70 [5AD], 541-70 [5TD]) 7.2. Check that the vacuum is sufficient for 3 or 4
pedal operations. The vacuum must decay
The procedure explains how to determine if the brake slowly with each pedal operation.
servo vacuum system is functioning correctly.
8. The brake vacuum pump and brake servo unit
The following test equipment is used to carry out this are non-serviceable parts. If they are suspected
test: as being faulty, install new parts.
• Vacuum gauge (range up to 1 bar). Figure 592. Typical Vacuum Pump Installation
• T-adaptor.
• Vacuum hose- 2 lengths x 75 mm (3 inch) long.
• Clips- worm drive.
A
Brake Vacuum Test (if applicable)
(PIL 06-06). A
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. B
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 A Brake vacuum line
mercury (Hg), carry out step 5. B T-adaptor
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.
24 - 63 9813/7600-3 24 - 63
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Remove and Install
6. Remove the clip and release the brake vacuum

(For: 526-56 [T4F], 531-70 [5AA], 531-70 hose from the pipe stub.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 7. Disconnect the oil feed hose.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], JCB 8. Install a cap on the open ends of the hoses to
prevent the ingress of dirt. Tie the hoses out of
Tier 4F Engine 4 Cyl) the way.
If the brake performance is poor and the brake servo 9. Remove the screws and carefully take out the
vacuum is suspected, do the brake vacuum test servo exhauster unit from the engine. Discard the
before you install a new servo exhauster unit. Refer gasket.
to brakes- service brake. Refer to (PIL 24-03).
Install
Remove
The servo exhauster unit is a non-serviceable part. If
it is suspected as being faulty it must be renewed as
2. Follow the general health and safety procedures. a complete assembly.
The special adaptor is installed with an oil feed
3. Disconnect the battery. Refer to (PIL 33-03). restrictor orifice (3 mm diameter). Check to make
sure that the orifice is not blocked before installing
4. Open the engine compartment cover. Refer to the servo exhauster unit.
(PIL 06-06).
5. Access to the servo exhauster unit is limited. If removal procedure. Additionally do the following
necessary remove the machine cooling pack to steps.
gain sufficient access. Refer to (PIL 21-03).
24 - 64 9813/7600-3 24 - 64
24 - Brake System
03 - Service Brake
46 - Vacuum Pump
Figure 593.
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 - 65 9813/7600-3 24 - 65
24 - Brake System
03 - Service Brake
50 - Light Switch
50 - Light Switch Diagram

Diagram ......................................................... 24-66 The foot brake pedal switch is connected to the panel
Adjust ............................................................ 24-67 harness.
Figure 594.
3 2 1 3 2 1
24 - 66 9813/7600-3 24 - 66
24 - Brake System
03 - Service Brake
50 - Light Switch
Adjust Brake Light Switch- (Reed Type)

Figure 596.
Brake Light Switch- Proximity Type
Figure 595.
D
E F
F
C
B
D Brake light switch
E Metal vane
F Switch faces
1. This type of switch is not adjustable.
2. If a switch failure is suspected, check all
associated wing and connectors for damage.
3. Make sure the vane moves between the switch
faces when the brake pedal is pressed.
4. If the switch does not work, it must be renewed.

Item Nm
A Proximity sensor C 20
B Brake lever
C Locknut
1. Set the ignition switch to the on position, do not
start the engine.
2. Adjust the proximity sensor to the correct
clearance between the sensor face and the edge
of the brake lever.
Length/Dimension/Distance: 2–3mm
3. Tighten the locknut to the correct torque.
4. Press the brake pedal and check that the sensor
operates (brake light illuminates) when the brake
pedal has travelled the correct distance. Check
that the sensor remains on throughout the rest of
the travel.
Length/Dimension/Distance: 10–15mm
5. Check that the brake lights illuminate when the
brake pedal is pressed.
24 - 67 9813/7600-3 24 - 67
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 597.
A Electrical connector B Bracket

C Screw D Switch
24 - 68 9813/7600-3 24 - 68
24 - Brake System
03 - Service Brake
50 - Light Switch
Install
removal procedure.
24 - 69 9813/7600-3 24 - 69
24 - Brake System
03 - Service Brake
57 - Pressure Sensor
57 - Pressure Sensor Component Identification

Component Identification ............................... 24-70 For: 550-80 [5AW], 550-80 [5UW]
................................................... Page 24-70
Diagram ......................................................... 24-72
For: 526-56 [T4F], 531-70 [5AA], 531-70
Check (Operation) ......................................... 24-76 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
Remove and Install ....................................... 24-77 [5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................... Page 24-70
(For: 550-80 [5AW], 550-80 [5UW])

The footbrake pressure Transducer is located in the
power brake circuit.
Figure 598.
1 Footbrake Pressure Transducer
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
The Footbrake Pressure Transducer is located on
the brake servo.
24 - 70 9813/7600-3 24 - 70
24 - Brake System
03 - Service Brake
Figure 599.
2
24 - 71 9813/7600-3 24 - 71
24 - Brake System
03 - Service Brake
Diagram
For: 550-80 [5AW], 550-80 [5UW], 560-80 Figure 600.

[5AY], 560-80 [5UY] .................. Page 24-72
For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................... Page 24-73 2 3
1 4
(For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY])
The Footbrake Pressure Transducer is connected to
the Chassis harness.
1 4
2 3
Table 238. Harness Connector C018

Connectors Pins Pins Pins Pins Details
C018 1 2 3 4
C003 1 - Chassis Earth
Point Refer to
(PIL 33-00-90)
i016 38 - 63 Refer to (PIL
33-00-50)
P002 18 - Fusebox B, Re-
fer to (PIL 33-09)
P069 - 9 Transmission
ECU (Electron-
ic Control Unit)
0711 Connector
A
24 - 72 9813/7600-3 24 - 72
24 - Brake System
03 - Service Brake
Figure 601.
(For: 526-56 [T4F], 531-70 [5AA], 531-70
- 1 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
A
+ 2 [5TE], 541-70 [5AD], 541-70 [5TD])
3
4
Wires and Connectors
C
ECU The Footbrake Pressure Transducer is connected to
the Chassis harness.
B Figure 602.
V
3 2 3
12 1 4
4
5.0
4.5
0.9
0.5
0 X 1 4
0 20 250
A Fuse 2 3
B Transmission 0711 ECU
C Pressure Transducer
3 Pin 3- Switch output- brake pedal operated
4 Pin 4- proportional output- brake pedal pressure
V Volts
X Pressure (bar)
Machines with Gearpump Parallel Hydraulic System

C027 1 2 3 4
Point - Refer to
(PIL 33-00-90)
33-00-50)
P002 18 - Fusebox B- Re-
fer to (PIL 33-09)
ECU 0711 Con-
nector A
24 - 73 9813/7600-3 24 - 73
24 - Brake System
03 - Service Brake
Machines with Electro Servo Hydraulic System (excluding 526-56)

C018 1 2 3 4
Point - Refer to
(PIL 33-00-90)
33-00-50)
fer to (PIL 33-09)
ECU 0711 Con-
nector A
526-56 Machines
C011 1 2 3 4
Point - Refer to
(PIL 33-00-90)
33-00-50)
fer to (PIL 33-09)
P74A - 9 Transmission
ECU 0711 Con-
nector A
24 - 74 9813/7600-3 24 - 74
24 - Brake System
03 - Service Brake
Schematic Diagram
Figure 603.
- 1
A
+ 2
4
C
ECU
V
3
12
4
5.0
4.5
0.9
0.5
0 X
0 20 250
A Fuse
B Transmission 0711 ECU
C Pressure Transducer
3 Pin 3- Switch output- brake pedal operated
4 Pin 4- Proportional output- brake pedal pressure
V Volts
X Pressure (bar)
24 - 75 9813/7600-3 24 - 75
24 - Brake System
03 - Service Brake
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 - 76 9813/7600-3 24 - 76
24 - Brake System
03 - Service Brake
Remove and Install
For: 550-80 [5AW], 550-80 [5UW], 560-80 (For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 24-77 [5AY], 560-80 [5UY])
For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 WARNING Before working on the brake system,
[5AC], 536-60 [5TC], 536-70 [5AE], make sure that the machine is on solid level
536-70 [5TE], 541-70 [5AD], 541-70 [5TD] ground. Put blocks on all wheels to prevent the
................................................... Page 24-78 machine rolling.
Figure 604.
Removal Install
1. Park the machine and make it safe. Obey the 1. Replacement is the opposite of the removal
care and safety procedures. Refer to (PIL 01-03). procedure.
2. Vent the hydraulic system pressure. Refer to (PIL 2. During the replacement procedure do this work
30-00-00). also:
3. Vent the braking system pressure. Refer to (PIL 2.1. Tighten the transducer to the specified
30-00-00). torque.
4. Remove the transducer from the circuit. Torque: 19N·m
2.2. Make sure that any O-ring seals are
renewed.
24 - 77 9813/7600-3 24 - 77
24 - Brake System
03 - Service Brake
(For: 526-56 [T4F], 531-70 [5AA], 531-70 2.4. Bleed the brake system. Refer to (PIL.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
machine rolling.
Figure 605.
2
1 Brake servo
3 Sensor
Removal
1. Park the machine and make it safe. Obey the
care and safety procedures. Refer to (PIL 01-03).
2. Vent the hydraulic system pressure. Refer to (PIL
30-00-00).
3. Get access to the brake servo
4. Disconnect the chassis harness electrical
connector from the sensor electrical connector.
5. Remove the transducer from the servo unit.
Install
1. Replacement is the opposite of the removal
procedure.
2. During the replacement procedure do this work
also:
2.1. Tighten the transducer to the specified
torque.
Torque: 19N·m
2.2. Replace any O Ring Seals.
2.3. Check the brake fluid level. Top up if
necessary.
24 - 78 9813/7600-3 24 - 78
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ........................................................................................................................... 24-81

24-18-03 Switch ............................................................................................................................. 24-96
24-18-06 Cable .............................................................................................................................. 24-97
24-18-15 Pad ............................................................................................................................... 24-107
24-18-18 Caliper .......................................................................................................................... 24-108
24-18-21 Disc .............................................................................................................................. 24-115
24-18-48 Actuator ........................................................................................................................ 24-125
24 - 79 9813/7600-3 24 - 79
Notes:
24 - 80 9813/7600-3 24 - 80
24 - Brake System
18 - Park Brake
00 - General
Introduction .................................................... 24-81 The park brake also called the hand brake is a
Technical Data ............................................... 24-82 latching brake usually used to keep the vehicle
Component Identification ............................... 24-82 stationary. It is also used to prevent a vehicle from
Operation ....................................................... 24-83 rolling when the operator needs both feet to operate
the clutch and throttle pedals.
Check (Condition) .......................................... 24-84
Check (Operation) ......................................... 24-85 The park brake usually consists of a cable directly
Adjust ............................................................ 24-87 connected to the brake mechanism on one end, and
Disassemble and Assemble .......................... 24-91 to a hand-operated lever, on the floor at the side of
the driver.
24 - 81 9813/7600-3 24 - 81
24 - Brake System
18 - Park Brake
00 - General

For: PS764, PS766 ................... Page 24-82
For: PS750 MK4 ....................... Page 24-82 (For: HM560 Variable Transmission)
Figure 606.
(For: PS764, PS766)
Table 242. Park Brake Multi-
pack Brakes (If Installed)
Description Acceptable Tolerances
(mm)
Friction pack assembly 37.1 to 39.6
thickness
(For: PS750 MK4)

Description Acceptable Tolerances
Disc minimum thickness 8.9mm
Pad minimum thickness 1mm
1 Capscrews
2 Park brake cable
3 Rear case
4 Brake actuator housing
5 Plug
6 Collar
7 O-ring
8 Special clevis pin
9 Brake actuator
24 - 82 9813/7600-3 24 - 82
24 - Brake System
18 - Park Brake
00 - General
Figure 607. Operation

For: PS750 MK4 ....................... Page 24-83
For: PS764, PS766 ................... Page 24-83
................................................... Page 24-84
(For: PS750 MK4)

The park brake is Independent of the service brakes.
It operates on the drive to the front axle by means of
a disc mounted on the gearbox output shaft.
When the operator moves the park brake lever to the

vertical position, the cable pulls the caliper reaction
lever and pressure is applied to the caliper mounted
brake pads to hold the brake disc.
1 Reaction pins
2 Brake multi-pack plates Figure 608.
B
C
D
A Gearbox output shaft

B Brake pads
C Caliper reaction lever
D Brake disc
The lever has a simple system for adjustment of the

cable when necessary.
An electrical switch senses if the park brake lever

is set to the brake on or brake off position. The
switch controls operator warnings and transmission
interlocks.
(For: PS764, PS766)
Internal park brake

The park brake is Independent of the service brakes.
It operates on the drive to the front axle via an oil
immersed, multi-plate brake pack housed inside the
gearbox. The brake assembly is mounted on the
gearbox layshaft.
When the operator moves the park brake lever to the

vertical position, the cable causes the brake plates
to be pressed together.
24 - 83 9813/7600-3 24 - 83
24 - Brake System
18 - Park Brake
00 - General
The lever has a simple system for adjustment of the Check (Condition)
cable when necessary.
For: HM560 Variable Transmission, PS764,
Figure 609. PS766 ....................................... Page 24-84
For: PS750 MK4 ....................... Page 24-85
(For: HM560 Variable Transmission,

A PS764, PS766)
Before inspecting the brake components carefully
remove all traces of sealing compound from
component mating faces. Use a suitable degreaser,
clean the brake components including the brake
housing in the gearbox rear case.
Multi-Plate Pack
1. Carefully inspect the friction plates and counter
plates. If any of the plates show signs of damage
A Multi-plate brake pack or distortion, renew the complete plate pack.
An electrical switch senses if the park brake lever Figure 610.

is set to the brake on or brake off position. The
switch controls operator warnings and transmission
interlocks. 1

The park brake is independent of the service brakes. 2
It operates on the drive to the rear axle via an oil
immersed, multiplate brake pack housed inside the
gearbox. The brake assembly is mounted on the
gearbox layshaft. When the operator moves the park 3
brake lever to the vertical position, the cable causes
the brake plates to be pressed together.
The park brake lever has a simple system for

adjustment of the cable when necessary. An
electrical switch senses if the park brake lever is 1 Thrust plate
set to the brake on or brake off position. The 2 Counter plates
switch controls operator warnings and transmission 3 Friction plates
interlocks.
2. Assemble the friction and counter plates
(including the thrust plate) on a suitable datum
table. Measure the overall thickness of the
assembled friction pack. The thickness X must
be between the recommended tolerances, refer
to Technical Data.
Figure 611.
X Friction pack assembly thickness

2.1. If the friction pack is outside these limits,
the complete friction pack assembly must
be renewed.
24 - 84 9813/7600-3 24 - 84
24 - Brake System
18 - Park Brake
00 - General
Note: The friction pack may be outside the maximum Check (Operation)
thickness value if the plates are distorted, typically
after the brake has performed an emergency stop. For: PS764, PS766 ................... Page 24-85
................................................... Page 24-86
(For: PS750 MK4)
WARNING Oil on the brake disc will reduce (For: PS764, PS766)
brake effectiveness. Keep oil away from the
brake disc. Remove any oil from the disc with WARNING! Before testing the park brake make
a suitable solvent. Read and understand the sure the area around the machine is clear of
solvent manufacturer's safety instructions. If the people.
pads are oily, install with the new pads.
1. Park the machine and make it safe.
1. Follow the brake pad removal instructions. refer 2. Follow the care and safety procedures. Refer to
to (PIL 24-03). (PIL 01-03).
2. Make sure that the minimum thickness of the 3. Apply the park brake fully.
friction material on either pad is 1mm (0.04 in),
but it is recommended to install new pads as it 4. Start the engine and raise the attachments to the
may not be possible to adjust pads worn to this appropriate travelling position.
limit.
5. Select the fourth gear.
3. Check the condition of the disc surface. Install a
new disc if the surface is badly warped, pitted or 6. Push down hard on foot brake pedal.
worn.
7. Select forward drive on the left hand column
4. Make sure the actuator is adjusted correctly. switch.
WARNING! If the machine starts to move during

the park brake test, immediately apply the foot
brake and reduce the engine speed.
8. Test the park brake as follows:

8.1. Move the park brake lever slowly forward
until the warning light is just extinguished.
8.2. Slowly release the foot brake pedal.
8.3. If the machine has not moved, use the
accelerator pedal to gradually increase the
engine speed to 1500 RPM (Revolutions
Per Minute) The machine should not move.
8.4. Do not do this test for more than the
specified time.
Duration: 20s
8.5. Reduce the engine speed to idle and select
neutral on the left hand column 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.
24 - 85 9813/7600-3 24 - 85
24 - Brake System
18 - Park Brake
00 - General
WARNING! Non approved modifications to drive 1. Park the machine on firm level ground and make
ratios, machine weight or wheel and tyre sizes may it safe. Refer to (PIL 01-03).
adversely affect the performance of the park brake.
2. Apply the park brake fully.
If you have any queries concerning this test
procedure or park brake adjustment, consult your 3. Start the engine and raise the attachments to the
local JCB distributor. appropriate travelling position.
4. Select snail mode by pressing and holding the
Figure 612.
gear downshift button. Make sure the snail
mode symbol is displayed. (Snail mode restricts
D D
the transmission to hydrostatic mode only and
enables the varispeed control). Refer to the
12
operators handbook.
P
9 3
5. Set the varispeed control to the specified

6
10 15
RPM x 100
20
5
percentage. (The percentage is displayed on the

0 25
B dashboard).
Percentage: 15%
6. Set the hand throttle control to the give the
correct engine speed. The correct engine speed
535 530
is 1500 RPM.
C 7. Push the drive pedal down gradually until full

pedal travel is reached.
8. The machine must not move. If the machine
moves at any time during the test, stop the test.
9. Do not do this test for more than the specified
A time.
Duration: 10s
A Park brake lever 10. When the test has finished, set the hand throttle
B Left hand column switch to idle speed and allow the engine to idle for the
C Foot brake pedal specified time allow the oil to be cooled.
D Warning light
Duration: 2min
11. Turn off the engine.
12. If the machine moved during this test, adjust the
WARNING Before testing the park brake make
park brake and repeat the test. Refer to brakes-
sure the area around the machine is clear of
park brake, refer to (PIL 24-18).
people.
WARNING If the machine starts to move during 13. When testing is finally completed, Lower the
the park brake test, immediately apply the foot attachments and stop the engine.
brake and reduce the engine speed.
If you have any queries concerning this test
WARNING Do not use a machine with a faulty procedure or park brake adjustment, consult your
park brake. local JCB distributor.
WARNING Non approved modifications to drive
ratios, machine weight or wheel and tyre sizes
may adversely affect the performance of the park
brake.
Notice: To prevent oil overheating and machine
damage, make sure that the test does not take
longer than the specified time. Make sure you
allow sufficient time between tests for the oil to
cool.
24 - 86 9813/7600-3 24 - 86
24 - Brake System
18 - Park Brake
00 - General
Adjust
For: PS750 MK4 ....................... Page 24-87 Figure 613.

For: HM560 Variable Transmission A
................................................... Page 24-87
For: PS764, PS766 ................... Page 24-88
(For: PS750 MK4)

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 pack
must be renewed. B
working on it. Park the machine on level ground
and lower the loader arm. Stop the engine and
engine being started. Block all four wheels. A Handle grip
B Pin
Notice: Over adjustment or failure to disengage
the park brake properly will cause excessive wear
of the park brake mechanism. (For: HM560 Variable Transmission)
WARNING The park brake must not be used to
Before you try to adjust the park brake after an slow the machine from travelling speed, except
emergency stop, remove and install new brake in an emergency, otherwise the efficiency of the
friction components. Install other new components if brake will be reduced. Whenever the park brake
necessary. has been used in an emergency the brake pack
must be renewed.
The park brake must be engaged fully when the
lever is vertical. The park brake indicator light should Notice: Over adjustment or failure to disengage
illuminate when the brake is engaged with the the park brake properly will cause excessive wear
forward and reverse lever away from neutral (starter of the park brake mechanism.
switch at IGN).
1. Park the machine and make it safe, Refer to (PIL
Do the park brake adjustment as follows: 01-03).
1. Disengage the park brake (lever horizontal). 2. Disengage the park brake and set it on the off
position, (lever horizontal).
2. Pull and turn the handle grip clockwise, half a
turn. 3. Rotate the handle grip clockwise, until the clevis
is in its lowest position (set the park brake lever
3. Test the park brake. Refer to brakes- park brake, in the vertical on position to check this and then
refer to (PIL 24-18). set the lever back to the off position).
4. If the brake fails the test, repeat steps 1, 2 and 3. 4. Adjust the nuts to take up the slack so that the
5. If no more adjustment is possible and the pin is pads are almost touching the disc.
at the end of its travel, then adjust the cable at 5. Test the park brake. Refer to brakes- park brake,
the calliper. Refer to brakes- service brake, refer refer to (PIL 24-18).
to (PIL 24-18).
24 - 87 9813/7600-3 24 - 87
24 - Brake System
18 - Park Brake
00 - General
Figure 614. Dual Tech Variable Transmission
A
D
A Cab (front) B Clevis

C Park brake lever (off position) D Park brake lever (on position)
E Cable F Oil immersed park brake assembly
has been used in an emergency the brake pack

(For: PS764, PS766) must be renewed.
Consumables
During normal operation little or no adjustment of
Description Part No. Size the brake cable at the lever is required. In the
JCB Multi-Gasket 4102/1212 0.05L event of poor brake performance it is likely that
components have failed or, after extended service,
WARNING Before working on the brake system, friction material is worn away. Remove, inspect and
make sure that the machine is on solid level renew components if necessary.
machine rolling. Adjustment at the park brake lever should only
Notice: Over adjustment or failure to disengage be required after renewal of the cable, brake
the park brake properly will cause excessive wear components or extended service.
of the park brake mechanism.
Lever Adjustment
WARNING Do not use a machine with a faulty
park brake. The parking brake should be fully engaged when
WARNING The park brake must not be used to the lever is vertical. The parking brake indicator light
slow the machine from travelling speed, except should illuminate when the brake is engaged with the
in an emergency, otherwise the efficiency of the forward and reverse lever away from neutral (starter
brake will be reduced. Whenever the park brake switch at IGN).
24 - 88 9813/7600-3 24 - 88
24 - Brake System
18 - Park Brake
00 - General
1. Make the machine safe. Refer to (PIL 01-03). damage to the brake components and excessive
overheating of the brake assembly.
2. Follow the health and safety procedures. Refer
to (PIL 01-03). 7.1. Remove the 5 screws and 2 bolts 1. Using a
flat blade screwdriver located in the housing
3. Disengage the parking bake (lever horizontal). cut out, lever off the cover plate.
4. Turn the hand grip half a turn clockwise. 7.2. Use the cover plate as a wear indicator.
Use a bolt 2 to install the plate at right
Figure 615. angles to the housing as shown. Pull the
plate down when tightening the bolt to take
up the clearance in the bolt hole.
Figure 617.
D G
A Screws H D
B Bolts 1
C Housing cut out D Cover plate
D Cover plate G Clevis pin
H Bolt 2
Figure 616.
7.3. Fully apply the park brake (lever vertical). If
the brake is within service limits, the clevis
pin hexagon must not be visible above the
cover plate. Renew the friction pack if any
of the clevis pin hexagon is visible.
8. If the friction pack components are distorted
E (typically after performing an emergency stop)
the clevis pin may not be visible in the check
F described. If the park brake performance is
poor it may be due to distorted components.
E Hand grip Disassemble and inspect the park brake
F Pin assembly as follows.
5. Test the park brake. Refer to (PIL 24-18). 8.1. Disengage the park brake (lever horizontal).
6. If the brake fails the test, do 3 and 4 again. If there 8.2. Make sure that the brake is fully released.
is no more adjustment and if the pin is at the end
of its travel, remove, inspect and renew the park 8.3. Remove the cover plate and feel the edge
brake components as necessary. of the brake pack plates.
7. After adjusting the park brake lever, do

the following steps to confirm correct brake
operation. Incorrect adjustment can result
24 - 89 9813/7600-3 24 - 89
24 - Brake System
18 - Park Brake
00 - General
Figure 618.
8.4. When the brake is released free play

between the plates should be easily
detectable. If the plates are not free, do not
operate the machine. Disassemble, inspect
and renew the park brake components as
required.
8.5. If the brake pack is serviceable, clean off
all traces of old sealant from the cover
plate and brake housing. Make sure that no
sealant enters the gearbox. Apply a bead of
multi-gasket to the brake housing.
Consumable: JCB Multi-Gasket
8.6. Install the cover plate.
value.

Item Description Nm
A Screws 16
B Bolts 1 56
24 - 90 9813/7600-3 24 - 90
24 - Brake System
18 - Park Brake
00 - General
(For: PS764, PS766)

Consumables
JCB Multi-Gasket 4102/1212 0.05L
24 - 91 9813/7600-3 24 - 91
24 - Brake System
18 - Park Brake
00 - General
Disassemble
Figure 619.
D
E
X
A
A Bolt (x2) B Screw (x5)

C Cover plate D Cover
E Needle roller thrust bearing. F Reaction pins
G Thrust plate H Friction plate
J Counter plate X Location1 and Location 2 for bolt removal
24 - 92 9813/7600-3 24 - 92
24 - Brake System
18 - Park Brake
00 - General
1. Position the output yoke as shown. Refer to 5.3. Friction plates.

Figure 620.
5.4. Counter plates.
Figure 620.
6. If the brake assembly is being removed before
you disassemble the gearbox, then remove the
reaction pins. Refer to Figure 619.
7. If the brake actuator is to be disassembled, or the
cable is to replaced, then remove the park brake
cable as follows: Refer to Figure 621.
Figure 621.
M
K
K Output yoke
2. Remove the cover plate as follows: Refer to
Figure 619.
2.1. Remove only two bolts from location1 and
location 2.
2.2. Remove the screws.
2.3. Before the cover plate is removed, place a
container below to collect the gearbox oil.
2.4. Remove the cover plate with a flat bladed
screwdriver.
3. Remove the remaining bolts (x4) and carefully N
remove the cover, keeping it parallel to the
mating face of the gearbox. Refer to Figure 619.
4. Be aware that the needle roller thrust bearing and
the reaction pins may come away with the cover. L Brake cable
Refer to Figure 619. M Circlip
N Clevis pin
5. Remove the following: Refer to Figure 619.
7.1. Remove the clevis pin.
5.1. Needle roller thrust bearing. 7.2. Remove the circlip and then remove the
5.2. Thrust plate cable from the cover.
24 - 93 9813/7600-3 24 - 93
24 - Brake System
18 - Park Brake
00 - General
Assemble
Figure 622.
G
D
E
A X
C
Z
A Bolt (x2) B Screw (x5)

E Needle roller thrust bearing. F Reaction pins
J Counter plate X Location 1 and Location 2 for bolt installation
Y Sealant location on gearbox case Z Sealant location on cover
24 - 94 9813/7600-3 24 - 94
24 - Brake System
18 - Park Brake
00 - General
1. Inspect the brake pack. 5. Apply a bead of sealant to the mating face on the
gearbox case. Refer to Figure 622.
2. Assemble the reaction pins and then install the
friction pack in the gearbox case. Refer to Figure Consumable: JCB Multi-Gasket
622. 6. Attach the cover with the bolts (x4). Refer to
2.1. Note that a counter plate is installed first Figure 622.
followed by a friction plate and so on. 6.1. Note that 2 bolts at location 1 and location
2.2. Install the thrust plate last. 2 are not installed at this stage.
3. If removed during disassembly install the park 7. Tighten the bolts to the correct torque value.
brake cable as follows: Refer to Figure 623. Refer to Figure 622.
Figure 623. 8. Apply a bead of sealant to the mating face on the

cover. Refer to Figure 622.
L R Consumable: JCB Multi-Gasket
M 9. Attach the cover plate with screws (x5) and the

bolts (x2). Refer to Figure 622.
10. Tighten the screws and bolts to the correct torque
value. Refer to Figure 622.
It is essential that the park brake cable is adjusted

Q correctly when the gearbox is installed into the
machine. Incorrect adjustment of the cable can
result in damage to the brake components and
excessive overheating of the brake assembly. See
the applicable machine Service Manual for the cable
adjustment procedure.

Item Nm
A 56
B 16
N N 9
L Brake cable
M Circlip
N Clevis pin
P Brake actuator
Q O-ring
R Collar
3.1. Put the cable into the housing and connect
the fork end to the brake actuator with clevis
pin.
3.2. Never replace the clevis pin with a normal
bolt or screw.
3.3. Make sure that the O-ring is not damaged
and correctly installed on the collar.
3.4. Locate the collar inside the brake housing
and secure with the circlip.
4. Make sure that the needle roller thrust bearing is
correctly installed on the actuator assembly.
24 - 95 9813/7600-3 24 - 95
24 - Brake System
18 - Park Brake
03 - Switch
03 - Switch Install
Remove and Install removal procedure.
2. When installing do the following steps also:
Remove
2.1. To align the switch correctly, engage the
1. Park the machine and make it safe. Follow all switch location dowel with the hole in the
safety precautions. Please see (PIL 01-03). mounting bracket.
2. Put chocks on both sides of the wheels to prevent

the machine rolling. Release the park brake.
3. Remove the rubber gaiter.
switch connector.
5. Hold the switch and remove the screw.
Figure 624.
B G D
F
C
A Rubber gaiter
B Switch
D Switch connector
E Screw
F Dowel
G Mounting bracket
24 - 96 9813/7600-3 24 - 96
24 - Brake System
18 - Park Brake
06 - Cable
06 - Cable Adjust
Adjust ............................................................ 24-97 For: PS750 Mk4, PS750 MK4
................................................... Page 24-97
For: PS764, PS766 ................... Page 24-98
(For: PS750 Mk4, PS750 MK4)

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.

2. Follow the care and safety procedures. Refer to
(PIL 01-03).
3. Disengage the park brake (lever horizontal).
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: 0.5–0.75mm
9. Test the park brake. Refer to brakes- park brake,
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 - 97 9813/7600-3 24 - 97
24 - Brake System
18 - Park Brake
06 - Cable
Figure 625.
C
A Hand grip
B Pin
C Locknuts
Figure 626.
D
D Operating lever
friction material is worn away. Dismantle, inspect and

(For: PS764, PS766) install components as required.
During normal operation little or no adjustment of The park brake should be fully engaged when
the brake cable at the lever is required. In the the lever is vertical. The park brake indicator light
event of poor brake performance it is likely that should illuminate when the brake is engaged with the
components have failed or, after extended service, forward and reverse lever away from neutral (starter
switch at IGN).
24 - 98 9813/7600-3 24 - 98
24 - Brake System
18 - Park Brake
06 - Cable
1. Before attempting to adjust the park brake 4. Turn the hand grip clockwise, half a turn.
after an emergency stop remove and inspect
the brake friction components. Install new 5. Test the park brake. If the brake fails the test
components if necessary. repeat steps 3 and 4. Refer to (PIL 24-18). If there
is no more adjustment and the pin is at the end
2. Make the machine safe. Refer to (PIL 01-03). of its travel, dismantle, inspect and renew park
brake components as required.
3. Disengage the park bake (lever horizontal)
Figure 627.
A Screws (x5) B Bolts (x2)

C Housing cut out D Cover plate
Figure 628. 6. After adjusting the park brake lever makes sure
you carry out the following steps to make sure
that the park brake operates correctly. Incorrect
adjustment can result damage to the brake
components and excessive overheating of the
brake assembly.
E Hand grip
F Pin
24 - 99 9813/7600-3 24 - 99
24 - Brake System
18 - Park Brake
06 - Cable
Figure 629.
H J
G Clevis pin hexagon H Bolt

J Cover plate
6.1. Remove (x5) screws and (x2) bolts. Using a Figure 630.
flat blade screwdriver located in the housing
cut out, lever off the cover plate.
6.2. Use the cover plate as a wear indicator.
Use a bolt to fit the plate at right angles
to the housing as shown. Pull the plate
down when tightening the bolt to take up the
clearance in the bolt hole.
6.3. Fully apply the park brake (lever vertical). If
the brake is within service limits the clevis
pin hexagon must not be visible above the
cover plate. Renew the friction pack if any
of the clevis pin hexagon is visible.
6.4. If the friction pack components are distorted
(typically after performing an emergency
stop) the clevis pin may not be visible
in the check described. If the park brake
performance is poor it may be due
to distorted components. Dismantle and
inspect the park brake assembly.
8. If the plates are not free make sure that you do
7. Disengage the park brake (lever horizontal).
not operate the machine, dismantle, inspect and
Make sure that the brake is fully released.
renew park brake components as required.
Remove the cover plate and feel the edge of the
brake pack plates. When the brake is released 9. If the brake pack is serviceable, clean off all
free play between the plates should be easily traces of old sealant from the cover plate and
detectable. brake housing. Make sure that no sealant enters
24 - 100 9813/7600-3 24 - 100

24 - Brake System
18 - Park Brake
06 - Cable
the gearbox. Apply a bead of JCB Multigasket to

the brake housing.
10. Install the cover plate. Tighten the bolts to the
correct torque.

Item Nm
A 16
B 56
24 - 101 9813/7600-3 24 - 101

24 - Brake System
18 - Park Brake
06 - Cable
Remove and Install
For: PS750 Mk4, PS750 MK4 Remove

................................................. Page 24-102
For: PS764, PS766 ................. Page 24-104 1. Make the machine safe. Obey all care and safety
procedures Refer to (PIL 01-03).
(For: PS750 Mk4, PS750 MK4) 2. Release the park brake lever (lever horizontal).
Consumables
Strength)
Figure 631.
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 - 102 9813/7600-3 24 - 102

24 - Brake System
18 - Park Brake
06 - Cable
Figure 632.
K
K
N L
M
P
Install
Table 247. 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 - 103 9813/7600-3 24 - 103

24 - Brake System
18 - Park Brake
06 - Cable
7. Adjust the sleeve and the locknut 2 until you get Figure 633.
the dimension measured between the sleeve and G
the locknut at the time of removal. A
8. If a new cable is installed make sure that the F

dimension between the sleeve and the locknut
will be of the specified value.
Dimension: 15mm Y
9. Tighten the locknut 2.

D
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 B
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.
C E
13. Adjust the cable. Refer to (PIL 24-18-06).
A Cable
Table 248. Torque Values B Bolts (x2)
C Screws (x5)
Item Description Nm D Cover plate
K Bracket fixing bolts 3 E Clevis screw
F Circlip
G Cable assembly
(For: PS764, PS766) Y O-ring
Consumables 3. Clean off all dirt from the gearbox brake housing.
Description Part No. Size Make sure there is no dirt or debris trapped in the
JCB Multi-Gasket 4102/1212 0.05L housing at the cable entry.
JCB Threadlocker 4101/0250 0.01L 4. Remove the screws and the bolts securing the
and Sealer (Medium 4101/0251 0.05L cover plate. Remove the cover plate.
Strength)
5. Remove the clevis screw and the circlip. Remove
Park Brake Maintenance the cable assembly from the housing.
Before working on the park brake, park on level 6. Working at the park brake lever, remove the
ground and put blocks on both sides of all wheels gaiter fixings and pull up the gaiter (not shown).
to prevent the machine rolling. Stop the engine and
disconnect the battery so that the engine cannot be 7. Disconnect the park brake switch electrical
started. If you do not take these precautions the connector.
machine could run over you.
8. Remove the lever fixing bolts and then remove
Internal park brake cable the lever assembly together with the cable.
9. Measure and record the dimension between the
Remove sleeve and the locknut.
1. Make the machine safe. Obey all care and safety 10. Remove the two buffer bracket fixing bolts.
procedures. Refer to (PIL 01-03).
11. Remove the cable sideways from the lever,
2. Release the park brake lever (lever horizontal). disengaging the cable nipple from the clevis
screw.
12. Remove the buffer assembly from the cable.
24 - 104 9813/7600-3 24 - 104

24 - Brake System
18 - Park Brake
06 - Cable
Figure 634.
H
J
N
S P
X Q
H Brake lever (Lever horizontal) J Electrical connector

K Lever fixing bolts L Clevis
M Buffer assembly N Buffer bracket fixing bolts
P Sleeve Q Locknut
R Cable X Dimension between the sleeve and the locknut
Install 5. Make sure that the buffer bracket assembly is

located correctly.
Installation is the opposite of the removal procedure.
During the installation procedure do these below 6. Tighten the buffer bracket fixing bolts to the
steps also. correct torque value.
1. Make sure you correctly route the cable. 7. Adjust the sleeve and the locknut until you get
the dimension measured between the sleeve and
2. Make sure that the locknut is screwed fully down. the locknut at the time of removal.
3. Adjust the sleeve to allow cable location to the 8. Tighten the locknut.
lever assembly.
9. Make sure that the O-ring is not damaged and
4. Apply JCB threadlocker to the buffer bracket install it properly.
fixing bolts.
10. After you connect both ends of the cable set the
Consumable: JCB Threadlocker and Sealer park brake lever to the off (horizontal) position.
(Medium Strength)
24 - 105 9813/7600-3 24 - 105

24 - Brake System
18 - Park Brake
06 - Cable
11. Feel the edge of the brake pack plates. When the Table 249. Torque Values
brake is released free play between the plates
Item Nm
should be easily detectable.
B 56
Figure 635. C 16
E 9
N 3
12. If necessary adjust sleeve until the plates are

free.
13. Clean off all traces of old sealant from the cover
plate and brake housing. Make sure that no
sealant enters the gearbox.
14. Apply a bead of JCB Multigasket to the brake
housing.
Figure 636.
T JCB Multigasket
15. Install the cover plate and secure it with the bolts.
24 - 106 9813/7600-3 24 - 106

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 - 107 9813/7600-3 24 - 107

24 - Brake System
18 - Park Brake
18 - Caliper
18 - Caliper Component Identification

Check (Condition) ........................................ 24-109
Figure 637.
R
M
M
L
N
F S
E
C
M
D G
Q B A
H P
K J
Table 250. Item Description

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 - 108 9813/7600-3 24 - 108

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 - 109 9813/7600-3 24 - 109

24 - Brake System
18 - Park Brake
18 - Caliper
Remove and Install
2. Release the park brake lever (horizontal).

(For: PS750 Mk4, PS750 MK4) 3. Remove the pin and disconnect the clevis joint,
Safety Critical Installation note which of the three holes on the lever is used.
This is a safety critical installation. Do not attempt 4. Remove the clip and disconnect the cable from
to do this procedure unless you are skilled and the bracket.
competent to do so.
Installation and mounting of the park brake caliper 5. Support the caliper and remove the two mounting
requires tightening of the mounting bolts to a specific bolts and hardened washers.
torque figure. Do not attempt to do this job unless you 6. Lift the caliper clear of the brake disc.
have the correct tools available.
7. Do not remove transmission mounting bracket,
Remove unless it is necessary to be replaced.
Figure 638.
A B C D
E
B
A Clip B Mounting bolts

C Clevis joint D Pin
E Operating lever F Transmission mounting bracket
24 - 110 9813/7600-3 24 - 110

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 - 111 9813/7600-3 24 - 111

24 - Brake System
18 - Park Brake
18 - Caliper
7. Push out the rotor the remove the ball spacer and
(For: PS750 Mk4, PS750 MK4) the ball bearings.
Safety Critical Installation 8. Make sure you keep the ball bearings properly in
a container.
This is a safety critical installation. Do not attempt
to do this procedure unless you are skilled and 9. Push out the mounting bushes and then remove
competent to do so. the dust seals.
Installation and mounting of the park brake caliper
requires tightening of the mounting bolts to a specific 10. Remove the O-rings.
torque figure. Do not attempt to do this job unless you 11. Remove the rotor seal and then the bearing ring.
have the correct tools available.
12. Note that the rotor seal may be located on the
Disassembly rotor shaft or may have been left in the calliper
housing.
1. Remove the caliper and the brake pads. Refer to
remove and install (PIL 24-18-18). 13. It is not necessary to replace the shaft seal
unless it is excessively worn or damaged.
2. Hold the lever against the tension of the spring.
13.1. If removal is necessary, use a suitable
3. Remove the screw and both the washer 1, spacer block and a bench press to push
washer 2. the seal out from inside the housing.
4. Note the position of the lever with respect to the 13.2. Clean out any remains of the seal after
splines of the rotor shaft. removal.
5. Mark the end of the shaft and lever to assist in Before assembly make sure all parts are clean
assembly. and serviceable. Refer to park brake caliper-check
condition (PIL 24-18-18).
6. Remove the lever and the spring.
24 - 112 9813/7600-3 24 - 112

24 - Brake System
18 - Park Brake
18 - Caliper
Figure 639.
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 252. 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 640.
Q Bearing ring
R Housing
S Shaft seal
Assembly
Before assembly make sure all parts are clean and
serviceable.
24 - 113 9813/7600-3 24 - 113

24 - Brake System
18 - Park Brake
18 - Caliper
Figure 640.
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 640.
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.
Table 253. Torque table

Item Torque value
Screw 13–16N·m
24 - 114 9813/7600-3 24 - 114

24 - Brake System
18 - Park Brake
21 - Disc
21 - Disc Introduction
Introduction .................................................. 24-115 A disc brake is a wheel brake that slows the rotation
Check (Condition) ........................................ 24-116 of the wheel by the friction caused by pushing brake
Remove and Install ..................................... 24-117 pads against a brake disc with a set of calipers.
24 - 115 9813/7600-3 24 - 115

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 - 116 9813/7600-3 24 - 116

24 - Brake System
18 - Park Brake
21 - Disc
Remove and Install
7. Do not use a steel hammer, damage can occur

(For: PS750 MK4) to the output shaft bearing.
Special Tools 8. If necessary remove the oil seal. Do not damage

Description Part No. Qty. the seal housing.
Flange Spanner 992/04800 1
Install
Remove 1. Make sure that the oil seal interface on the brake
disc is clean and free from wear or damage.
1. If installed remove the park brake caliper.
2. If necessary install a new oil seal. Lubricate the
2. Bend back the stake nut locking ring.
lips of the seal.
3. Clean the brake disc and the gearbox around the
3. Install the brake disc onto the output shaft.
brake disc. Make sure no contamination enters
the gearbox when the brake disc is removed. 4. Install the washer.
4. Hold the brake disc with the service tool and 5. Hold the brake disc with the service tool.
remove the output shaft stake nut. Discard the
stake nut. 6. Install a new stake nut.
Special Tool: Flange Spanner (Qty.: 1) 7. Progressively tighten the nut to the correct torque
5. Remove the washer. value.
6. Lift off the brake disc. If necessary use a soft 8. Stake the nut to the shaft with a square ended
faced mallet to remove the brake disc. staking tool.
24 - 117 9813/7600-3 24 - 117

24 - Brake System
18 - Park Brake
21 - Disc
Figure 641.
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 - 118 9813/7600-3 24 - 118

24 - Brake System
18 - Park Brake
21 - Disc
A separate disassembly procedure is given for each

(For: PS764, PS766) sub-assembly.
The internal park brake consists of a wet multi plate

friction pack and a mechanical actuator assembly.
24 - 119 9813/7600-3 24 - 119

24 - Brake System
18 - Park Brake
21 - Disc
Disassemble the multi-plate brake pack
Figure 642.
D
E
X
A
A Bolt B Screw (x5)

E Needle roller thrust bearing F Reaction pins
J Counter plate X Location 1 and Location 2 for bolt removal
24 - 120 9813/7600-3 24 - 120

24 - Brake System
18 - Park Brake
21 - Disc
1. From inside the cab, disengage the park brake 4. From underneath the machine, remove the two
(lever horizontal). Rotate the park brake lever to bolts and five screws that attach the cover plate.
fully slacken the cable.
5. Before the cover plate is removed, place a
2. Remove the rear propshaft. container below to collect the gearbox oil.
3. Position the output yoke. Refer to Figure 643. 6. Use a flat bladed screwdriver at the cover cutout
to remove the cover plate.
Figure 643.
7. Remove the remaining four bolts and carefully
remove the cover but make sure you keep it
square to the mating face on the gearbox. The
park brake cable is still attached at this stage.
8. If the cover does not come free then one or more
reaction pins will have remained in the cover.
9. Use a pair of long nosed pliers to push the pins
back into the gearbox case. Make sure that the
surface of the pin is not damaged.
10. Remove the needle roller thrust bearing, thrust
plate, friction plates and the counter plates.
11. If the brake actuator is to be disassembled, or the
K cable to be replaced then do the following steps.
K Output yoke (Shown in position required)
11.1. Remove the park brake cable.
Figure 644.
L Brake cable M Circlip

N Clevis screw pin
11.2. Remove the clevis screw pin. 11.3. Remove the cable from the housing.
24 - 121 9813/7600-3 24 - 121

24 - Brake System
18 - Park Brake
21 - Disc
Disassemble the brake actuator Inspection

Refer to park brake actuator (PIL 24-18-48). Refer to (PIL 24-18-00).
For inspection refer to park brake, check(condition) Assemble the brake actuator
(PIL 24-18-00).
Refer to park brake actuator (PIL 24-18-48).
Assemble the multi-plate brake pack
Figure 645.
G
D
E
A X
C
Z
24 - 122 9813/7600-3 24 - 122

24 - Brake System
18 - Park Brake
21 - Disc
A Bolts B Screws (x5)

E Needle roller thrust bearing F Reaction pins
J Counter plate X Location 1 and Location 2 for bolt installation
Y Sealant location on gearbox case Z Sealant location on cover
1. From underneath the machine, assemble the 2.1. Feed the cable into the housing and
reaction pins followed by the friction pack into the connect the fork end to the brake actuator
gearbox case. with the screw. Tighten to the correct torque.
1.1. Note that a counter plate is installed first, 2.2. The screw is a special clevis pin. Make sure
then a friction plate and so on. Install the that only the special screw clevis pin used.
thrust plate at last. Make sure that a normal bolt or screw is not
used.
2. If the park brake cable is removed then install the
park brake cable.
Figure 646.
L R
L Brake cable M Circlip

N Clevis screw pin P Brake actuator
Q O-ring R Collar
2.3. Make sure that the O-ring is not damaged 4. Before you install the cover, apply bead of JCB
and correctly installed on the collar. Locate Multigasket sealant to the mating face on the
the collar inside the brake housing and keep gearbox case.
with circlip.
5. Install the cover and four bolts. Tighten the bolts
3. Make sure that the needle roller thrust bearing is to the correct torque value.
correctly located on the brake actuator assembly,
if necessary apply grease to keep the bearing. 5.1. Do not install the two cover plate bolts at
this stage.
24 - 123 9813/7600-3 24 - 123

24 - Brake System
18 - Park Brake
21 - Disc
5.2. Carefully feed the park brake cable up into

the cab, through the opening in the cab
floor.
6. From inside the cab, connect the park brake
cable to the park brake lever and adjust the lever.
7. From under the machine, view the brake friction
pack through the housing aperture. Check the
operation. Play in the paltes will be easily felt
when the brake is off
8. Before you install the cover plate, apply a bead
of JCB Multigasket sealant to the mating face on
the cover.
8.1. Install all the five screws and remaining two
bolts.
8.2. Tighten the screws and bolts to the correct
toque value.
9. If any brake components have been replaced it
must be assumed that the gearbox oil will be
contaminated. Change the gearbox oil and filter.
Refer to clean, (PIL 27-06-00).
A small quantity of gearbox oil will be transferred from

the sump to fill the brake cavity when the engine is
started. Check the gearbox oil level and top up if
necessary. Refer to the operators manual.

Item Nm
A 56
B 16
N 9
24 - 124 9813/7600-3 24 - 124

24 - Brake System
18 - Park Brake
48 - Actuator
48 - Actuator Check (Condition)

Check (Condition) ........................................ 24-125
(For: PS764, PS766)
Before you check the brake components use a
suitable degreaser to clean the brake components.
Check the following components for signs of

excessive wear or damage:
• Ball bearings and their tapered locating slots.

• Needle roller thrust bearing and the
corresponding bearing surfaces.
Note: Some discolouration of the needle rollers is

acceptable providing the surface of the rollers is
otherwise undamaged.
Figure 647.
4
1 Tapered locating slots
2 Ball bearings
3 Tapered locating slots
4 Needle roller thrust bearing
• Make sure that the park brake cable is smooth
and free in operation. Check the cable outer
for signs of damage. Replace the cable if it is
damaged or hard to operate.
24 - 125 9813/7600-3 24 - 125

24 - Brake System
18 - Park Brake
48 - Actuator
2. Remove the washer 1 and washer 2.

(For: PS764, PS766) 3. Remove the spring 1 and spring 2.
Disassembly 4. Remove the brake actuator plate then the ball
bearings.
1. Carefully remove the screw.
1.1. Be careful the screw is under tension from
spring 1 and spring 2.
Figure 648.
Item Description
Table 256. E Washer 2
Item Description F Actuator plate
A Screw G Ball bearings (x5)
B Spring 1 H Brake actuator cover
C Spring 2
D Washer 1
24 - 126 9813/7600-3 24 - 126

24 - Brake System
18 - Park Brake
48 - Actuator
Assembly
1. Locate the ball bearings in their slots in the cover.
2. Install the actuator plate then the springs.
3. Install the washers.
4. Compress the springs and install the screw.
4.1. Tighten the screw to the correct torque
value.

Item Description Nm
A Screw 16
24 - 127 9813/7600-3 24 - 127

24 - Brake System
36 - Trailer Brake
36 - Trailer Brake
Contents Page No.
24-36-00 General ......................................................................................................................... 24-129
24 - 128 9813/7600-3 24 - 128

24 - Brake System
36 - Trailer Brake
00 - General
00 - General
Operation

The TBV (Trailer Brake Valve) is mounted in
the chassis. It provides a proportional braking
pressure to a trailer brake circuit connected to the
ISO (International Organization for Standardization)
connector on the rear of the machine.
The TBV is supplied with oil from the charge

priority valve. When the service brake is applied,
a pilot signal to the TBV operates it and delivers
a maximum pressure up to the specified value at
the ISO coupling. The specified pressure is 150bar
(2,173.9psi)
Releasing the service brake releases the trailer

brake.
24 - 129 9813/7600-3 24 - 129

Notes:
24 - 130 9813/7600-3 24 - 130

Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-00-03 Manual Steer Mode System .......................................................................................... 25-24
25-00-06 Auto Steer Mode System ............................................................................................... 25-38
25-01 Pump
25-01-00 General ........................................................................................................................... 25-51
25-03 Priority Valve
25-03-00 General ........................................................................................................................... 25-53
25-06 Steer Unit/Valve
25-06-00 General ........................................................................................................................... 25-61
25-09 Mode Valve
25-09-03 Manual Mode Valve ....................................................................................................... 25-71
25-09-06 Auto Mode Valve ............................................................................................................ 25-79
25-12 Column
25-12-00 General ........................................................................................................................... 25-83
25-15 Proximity Switch
25-15-00 General ........................................................................................................................... 25-87
25-18 Front Track Rod
25-18-00 General ........................................................................................................................... 25-93
25-33 Link Arm
25-33-00 General ......................................................................................................................... 25-111
9813/7600-3
2017-10-02
Acronyms Glossary
2WS Two Wheel Steer

4WS Four Wheel Steer
LS Load Sense
9813/7600-3
2017-10-02
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3

25-00-03 Manual Steer Mode System .......................................................................................... 25-24
25-00-06 Auto Steer Mode System ............................................................................................... 25-38
25 - 1 9813/7600-3 25 - 1
Notes:
25 - 2 9813/7600-3 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.
Component Identification ................................. 25-5
Operation ....................................................... 25-11 Manual Steer Mode System
Diagram ......................................................... 25-13 In a manual steer system, there are three steering
Fault-Finding .................................................. 25-16 modes available:
Check (Leaks) ............................................... 25-19
Check (Pressure) .......................................... 25-20 1. 2WS (Two Wheel Steer) (front axle only)- only
the front wheels are steered.
Adjust ............................................................ 25-21
Bleed ............................................................. 25-22 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 9813/7600-3 25 - 3
00 - General

Engine/Steering Failure For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
If the engine or steering fails, stop the machine as [5AC], 536-60 [5TC], 536-70 [5AE],
quickly as possible. Do not operate the machine until 536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
the fault has been corrected. ..................................................... Page 25-4
Working Under the Machine For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................... Page 25-4
correctly attached. Engage the park brake, remove (For: 526-56 [T4F], 531-70 [5AA], 531-70
the ignition key, disconnect the battery. If the machine [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
has wheels use blocks to prevent unintentional [5AC], 536-60 [5TC], 536-70 [5AE], 536-70
movement. [5TE], 541-70 [5AD], 541-70 [5TD])
Fluid Under Pressure
Table 258.
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under Model Rexroth Bosch Eaton 160cc
pressure and wear personal protective equipment. LAGC 160
Hold a piece of cardboard close to suspected Volumetric 160 cc/rev 160 cc/rev
leaks and then examine the cardboard for signs of displacement
fluid. If fluid penetrates your skin, get medical help gerotor 1:
immediately. Volumetric - -
Hydraulic Pressure displacement
gerotor 2:
Relief Valve Op- 195–200bar 175bar
Before connecting or removing any hydraulic hose,
erating Pres- (2,826.1– (2,536.2psi)
sure (at 1500 2,898.5psi)
RPM (Rev-
service line has been vented before connecting or
olutions Per
removing hoses. Make sure the engine cannot be
Minute))
started while the hoses are open.
Shock valve op- 250bar 235bar
WARNING! When getting access for maintenance erating pres- (3,623.2psi) (3,405.8psi)
work, make sure no-one is in a position to be caught sure- if installed
and/or crushed by the wheels when the steering
wheel is turned.
(For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY])
Table 259.
Model Eaton SXB
Volumetric displacement 125 cc/rev
gerotor 1:
Volumetric displacement 285 cc/rev
gerotor 2:
Relief valve operating 175–182bar (2,536.2–
pressure (at 1500 RPM) 2,637.7psi)
Shock valve operating 235–242bar (3,405.8–
pressure- if installed 3,507.2psi)
25 - 4 9813/7600-3 25 - 4
00 - General

..................................................... Page 25-5
For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW], 550-80
[5UW] .......................................... Page 25-7
For: 526-56 [T4F] ........................ Page 25-9
Figure 649. Dual Tech Variable Transmission- Steering System

A
B C
F
D E
H J
G
K L
N
S P
333/D7602-4
Q
A Steer valve B Port T

C Port L D Port P
E Port R F Port LS
G Steer mode valve H Port R2
J Port F2 K Port R1
L Port F1 M From DLS port on control valve port
N From D port on control valve port P Front steering ram
Q Yellow line R Return to tank
S Rear steering ram
25 - 5 9813/7600-3 25 - 5
00 - General
Figure 650. Auto Steer Mode Figure 651. Auto Steer Mode System- Sensors
System- Auto Steer Valve
A
A A C
B
A
A Rear steer sensor
B Front steer sensor
C Front axle
A Auto steer valve D Rear axle
B Steer mode switch
25 - 6 9813/7600-3 25 - 6
00 - General
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80
[5UW])
Manual Steer Mode System
Figure 652.
B
A
A Steer mode selection lever B Steer mode selection unit

C Steer mode unit cable D Steer mode valve
25 - 7 9813/7600-3 25 - 7
00 - General
Figure 653.
A Steer mode switch B Front steer proximity switch

C Rear steer proximity switch
Figure 654. Auto Steer Mode Valve
C B
D A
1
25 - 8 9813/7600-3 25 - 8
00 - General
1 Located under the LH centre of the chassis
(For: 526-56 [T4F])
Figure 655.
B
A
A Steer mode selection lever B Steer mode selection unit

C Steer mode unit cable D Steer mode valve
25 - 9 9813/7600-3 25 - 9
00 - General

Figure 656.
A Steer mode switch

B Rear steer proximity switch
C Front steer proximity switch
Figure 657. Auto Steer Mode Valve
B A
C D
2 Located under the LH centre of the chassis
25 - 10 9813/7600-3 25 - 10
00 - General
Operation
When the you turn the steering wheel, a pressure

(For: 526-56 [T4F], 531-70 [5AA], 531-70 signal (demand) is generated in the load sense line
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 from the steer unit to the priority valve. The priority
valve then directs oil from the hydraulic pump to the
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 steer unit, which in turn directs the flow to the steer
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 rams on the axles.
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY]) When the steering lock is achieved, the pressure
signal in the load sense line ceases. The priority
The main components of the steering system are the valve then directs the oil from the hydraulic pump
priority valve (PIL 25-03) , the load sensing steer into the main hydraulic system for operation of the
unit (PIL 25-06), the steer mode control valve (PIL hydraulic services.
25-09) (if installed) and the double acting steer rams
or power track rods as applicable (PIL 25-18 and or The maximum steering system pressure is set by a
19). relief valve housed inside the steer unit.
Figure 658. Machine with Power Track Rods
A,B
D
E
C
25 - 11 9813/7600-3 25 - 11
00 - General
Figure 659. Machine with Steer Rams
F
D
A, B
F
C
Table 260.
Item Description
A Hydraulic pump
B Priority valve
C Steer unit
D Control valve
E Power track rods
F Steer rams
25 - 12 9813/7600-3 25 - 12
00 - General
Diagram Figure 660.

C
(For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY])
Gear Pump Machines D E
These diagrams are for illustration purposes, a

typical hydraulic circuit is shown. For specific details
of the circuit refer to the applicable hydraulic
schematic, refer to hydraulic system, general,
schematic circuit, (PIL 30-00-50).
Machines with Steer Rams

The diagram shows the complete steer circuit. There
are different steer modes. Refer to steering system-
steer mode system, refer to (PIL 25-00). B
B1 B2
A1
A Hydraulic pump
A1 Priority valve
B Steer unit
B1 Relief valve
B2 Non-return valve
C Steer mode control valve
D Steer rams- front axle
E Steer rams- rear axle
T Hydraulic tank
Machines with Power Track Rods

steer mode system, refer to (PIL 25-00).
25 - 13 9813/7600-3 25 - 13
00 - General
Figure 661. Variflow Machines

C
steer mode system, refer to (PIL 25-00).
D E A dual gerotor unit is fitted to the steer unit of 550-80

machines.
B2
B
B1
A1
A
A Hydraulic pump
A1 Priority valve
B Steer unit
B1 Steering system relief valve
B2 Shock valves
C Steer mode control valve
D Power track rod- front axle
E Power track rod- rear axle
F Hydraulic tank
X Steering pressure test point
25 - 14 9813/7600-3 25 - 14
00 - General
Figure 662.
E F
C2
C
C1
M LS D
DLS
0.8
B
8 BAR
B1
X
X1
T
LIFT
A Hydraulic pump
B Control valve block- priority inlet section
B1 Priority valve
C Steer unit
C1 Steering system relief valve
C2 Shock valves
D Steer mode control valve
E Power track rod- front axle
F Power track rod- rear axle
G Hydraulic tank
X Pump output pressure test point
X1 Load sense pressure test point
25 - 15 9813/7600-3 25 - 15
00 - General
Fault-Finding
Fault
Steering wheel difficult to turn Table 261. Page 25-16
Steering wheel turns on its own. Table 262. Page 25-16
Machine will not turn when the steering wheel turned. Table 263. Page 25-16
Steering 'drifts' out of phase during operation. Table 264. Page 25-17
Steering fails to respond to selected mode (solenoid operated mode valve Table 265. Page 25-17
only).
Table 261. 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 262. 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 263. 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 - 16 9813/7600-3 25 - 16
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 264. 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 265. 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 - 17 9813/7600-3 25 - 17
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 - 18 9813/7600-3 25 - 18
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 663.
B C
B
A Hydraulic hoses
B Isolating ball valve
C Track rod
25 - 19 9813/7600-3 25 - 19
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: 5.9–8.7bar (85.5–126.1psi)
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.
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 664. 1)
G H Figure 665.
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 - 20 9813/7600-3 25 - 20
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 666.
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 667.
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 - 21 9813/7600-3 25 - 21
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 - 22 9813/7600-3 25 - 22
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 - 23 9813/7600-3 25 - 23
03 - Manual Steer Mode System
Operation
For: 531-70 [5AA], 531-70 [5TA], 535-95 Figure 668. Right turn shown
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY] A
................................................... Page 25-24
For: 526-56 [T4F] ...................... Page 25-30
(For: 531-70 [5AA], 531-70 [5TA], 535-95 L R

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY])
Manual Steer Mode System P

B
Machines with power track rods E
T
2-wheel steer selected
D
With the spool of the steer mode control valve in the V
2-wheel steer position there is a hydraulic connection
between the steer unit and the front power track
rod. Steer mode control valve ports are internally
connected. The oil feed to the rear axle power track
rod is blocked by the spool assembly and the axle is
held in the straight ahead position by the locked-up
hydraulic oil in the track rod ram.
When the steering wheel is turned, the steering

system only operates the front power track rod.
If the steering wheel is turned to the left, the oil flow

is reversed and the machine will turn in the opposite C
direction.
Table 266.
Item Description
A Front power track rod
B Steer unit
C Rear axle power track rod
D Steer mode control valve port
E Steer mode control valve port
L Left side
P Steer mode control valve port
R Right side
T Steer mode control valve port
V Steer mode control valve
(T and P) (Steer mode valve ports connected internally for 2
wheel steer)
25 - 24 9813/7600-3 25 - 24
4-wheel steer selected Figure 669. Right turn shown
With the spool of the steer mode valve in the 4-

wheel steer position there is a hydraulic connection A
between the steer unit and the front and rear axle
power track rods. Steer mode control valve ports
are internally connected. When the steering wheel is
turned to the right, oil is fed to the rear power track rod
and the displaced oil is fed to the front power track L R
rod through the valve spool. The front power track
rod turns the wheels in the opposite direction to the
rear wheels and displaced oil returns to tank.

is reversed and the machine will turn in the opposite
direction. P
E
B
D T
Table 267.
Item Description
B Steer unit
L Left side
R Right side
(T and B / A and P) (Steer mode valve ports connected internally for 4
wheel steer)
Crab steer selected axle power track rods. Steer mode valve ports are
internally connected. When the steering wheel is
With the spool of the steer mode valve in the turned to the right, oil is fed to the rear power track
crab steer position there is a hydraulic connection rod and the displaced oil is fed to the front power
between the steer unit and the front and rear
25 - 25 9813/7600-3 25 - 25
track rod through the valve spool. The front power Figure 670. Right turn shown
track rod turns the wheels in the same direction as
the rear wheels, causing the machine to crab to the
right. Displaced oil returns to tank. A

is reversed and the machine will crab in the opposite
direction.
L R
P
B
E
D V T
Table 268.
Item Description
B Steer unit
L Left side
R Right side
(T and A / B and P) (Steer mode valve ports connected internally for crab
steer)
25 - 26 9813/7600-3 25 - 26
Machines with steer rams Figure 671.
With the spool of the steer mode control valve in the

between the steer unit and the front steer rams. Steer
mode control valve ports are internally connected.
The oil feed to the rear axle steer rams is blocked by
the spool assembly and the axle is held in the straight L R
ahead position by the locked-up hydraulic oil in the F G
rams.
When the steering wheel is turned, only the front axle

rams are operated by the steering unit.
If the steering wheel is turned to the left, the oil flow P

direction. B
E
D T
H J
Table 269.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
wheel steer)
25 - 27 9813/7600-3 25 - 27
4-wheel steer selected Figure 672.

wheel steer position there is a hydraulic connection
steer rams. Steer mode control valve ports are
turned to the right, oil is fed to the rear rams and
the displaced oil is fed to the front rams through the
spool assembly. The front rams turn the wheels in the L
opposite direction to the rear wheels and displaced F R
G
oil returns to tank.

direction. P
E T
B
D
H J
Table 270.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
wheel steer)
25 - 28 9813/7600-3 25 - 28
Crab steer selected Figure 673.
With the spool of the steer mode valve in the

crab steer position there is a hydraulic connection
steer rams. Steer mode valve ports are internally
connected. When the steering wheel is turned to the
right, oil is fed to the rear rams through the spool
assembly. The front rams turn the wheels in the same
direction as the rear wheels, causing the machine to L R
crab to the right. Displaced oil returns to tank. F G

direction.
P
B
E
T
D
V
H J
Table 271.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
steer)
25 - 29 9813/7600-3 25 - 29
(For: 526-56 [T4F]) Figure 674. Right turn shown

A
Machines with power track rods
With the spool of the steer mode control valve in the L R

between the steer unit and the front power track
rod. Steer mode control valve ports are internally
connected. The oil feed to the rear axle power track
rod is blocked by the spool assembly and the axle is
held in the straight ahead position by the locked-up
hydraulic oil in the track rod ram.
P
When the steering wheel is turned, the steering B
system only operates the front power track rod. E
T
is reversed and the machine will turn in the opposite D
direction.
V
Table 272.
Item Description
B Steer unit
L Left side
R Right side
wheel steer)
4-wheel steer selected power track rods. Steer mode control valve ports
are internally connected. When the steering wheel is
With the spool of the steer mode valve in the 4- turned to the right, oil is fed to the rear power track rod
wheel steer position there is a hydraulic connection and the displaced oil is fed to the front power track
between the steer unit and the front and rear axle rod through the valve spool. The front power track
25 - 30 9813/7600-3 25 - 30
rod turns the wheels in the opposite direction to the Figure 675. Right turn shown
If the steering wheel is turned to the left, the oil flow A

direction.
L R
E
B
D T
Table 273.
Item Description
B Steer unit
L Left side
R Right side
wheel steer)
Crab steer selected axle power track rods. Steer mode valve ports are
With the spool of the steer mode valve in the turned to the right, oil is fed to the rear power track
crab steer position there is a hydraulic connection rod and the displaced oil is fed to the front power
between the steer unit and the front and rear
25 - 31 9813/7600-3 25 - 31
track rod through the valve spool. The front power Figure 676. Right turn shown
track rod turns the wheels in the same direction as
the rear wheels, causing the machine to crab to the
right. Displaced oil returns to tank. A

direction.
L R
P
B
E
D V T
Table 274.
Item Description
B Steer unit
L Left side
R Right side
steer)
25 - 32 9813/7600-3 25 - 32
Machines with steer rams Figure 677.
With the spool of the steer mode control valve in the

between the steer unit and the front steer rams. Steer
mode control valve ports are internally connected.
The oil feed to the rear axle steer rams is blocked by
the spool assembly and the axle is held in the straight L R
ahead position by the locked-up hydraulic oil in the F G
rams.

rams are operated by the steering unit.
If the steering wheel is turned to the left, the oil flow P

direction. B
E
D T
H J
Table 275.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
wheel steer)
25 - 33 9813/7600-3 25 - 33
4-wheel steer selected Figure 678.

wheel steer position there is a hydraulic connection
steer rams. Steer mode control valve ports are
turned to the right, oil is fed to the rear rams and
the displaced oil is fed to the front rams through the
spool assembly. The front rams turn the wheels in the L
opposite direction to the rear wheels and displaced F R
G
oil returns to tank.

direction. P
E T
B
D
H J
Table 276.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
wheel steer)
25 - 34 9813/7600-3 25 - 34
Crab steer selected Figure 679.
With the spool of the steer mode valve in the

crab steer position there is a hydraulic connection
steer rams. Steer mode valve ports are internally
connected. When the steering wheel is turned to the
right, oil is fed to the rear rams through the spool
assembly. The front rams turn the wheels in the same
direction as the rear wheels, causing the machine to L R
crab to the right. Displaced oil returns to tank. F G

direction.
P
B
E
T
D
V
H J
Table 277.
Item Description
B Steer unit
F Front steer ram
G Front steer ram
H Rear steer ram
J Rear steer ram
L Left side
R Right side
steer)
25 - 35 9813/7600-3 25 - 35
Electrical operation and schematics- If the indicator lights do not work correctly re-phase
Indicated system (if installed) the road wheels before fault finding the electrical
system.
526-56 machines have front wheels straight ahead
indicator lights and rear wheels straight ahead When the front and rear wheels are in the straight
indicator lights. When both the lights are on the front ahead position the axle proximity switches, connect
and rear wheels are in the straight ahead position. power to the indicator lights.
The wheels must be set to the straight ahead position When the transmission is set to neutral the ECU
before you change the steer mode. (Electronic Control Unit) energises relay. The relay
connects the forward and rear lights earth and the
lights come on.
Figure 680.
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
Table 278.
Item Description
A Front axle proximity switch
B Rear axle proximity switch
C Wheel align indicator light relay
25 - 36 9813/7600-3 25 - 36
Item Description
D Drive control ECU
(1)
E Indicator light unit

F Indicator light- front wheels straight ahead
G Fuse box
H Indicator light- rear wheels straight ahead
(1) Refer to (PIL 33-45).
25 - 37 9813/7600-3 25 - 37
06 - Auto Steer Mode System
Operation
When the steering wheel is turned, the steering unit

(For: 526-56 [T4F], 531-70 [5AA], 531-70 operates only the front power track rod.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 If the steering wheel is turned to the left, the oil flow
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 is reversed and the machine will turn in the opposite
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 direction.
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY]) Figure 681.

There are 3 steering modes available: F
• 2WS (Two Wheel Steer) (front axle only)

• 4WS (Four Wheel Steer)
• Crab steer
In the 2WS mode, only the front wheels are steered. L R

In 4WS mode, both the axles are steered, giving a
smaller turning circle. The crab steer mode allows the
machine to be driven diagonally.
E.C.U.
The system is prevented from changing mode until
all the wheels are in the straight ahead position. This
is detected by proximity sensors on the front and
rear axles. If the system is set in 4WS and 2WS
is selected, the system will stay in 4WS until the
rear wheels are turned to the straight ahead position. S
The rear wheels are then hydraulically locked in the
straight ahead position. V
The operation of the steer mode switch, solenoids

and proximity switches is controlled by the hydraulic
control ECU (Electronic Control Unit) and the T
transmission control ECU. Refer to steering system- A
Hydraulic Operation and Schematics
Machines with power track rods

Operation- 2-wheel steer selected
The illustrations shown are for the purpose of circuit

explanation only. Actual installations may not be as B
shown.
With the spools of steer mode control valve in

the 2WS position (solenoid energised), there is a A Solenoid Energised
hydraulic connection between the steer unit and the B Rear power track rod
front power track rod. The oil feed to the rear axle F Front power track rod
power track rod is blocked by the spool assembly and L Left
the axle is held in the straight ahead position by the R Right
locked-up hydraulic oil in the track rod ram. S Steer unit
V Control valve
25 - 38 9813/7600-3 25 - 38
Operation- 4-wheel steer selected Figure 682.

explanation only. Actual installations may not be as
shown. F
With the spools of steer mode valve in the 4WS

position (solenoid 1 and solenoid 2 energised), there
is a hydraulic connection between the steer unit and
the front and rear axle power track rods. When the
steering wheel is turned (right turn shown), oil is fed L R
to the rear power track rod and the displaced oil is fed
to the front power track rod via the valve spools. The
front power track rod turns the wheels in the opposite
direction to the rear wheels and displaced oil returns E.C.U.
to tank.

direction.
S
C
D T
B Rear track rod

C Solenoid 1
D Solenoid 2
F Front track rod
L Left
R Right
S Steer unit
T Tank
V Steer mode valve
Operation- Crab Steer Selected

shown.
With the spools of steer mode valve in the crab

steer position (solenoid 1 and solenoid 2 energised),
there is a hydraulic connection between the steer unit
and the front and rear power track rods. When the
steering wheel is turned (right turn shown), oil is fed
to the rear power track rod and the displaced oil is fed
25 - 39 9813/7600-3 25 - 39
to the front power track rod via the valve spools. The R Right
front power track rod turns the wheels in the same S Steer unit
direction as the rear wheels, causing the machine to V Steer mode valve
crab to the right. Displaced oil returns to tank.
Schematics
is reversed and the machine will crab in the opposite The steer mode valve spools have mechanical
direction. detents. Loss of electrical power to the valve solenoid
coils will not cause the system to change steer mode
Figure 683. suddenly.
L R
E.C.U.
C
D
B Rear track rod

C Solenoid 1
D Solenoid 2
F Front track rod
L Left
25 - 40 9813/7600-3 25 - 40
2- wheel steer
Figure 684.
R2 C B F2
F1
R1 D A
S
R2 F2
R L
B A FR
R1 F1
D C
R Oil flow direction- right

turn
Table 279. 2- wheel steer
L Oil flow direction- left
Steer Mode 2WS turn
Ports internally connect- F2 - F1 V Steer mode valve
(1)
ed FR Front axle
Ports internally blocked R1 - R2
(1) Refer to component location for variation of valve
Solenoids energised A orientation.
Key
S Steer unit
25 - 41 9813/7600-3 25 - 41
4- wheel steer
Figure 685.
R2 F2
C B
D A F1
R1
V
S
R2 F2
R L
B A FR
R1 F1
D C
S Steer unit
Table 280. 4- wheel steer
turn
Steer Mode 4WS L Oil flow direction- left
Ports internally connect- F1 - R2 turn
ed F2 - R1 V Steer mode valve
(1)
Ports internally blocked - FR Front axle

Solenoids energised B, D (1) Refer to component location for variation of valve
Key orientation.
25 - 42 9813/7600-3 25 - 42
Crab steer
Figure 686.
R2 F2
C B
D A F1
R1
V
S
R2 F2
R L
B A FR
R1 F1
D C
Machines With Steer Rams

Table 281. crab steer
Steer Mode Crab Steer
Ports internally connect- F1 - R1 The illustrations shown are for the purpose of circuit
ed explanation only. Actual installations may not be as
F2 - R2
shown.
Ports internally blocked -
Solenoids energised B, C With the spools of the steer mode control valve in
Key the 2WS position, there is a hydraulic connection
between the steer unit and the front steer ram 1 and
S Steer unit
front steer ram 2. The oil feed to the rear axle steer
R Oil flow direction- right ram 1 and the rear axle steer ram 2 is blocked by the
turn spool assembly and the axle is held in the straight
L Oil flow direction- left ahead position by the locked-up hydraulic oil in the
turn rams.
V Steer mode valve
(1)

FR Front axle rams (or front power track rod) are operated by the
(1) Refer to component location for variation of valve steering unit.
orientation.
25 - 43 9813/7600-3 25 - 43
If the steering wheel is turned to the left, the oil flow With the spools of the steer mode valve in the 4WS
is reversed and the machine will turn in the opposite position, there is a hydraulic connection between the
direction. steer unit and the front and rear axle steer rams.
When the steering wheel is turned (right turn shown),
Figure 687. oil is fed to the rear rams and the displaced oil is fed
to the front rams via the spool assembly. The front
rams turn the wheels in the opposite direction to the

direction.
Figure 688.
L R
F1 F2
S
R
V L
F1 F2
H
S
V
T
F3 F4
F1 Front steer ram 1

F3 Rear steer ram 1
F4 Rear steer ram 2
L Left
R Right
S Steering unit
T Tank
F3 F4
The illustrations shown are for the purpose of circuit F3 Rear steer ram 1
explanation only. Actual installations may not be as F4 Rear steer ram 2
shown. L Left
R Right
25 - 44 9813/7600-3 25 - 44
S Steer unit Figure 689.

T Tank
V Steer mode valve
Operation- Crab Steer Selected

shown.
With the spools of steer mode valve in the crab steer R

position there is a hydraulic connection between the F1 L F2
steer unit and the front and rear axle steer rams.
When the steering wheel is turned (right turn shown),
oil is fed to the rear rams and the displaced oil is fed
to the front rams via the spool assembly. The front
rams turn the wheels in the same direction as the
rear wheels, causing the machine to crab to the right.
Displaced oil returns to tank.
If the steering wheel is turned to the left, the oil flow S

direction. V
F3 F4
F3 Rear steer ram 1
F4 Rear steer ram 2
L left
R Right
S Steering unit
T Tank
V Steer mode valve
Schematics
The steer mode valve spools have mechanical
detents. Loss of electrical power to the valve solenoid
coils will not cause the system to change steer
mode suddenly. Faulty electrical connections to the
solenoid coils (energising the coil) could cause the
steer mode to change suddenly with no operator
input.
25 - 45 9813/7600-3 25 - 45
2- wheel steer
Figure 690.
F1 R1
A D
B C
F2 R2
C
F1 D
R1
A
FR B
S
F2 R2
R L
S Steer unit
Table 282.
turn
Steer Mode 2WS L Oil flow direction- left
Ports internally connect- F2 - F1 turn
ed V Steer mode valve
Ports internally blocked R1, R2 FR Front axle
Solenoids energised A
Key
25 - 46 9813/7600-3 25 - 46
4- wheel steer
Figure 691.
F1 A D R1
F2 B C R2
C D
F1 R1
A B
FR
S
F2 R2
R L
Key
S Steer unit
Table 283.
Steer Mode 4WS turn
Ports internally connect- F1 - R2 L Oil flow direction- left
ed F2 - R1 turn
Ports internally blocked - V Steer mode valve
Solenoids energised B, D FR Front axle
25 - 47 9813/7600-3 25 - 47
Crab steer
Figure 692.
V
F1 R1
A D
B C R2
F2
C
F1 D
R1
A B
FR
S
F2 R2
R L
V Steer mode valve

Table 284. FR Front axle
Steer Mode Crab Steer
Ports internally connect- F1 - R1
ed F2 - R2
Ports internally blocked -
Solenoids energised B, C
Key
S Steer unit
turn
L Oil flow direction- left
turn
25 - 48 9813/7600-3 25 - 48
01 - Pump
01 - Pump
Contents Page No.
25-01-00 General ........................................................................................................................... 25-51
25 - 49 9813/7600-3 25 - 49
Notes:
25 - 50 9813/7600-3 25 - 50
01 - Pump
00 - General
00 - General
Introduction
Refer to gear pump, (PIL 30-11-00).
25 - 51 9813/7600-3 25 - 51
03 - Priority Valve
03 - Priority Valve
Contents Page No.
25-03-00 General ........................................................................................................................... 25-53
25 - 52 9813/7600-3 25 - 52
03 - Priority Valve
00 - General
00 - General Component Identification

Component Identification ............................... 25-53 For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
Operation ....................................................... 25-55 [5AC], 536-60 [5TC], 536-70 [5AE], 536-70
Clean ............................................................. 25-57 [5TE], 541-70 [5AD], 541-70 [5TD], 550-80
Remove and Install ....................................... 25-58 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80
[5UY] ......................................... Page 25-53
For: 526-56 [T4F] ...................... Page 25-54
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
Gear pump machines

The priority valve is mounted on the side of the gear
pump.
Figure 693.
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).
25 - 53 9813/7600-3 25 - 53
03 - Priority Valve
00 - General
Electro servo (Agri Xtra) machines (For: 526-56 [T4F])

Figure 694. Figure 696. 526-56
EF
G
PP
P
LS P EF
LS
A
A Control valve block priority inlet section G

Electro servo (Agri excluding Extra)
machines PP
The priority valve is an integral part of the control
valve block priority inlet section. Refer to (PIL 30-00).
Figure 695.
A Control valve block priority inlet section
25 - 54 9813/7600-3 25 - 54
03 - Priority Valve
00 - General
Operation
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
Neutral
The priority valve supplies hydraulic oil to the
steering circuit when it is necessary.
Figure 697. Gear pump type valve shown
LS P EF
LS
A
B
P EF
Item Description
LS Load sense line
Table 285.
EF Port
Item Description
A Pump outlet When the steering is not being operated, flow to the
B Orifice 1 steering circuit is dead ended by the closed centre
C Priority valve spool steering unit, and no pressure signal (demand) is
generated in the load sense line. Pressure from the
D Orifice 2 pump outlet is directed through the orifice 1 and
E Steering unit orifice 2, onto the end of the priority valve spool. This
P Pressure line creates a large pressure difference across the spool,
25 - 55 9813/7600-3 25 - 55
03 - Priority Valve
00 - General
causing it to move up against the force of the spring. Pressure is then applied to the spring end of
This allows the full pump flow to be directed through the priority valve spool. This reduces the pressure
port (EF) back to the tank or join with the main flow difference across the spool, causing it to move down
to the control valve. under spring force. This allows some of the pump
outlet flow to be directed through the pressure port
Turning to the steering unit, which in turn directs the flow to
the corresponding steer rams to turn the wheels.
When the steering wheel is turned, a pressure signal
is generated in the load sense line from the steering
unit.
Figure 698. Gear pump type valve shown
LS P EF
LS
A
B
P EF
When the steering reaches the required position,

the pressure signal in the load sense line from
Table 286. the steering unit ceases and restore the pressure
Item Description difference across the spool. The spool moves back
up and allow the pump full flow to be directed through
A Pump outlet
port (EF) back to the tank or joins with the main flow
B Orifice 1 to the control valve.
C Priority valve spool
D Orifice 2 The maximum steering system pressure is set by a
relief valve located inside the steering unit.
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.
25 - 56 9813/7600-3 25 - 56
03 - Priority Valve
00 - General
Clean 8. Install the priority valve spool and make sure that
the spring seat end of the spool faces towards
the LS port.
(For: 526-56 [T4F], 531-70 [5AA], 531-70 9. Install the blanking plug and tighten it to the
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 correct torque value.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 10. Reconnect the hose to the LS port, and bleed the
LS line as described below.
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY]) 10.1. Start the engine.
The priority valve spool and spring may be removed 10.2. Loosen the connection on the valve, then
for cleaning with the pump in the machine. turn and hold the steering wheel fully in
either direction.
1. Make the machine safe. Refer to (PIL 01-03). 10.3. When bubble free oil seeps from the joint,
tighten the connection.
2. Follow the general health and safety procedure.
Refer to (PIL 01-03). Table 287.
3. Discharge the hydraulic pressure. Refer to (PIL Item Description
30-00). B 100–105N·m
4. Turn the steering wheel to the left and to the right C 75–81N·m
several times to discharge system pressure.
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 699.
B D C
A Hose
B Adaptor
C Blanking plug
D Priority valve
25 - 57 9813/7600-3 25 - 57
03 - Priority Valve
00 - General
Remove and Install
2. Remove the plunger and the washer.

(For: 531-70 [5AA], 531-70 [5TA], 536-60 3. Remove the spring.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Agri- 4. Carefully remove the spool from the valve body.
Xtra) 5. Use an allen key to remove the screw 2 and then
Consumables remove the filter.
6. When you remove the retaining screw hold the
JCB High Strength 4102/0551 0.05L spool carefully to prevent damage.
Threadlocker
JCB Hydraulic Fluid HP 4002/1001 5L 7. Remove the spring, ball and the screw 1.
32 4002/1025 20L 8. When you remove O-rings and seals, use a
4002/1024 200L rounded tool so that will not cause any damage
to the seal grooves. Discard all O-rings and back-
Electro servo control valve- Steer up rings. Do not use worn or damaged items.
priority valve
Remove
1. Remove the end cap and discard the O-ring.
Figure 700.
B
D
E
G
H
K
C M
F
J
L
Item Description
Table 288.
G Screw 2
Item Description
H Spring
A Valve block
J Washer
B Screw 1
K Plunger
C Ball
L O-ring
D Spring
M End cap
E Spool
F Filter
25 - 58 9813/7600-3 25 - 58
03 - Priority Valve
00 - General
Install
1. Lubricate the parts with hydraulic fluid before you
assemble them.
Consumable: JCB Hydraulic Fluid HP 32
2. Apply sealant to the screws and tighten the
screw1 into the housing.
3. Install the ball and the spring into the housing.
4. Put the filter into the spool assembly.
5. Apply sealant to the screw 2 and tighten onto the
spool.
6. Put the spring, washer and plunger into the valve
block.
7. Replace the o-ring with new one.
8. Install the end cap into the valve housing.

Item Description Nm
B Screw 1 10
G Screw 2 10
M End cap 100
25 - 59 9813/7600-3 25 - 59
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ........................................................................................................................... 25-61
25 - 60 9813/7600-3 25 - 60
00 - General
Introduction .................................................... 25-61 The steer unit valve controls the amount of hydraulic
Component Identification ............................... 25-62 fluid flow in the steering system.
Operation ....................................................... 25-64
25 - 61 9813/7600-3 25 - 61
00 - General
For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................... Page 25-62
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] .................. Page 25-63
(For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD])
Figure 701.
D E
C C
A
B
G D
G K J F
J
F E
25 - 62 9813/7600-3 25 - 62
00 - General
Item Description
F Valve inlet
Table 290.
G Return line
Item Description
H Steer valve
A Hydraulic steer unit
J Load sense port
B Shock Valves (if in-
K Steering system relief
stalled)
valve
C Check valve
D Left feed/ return port
E Right feed/ return port
(For: 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY])
Figure 702.
L R
A B
C C
T D
E
L
LS
P F
R
J
K H
T LS P
A Shock valve B Shock valve

C Anti cavitation valves D Gerotor (power steering only)
E Logic valve F Gerotor (power and manual steering)
G Integral steer control valve H Inlet check valve
J Manual steer check valve K Steering system relief valve
L Left feed/ return port R Right feed/ return port
P Valve inlet port T Valve return port
LS Load sense port
25 - 63 9813/7600-3 25 - 63
00 - General
Operation
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY])
Refer to Steer/unit valve, general, diagram (PIL
25-06-00).
Integral valves and oil displacement gerotors are

installed in the hydraulic steering unit to control the
flow of oil to the axle mounted power track rods.
When the steering wheel is turned, the spool of the

control valve moves and allows oil pressure from the
machine hydraulic pump to flow to the gerotors. The
gerotors rotate as the steering wheel is turned and
oil is displaced to and from the power track rods.
When there is no hydraulic pressure from the

machine, the hydraulic pump (engine stopped) and
the spool of the logic valve moves due to the force
from its actuating spring. The valve isolates the
(power steering only) gerotor from the power track
rods.
When the steering is turned, only the smaller

displacement (power and manual steering) gerotor
displaces the oil to and from the power track rods.
Since the reduced displacement requires less torque
at the steering wheel, it is possible to operate the
steering when the engine is stopped.
25 - 64 9813/7600-3 25 - 64
00 - General
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 535-95 5. Make sure that the steering wheel is in the
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 straight ahead position.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD] .................. Page 25-65 6. Get access to the steer unit. Remove the front
For: 526-56 [T4F] ...................... Page 25-66 panel from the cab.
For: 550-80 [5AW], 550-80 [5UW], 560-80 Refer to: PIL 06-06-12.
[5AY], 560-80 [5UY] .................. Page 25-68
(For: 531-70 [5AA], 531-70 [5TA], 535-95 8. Disconnect the hydraulic hoses from the steering
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 unit.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD]) contamination.
Remove 10. Mark the orientation of steering unit to the splined

shaft.
11. Remove the bolts from inside the cab. At the
2. Follow all the general health and safety same time, get an assistant to support the
procedure. Refer to (PIL 01-03). steering unit from under the machine.
3. Discharge the hydraulic pressure. Refer to (PIL 12. Remove the steering unit.
30-00).
Figure 703.
C
B
B Steering unit C Bolts (x 4)

D Splined shaft
Install 1.2. Make sure that the hoses are connected in

the correct positions.
1.3. If the hydraulic adaptors are removed make
sure that they are tightened to the correct
steps.
torque value.
25 - 65 9813/7600-3 25 - 65
00 - General
Figure 704.
E Hydraulic adaptor 1 F Hydraulic adaptor 2
1.4. The steering unit is spring loaded to the (For: 526-56 [T4F])
neutral position. Make sure that the steering
wheel is in the straight ahead position when Remove
you connect the splined shaft.
1.5. Before you drive the machine, bleed the 1. Make the machine safe. Refer top (PIL 01-03).
system. Refer to (PIL 25-00).
1.6. If a new steering unit is installed then Refer to (PIL 01-03).
the system relief valve must be tested for
correct pressure setting. 3. Discharge the hydraulic pressure. Refer to (PIL
30-00).
1.7. Check the hydraulic oil level and top up as
required. Refer to (PIL 30-00). 4. Turn the steering wheel to the left and to the right
5. Make sure that the steering wheel is in the
Item Nm straight ahead position.
C 45
E 48 6. Get access to the steer unit. Remove the front
panel from the cab.
F 14
Figure 705.
A Front panel
7. Put a label on the hoses to help installation. 8. Disconnect the hydraulic hoses from the steering
unit.
25 - 66 9813/7600-3 25 - 66
00 - General
9. Plug all the open ports and hoses to prevent 11. Remove the bolts from inside the cab. At the
contamination. same time, get an assistant to support the
steering unit from under the machine.
10. Mark the orientation of the steering unit to the
splined shaft. 12. Remove the steering unit.
Figure 706.
C
B
B Steering unit C Bolts (x4)

D Splined shaft
Install 1.2. Make sure that the hoses are connected in

the correct positions.
1.3. If the hydraulic adaptors are removed make
sure that they are tightened to the correct
steps.
torque value.
Figure 707.
E Hydraulic adaptor 1 F Hydraulic adaptor 2
1.4. The steering unit is spring loaded to the 1.6. If a new steering unit is installed then the
neutral position. Make sure that the steering system relief valve must be tested for the
wheel is in the straight ahead position when correct pressure setting.
you connect the splined shaft.
1.5. Before you drive the machine, bleed the 30-00).
25 - 67 9813/7600-3 25 - 67
00 - General
Table 292. Torque Values you have done this, make sure that the steering
wheel is in the straight ahead position.
Item Nm
C 45 4. Disconnect the five hydraulic hoses at the
E 77 steering unit.
F 22 5. Put a label on each hydraulic hose to help
installation.
(For: 550-80 [5AW], 550-80 [5UW], 560-80 6. Disconnect the hydraulic hoses.
[5AY], 560-80 [5UY]) 7. Plug all the open ports and hoses to prevent
contamination.
Remove
8. Mark the orientation of the steering unit to the
1. Make the machine safe. Refer to (PIL 01-03). splined shaft.
2. Follow the general health and safety procedures. 9. Remove the four bolts from inside the cab. At
Refer to (PIL 01-03). the same time get an assistant to support the
steering unit beneath the machine.
several times to vent system pressure. When 10. Remove the steering unit.
Figure 708.
D
C
B E
A-E Hoses F Steering unit

G Bolts H Splined shaft
25 - 68 9813/7600-3 25 - 68
00 - General
Table 293. Hose Colour Code Bands

item Band Colour Port
A White P
B Blue T
C Yellow L
D Green / Yellow R
E Grey LS
Install
steps.
value.
1.2. Make sure that the hoses are installed
correctly. The hoses have colour
identification bands. Refer to Table 293.
1.3. The steering unit is spring loaded to the
neutral position (i.e. straight ahead). Make
sure the steering wheel is in the straight
ahead position when you re-connect the
splined shaft.
1.4. Before you drive the machine, bleed the
steering system. Refer to (PIL 25-00).

Item Description Nm
G Bolts 45
25 - 69 9813/7600-3 25 - 69
09 - Mode Valve
09 - Mode Valve
Contents Page No.
25-09-03 Manual Mode Valve ....................................................................................................... 25-71

25-09-06 Auto Mode Valve ............................................................................................................ 25-79
25 - 70 9813/7600-3 25 - 70
09 - Mode Valve
03 - Manual Mode Valve
03 - Manual Mode Valve Remove and Install

(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
Remove
30-00).
several times to discharge the system pressure
fully.
6. Make sure that the steering wheel is in the
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 - 71 9813/7600-3 25 - 71
09 - Mode Valve
Figure 709.
A C
A B
A
A Hoses B Bolts
C Steer mode valve
25 - 72 9813/7600-3 25 - 72
09 - Mode Valve
Figure 710.
D Steer mode selector control handle
25 - 73 9813/7600-3 25 - 73
09 - Mode Valve
Figure 711.
E E
E Nuts F Steer mode selector unit
Figure 712.
G A B
H C
A Spacer plates B Bolts

C Steer mode valve G Chassis side plate
H Washer
25 - 74 9813/7600-3 25 - 74
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 - 75 9813/7600-3 25 - 75
09 - Mode Valve
3. Remove the locknut 1. Rotate the locknut 1 and

(For: 526-56 [T4F], 531-70 [5AA], 531-70 the end cap 1 counterclockwise (so that the parts
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 travel away from the valve) until they disengage
the operating cable thread.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD]) 4. Remove the locknut 2 and disconnect the
operating cable from valve adaptor.
Consumables
Description Part No. Size 5. Remove the screws 2 from the end cap 2.
6. Remove the locknut 3. Rotate the locknut 3 and
and Sealer (Medium 4101/0251 0.05L the end cap 2 counterclockwise (so that the parts
Strength)
travel away from the valve) until they disengage
the operating cable thread.
Disassemble
7. Disengage the operating cable from the steer
1. Remove the steer mode valve assembly from the mode selector.
machine. Refer to (PIL 25-09).
2. Remove the screws 1 from the end cap 1.
Figure 713.
H K
E
A
C D
A Screws 1 B End cap 1

C Locknut 1 D Locknut2
25 - 76 9813/7600-3 25 - 76
09 - Mode Valve
E Operating cable F Adaptor

G Screws 2 H End cap 2
J Locknut 3 K Steer mode selector
25 - 77 9813/7600-3 25 - 77
09 - Mode Valve
Assemble
following steps.
Figure 714.
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 714. 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 - 78 9813/7600-3 25 - 78
09 - Mode Valve
06 - Auto Mode Valve
06 - Auto Mode Valve Check (Operation)

Check (Operation) ......................................... 25-79
(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 541-70 [5AD], 541-70
[5TD], 550-80 [5AW], 550-80 [5UW],
560-80 [5AY], 560-80 [5UY])
Machines may be installed with different types of
steer mode solenoid valve.
The solenoids operate according to the selected

steer mode.
Figure 715.
A D
C
B
A Solenoid1
B Solenoid2
C Solenoid3
D Solenoid4
Table 295.
Mode Solenoid(s) energised
2 Wheel Steer A
4 Wheel Steer B, C
Crab Steer B, D
Operation (energisation) of a solenoid can be easily

identified by placing a steel object (e.g. screwdriver
blade) close to the outer case. magnetic attraction
of the steel object towards the solenoid indicates
energisation.
If a solenoid is not energising do the following

checks:
1. Check the appropriate fuse. If it has blown, make

sure the wiring is not damaged and then renew
the fuse. Check that all steer mode solenoid
combinations function correctly.
25 - 79 9813/7600-3 25 - 79
09 - Mode Valve
2. If the fuse is ok then, remove the electrical Remove and Install

connector from the malfunctioning solenoid(s)
and check that the 12V supply is available across
the connector pins. If not, check the supply (For: 526-56 [T4F])
circuit.
WARNING Make the machine safe before getting
3. Check the solenoid coil resistance which should beneath it. Make sure that any attachments on
measure a few ohms (if you are not sure about the machine are correctly attached. Engage the
the value compare with a known good solenoid). park brake, remove the ignition key, disconnect
the battery.
3.1. Replace the solenoid, if the reading
indicates a short circuit (zero ohms) or open WARNING Hydraulic fluid at system pressure
circuit (infinite resistance). If a reading is can injure you. Before connecting or removing
somewhere between the zero and infinite, any hydraulic hose, residual hydraulic pressure
then reverse the two instrument probes and trapped in the service hose line must be vented.
repeat for a valid check. Make sure the hose service line has been vented
before connecting or removing hoses. Do not start
The electrical connectors at the steer mode valve the engine with loose or open hose connections.
solenoids are identical. Before you remove any of the WARNING Fine jets of fluid at high pressure can
connectors, make sure you label them A, B, C or D penetrate the skin. Keep face and hands well
as applicable. If you think that the connectors have clear of fluid under pressure and wear personal
been made to the wrong solenoids see the electrical protective equipment. Hold a piece of cardboard
connection data for wire number identification. close to suspected leaks and then examine the
cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
Remove
30-00).
Make sure that the steering wheel is in the
5. Disconnect the electrical solenoid connections.
6. Put a label on each connector before you remove
to help installation. Identify the wires as shown in
the figure. Refer to Figure 716.
8. Disconnect all the hydraulic hoses from the steer
mode valve assembly.
contamination.
10. Support the steer mode valve assembly and
remove the screws. Remove the steer mode
valve from the machine.
11. Make sure to keep two washers to the rear of the
valve block which may fall out when you remove
the screws.
25 - 80 9813/7600-3 25 - 80
09 - Mode Valve
Figure 716. 1.1. Make sure that the electrical solenoid

connections are installed in the correct
position.
1.2. Make sure that the hoses are correctly
installed.
1.3. Make sure that the two washers are
installed between the valve block and the
chassis side plate.
1.4. Tighten the screws to the correct torque
value.
1.5. Bleed the steering system. Refer to (PIL
25-00).

Item Description Nm
E Screw 40
B A
C D
A-D Electrical solenoid connector wires

E Screw
Figure 717.
G H
E Screw
F Chassis side plate
G Washer
H Valve block
Install
steps.
25 - 81 9813/7600-3 25 - 81
12 - Column
12 - Column
Contents Page No.
25-12-00 General ........................................................................................................................... 25-83
25 - 82 9813/7600-3 25 - 82
12 - Column
00 - General
00 - General Figure 718.

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 - 83 9813/7600-3 25 - 83
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 - 84 9813/7600-3 25 - 84
15 - Proximity Switch
Contents Page No.
25-15-00 General ........................................................................................................................... 25-87
25 - 85 9813/7600-3 25 - 85
Notes:
25 - 86 9813/7600-3 25 - 86
00 - General
Introduction .................................................... 25-87 These are installed on machines with auto steer
Adjust ............................................................ 25-88 mode system or manual (indicated) mode system.
25 - 87 9813/7600-3 25 - 87
00 - General
Adjust
The proximity switch is the same for both the front

(For: 550-80 [5AW], 550-80 [5UW], 560-80 and rear axles.
[5AY], 560-80 [5UY]) The proximity switch is not adjustable. The switch
Raised Equipment senses the position of the power track rod via a
magnet located centrally on the power track rod
Never walk or work under raised equipment unless piston head.
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.
Figure 719.
A
C
E D
A Proximity switch B Electrical connector

C Electrical schematic D Signal
E Feed F Earth
If necessary the proximity switch operation can be

tested using a suitable multi-meter or test light at the
electrical connector. When you connect a test device
refer to the electrical schematic.
If the proximity switch is defective, replace it. Refer

to Remove and install, (PIL 25-15-00).
25 - 88 9813/7600-3 25 - 88
00 - General
Remove and Install
For: 526-56 [T4F], 531-70 [5AA], 531-70 The following procedure applies to each of the steer
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 proximity switches on the front and rear axles.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 560-80 [5AY], Remove
560-80 [5UY] ............................. Page 25-89
1. Make the machine safe. Follow all the general
For: 550-80 [5AW], 550-80 [5UW], 560-80 safety procedures. Refer to (PIL 01-03).
[5AY], 560-80 [5UY] .................. Page 25-90
2. Disconnect the harness electrical connector from
(For: 526-56 [T4F], 531-70 [5AA], 531-70 the switch electrical connector.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 3. Remove the proximity switch cover.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1], 4. Remove the bolt and nut that secure the
proximity switch to the support bracket.
541-70 [5AD], 541-70 [5TD], 560-80 [5AY],
560-80 [5UY]) 5. Remove the proximity switch from the support
bracket.
movement.
Figure 720.
C B
A Proximity switch B Nut

C Support bracket D Proximity switch electrical connector
25 - 89 9813/7600-3 25 - 89
00 - General
Install
During the installation procedure do this below step
also.
1. Make sure to set the proximity switch air gap.
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY])
If the proximity switch is defective replace it. Refer
to track rod, remove and install (550-80), (PIL
25-18-00).
25 - 90 9813/7600-3 25 - 90
18 - Front Track Rod
Contents Page No.
25-18-00 General ........................................................................................................................... 25-93
25 - 91 9813/7600-3 25 - 91
Notes:
25 - 92 9813/7600-3 25 - 92
00 - General

Check (Condition) .......................................... 25-93
Check Energiser Seals
Disassemble and Assemble ........................ 25-103 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 721.
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 722.
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 - 93 9813/7600-3 25 - 93
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 723.
25 - 94 9813/7600-3 25 - 94
00 - General
Remove and Install
For: 526-56 [T4F], 531-70 [5AA], 531-70 10.1. Put a label on the hoses to help
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 installation.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1], 10.2. Disconnect the pipe assembly from the
541-70 [5AD], 541-70 [5TD], 550-80 [5AW], power track rod at the end point 1 and the
550-80 [5UW], 560-80 [5AY], 560-80 [5UY], end point 2.
Front, Rear ................................ Page 25-95
10.3. Remove the mounting screw 1.
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY], Front ......... Page 25-97 10.4. Remove the pipe assembly.
10.5. Remove the adaptor 2.
(For: 526-56 [T4F], 531-70 [5AA], 531-70 10.6. Plug all the open ports and hoses to
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 prevent contamination.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1], 11. At this point, if the power track rod is to be
dismantled, loosen the track rod link arms while
541-70 [5AD], 541-70 [5TD], 550-80 the track rod is still securely clamped. Refer to
[5AW], 550-80 [5UW], 560-80 [5AY], steering system, Arm. Refer to (PIL 25-33).
560-80 [5UY], Front, Rear)
12. Remove the screw and the pin at each end
Remove of the axle and separate the link arms from
their mounting points. Discard the two web seals
1. Make the machine safe. Refer to (PIL 01-03). seated in the eye of each link arm.
2. Follow the general health and safety procedures 13. Make alignment marks on the cylinder flange,
for the hydraulic system. Refer to (PIL 30-00). the end cover of the power track rod and on the
housing flange of the axle.
30-00). 14. Remove the mounting screws 2 (x4).
4. Turn the steering wheel to the left and to the right 15. If you work on the front axle, do the following
several times to discharge the system pressure. steps:
Make sure that the steering wheel is in the
15.1. Use suitable jacks to support both ends
of the axle and then remove the mounting
5. Before you start work, clean the area around the nuts from both ends. Leave the bolts in
axle and the power track rod. position.
15.2. Lower the jack at the left end so that there
6. Raise the front or the rear wheels from the
is sufficient room for removal of the power
ground with suitable lifting equipment.
track rod.
7. Block the chassis. 15.3. Use a soft-faced hammer to gently tap the
closed end of the track rod cylinder to the
8. Remove the front left or the rear right wheel as
left and out of its mounting.
applicable.
16. If you work on the rear axle, do the following
9. If you work on the front axle, do the following
steps:
steps:
16.1. Use a suitable jack to raise the left end of
9.1. Put a label on the hoses to help installation.
the axle so as to swivel the right end down
9.2. Disconnect hose 1 and hose 2 and then to make room for removal of the power
remove the adaptor 1. track rod.
9.3. Plug all the open ports and hoses to prevent 16.2. Use a soft-faced hammer to gently tap the
contamination. closed end of the track rod cylinder to the
right and out of its mounting.
10. If you work on the rear axle, do the following
steps:
25 - 95 9813/7600-3 25 - 95
00 - General
Figure 724.
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 - 96 9813/7600-3 25 - 96
00 - General
Install Figure 725.

removal procedure. Additionally do the following A
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 P
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. A Proximity switch
1.4. Check the steer proximity switch setting. P Screws 2
2. Loosen the check nuts on the joints of the link
1.5. Before you drive the machine, bleed the arms. Remove the nuts. Refer to Figure 726.
Figure 726.
Item Description Nm
G Mounting screw 56
H Adaptor 2 56
J Screw 56 E
F
M Mounting screw 166
N Mounting nut 600 G
D
P Bolts 600
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY], Front)
D Check nuts 1
Consumables E Joints
Description Part No. Size F Link arms
JCB Activator 4104/0251 0.2L G Swivels
4104/0253 1L 3. If the joint rotates, hold it with a hex wrench
JCB Threadlocker 4101/0250 0.01L inserted in the seat provided.
Strength) 4. Replace the self locking nuts once in every five
disassemblies.
Remove 5. Disconnect the tapered pins of the joints from
the steering swivels with a puller. Refer to Figure
1. Remove the proximity switch. Refer to Figure 727.
725.
25 - 97 9813/7600-3 25 - 97
00 - General

K
E
G
E Joints J Check screws

G Swivels K Steering cylinder
6. Disconnect the left and right link arms from the 9. Remove the steering cylinder using a plastic
power track rod. Refer to Figure 728. hammer. Refer to Figure 730.
H K
H Power track rod K Steering cylinder
7. If necessary, heat the threads portion of the Install

power track rod to the specified temperature with
a heat gun. 1. Check the condition of the axle unit’s O-rings.
Temperature: 100°C (211.9°F) Apply grease on the piston seats with Tecnolube
Seal 101 and install cylinder using a plastic
8. Loosen and remove the check screws of the hammer. Refer to Figure 731.
steering cylinder. Refer to Figure 729.
Figure 731.
K Steering cylinder
25 - 98 9813/7600-3 25 - 98
00 - General
2. Lock the steering cylinder with the check screws Figure 734.
coated with JCB sealant and tighten to the
specified torque value. Refer to Figure 732.
(Medium Strength)
Figure 732. E
F
J K
G
D
D Check nuts 1
E Joints
F Link arms
G Swivels
6. If necessary, install the proximity switch for
J Check screws checking the piston centring. Tighten the screws
K Steering cylinder 2 to the specified torque value. Refer to Figure
735.
3. Apply JCB sealant to the threaded portion of the
steering bars and connect the bars by tightening Figure 735.
the ends in the piston rod to the specified torque
value. Refer to Figure 733. A
Torque: 450N·m
(Medium Strength)
Figure 733.
H P
A Proximity switch
P Screws 2
7. Attach the Dana tool T10 onto the wheel hubs
and lock tools.
8. Check that tools are perfectly flat and parallel to
each other using a level 1. Refer to Figure 736.
H Power track rod
4. Accurately remove the grease from the threads
using an activator before applying the thread
locking compound.
Consumable: JCB Activator
5. Install the pins in the steering cases and lock into
position with the check nuts 1 tightened to the
specified torque value. Refer to Figure 734.
25 - 99 9813/7600-3 25 - 99
00 - General
Figure 736. 11. Check the dimension of the piston rod on either
of the two sides and note down the dimension
to check the subsequent adjustments. Refer to
Figure 739.
Figure 739.
B
B Level 1
9. Connect the proximity switch to a test device.
Refer to steering system- proximity switch, refer
to (PIL 25-15). Refer to Figure 737.
C Dimension of the piston rod
Figure 737.
12. Lay the level 2 on two upper studs and line
them up. Attach the Dana tool T10 to the two
A horizontal studs. Hold them in position with two
nuts, level them, and finally lock into position.
Figure 740.
A Proximity switch
10. Centre by slowly moving the piston rod first
in one direction, then in the opposite one and
position the piston rod in the middle point of
the stroke, which is determined by the control
device signalling lamp turning on and switching
off. Refer to Figure 738. L Level 2
Figure 738. 13. Make sure that the Dana tool T10 perfectly mate
with the hub wheel mount facing.
14. Without moving the piston rod, check front and
rear distance between the edges of the Dana tool
T10. The maximum allowed difference must be
of the specified value.
Length/Dimension/Distance: 1–1.5mm
15. If necessary, adjust the parallelism after
loosening the check nuts 2 of the ball pins. Refer
to Figure 741.
25 - 100 9813/7600-3 25 - 100

00 - General

N N
M M
M Check nuts 2 M Check nuts 2

N Ball pins N Ball pins
16. Hold the joints tight and rotate the ball pins until 19. Adjust the steering angle lock stops:
the Dana tools T10 become parallel to each
other. Refer to Figure 742. 19.1. Perform the same operations on both
sides and loosen the nut of one of the
Figure 742. adjusting screws on cylinder side. Refer to
Figure 744.
N Figure 744.
N Ball pins
17. Loosen the nuts by a few turns. Half a turn of the
pin will reduce the front distance by about 3 mm
and increase the rear one by about 3 mm. 19.2. Adjust the protrusion of the screw 3 and
18. Once the toe-in has been adjusted, tighten the lock into position with nut 2 tightened to
check nuts 2 to the specified torque value. Refer the specified torque value. Refer to Figure
to Figure 743. 745.
25 - 101 9813/7600-3 25 - 101

00 - General

1 a b c d e f
2
T Q S
R Q
Q Nut 2
1 Steering angle (in degrees)
S Screw 4
a Steering angle (1) = 43° / Distance (B) =
T Axle arm stop
58.5mm
b Steering angle (1) = 45° / Distance (B) = 19.5. The screw 3 and the screw 4 must touch
53.5mm the respective axle arm stops at the same
c Steering angle (1) = 35° / Distance (B) = time.
51.6mm
d Steering angle (1) = 55° / Distance (B) = Table 298. Torque Values
23.8mm
e Steering angle (1) = 40° / Distance (B) = Item Description Nm
36.6mm D Check nuts 1 370
f Steering angle (1) = 50° / Distance (B) = J Check screws 190
38.2mm M Check nuts 2 346
2 Distance
B Distance P Screws 2 6
Q Nut 2 Q Nut 2 148
R Screw 3
19.3. Turn the steering until the adjusted screw 3
touches the axle arm stop. Refer to Figure
746.
Figure 746.
R
Q
Q Nut 2
R Screw 3
19.4. As you hold the adjusted screw 3 in
position against the arm stop, adjust the
screw 4 opposite, on link arm side, until it
touches the axle arm stop. Refer to Figure
747.
25 - 102 9813/7600-3 25 - 102

00 - General
For: 526-56 [T4F], 531-70 [5AA], 531-70 Disassemble

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 1. Fix the ram assembly on a locally manufactured
[5TE], 536-70LP [5A1], 536-70LP [5T1], strip/ rebuild bench.
541-70 [5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY] 2. Remove the steering link arm 1 and the steering
................................................. Page 25-103 link arm 2. Refer to steering system- track rod,
For: 550-80 [5AW], 550-80 [5UW], 560-80 refer to (PIL 25-18).
[5AY], 560-80 [5UY] ................ Page 25-105
3. Remove the end cap and then pull the piston rod
assembly from the cylinder.
(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 4. Do not allow the piston rod to come into contact
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 with the cylinder bore. The cylinder bore may be
[5TE], 536-70LP [5A1], 536-70LP [5T1], damaged by careless dismantling.
541-70 [5AD], 541-70 [5TD], 550-80 5. Position the piston rod assembly on the bench in
[5AW], 550-80 [5UW], 560-80 [5AY], place of the ram cylinder.
560-80 [5UY])
6. Remove and discard the wear rings and the seal/
Consumables energising ring.
7. The piston head cannot be removed from the
Cleaner/Degreaser 4104/1557 0.4L rod, if there is damage to the rod or piston head,
- General purpose replace the complete assembly.
solvent based parts
cleaner 8. Carefully inspect the bore of the cylinder and the
JCB Multi-Gasket 4102/1212 0.05L piston rod outer diameter for scoring, nicks and
burrs. If damaged, install a new component.
Use the alphabetical sequence shown on the
illustration as a guide to disassembly. Refer to Figure
748.
25 - 103 9813/7600-3 25 - 103

00 - General
Figure 748.
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 - 104 9813/7600-3 25 - 104

00 - General

F G E
H
E Wear ring 1
F Wear ring 2
G Seal
Figure 750. 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 750.
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 (For: 550-80 [5AW], 550-80 [5UW], 560-80
correctly into the closed end of cylinder and into [5AY], 560-80 [5UY])
the cover along with the cover seal.
5. Make sure that the energiser ring is not twisted. Disassemble
6. If the installation is not correct, it may lead to 1. Before you disassemble the unit, drain the oil in
leakage of the hydraulic fluid between the two the cylinder chambers completely.
sides of the power track rod and will cause
steering problems. 2. Using a screwdriver, remove the snap ring of the
cylinder head. Refer to Figure 752.
7. Make sure that three white marks are visible on
the outside diameter arrowed before install the
seal.Refer to Figure 751.
25 - 105 9813/7600-3 25 - 105

00 - General
B
C
A
D
A Snap ring C Cylinder

B Cylinder head D Stop ring
3. Lightly tap the cylinder head with a plastic 6. Using a plastic hammer, hit the piston rod so that
hammer so as to push it inside the cylinder. Refer it strikes against the head. Refer to Figure 755.
to Figure 753.
Figure 755.
Figure 753.
E
B C
C
B Cylinder head
B Cylinder head C Cylinder
C Cylinder E Piston rod
4. Insert the cylinder head so it is flush with the 7. Continue until the head is ejected from the
cylinder. cylinder.
5. Using a punch, force the stop ring located inside 8. Take the cylinder unit apart by extracting the
the cylinder and extract ring using a screwdriver. head first, followed by the piston rod. Refer to
Refer to Figure 754. Figure 756.
25 - 106 9813/7600-3 25 - 106

00 - General
E B
G F
B Cylinder head B Cylinder head

C Cylinder F Seal ring
E Piston rod G Scraper ring
9. Note down the direction of installation of the 3. Install the seal 1 on the outside of the cylinder
piston rod. The sealing ring whose seal ring is head. Refer to Figure 759.
oriented towards cylinder head.
Figure 759.
10. Remove all the seals, the anti-extrusion rings and
the scraper rings from the head, the cylinder and H
the piston rod. B
11. All seals must be replaced at each disassembly.

Do not damage the seal seats and the piston
beds.
Assemble
1. Apply grease and install the piston rod seal ring
and the scraper ring into the cylinder. Refer to
Figure 757.
Figure 757. B Cylinder head
H Seal 1
4. To ease installation, put grease on the outer
F G surface of the piston. Do not roll the seal 1.
5. Prepare piston rod by installing it with the guide
ring, magnetic ring, O-ring and the seal 2. Refer
to Figure 760.
F Seal ring
G Scraper ring
2. Apply grease and install the piston rod seal ring
and the scraper ring into the cylinder head. Refer
to Figure 758.
25 - 107 9813/7600-3 25 - 107

00 - General
K
M J
E
L
E Piston rod E Piston rod

J Guide ring
K Magnetic ring 9. Remove the Dana tool T11, and attach it to the
L O-ring opposite side of the piston rod. Refer to Figure
M Seal 2 763.
6. To ease installation, lubricate with grease. Figure 763.
7. Attach the Dana tool T11 to the piston rod on

the non-head side and the centre rod into the
cylinder so as to install it into the piston. Refer to
Figure 761.
Figure 761.
E Piston rod
C 10. Put grease on the seals of the cylinder head
and install the head onto the piston rod. Using a
E plastic hammer, install the head into the cylinder.
C Cylinder Figure 764.
E Piston rod
8. Install the piston rod into the cylinder by the B C
specified length using a plastic hammer. Refer to
Figure 762.
B Cylinder head
C Cylinder
11. Insert the head so that it is flush with the cylinder.
25 - 108 9813/7600-3 25 - 108

00 - General
12. Insert the stop ring and make sure that it sets in 15. Make sure that the snap ring seats perfectly in
the seat of cylinder. Refer to Figure 765. its seat.
Figure 765. 16. If necessary, force it into the seat with a punch
and hammer.
D C
C Cylinder
D Stop ring
13. Using two screwdrivers or levers, force the head
until it is seated against the stop ring. Refer to
Figure 766.
Figure 766.
D Stop ring
14. Install the snap ring of the cylinder head. Refer
to Figure 767.
Figure 767.
A Snap ring
B Cylinder head
25 - 109 9813/7600-3 25 - 109

33 - Link Arm
33 - Link Arm
Contents Page No.
25-33-00 General ......................................................................................................................... 25-111
25 - 110 9813/7600-3 25 - 110

33 - Link Arm
00 - General
00 - General
Remove and Install
Consumables Figure 768.

Strength)
Remove
If you have to dismantle the power track rod or
replace the link arms, do the following steps:
Remove
1. Fix the assembly on a locally made strip/rebuild 2. Use two suitable open ended spanners at point1
bench. Refer to Figure 768. and point2 and turn against each other until one
ball joint unscrews as shown. Refer to Figure
769.
3. For this explanation, assume the ball joint at
point1 is now loose, do as follows:
25 - 111 9813/7600-3 25 - 111

33 - Link Arm
00 - General
Figure 769.
A
B
A Point1 B Point2
25 - 112 9813/7600-3 25 - 112

33 - Link Arm
00 - General
C Point3 D Point4
3.1. Unscrew the ball joint until you can fit an Install
open ended spanner on the rod at point3.
Turn the ball joint towards the spanner to If the you have to dismantle the power track rod
secure it and to prevent damage to the rod. ram, carry out the procedure before you remove and
install the link arms. Refer to (PIL 30-15).
3.2. The piston rod operates at full length. Any
damage to the surface will cause fluid leaks. 1. The installation procedure is the opposite of the
Make sure you do not damage it or attempt removal procedure.
to grip the rod diameter with pipe grips etc.
3.3. Hold the spanner at point3 and remove the 2. When you install, also do the following steps:
ball joint at point4 by moving it against the 2.1. Install the target disc (where applicable).
spanner at point3.
2.2. Apply threadlocker and sealer on the first
4. Remove the target disc where applicable. three threads of the inner ball joint where it
screws into the end of the track rod.
5. If you replace the inner or outer ball joints, make
sure you install a replacement link arm assembly. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
Figure 770.
2.3. If the link arms have been renewed, make
sure you check the wheel alignment.
2.4. Bring the wheels to straight ahead position.
J 2.5. Measure the distance1 and distance2

between the outer edges of the wheel hub
as shown.
2.6. Make sure that the difference between
the distance1 and the distance2 is of the
specified value for correct alignment.
E F G H 2.7. To adjust the wheel alignment, remove
the lock nuts. Turn the threaded adjusters
equally to get the correct alignment. Tighten
E Lock nut the lock nuts.
F Threaded adjuster 2.8. Check the target disc and proximity switch
G Spanner flat on ball joint setting (where applicable). Refer to steering
H Spanner flat on the rod system- track rod, refer to (PIL 25-18).
J Target disc
25 - 113 9813/7600-3 25 - 113

33 - Link Arm
00 - General
Figure 771.
X Distance1 Y Distance2

Item Description Nm
G Ball joint 250
G Rod 250
E Lock nut 250
F Adjuster 250
25 - 114 9813/7600-3 25 - 114

27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-03 Manual Gearbox
27-03-00 General ............................................................................................................................. 27-9
27-03-06 Clutch - Forward/Reverse .............................................................................................. 27-54
27-03-07 Clutch - 2WD/4WD ......................................................................................................... 27-61
27-03-15 Solenoid Control Valve ................................................................................................... 27-82
27-03-16 Check Valve ................................................................................................................... 27-84
27-03-18 Pressure Relief Valve ..................................................................................................... 27-86
27-03-21 Pressure Maintenance Valve (PMV) .............................................................................. 27-89
27-03-24 Oil Pump ........................................................................................................................ 27-90
27-03-30 Oil Pressure Sensor ....................................................................................................... 27-92
27-03-33 Oil Temperature Sensor ................................................................................................. 27-94
27-03-45 Piston Ring Seal ............................................................................................................ 27-96
27-03-47 Oil Seal .......................................................................................................................... 27-98
27-03-52 Driveshaft ..................................................................................................................... 27-100
27-03-54 Main Shaft .................................................................................................................... 27-102
27-03-56 Layshaft ........................................................................................................................ 27-111
27-03-58 Output Shaft ................................................................................................................. 27-117
27-03-74 Synchromesh Gear 1 and 2 ......................................................................................... 27-122
27-03-78 Direct Shift Turret ......................................................................................................... 27-132
27-03-79 Remote Shift Turret ...................................................................................................... 27-136
27-03-81 Mount ........................................................................................................................... 27-139
27-03-90 Front Case ................................................................................................................... 27-140
27-03-91 Rear Case .................................................................................................................... 27-147
27-03-94 Coupling Yoke .............................................................................................................. 27-149
27-05 Hybrid Gearbox
27-05-00 General ......................................................................................................................... 27-153
27-05-07 Clutch - 2WD/4WD ....................................................................................................... 27-186
27-05-11 Clutch - Forward (Input) ............................................................................................... 27-190
27-05-15 Solenoid Control Valve ................................................................................................. 27-197
27-05-18 Pressure Relief Valve ................................................................................................... 27-199
27-05-19 Control Valve ................................................................................................................ 27-200
27-05-21 Pressure Maintenance Valve (PMV) ............................................................................ 27-204
27-05-23 Motor ............................................................................................................................ 27-205
27-05-24 Oil Pump ...................................................................................................................... 27-211
27-05-27 Speed Sensor .............................................................................................................. 27-215
27-05-30 Oil Pressure Sensor ..................................................................................................... 27-217
27-05-33 Oil Temperature Sensor ............................................................................................... 27-221
27-05-39 Filter ............................................................................................................................. 27-225
9813/7600-3
2018-03-03
27-05-40 Suction Strainer ............................................................................................................ 27-227
27-05-42 Dipstick ......................................................................................................................... 27-229
27-05-45 Piston Ring Seal .......................................................................................................... 27-230
27-05-47 Oil Seal ........................................................................................................................ 27-232
27-05-62 Clutch - Pump .............................................................................................................. 27-234
27-05-63 Clutch - Motor .............................................................................................................. 27-240
27-05-65 Clutch - Front (Output) ................................................................................................. 27-247
27-05-81 Mount ........................................................................................................................... 27-254
27-05-90 Front Case ................................................................................................................... 27-255
27-05-91 Rear Case .................................................................................................................... 27-257
27-05-93 Hose ............................................................................................................................. 27-259
27-05-95 Coupling Yoke .............................................................................................................. 27-261
27-06 Semi-Automatic Gearbox
27-06-00 General ......................................................................................................................... 27-265
27-06-06 Clutch - Reverse .......................................................................................................... 27-343
27-06-07 Clutch - 2WD/4WD ....................................................................................................... 27-347
27-06-08 Clutch - Layshaft .......................................................................................................... 27-376
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-396
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-410
27-06-24 Oil Pump ...................................................................................................................... 27-441
27-06-27 Speed Sensor .............................................................................................................. 27-443
27-06-39 Filter ............................................................................................................................. 27-467
27-06-45 Piston Ring Seal .......................................................................................................... 27-471
27-06-47 Oil Seal ........................................................................................................................ 27-473
27-06-52 Driveshaft ..................................................................................................................... 27-475
27-06-54 Main Shaft .................................................................................................................... 27-478
27-06-56 Layshaft ........................................................................................................................ 27-481
27-06-57 Input Shaft .................................................................................................................... 27-482
27-06-58 Output Shaft ................................................................................................................. 27-483
27-06-81 Mount ........................................................................................................................... 27-493
27-06-85 Oil Feed Pipe ............................................................................................................... 27-494
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-495
27-06-90 Front Case ................................................................................................................... 27-496
27-06-91 Rear Case .................................................................................................................... 27-506
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-508
27-12 Transfer Gearbox
27-12-00 General ......................................................................................................................... 27-513
27-14 Torque Converter
27-14-00 General ......................................................................................................................... 27-539
27-14-06 Control Valve ................................................................................................................ 27-547
27-14-09 Relief Valve .................................................................................................................. 27-549
27-20 Axle
27-20-00 General ......................................................................................................................... 27-553
9813/7600-3
2018-03-03
27-20-15 Breather ........................................................................................................................ 27-585
27-20-81 Mount ........................................................................................................................... 27-587
27-22 Drivehead
27-22-00 General ......................................................................................................................... 27-589
27-22-06 Crownwheel .................................................................................................................. 27-590
27-22-09 Pinion Gear .................................................................................................................. 27-592
27-24 Differential
27-24-00 General ......................................................................................................................... 27-595
27-24-09 Pinion Gear .................................................................................................................. 27-619
27-27 Hub
27-27-00 General ......................................................................................................................... 27-639
27-27-03 Upper Trunnion ............................................................................................................ 27-653
27-27-60 Swivel ........................................................................................................................... 27-655
27-27-66 Wheel Stud ................................................................................................................... 27-663
27-29 Wheel
27-29-00 General ......................................................................................................................... 27-665
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-669
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-673
27-51 Driveshaft
27-51-00 General ......................................................................................................................... 27-681
27-51-15 Shaft Hub Side ............................................................................................................. 27-689
9813/7600-3
2018-03-03
Acronyms Glossary
2WD Two Wheel Drive

Transmission
HP High Pressure
LLMC Longitudinal Load Moment Control
LSD Limited Slip Differential
LSP Load Sense Pump
LSRV Load Sense Relief Valve
MRV Main Relief Valve
PIL Parts Identification List
PMV Pressure Maintenance Valve
PRV Pressure Relief Valve
PTFE Polytetrafluoroethylene
PTO Power Take-Off
RAS Rear Axle Stabilization
RWD Rear Wheel Drive
SAE Society of Automotive Engineers
TCM Transmission Control Module
9813/7600-3
2018-03-03
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9813/7600-3 27 - 1
Notes:
27 - 2 9813/7600-3 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 ......................................................... 27-6 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 9813/7600-3 27 - 3
27 - Driveline
00 - Driveline
00 - General
Technical Data
(For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY],
JCB Tier 4F Engine 4 Cyl)
Table 300.
Machine Transmission Front Axle Rear Axle Front Differen- Rear Differen-
tial (Option)
(1)
tial
526-56
Agri SS700 SD70 Pad SD55 Trunnion LSD or Maxtrac Maxtrac
Agri PS754 mount mount
Agri Plus PS764
531-70
Agri PS754 SD70 Pad SD55 Trunnion LSD or Maxtrac Maxtrac
Agri Plus PS764 mount mount
Agri Super, Agri PS766
Extra
Agri Pro DTVT
535-95
mount mount
536-60
Agri Super PS766
Agri Pro DTVT
536-70
Extra
Agri Pro DTVT
536-70LP
Agri Plus, Agri PS764 mount mount
Super
Agri Plus, Agri PS766
Super
541-70
Extra
Agri Pro DTVT
550/80
Agri Plus PS764 Dana 213 Pad Dana 223 Trun- LSD or Maxtrac Standard
Agri Super PS766 mount nion mount
27 - 4 9813/7600-3 27 - 4
27 - Driveline
00 - Driveline
00 - General
Machine Transmission Front Axle Rear Axle Front Differen- Rear Differen-
tial (Option)
(1)
tial
560/80
Agri Plus PS764 Dana 213 Pad Dana 223 Trun- LSD or Maxtrac Standard
Agri Super PS766 mount nion mount
(1) If the LSD differential option is not installed, a JCB Maxtrac differential (for SD70 axles) or a standard Dana
differential (for 213 axles) is installed.
27 - 5 9813/7600-3 27 - 5
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 (526-56 Drive is taken from the bevel gearbox to the main
machines have the option of a Manually Controlled hydraulic pump via a short splined tube.
gearbox). Drive from the gearbox is transmitted to the
steer drive front axle and to the steer drive rear axle The engine has a vibration damper bolted to the
via the propshafts. flywheel.
Figure 772.
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 - 6 9813/7600-3 27 - 6
27 - Driveline
03 - Manual Gearbox
03 - Manual Gearbox
Contents Page No.
27-03-00 General ............................................................................................................................. 27-9

27-03-06 Clutch - Forward/Reverse .............................................................................................. 27-54
27-03-07 Clutch - 2WD/4WD ......................................................................................................... 27-61
27-03-15 Solenoid Control Valve ................................................................................................... 27-82
27-03-16 Check Valve ................................................................................................................... 27-84
27-03-18 Pressure Relief Valve ..................................................................................................... 27-86
27-03-21 Pressure Maintenance Valve (PMV) .............................................................................. 27-89
27-03-24 Oil Pump ........................................................................................................................ 27-90
27-03-30 Oil Pressure Sensor ....................................................................................................... 27-92
27-03-33 Oil Temperature Sensor ................................................................................................. 27-94
27-03-45 Piston Ring Seal ............................................................................................................ 27-96
27-03-47 Oil Seal .......................................................................................................................... 27-98
27-03-52 Driveshaft ..................................................................................................................... 27-100
27-03-54 Main Shaft .................................................................................................................... 27-102
27-03-56 Layshaft ........................................................................................................................ 27-111
27-03-58 Output Shaft ................................................................................................................. 27-117
27-03-78 Direct Shift Turret ......................................................................................................... 27-132
27-03-79 Remote Shift Turret ...................................................................................................... 27-136
27-03-81 Mount ........................................................................................................................... 27-139
27-03-90 Front Case ................................................................................................................... 27-140
27-03-91 Rear Case .................................................................................................................... 27-147
27-03-94 Coupling Yoke .............................................................................................................. 27-149
27 - 7 9813/7600-3 27 - 7
Notes:
27 - 8 9813/7600-3 27 - 8
27 - Driveline
03 - Manual Gearbox
00 - General
Introduction ...................................................... 27-9 A manual gearbox is a type of transmission used in
Technical Data ............................................... 27-10 motor vehicle applications. It uses a driver operated
Component Identification ............................... 27-12 clutch, engaged and disengaged by a foot pedal,
Fault-Finding .................................................. 27-17 for regulating torque transfer from the engine to the
transmission and a gear lever operated by hand.
Drain and Fill ................................................. 27-26
Clean ............................................................. 27-27 A typical JCB manual transmission is called Synchro
Check (Condition) .......................................... 27-28 Shuttle, of which the following types exist:
Calibrate ........................................................ 27-28
• SS500
Remove and Install ....................................... 27-33 • SS600
Disassemble and Assemble .......................... 27-36 • SS620
• SS700
• SS750
27 - 9 9813/7600-3 27 - 9
27 - Driveline
03 - Manual Gearbox
00 - General
Technical Data
Table 301.
Description Combined torque converter, reverser, and gearbox unit. Synchromesh
manual gear selection. Electro hydraulic selection of forward and re-
verse.
Weight (dry) 317.5kg
Gear Ratio
1st 6.295:1
2nd 3.902:1
3rd 1.821:1
4th 0.96:1
Torque Converter
Torque Converter Diameter 279mm
Torque Multiplication at Stall 2.2:1
Table 302.
Converter Pressures (in bar (psi)
neutral)
Converter In at 50°C 1000 RPM 1.5 - 2.5
(121.9°F) (Revolu-
tions Per
Minute)
2000 RPM 5.3 - 6.7
Converter In at 100°C 1000 RPM 0.5 - 1.3
(211.9°F)
2000 RPM 4.1 - 4.9
Converter Out at 50°C 1000 RPM 0.8 - 1.6
(121.9°F)
2000 RPM 3.0 - 4.0
Converter Out at 100°C 1000 RPM 0.3 - 0.9
(211.9°F)
2000 RPM 2.1 - 2.9
Table 303.
Lubrication Pressures bar (psi)
(in neutral)
At 50°C (121.9°F) 1000 RPM 0.3 - 0.9
2000 RPM 1.8 - 2.4
At 100°C (211.9°F) 1000 RPM 0.1 - 0.3
2000 RPM- 1.3 - 2.1
rev/min
Main Line Pressure (in bar (psi)
neutral)
At 50°C (121.9°F) 1000 RPM 11.0 - 13.0
2000 RPM 13.0 - 15.6
At 100°C (211.9°F) 1000 RPM 10.2 - 12.2
2000 RPM 11.4 - 14.0
Flow Rates (in neutral) L/min
Cooler at 50°C 1000 RPM 7.7 - 11.0
(121.9°F)
2000 RPM 13.9 - 20.0
27 - 10 9813/7600-3 27 - 10
27 - Driveline
03 - Manual Gearbox
00 - General
Cooler at 100°C 1000 RPM 5.2 - 8.2

(211.9°F)
2000 RPM 14.5 - 17.5
Pump at 50°C (121.9°F) 1000 RPM 11.5 - 15.5
2000 RPM 24.0 - 33.0
Clutch Pressures All clutch pressures
should be the same as
Mainline Pressure to
within 0.7bar (10.1psi)
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03 - Manual Gearbox
00 - General
The gearbox serial number is stamped on the unit

(For: SS700 MK2) identification plate as shown. When you make an
order for parts replacement, always give the details
mentioned on the unit identification plate. In the case
Unit Identification of gear replacements, always check the part number
There is more than one gearbox design variant. The
SS700 type 2 variant described in this section is Figure 774.
identified as having an enclosed layshaft rear case.
Make sure you refer to the correct procedure before
you disassemble or assemble the gearbox.
Figure 773.
B
B Identification plate
A Layshaft rear case
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00 - General
Main Component Identification
Figure 775. SS700 Type 2 Synchro Shuttle
S B A R E
K
T
W
L M P H J F G
V C
Y X Q
A Forward and reverse clutch unit B Transmission oil pump

C Torque converter pressure regulating valve D Oil pressure maintenance valve
E Solenoid control valve F Main shaft
G Synchromesh unit (3rd and 4th gears) H Layshaft
J Synchromesh unit (1st and 2nd gears) K Transfer gear, output shaft and yoke
27 - 13 9813/7600-3 27 - 13
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03 - Manual Gearbox
00 - General
L 4WD (Four Wheel Drive) output yoke (if M 2WD (Two Wheel Drive) and 4WD clutch unit (if
installed) installed)
N 4WD solenoid control valve (if installed) P Oil strainer
Q Oil filter R Gear shift turret assembly. There are two types
of turret. A direct acting shift lever type (shown)
and a remote shift lever type (not shown)
S Torque converter T Driveshaft (typically drives a hydraulic pump)
U Hydraulic pump mounting face V Torque converter relief valve
W Oil pressure switch X Hose connection (to oil cooler)
Y Hose connection (from oil cooler)
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00 - General
Sectional Drawing
Figure 776. SS700 Type 2 Synchro Shuttle
39
37
41
40
15
38
36
42
43
35
32 33 34
31
29
28
30
27
24
21 23
26
22
25
20
19
16 18
17
13 14
10
7
6
11 12
8
9
5
4
2
3
1 Coupling yoke 2 Washer

3 Stake nut 4 Transfer gear output shaft
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00 - General
5 Oil seal 6 Bearing 1 (taper roller)

7 Bearing 2 (taper roller) 8 Seal
9 Spacer 1 10 Synchromesh unit (3rd and 4th gears)
11 Bearing 3 (taper roller) 12 Spacer 2
13 2WD/4WD solenoid control valve (if installed) 14 Forward and reverse solenoid control valve
15 Spacer 3 16 Bearing 4 (taper roller)
17 Bearing 5 (needle roller) 18 Layshaft
19 Bearing 6 (needle roller) 20 Bearing 7 (needle roller)
21 2nd Gear 22 Bearing inner race
23 Synchromesh unit (1st and 2nd gears) 24 1st Gear
25 3rd Gear 26 Main shaft
27 Gearbox case (rear) 28 Forward and reverse clutch
29 Gearbox case (front) 30 4WD gear (if installed)
31 2WD and 4WD clutch (if installed) 32 4WD housing (if installed)
33 Oil seal 34 Coupling yoke (4WD)
35 Flanged bolt 36 Bearing 8 (taper roller)
37 Transfer gear (4WD) 38 Dowel
39 Spacer 4 40 Bearing (taper roller)
41 Oil pump 42 O-Ring
43 Flywheel housing
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00 - General
Fault-Finding
Fault
The transmission is noisy Table 304. Page 27-17
The transmission is overheating Table 305. Page 27-19
The transmission will not pull Table 306. Page 27-21
There is no drive in one or both directions Table 307. Page 27-23
The transmission is jumping out of gear Table 308. Page 27-24
The transmission is sticking in gear Table 309. Page 27-25
The gear ratios are crash changing Table 310. Page 27-25
Before you do the following checks, make sure that For fault-finding of the transmission hydraulic
you operate the machine to determine the fault area. system, refer to Hydraulic System, General, Fault
Make sure that the system is at its normal working Finding- (PIL 30-00).
temperature. For fault-finding of the transmission oil cooling
Make sure that the you use the correct quantity and system, refer to Manual Gearbox, Check
grade of oil. (Operation)- (PIL 27-03).
Make sure that there are no leaks in the system.
Table 304. The transmission is noisy

Check Action
1 Is there noise when selecting direction? Yes Check 3.
No Check 2.
2 Is there noise when running with direction Yes Check 9.
selector in neutral and ratio selector in first? No Check 19.
3 Is there air in the hydraulic system? Yes Continue to run the engine to expel air.
No Check 4.
4 Is the fluid level correct? Yes Check 5.
No Allow machine to cool down. Check the oil
level. If necessary, top up as required.
5 Are the oil passages restricted? Yes Clear the restrictions.
No Check 6.
6 Is the suction strainer restricted? Yes Remove and clean the strainers.
No Check 7.
7 Is pump pressure as specified? Yes Check 9.
No Check the condition of the clutch PMV
(Pressure Maintenance Valve). Make sure
that it is free to operate.
8 When flow testing pump, is output low? Yes Replace the pump.
No Check the condition of the converter sprag
clutch for wear or slip.
9 Does the noise continue when direction Yes Check 10.
selector is in forward or reverse? No Check 11.
10 Is transmission misaligned? Yes Replace the mounting. Check the position
of the transmission.
No Check the converter out pressure and flow.
11 Are the pump bushes worn? Yes Replace the bushes.
No Check the converter for wear or cooler for
restriction to flow.
12 Is the transmission not pulling in one Yes Check 16.
direction only? No Check 13.
13 Is the transmission not pulling in both Yes Stall test the machine.
forward and reverse? Check 14.
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Check Action
No Check 16.
14 Is the converter in pressure is as specified? Yes Check 15.
No Inspect the converter relief valve for
damage.
15 Is pump being driven by converter? Yes Check the pump pressure.
No Replace the damaged components.
16 Are clutch sealing rings damaged? Yes Tap the pressure gauge into clutch feed
lines to monitor pressure.
No Check the clutch plates for damage.
17 Is there drive in one direction only? Yes Check 19.
No Check 18.
18 Is the start switch in the run position and Yes Check 19.
supplying current to the neutral start relay? No Repair as necessary.
19 Is the fault only when the transmission is Yes Disassemble the solenoid. Check the
hot? condition of the components.
No Check the condition of the microswitches,
relay and wiring loom.
20 Is the noise a growl, hum or grinding? Yes Check the condition of the gears for
damage or wear.
No Check 21.
21 Is the noise a hiss, thump or bumping? Yes Check the condition of the bearings for
damage or wear.
No Check 22.
22 Is the noise a squeal? Yes Check the free running gears for seizure.
No Check 23.
23 Is the noise present when in neutral? Yes Check 25.
No
24 Is the noise present when in gear? Yes Check 28.
No
25 Is the countershaft or its bearings worn or Yes Replace the damaged parts.
damaged? No Check 26.
26 Is there excessive backlash in the gears? Yes Check the shaft end float. Adjust as
necessary.
No Check 27.
27 Is the mainshaft pilot bearing worn? Yes Replace as necessary.
No Check the gear teeth for scuffing.
28 Is the mainshaft rear bearing worn? Yes Replace as necessary.
No Check 29.
29 Are the sliding gear teeth worn or Yes Replace the gears as necessary.
30 Are the selector forks loose? Yes Tighten the screws.
No Check 31.
31 Are the selector fork pads or grooves in Yes replace the worn parts.
gears worn? No Check 32.
32 Are the dog gear teeth worn? Yes Replace as necessary.
No Check 33.
33 Are the selector rod detent springs broken? Yes Replace as necessary.
No Check 34.
34 Are the selector rods worn or damaged? Yes Replace as necessary.
No Check 35.
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03 - Manual Gearbox
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Check Action
35 Are the selector fork pads out of position? Yes Reposition the selector fork pads. Replace
as necessary.
No Check 36.
36 Is there excessive end float in gears or Yes Adjust the end float.
shafts? No Check the thrust washers and mating faces.
37 Is the synchroniser bronze worn? Yes Replace the synchro pack.
No Check 38.
38 Are steel chips embedded in the bronze? Yes Continue using, chips will either embed
below bronze or be rejected.
No Check 39.
39 Are the synchroniser components Yes Replace as necessary.
damaged? No Check the free running gears for seizure or
damage.
40 Are the sliding gears tight on the splines? Yes Replace as necessary.
No Check 41.
41 Are chips wedged between splines of shaft Yes Remove the chips.
or gear? No Make sure that the clutch is disengaged
when dump pedal is pressed.
No Check 43.
43 Are the synchroniser spring pins damaged? Yes Replace the synchro pack.
No Check 44.
No Check the blocker pins.
Table 305. The transmission is overheating

Check Action
1 Is the fluid level correct? Yes Check 2.
No Allow machine to cool down. Check the oil
level. If necessary, top up as required.
2 Are the oil passages restricted? Yes Clear the restrictions.
No Check 3.
3 Is the suction strainer restricted? Yes Remove and clean the strainers.
No Check 4.
4 Is pump pressure as specified? Yes Check 6.
No Check the condition of the clutch PMV.
Make sure that it is free to operate.
5 When flow testing pump, is output low? Yes Replace the pump.
No Check the condition of the converter sprag
clutch for wear or slip.
6 Does the noise continue when direction Yes Check 7.
selector is in forward or reverse? No Check 8.
7 Is transmission misaligned? Yes Replace the mounting. Check the position
of the transmission.
No Check the converter out pressure and flow.
8 Are the pump bushes worn? Yes Replace the bushes.
No Check the converter for wear or cooler for
restriction to flow.
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00 - General
Check Action
No Check 13.
damage.
No Check 15.
damage or wear.
No Check 18.
damage or wear.
No Check 19.
No Check 20.
No
No
necessary.
No Check 24.
No Check 26.
No Check 28.
No Check 30.
No Check 31.
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Check Action
No Check 32.
as necessary.
No Check 33.
No Check 35.
No Check 36.
damage.
No Check 38.
No Check 40.
No Check 41.
Table 306. The transmission will not pull

Check Action
No Check 5.
damage.
No Check 7.
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00 - General
Check Action
damage or wear.
No Check 10.
damage or wear.
No Check 11.
No Check 12.
No
No
necessary.
No Check 16.
No Check 18.
No Check 20.
No Check 22.
No Check 23.
No Check 24.
as necessary.
No Check 25.
No Check 27.
No Check 28.
damage.
No Check 30.
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Check Action
No Check 32.
No Check 33.
Table 307. There is no drive in one or both directions

Check Action
No Check 2.
damage or wear.
No Check 5.
damage or wear.
No Check 6.
No Check 7.
No
No
necessary.
No Check 11.
No Check 13.
No Check 15.
No Check 17.
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00 - General
Check Action
No Check 18.
No Check 19.
as necessary.
No Check 20.
No Check 22.
No Check 23.
damage.
No Check 25.
No Check 27.
No Check 28.
Table 308. The transmission is jumping out of gear

Check Action
No Check 2.
No Check 4.
No Check 5.
No Check 6.
as necessary.
No Check 7.
No Check 9.
No Check 10.
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00 - General
Check Action
damage.
No Check 12.
No Check 14.
No Check 15.
Table 309. The transmission is sticking in gear

Check Action
No Check 2.
No Check 4.
No Check 5.
Table 310. The gear ratios are crash changing

Check Action
No Check 2.
No Check 3.
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03 - Manual Gearbox
00 - General
Drain and Fill Figure 778.
Drain
1. Make sure that all oil has been drained from
the gearbox case by removing the bolts and the
suction strainer. Discard the gasket. Refer to
Manual Gearbox, Suction Strainer - Remove and
Install (PIL 27-03-40).
2. Remove the drain plug. Discard the sealing
washer.
Figure 777.
Fill
1. Install a new gasket to a clean suction strainer
and insert into the gear case. Refer to Manual
Gearbox, Suction Strainer - Remove and Install
(PIL 27-03-40).
2. Install the drain plug with a new sealing washer.
Tighten to the correct torque value.
1 Drain plug
2 Sealing washer
3 Bolts
4 Suction strainer
5 Gasket
3. Remove and discard the oil filter. Refer to
Manual Gearbox, Filter - Remove and Install (PIL
27-03-39).
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00 - General
Figure 779. Clean

Consumables
Cleaner/Degreaser 4104/1557 0.4L
- General purpose
solvent based parts
cleaner
Clean the exterior of the gearbox assembly as

follows:
1. Make sure that all open ports and orifices are

effectively plugged.
2. Remove any deposits of dirt, grit and oil from
the outer cases using a suitable degreaser and
water.
3. Dry the cases.
1 Drain plug
2 Sealing washer
3 Bolts
4 Suction strainer
5 Gasket
3. Install a new oil filter. Refer to Manual Gearbox,
Filter - Remove and Install (PIL 27-03-39).
Figure 780.

Item Nm
1 102
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03 - Manual Gearbox
00 - General
Before assembling the gearbox make sure that a (For: SS700 MK2)
thorough inspection of all components is carried out.
Remember that although a failed component may Special Tools
be easy to identify, the cause of that failure may be Description Part No. Qty.
less easy to trace. It is also possible that a failed Spacer Kit 459/70378 1
component may have caused damage to other areas
Spacer Kit 459/70379 1
of the gearbox.
Drive Coupling 892/00812 1
1. Carefully remove all traces of gasket compound Spanner
from components as follows: End Float Setting Tool 990/00083 1
1.1. Front and rear case mating faces.
Shafts (End Float Measurement)
1.2. Front case and torque converter housing
mating faces. After replacement of the gearbox shafts, check
the end float measurements. The component
2. Clean the inside of the case using a suitable manufacturing system makes sure that the end
degreasing agent. float is controlled within specified limits. To check
for correct assembly and installation of the shafts,
3. Carefully inspect all gears, bearings and shafts
measure the end float dimensions as follows:
for signs of excessive wear or damage. If wear
renewed. End float adjustment (Layshaft)
4. Make sure that all oil way cross drillings in the 1. Remove the 2WD (Two Wheel Drive)/4WD (Four
cases, shafts and gears are clear and free from Wheel Drive) unit, if it is installed.
debris. Blocked oil ways are a common cause of 2. Screw a suitable M8 bolt into the end of the
bearing failure. Use an air line to blow through layshaft.
cross drillings.
3. Rotate the shaft and at the same time pull up on
If failure of the forward and reverser clutch or the bolt.
power take-off clutch is suspected, see the relevant
dismantling and assembly procedure. 4. Measure the layshaft end float and it must be
within the specified limit.
Dimension: 0.03–0.08mm
5. The layshaft and its associated components are
manufactured with a "set right" system. If the
components are assembled correctly, the shaft
end float must be within the specified limit. Refer
to: 4.
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03 - Manual Gearbox
00 - General
A
G Torque converter housing
C
2. Install the service tool on the main shaft end
bearing and spacer 1 with the bolt 1. Refer to:
Special Tool: End Float Setting Tool (Qty.: 1)
3. Tighten the bolt 1 to the correct torque value.
B 4. Measure the main shaft end float and it must be
within the specified limit.
A Bolt
B Spacer Dimension: 0.03–0.08mm
C DTI (Dial Test Indicator) 5. Rotate the shaft when you take the measurement
6. If the gearbox is assembled with new to install the bearings fully.
components such as bearings or cases, the 6. Set the pointer of the DTI on the chamfer of the
end float measurement may be more than the shaft, not on the end face. This will make sure
specified limit mentioned in the step 4. that a constant reading is given.
7. If necessary adjust the end float. 7. An M8 bolt installed on the end of the main shaft,
7.1. Remove the front and rear case. can be used to push and pull the shaft.
7.2. Remove the layshaft.

7.3. Remove the bearing outer cup followed by
the spacer from the front case.
7.4. Measure the spacer.
7.5. If necessary, Use the end float
measurement to select and install the
correct size spacer from the kit.
Special Tool: Spacer Kit (Qty.: 1)
7.6. Assemble the gearbox.
8. Install the 2WD/4WD unit, if it is removed.
End float adjustment (Main shaft)

1. Remove the torque converter housing.
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03 - Manual Gearbox
00 - General
H C
C DTI
C H Forward reverse unit shaft
E 4. The forward reverse shaft and its associated

components are manufactured with a "set right"
system. If the components are assembled
correctly, the shaft end float must be in the
C DTI specified limit. Refer to: 1.
D End float setting tool
E Spacer 1 5. If there is no float, or too much end float, separate
F Bolt 1 the cases and check that the bearings inner and
outer cups are installed correctly.
8. The main shaft and its associated components
are manufactured with a "set right" system. If the 6. If the forward reverse shaft and clutch
components are assembled correctly, the shaft assemblies are disassembled, then check that
end float must be within the specified limit. Refer the assembly has been carried out correctly.
to: 4.
Transfer gear- output shaft end float check.
9. If the gearbox is assembled with new
components such as bearings or cases, the 1. If installed, follow below steps. Refer to Figure
end float measurement may be more than the 785.
specified limit mentioned in the step 4.
1.1. If necessary, Unstake the nut. Whilst
10. If necessary adjust the end float. holding the output yoke with the drive
coupling spanner tool, remove the output
10.1. Remove the end float setting tool followed shaft nut and the washer 2 below it. From
by the spacer 1. below support the output shaft and lift off the
10.2. Measure the spacer 1. yoke.
10.3. If necessary, Use the end float Special Tool: Drive Coupling Spanner (Qty.:
measurement to select and install the 1)
correct size spacer1 from the kit. 1.2. Prise out the oil seal and discard it.
End float adjustment (Forward-reverse clutch)

1. Measure the end float of the forward reverse unit
shaft, it must be within the specified limit.
2. Rotate the shaft when you take the measurement
to install the bearings fully.
3. Set the pointer of the DTI on the chamfer of the
shaft, not on the end face. This will make sure
that a constant reading is given.
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03 - Manual Gearbox
00 - General

AX
K C
AV
AW
N
J
BB
AV Retaining nut
AW Washer 2
AX Yoke
BB Oil seal
2. Transfer gear- output shaft end float check. Refer L
to Figure 786. C DTI
J Special sleeve tool
2.1. Install the special tool sleeve which K Special tool nut
temporarily replace the output yoke and L Bolt 2
attached with special tool nut and tighten M Support pillar
the nut to the correct torque value. N Torque wrench
2.2. Check for the end float while tightening nut.
2.9. Subtract the end float obtained in step 2.7
2.3. If there is no end float then check that the from the solid spacer thickness value (13.70
bearing cups are pushed fully into the case. mm).
2.4. Refer to the parts catalogue for the correct 2.10. Subtract 0.120mm to allow for theoretical
bearing installation. bearing tolerance and pre-load.
2.5. Install the special tool so that the fork end 2.11. If the there is no spacer of the thickness
can engage in the special tool nut and then valued derived in step 2.10 use the next
tighten the bolt 2. smallest spacer.
2.6. Install a DTI. 2.12. Remove the special nut and sleeve, also
2.7. Set the torque wrench to the specified remove the rear bearing and the 13.70 mm
value and then measure the end float while solid spacer.
rotating the output shaft. 2.13. Install the correct size spacer. Do not
Torque: 35N·m install the oil seal at this stage. Make sure
that the outer bearing is not damaged.
2.8. To select the right size spacer 3 do the step
from 2.9 to 2.11. 2.14. Install the sleeve and initially tighten the
nut to the correct torque value. Check that
there is no end float and rolling torque
is less than 1.5 Nm (1.0 lb-ft). If the
rolling torque exceeds 1.5 Nm (1.0 lb-ft),
check that the output shaft is assembled
correctly.
2.15. If the rolling torque is too high, install the
next larger size spacer 3. If there is end
float, install the next smaller size spacer 3.
2.16. Remove the special nut and sleeve.
3. If removed, follow the below steps. Refer to
Figure 787.
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00 - General
3.1. Lubricate between the seal lips before

installing the new oil seal. The seal is not
attached to the back of the housing.
3.2. Use a service tool to locate the seal and
install the output yoke.
3.3. Installed the washer 2 in the correct
orientation with plain face uppermost as
shown in figure.
3.4. Install a new retaining nut and tighten the
nut to the correct torque value.
Figure 787.
AX
AV
AW
BB
AV Retaining nut
AW Washer 2
AX Yoke
BB Oil seal
3.5. If the correct size spacer is selected the
rolling torque must be the specified value
when the retaining nut is fully tightened.
Torque: 2N·m
next larger size spacer. If there is end float,
install the next smaller size spacer.
3.7. Use a square-ended staking tool to carefully
stake the nut into the slot.
Table 312. Spacer Selection Example

Value
Service Spacer 13.70
Subtract end float 0.41
Total 13.29
Subtract tolerance and 0.12
preload
Result 13.17
Use next smallest spac- 13.15
er

Item Description Nm
F Bolt 1 56
AV Retaining nut 300
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00 - General
Remove and Install
Remove 4. Make sure that the engine will be safely

supported when the transmission components
The following procedures are for a typical are removed.
gearbox installation. There will be some procedural
differences dependant on machine variant. Before 5. Put a label on the hoses to help installation.
you attempt to remove the engine and gearbox make 6. Disconnect the external oil hoses and pipes,
sure that all the necessary components have either typically as follows.
been removed, or safely disconnected.
6.1. Oil cooler hose 1 and hose 2.
6.2. Bevel gearbox drain pipe.
2. Due to the configuration of the engine and
transmission mounting system the gearbox 6.3. Plug all the open ports and hoses to prevent
should be removed from the machine, together contamination.
with the engine, bevel gearbox, torque converter 7. Support the gearbox with suitable lifting
and hydraulic pump as a complete assembly. equipment.
8. Remove the gearbox to torque converter housing
3. Support the engine and transmission assembly bolts.
on a suitable frame, then remove the engine
lifting beam. 9. Carefully remove the gearbox from the torque
converter, keeping the assemblies aligned to
each other.
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Figure 788.
B
A Hose 1 B Hose 2
C Gearbox drain pipe D Torque converter housing bolts
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00 - General
Install
steps.
1.1. When you install, make sure that the
gearbox is aligned to the torque converter
housing.
1.2. Make sure that the alignment pin on the
torque converter pump drive shaft engage
with the recesses in the pump.
1.3. Do not damage the oil seal.
1.4. Do not use housing bolts or any other
device to pull the assemblies together.
1.6. Make sure you install any cable tie locators
retained by the bolts
1.7. Connect and adjust the gear shift cables.
Refer to (PIL 09-28-00)
1.8. Fill the engine with the correct oil. Refer to
(PIL 15-00).
1.9. Check the transmission oil level and top up
as required. Refer to (PIL 27-00).
1.10. Adjust the park brake. Refer to (PIL
24-18).
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(For: SS700 MK2)

Special Tools
Bearing Press 892/00179 1
Spanner
Selector Shaft Lock 892/01077 1
Screw
Main Shaft Adjuster 892/01078 1
Consumables
JCB Multi-Gasket 4102/1212 0.05L E D
and Sealer (Medium 4101/0251 0.05L D Bolt 1
Strength) E Pump 1
Lifting Equipment 1.3. Remove the pump 1 from the gearbox.

You can be injured if you use incorrect or faulty lifting 2. Some applications do not have a gearbox driven
equipment. You must identify the weight of the item to main hydraulic pump. if there is no gearbox
be lifted then choose lifting equipment that is strong driven pump start from: 3.
equipment is in good condition and complies with all 3. Remove the circlip 1 and then remove the pump
local regulations. 1 drive shaft with its bearing. Refer to Figure 790.
Cleanliness is of the utmost importance when

servicing the gearbox. All precautions to prevent any
ingress of dirt, grit etc. must be taken.
Clean the exterior of the gearbox assembly. Refer to

Manual Gearbox- Clean. Refer to (PIL 27-03).
Disassembly
1. Remove the main hydraulic pump 1 from the
gearbox if it is not removed. Refer to Figure 789.
1.1. Support the pump 1.
1.2. Remove the bolt 1.
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G C
C 2WD and 4WD clutch

H
9. Some types of torque converter housing prevent
the 2WD/ 4WD clutch unit being removed unless
the torque converter housing is removed first. If
J necessary remove all the bolt 2 and lift of the
torque converter housing. Refer to Figure 792.
F
F Circlip 1 Figure 792.
G Pump 1 drive shaft
H Shaft sealing ring
J Bearing 1
4. Remove and discard the shaft sealing ring. Refer
to Figure 790.
5. Drain the oil from the gearbox.
6. Remove the suction strainer. Refer to Manual CX
Gearbox, Suction Strainer- Remove and Install
(PIL 27-03-40).
7. Remove the oil filter. Refer to Manual Gearbox,
Filter- Remove and Install (PIL 27-03-39).
8. Remove the 2WD (Two Wheel Drive) and 4WD
(Four Wheel Drive) clutch. Refer to Figure 791.
CX Bolt 2
10. Remove all the bolts 3 and lift off the pump 2 from
the input shaft. Refer to Figure 793.
11. Remove and discard the pump 2 sealing washer.
27 - 37 9813/7600-3 27 - 37
27 - Driveline
03 - Manual Gearbox
00 - General

B A Q P
R
S
L
N
A Bolt 3 (x4) T
B Pump
K Pump 2 sealing washer M Capscrew (x4)
L Sealing ring N Bolt 4 (x4)
P Screw
12. Remove and discard the pump 2 sealing ring. Q Clamp
Refer to Figure 793. R 2WD and 4WD clutch solenoid control valve
S Electrical connector block
13. If a pump 2 is worn out or damaged, it may cause T Hydraulic pipe
more damage to the gearbox. Disassemble and
check the gearbox. Refer to Figure 793. 18.5. Remove the screw and then remove the
clamp.
14. Put the transmission in a vertical position with the
torque converter housing face down. 18.6. Make sure that you do not hold the
component by its electrical connector
15. If the housing was removed, temporarily install it. block.
16. Remove the capscrews and then remove the 18.7. The connector block is not designed as a
solenoid control valve. Refer to Figure 794. leverage point.
17. Remove the O-rings installed around the ports on 19. Mark the position of the gear shift turret, to make
the mating face of the solenoid valve body. Refer sure correct assembly of the gear shift turret.
to Figure 794. Refer to Figure 794.
18. On a 4WD clutch transmission, do the following: 20. Remove all the bolt 4 and remove the gear shift
Refer to Figure 794. turret. Refer to Figure 794.
18.1. Remove the 2WD and 4WD clutch 21. Remove the gasket 1. Refer to Figure 794.
hydraulic pipe.
22. If installed, remove the baffle plate. Refer to
18.2. Remove the 2WD and 4WD clutch Figure 794.
solenoid control valve.
23. Some gearboxes have a gear shift turret for use
18.3. Note the phasing of the electrical block to with a remote gear shift. For removal refer to: 19
make sure the correct phasing at the time to 22. Refer to Figure 794.
of assembly.
24. Remove the plug 1. Refer to Figure 795.
18.4. Remove the valve cartridge from the case.
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03 - Manual Gearbox
00 - General
25. Remove the pressure maintenance valve spool, Figure 796.

and spring 1. Refer to Figure 795. AU AT
Figure 795.
U
AP BX AD
AB
AC
AS AN AQ
BU
AR
AD Plug 2
AN Washer 1
AP Torque converter pressure relief valve ball
AQ Plug 3
U Plug 1 AR Spring 3
V Pressure maintenance valve spool AS Torque converter pressure regulating valve
AB Spring 1 spool
AC Pressure maintenance valve body AT Bolt 6
BU Bolt5 AU Gear case (rear)
BX Spring 2
26. Remove all the bolts 5 and remove the pressure
maintenance valve body. Refer to Figure 795. 31. Remove the torque converter pressure
regulating valve spool and spring 3 assembly.
27. Remove and discard the gasket 2. Refer to Refer to Figure 796.
Figure 795.
32. Remove all the bolt 6 and lift off the rear case.
28. Remove the plug 2. Refer to Figure 796. Refer to Figure 796.
29. Remove the torque converter pressure relief 33. Make sure that you retrieve the bearing outer
valve ball, washer 1 and spring 2 assembly. Refer cups from inside the case. Keep the cups
to Figure 796. together with their associated bearing. Refer to
Figure 796.
30. Remove the plug 3. Refer to Figure 796.
34. Remove the selector detent plugs. Refer to
Figure 797.
35. Remove the selector detent balls and spring 4.
36. Remove the selector fork retaining screws and
lift off the selector rods. Refer to Figure 797.
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03 - Manual Gearbox
00 - General
Figure 797. Figure 798. Blocking pin type synchro
BM
BL
Z
AA
BN
X W
Y
W Selector detent plug BL Interlock plunger
X Selector detent ball BM 3rd and 4th synchro hub
Y Spring 4 BN Layshaft
Z Selector fork retaining screw
AA Selector fork 42. Lift off the layshaft assembly. Refer to Figure 798.
37. The selector forks are not interchangeable. Mark 43. Remove the bearing outer cup and its spacer 1
the forks to make sure that they are placed from the front case. Keep the cup and spacer
correctly at the time of assembly. Refer to Figure 1 together with its associated bearing. Refer to
797. Figure 798.
38. Remove the selector forks. Refer to Figure 797. 44. Remove the idler gear upper thrust washers and
bearing 2. Keep the thrust washers and bearing
39. At the time of disassembly, push out the interlock 2 together. Refer to Figure 799.
plunger. Refer to Figure 797.
45. Tilt the main shaft to one side and lift off the
40. Remove the torque converter pressure idler gear together with the needle roller bearing.
regulating valve spool and spring. Refer to Figure Refer to Figure 799.
797.
46. Remove the idler gear lower thrust washers and
41. Disassembly- Blocking pin type synchro. Refer to bearing 3. Keep the thrust washers and bearing
Figure 798. 3 together. Refer to Figure 799.
41.1. Lift off the 3rd and 4th synchro hub. Mark 47. Remove the idler gear spacer. Refer to Figure
the positions of the synchro hubs to make 799.
sure that they are installed correctly with
the mating cups at the time of assembly.
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03 - Manual Gearbox
00 - General
Figure 799. Special Tool: Drive Coupling Spanner (Qty.: 1)

AE 54. Prise out the oil seal and discard it. Refer to
AG
Figure 800.
AM
55. Remove the output shaft assembly and take out
the outer bearing. Remove the spacer 3 and
AH keep it for assembly. Refer to Figure 800.
AF AJ
Figure 800.
AK AV
AW
AL
AX
BB
AZ
BA
AE Upper thrust washer and bearing 2
AF Main shaft AY
AG Idler gear
AH Needle roller bearing BD
AJ Lower thrust washer and bearing 3
AK Idler gear spacer BE
AL Reverse clutch
AM Idler gear spindle
AV Retaining nut
48. Tilt the main shaft to one side and lift off the AW Washer 2
forward and reverse clutch. Discard the sealing AX Yoke
rings. Refer to Figure 799. AY Output shaft assembly
AZ Outer bearing
49. Remove the main shaft. Refer to Figure 799. BA Spacer 3
BB Oil seal
50. Remove the bearing outer cup and its spacer2 BD Output shaft inner bearing
from the front case. Keep the cup and spacer BE Main shaft bearing outer cup
2 together with its associated bearing. Refer to
Figure 799. 56. Make sure that you use a suitable puller to
remove the output shaft inner bearing. Refer to
51. The idler gear spindle is a press fit in the case. Figure 800.
Use a suitable puller, screwed into the 1/2 in.
B.S.P. hole in the end of the spindle for extraction. 57. Remove the main shaft bearing outer cup from
Refer to Figure 799. the centre of the output shaft transfer gear. Refer
to Figure 800.
52. The spindle should only be removed if it is
damaged, and needs to be replaced. Refer to 58. Main shaft- blocking pin type synchroniser
Figure 799. disassembly. Refer to Figure 801.
53. Unstake the nut. Whilst holding the output yoke 58.1. Using a bearing press and a bearing
with the drive coupling spanner tool, remove the adaptor to pull out the 3rd gear with
output shaft nut and the washer 2 below it. From the synchro cup, gear, spacer washer, oil
below support the output shaft and lift off the retention washer and the bearing 4. Keep
yoke. Refer to Figure 800.
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27 - Driveline
03 - Manual Gearbox
00 - General
the synchro hubs and cups in their original Figure 802.

relationship.
CM CW CT
Special Tool: Bearing Press (Qty.: 1)
58.2. Remove the needle roller bearings.
Figure 801. Blocking pin type synchroniser
CH CG CF CE CD CC CJ
CS CU CR CQ CN CP
CM Bearing 6
CN 4WD transfer gear
CP Bearing 7
CK CQ 1st gear
CR 1st gear needle roller bearing
CC 3rd gear CS Synchro assembly
CD Synchro cup CT 2nd gear
CE Gear CU 1st gear needle roller track ring
CF Spacer washer CW 2nd gear needle roller bearing
CG Oil retention washer
CH Bearing 4 59.5. Be careful about the components which
CJ Needle roller bearing can be lost at the time of removal.
CK Bearing 5 59.6. Hold the unit together with the synchro
cones on each side and lift off.
58.3. Remove the bearing 5 from the main shaft
using a press tool. 59.7. Keep the synchro cones, rings and hub in
their original relationship.
Special Tool: Bearing Press (Qty.: 1)
59.8. Remove the 2nd gear needle roller
59. Layshaft- disassembly. Refer to Figure 802. bearing.
59.1. Remove the bearing 6. Remove the 4WD 60. If in an earlier step, the torque converter housing
transfer gear and bearing 7 from the is not removed, then remove all the bolt 2 and
layshaft. On 2WD machines a spacer 4 is remove the housing. Refer to Figure 803.
installed in place of the transfer gear.
59.2. Lift off 1st gear.
59.3. Remove 1st gear needle roller bearings.
59.4. Use a press to push off the 2nd gear, the
synchro assembly and the 1st gear needle
roller track ring.
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03 - Manual Gearbox
00 - General

BG BF
CX
BF
CX Bolt 2
Before assembly inspect the gearbox. Refer to

Gearbox- Check condition (PIL 27-03).
Note: All bearings must be lightly oiled before BF Adaptor

assembly. Make sure all components are thoroughly BG Orifice restrictor
clean and renew all O-rings.
1.4. Apply sealant to the threads of the plugs.
Assembly Consumable: JCB Threadlocker and Sealer
(Medium Strength)
Important: Spacers are used to control the main 1.5. If the new plugs are supplied with a sealant
shaft and layshaft end float. Usually these spacers patch, then case sealant is not necessary.
can be installed again to get the correct end float,
even if the components are replaced. However, 1.6. Before you install the adaptor make sure
after assembly, the clutch shaft end floats must be that the orifice restrictor is installed inside
checked to confirm correct assembly and tolerances. the port.
This is particularly important if components such as
1.7. Tighten the restrictor to the correct value.
the clutch shafts or the gearbox case are replaced. If
the end float is found to be more than the permissible 2. If the torque converter housing is removed,
limits new spacers must be installed. Make sure that temporarily install it. The gearbox can again be
the correct spacer kit is available. positioned standing on the face of the housing
ready for assembly.
1. Case- assembly. Refer to Figure 804.
3. Layshaft- assembly. Refer to Figure 805.
1.1. If the gearbox cases are to be replaced,
make sure that you put the blanking plugs 3.1. Lubricate the bearing surface of the shaft.
and adaptors where it is necessary.
3.2. Install the needle roller bearings (wider
1.2. Check the original cases and identify the bearing first), followed by the 2nd gear.
blanking plugs and adaptor positions.
3.3. Install the synchro assembly, then push fit
1.3. Move the plugs and the adaptors to the new the bearing track.
case.
3.4. Move the 1st gear needle roller bearings
over the track.
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03 - Manual Gearbox
00 - General
Figure 805. Figure 806. Blocking pin type synchroniser

CM CW CT
CH CG CF CE CD CC CJ
CK
CS CU CR CQ CN CP
CC 3rd gear
CM Bearing 6 CD Synchro cup
CN 4WD transfer gear CE Gear
CP Bearing 7 CF Spacer washer
CQ 1st gear CG Oil retention washer
CR 1st gear needle roller bearing CH Bearing 4
CS Synchro assembly CJ Needle roller bearing
CT 2nd gear CK Bearing 5
CU 1st gear needle roller track ring
CW 2nd gear needle roller bearing 4.6. Note the correct orientation of both the
washers.
3.5. Apply oil on the bearings.
4.7. Lubricate the bearing 4 and push the
3.6. Install the 1st gear over the needle roller bearing 3 onto the shaft.
bearings.
4.8. Lubricate bearing 5 and push the bearing
3.7. Assemble the 4WD transfer gear over onto the assembled main shaft.
the splines. On 2WD machines move the
spacer over the splines. 5. Make sure that the layshaft bearing outer cup
3.8. Put the bearing 6 and bearing 7 on the is installed to the rear case before installing the
assembled layshaft. Lubricate the bearings. transfer gear/output shaft. Refer to Figure 807.
4. Main shaft assembly- blocking pin type 6. Transfer gear- output shaft assembly. Refer to
synchroniser. Refer to Figure 806. Figure 807.
4.1. Lubricate the main shaft bearing surface. 6.1. Before you install, lubricate the output shaft
inner bearing.
4.2. Install the needle roller bearings.
6.2. Install the bearing outer cup to the case and
4.3. Assemble the 3rd gear and the synchro cup. cup to the rear case.
4.4. Install the synchro gear. 6.3. Install the service solid spacer 921/52620
4.5. Install the spacer washer and the oil (13.70 mm) over the output shaft and
retention washer. assemble into the case.
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03 - Manual Gearbox
00 - General

AX
BH
AV
BJ
AW
AV
AW
BB
AX
BB
AZ
AV Retaining nut
AW Washer 2
AX Yoke
BB Oil seal
11. If the correct size spacer is selected the rolling
BA torque should be the specified value when the
retaining nut is fully tightened. Refer to Figure
AY 808.
Torque: 2N·m
BD
12. If the rolling torque is too high, install the next
AV Retaining nut largest size spacer. If there is end float, install the
AW Washer 2 next smallest size spacer. Refer to Figure 808.
AX Yoke
AY Output shaft assembly 13. Use a square-ended staking tool to carefully
AZ Outer bearing stake the nut into the slot. Refer to Figure 808.
BA Spacer 3
BB Oil seal 14. Push the idler gear spindle into the front gear
BD Output shaft inner bearing case. Refer to Figure 809.
BH Layshaft bearing outer cup
15. Make sure that the forward reverse shaft front
BJ Output shaft bearing outer cup
bearing outer cup is correctly located inside the
6.4. Lightly oil on the output shaft outer bearing front case. Refer to Figure 809.
and on the cup, then attach them to the
16. Lubricate the forward reverse shaft front bearing.
output shaft.
6.5. Do not install the oil seal at this stage.
7. Install the new oil seal and lubricate the seal lips
before installing. The seal is not attached to the
back of the housing. Refer to Figure 808.
8. Use a service tool to locate the seal and install
the output yoke. Refer to Figure 808.
9. Installed the washer 2 in the correct orientation
with plain face uppermost as shown in figure.
10. Install a new retaining nut and tighten the nut to
the correct torque value. Refer to Figure 808.
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03 - Manual Gearbox
00 - General

AM AL AE AG
BW
AM
AH
AF AJ
BK AK
AL
BV
AL Forward reverse shaft

BK Position 1
BW Gear case (front)
17. Install the bearing outer cup in the front case at
the position 1. Refer to Figure 809.
18. Carefully lower the forward reverse shaft unit into
the case. Refer to Figure 809. AE Upper thrust washer and bearing 2
AF Main shaft
19. Lubricate the shaft sealing ring and then install AG Idler gear
them. Refer to Figure 809. AH Needle roller bearing
AJ Lower thrust washer and bearing 3
20. Lubricate the main shaft front bearing. Refer to AK Idler gear spacer
Figure 810. AL Reverse clutch
21. Install the bearing spacer followed by the bearing BV Position 2
outer cup in the front case at the position 2. Refer
to Figure 810. 24. Install the lower thrust washers and bearing 3
assembly. Then lubricate and install the needle
22. Carefully lower the main shaft assembly into the roller bearing. Refer to Figure 810.
case. Refer to Figure 810.
25. Install the idler gear to the spindle, while tilting
23. Install the idler gear spacer. Refer to Figure 810. the main shaft to one side. Refer to Figure 810.
26. Install the upper thrust washers and bearing 2
assembly. Refer to Figure 810.
27. Lubricate the front end bearing of the layshaft.
28. Install the bearing spacer and the outer cup in the
front case at the postion3. Refer to Figure 811.
29. Carefully lower the layshaft assembly into the
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03 - Manual Gearbox
00 - General

DN DM Z
BM
BL
X Y
AA
BN
BQ
DT DU W
BL Interlock plunger
DQ DP
BM 3rd and 4th synchro hub
BN Layshaft W Selector detent plug
BQ Position 3 X Selector detent ball
Y Spring 4
30. Install the remaining synchronising components Z Selector fork retaining screw
to the main shaft. Make sure that you install all of AA Selector fork
the synchronising components into there original DM Selector rod
locations. Refer to Figure 811. DN Main shaft
31. Use a suitable wire support to locate the interlock DP Selector shaft lock screw
plunger into its bore. Lubricate the plunger to hold DQ Main shaft adjuster
the plunger in position. If necessary, access is DT 3rd and 4th gear selector detent assembly
available through a 1/4 BSP side drilling. Refer DU 1st gear selector detent ball and spring
to Figure 811. assembly
32. Install the selector forks into there original 37. Make sure that the each gear is engaged
location. Refer to Figure 812. correctly. Refer to Figure 812.
33. Move the selector rods into the position, make 38. Make sure that the interlock plunger does not let
sure that the interlock plunger is not moved. two gear ratios engage at the same time. Refer
Refer to Figure 812. to Figure 812.
34. Apply sealant to the selector fork retaining 39. Remove the 3rd and 4th gear selector detent
screws and tighten the retaining screws to the assembly. Refer to Figure 812.
correct torque value. Refer to Figure 812. 40. Lift the selector rod to select the 4th gear. Refer
Consumable: JCB Threadlocker and Sealer to Figure 812.
(Medium Strength)
41. With 4th gear selected temporarily, lock the rod in
35. Install the gear selector detent ball and spring 4 position by screwing in the locking screw. Refer
into the position on the case. Apply sealant to the to Figure 812.
selector detent plug and then tighten the selector Special Tool: Selector Shaft Lock Screw (Qty.: 1)
detent plug correctly. Refer to Figure 812.
Consumable: JCB Threadlocker and Sealer 42. Temporarily install a shaft adjuster tool to the
(Medium Strength) torque converter end of the main shaft. If the
tool is not available use an approximately 100mm
36. Temporarily install the 3rd and 4th gear selector long suitable M8 bolt. Refer to Figure 812.
detent assembly, do not apply sealant to the plug Special Tool: Main Shaft Adjuster (Qty.: 1)
at this stage. Refer to Figure 812.
27 - 47 9813/7600-3 27 - 47
27 - Driveline
03 - Manual Gearbox
00 - General
43. Apply a bead of JCB Multi-gasket to the mating engages with the case first, followed by 3rd and
surfaces of the case. Put the O-rings on the 4th gear selector rod. Refer to Figure 815.
mating surface of the front case. Refer to Figure
813. 48. Make sure that the main shaft locates with the
output shaft. Refer to Figure 815.
49. It is necessary to push the shaft adjuster tool to
44. Lubricate the reverser shaft ring seals and to keep the shaft correctly aligned. Refer to Figure
the bearings installing into the output end case. 815.
50. Rotate the output shaft back and forth to engage
Figure 813. the gears on the layshaft. Refer to Figure 815.
BZ BW Figure 815.
AX
AT
BW Gear case (Front)

BZ O-ring
45. Make sure that the forward reverse shaft ring
seals are in good condition before installing into
the output end case. Refer to Figure 813.
46. Make sure that the three bearing outer cups are
correctly located. Two are located inside the case
and the other one is located in the centre of the DQ DP
output shaft transfer gear. Refer to Figure 814.
Figure 814. AT Bolt 6
AX Yoke
DR DP Selector shaft lock screw
DQ Main shaft adjuster
DR 51. Do not give excessive force when installing the
output end case. Refer to Figure 815.
52. Apply sealant to all the bolt 6 and tighten the bolt
6 to the correct torque value. Refer to Figure 815.
(Medium Strength)
DR 53. Remove the shaft lock screw and install the
DS selector detent ball and spring 5 at the same
position. Refer to Figure 815.
DR Bearing outer cup
DS Output shaft transfer gear 54. Apply sealant and install the selector detent plug.
47. Carefully lower the rear case into its position.
Make sure that the forward reverse unit shaft Consumable: JCB Threadlocker and Sealer
(Medium Strength)
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27 - Driveline
03 - Manual Gearbox
00 - General
55. Tighten the selector detent plug correctly. Refer Figure 817.
to Figure 815.
56. End float check- forward and reverse unit.
57. End float check- main shaft unit.
58. End float check- layshaft.
59. Install the 2WD / 4WD unit.
60. Before you install the SAE (Society of Automotive
Engineers) type housing, install the bolt 8
(M10*30). It is not possible to install the bolt 8
after the housing is attached with the gearbox.
Refer to Figure 816. CL
Figure 816.
CL Gearbox cover mating surface

62. Install the torque converter housing. Apply
sealant to the bolt 2. Refer to Figure 818.
Figure 818.
BC
CX
BC Bolt 8 (M10x30mm)
61. Apply a bead of JCB Multi-gasket to the mating CX Bolt 2
face of the gearbox cover. Refer to Figure 817.
Consumable: JCB Multi-Gasket 63. Tighten the bolt 2 to the correct torque value.
64. Put a new pump 2 sealing ring into its correct
position. Refer to Figure 819.
65. At the time of installation make sure that the
pump 2 is aligned with the mounting holes. Refer
to Figure 819.
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03 - Manual Gearbox
00 - General
Figure 819. 74. Use a new gasket and mount the pressure
maintenance valve body on the case. Refer to
B A Figure 820.
Figure 820.
AB U
K
AC
AP AN AD
BU
L AS BX AQ
A Bolt 3 (x4)
B Pump
K Pump 2 sealing washer
AR
L Sealing ring
U Plug 1
66. Install the new sealing washer and the bolt 3. V Pressure maintenance valve spool
Refer to Figure 819. AB Spring 1
67. Tighten the bolt 3 to the correct torque value. AC Pressure maintenance valve body
Refer to Figure 819. AD Plug 2
AN Washe r1
68. Install the torque converter pressure relief valve AP Torque converter pressure relief ball
assembly. Install the valve ball and the spring 2. AQ Plug 3
Refer to Figure 820. AR Spring 3
AS Torque converter pressure regulating valve
69. Make sure that a larger diameter of spring 2 is spool
located correctly over the spigot on the plug 2. BU Bolt 5
Refer to Figure 820. BX Spring 2
70. Use a new sealing washer 1 and apply sealant to 75. Apply sealant to the bolt 5 and tighten the bolt5
the plug 2. Refer to Figure 820. to the correct torque value. Refer to Figure 820.
Consumable: JCB Threadlocker and Sealer Consumable: JCB Threadlocker and Sealer
(Medium Strength) (Medium Strength)
71. Tighten the plug 2 correctly. Refer to Figure 820. 76. Do not remove the protective cover of the
gasket until it is required. This is to prevent
72. Install the torque converter pressure regulating contamination of the sealant applied on the
valve assembly. Install the valve spool and the gasket. Refer to Figure 820.
spring 3. Refer to Figure 820.
77. Assemble the pressure maintenance valve spool
73. Apply sealant to the plug 3 and tighten the plug and spring 1 into the valve block. Refer to Figure
3 correctly. Refer to Figure 820. 820.
(Medium Strength) 78. Apply sealant to the plug 1 and tighten the plug 1
to the correct torque value. Refer to Figure 820.
(Medium Strength)
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03 - Manual Gearbox
00 - General
79. Do not over tighten the Plug 1, as it can damage 87. The connector block is not designed as a
the aluminium housing. Refer to Figure 820. leverage point. Refer to Figure 821.
80. Put the new O-rings around the ports on the 88. Install the clamp and then install the screw. Refer
mating surface of the solenoid control valve. to Figure 821.
89. Tighten the screw to the correct torque value.
81. Install the solenoid valve onto the pressure Refer to Figure 821.
maintenance valve and make sure that the port
P aligns with the metering orifice in the pressure 90. Tighten the union nuts to the specified torque
maintenance valve body. Refer to Figure 821. value. Refer to Figure 821.
Torque: 24N·m
82. Apply sealant to the capscrews. Refer to Figure
821. 91. Put a new gasket (not shown) on the case
Consumable: JCB Threadlocker and Sealer followed by the gear lever turret baffle plate (if
(Medium Strength) installed). Make sure the plate is in the correct
orientation. Refer to Figure 822.
83. Tighten the capscrews to the correct torque
value. Refer to Figure 821. Figure 822.
84. Install the 2WD / 4WD solenoid control valve.

BT
85. Make sure that its electrical connector block is
phased correctly. Refer to Figure 821.
86. Make sure that you do not hold the component
by its electrical connector block. Refer to Figure
821.
Figure 821.
Q P
R
S
BT Baffle plate
92. If necessary, put a second gasket in position and
then install the gear lever turret assembly. Refer
to Figure 823.
93. Make sure that the turret assembly is in the
correct orientation. Refer to Figure 823.
M Capscrew (x4)
P Screw
Q Clamp
R 2WD / 4WD solenoid control valve
S Electrical connector block
T Hydraulic pipe
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03 - Manual Gearbox
00 - General
Figure 823. 102.2.Insert the tube fully down bore in the case.
Engage the nut and tighten down loosely
onto the seal.
102.3.Tighten the nut fully after the tube has
been correctly routed.
103.If necessary, assemble the pump 1 (main
hydraulic pump). Refer to Figure 824.
103.1.Install a new sealing ring on the pump 1
drive shaft.
Figure 824.
N Bolt4 (x4)
94. Make sure that the turret selector mechanism G
engages correctly with the gearbox selector
forks. Refer to Figure 823. H
95. Apply sealant to the bolt 4 and secure the turret
assembly with the bolt 4. Refer to Figure 823.
Consumable: JCB Threadlocker and Sealer J
(Medium Strength)
F
96. Tighten the bolt 4 to the correct torque value. F Circlip 1
Refer to Figure 823. G Pump 1 drive shaft
97. Check the gear selection. Refer to Figure 823. H Shaft sealing ring
J Bearing 1
98. It is recommended that a 75 micron (0.075mm)
service suction strainer is installed to clean the 103.2.Install the pump 1 drive shaft followed by
system after a major overhaul. the bearing 1 and circlip 1.
99. After the first 100 hours of operation remove the 104.The pump 1 (main hydraulic pump) can be
service strainer and install a production strainer. installed at this stage or after the gearbox has
been installed to the machine.
100.Put a new gasket and install the suction strainer.
Refer to Manual Gearbox, Suction Strainer-
Remove and Install (PIL 27-03-40).
101.Install a new filter. Refer to Manual Gearbox,
Filter- Remove and Install (PIL 27-03-39).
102.Install the dipstick or oil filler tube (not shown).
102.1.Install the nut into the tube followed by the
seal.
27 - 52 9813/7600-3 27 - 52
27 - Driveline
03 - Manual Gearbox
00 - General

Item Description Nm
BG Orifice restrictor 18
AV Retaining nut 300
Z Selector fork retaining screw 35
AT Bolt 6 56
CX Bolt 2 56
A Bolt 3 28
BU Bolt 5 10
U Plug 1 56
M Capscrew 5
P Screw 12
N Bolt 4 56
27 - 53 9813/7600-3 27 - 53
27 - Driveline
03 - Manual Gearbox
06 - Clutch - Forward/Reverse
06 - Clutch - Forward/Reverse Introduction

Introduction .................................................... 27-54 The clutch is a mechanical device that engages
Check (Condition) .......................................... 27-55 and disengages the transmission, from driving shaft
Calibrate ........................................................ 27-55 to driven shaft. The clutch is located between the
Disassemble and Assemble .......................... 27-56 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 - 54 9813/7600-3 27 - 54
27 - Driveline
03 - Manual Gearbox
(For: SS700 MK2) (For: SS700 MK2)

Carry out a visual inspection of the friction and End Float Setting
counter plates:
1. Use a DTI (Dial Test Indicator) to measure the
Counter plates end float of the pressure end plate.
1. Light scoring or polishing is permissible, plates 2. The pressure end plate end float should be within
that are not flat, worn or heavily marked or scored the specified limit.
must be replaced with a new set. Dimension: 2.5–4.4mm
Friction plates Figure 825.
1. The cross hatching should be clearly visible,

plates that are not flat, have friction material
damage or scoring must be replaced with a new
set.
2. DO NOT mix old and new plates, if a plate is
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
freely, do not bend or distort the cage to install. If
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
3. If it is necessary to adjust the end float, to bring

it within the specified limit mentioned in step 2,
install shims between the retaining circlip and the
pressure end plate.
27 - 55 9813/7600-3 27 - 55
27 - Driveline
03 - Manual Gearbox
D
(For: SS700 MK2) C
D
Disassembly
1. Carefully remove the piston ring seals. Refer to
Manual Gearbox, Piston Ring Seal, Remove and
Install (PIL 27-03-45). Refer to Figure 826. E
Figure 826.
A
A
A C Thrust bearing 1
D Thrust washer 1
B E Gear and splined hub assembly
5. Remove the gear and the splined hub assembly
with the needle roller bearing and the spacer.
6. Make sure that you have note the location of the
spacer for its correct assembly. Refer to Figure
827.
7. Remove the thrust bearing 2 and the thrust
washer 2. Refer to Figure 828.
Figure 828.
A Piston ring seal
B Clutch end bearing
G
2. If the piston ring seals are excessively worn then F
check for burrs or damage on the shaft grooves.
If necessary remove burrs with a fine grade G
abrasion paper and oil. Refer to Figure 826.
3. Use a puller to remove the clutch end bearing. H
J
4. Remove the thrust bearing 1 and the thrust
washer 1. Refer to Figure 827.
F Thrust bearing 2
G Thrust washer 2
H Friction and counter plates retaining circlip
J Pressure end plate
27 - 56 9813/7600-3 27 - 56
27 - Driveline
03 - Manual Gearbox
8. Remove the friction and counter plate retaining Figure 830.

circlip. Refer to Figure 828.
9. Remove the pressure end plate. Refer to Figure
828.
10. Remove the friction plates and the counter
plates. Keep them together in set. Refer to Figure
829.
11. Do not mix the plates with those from other
clutches assemblies. Refer to Figure 829.
Figure 829.
L 14. Lift off the spring retaining plate. Refer to Figure

831.
15. Remove the spring. Refer to Figure 831.
M
Figure 831.
N
P
K Friction plate
L Counter plate
M Disc spring
12. Remove the disc spring. Refer to Figure 829.
13. Put the clutch assembly in a suitable press to
compress the piston spring then remove the
circlip. Refer to Figure 830.
N Spring retaining plate

P Spring
Q Oil baffle
16. Remove the oil baffle plate. Refer to Figure 831.
17. Turn the assembly over and hit the clutch shaft
gently on a piece of aluminium (or wooden) block
to loosen the piston. Refer to Figure 832.
27 - 57 9813/7600-3 27 - 57
27 - Driveline
03 - Manual Gearbox
R Piston
S Piston O-ring
T Shaft O-ring
18. If the piston does not loosen when you hit the
clutch shaft is on aluminium (or wooden) block, 2. Install the oil baffle and the piston spring. Refer
then the hand pump air down the shaft oil inlet to Figure 835.
hole. Refer to Figure 832.
3. Make sure that the spring seats in the piston.
19. Remove the piston. Refer to Figure 833. Refer to Figure 835.
S
N
R
P
T
R Piston
S Piston O-ring
T Shaft O-ring
20. Remove and discard the piston O-ring and shaft
O-ring. Refer to Figure 833.
21. Do the step from 3 to 20 again, to disassemble
the opposite side clutch.
N Spring retaining plate
Before you assemble the clutch assembly check P Spring
the condition of the clutch assembly. Refer to Q Oil baffle
Manual Gearbox, Clutch- Forward/Reverse, Check
Condition (PIL 27-03-06). 4. Install the spring retaining plate. Refer to Figure
835.
Assembly
5. Compress the spring and install the circlip. Refer
1. Install new O-rings to the piston and shaft. to Figure 836.
Lubricate the piston with oil and push fully into the
bore of the clutch housing. Refer to Figure 834.
27 - 58 9813/7600-3 27 - 58
27 - Driveline
03 - Manual Gearbox
6. Install the disc spring and then install the

assembly so that the outer diameter curves are
away from the clutch piston. Refer to Figure 837.
Figure 837.
K
H Friction and counter plates retaining circlip
J Pressure end plate
L 10. Make sure that the teeth are not aligned with the
lubrication slots in the housing. Refer to Figure
838.
M 11. Install the clutch friction and counter plate

retaining circlip. Using an air line, blow air down
the shaft oil inlet hole and check the piston and
clutch pack is free to operate smoothly. Refer to
Figure 838.
end float of the pressure end plate. Refer to
Figure 839.
Figure 839.
K Friction plate
L Counter plate
M Disc spring
7. Install the counter plates and friction plates
alternately, start with a counter plate and finish
with a friction plate. Refer to Figure 837.
8. Install the pressure end plate. Refer to Figure
838.
9. Make sure that the chamfered face is installed,
facing the clutch pack. Refer to Figure 838.
27 - 59 9813/7600-3 27 - 59
27 - Driveline
03 - Manual Gearbox
13. The pressure end plate end float should be within Figure 841.
the specified limit.Refer to Figure 839.
Dimension: 3.2–4.4mm D
C
14. If it is necessary to adjust the end float, to bring it D
within specified limit mentioned in step 13, install
shim between the retaining circlip and pressure
end plate. Refer to Figure 839.
15. Install the thrust washer 2 and thrust bearing 2. E
Figure 840.
G
F
C Thrust bearing 1
G D Thrust washer 1
E Gear and splined hub assembly
20. Lubricate the clutch end bearing and push the
bearing onto the shaft. Refer to Figure 842.
Figure 842.
A
A
A
B
F Thrust bearing 2
G Thrust washer 2
16. Carefully use a thin rod (or screwdriver) to align
the teeth of the clutch plates. Install the gear and
splined hub. Refer to Figure 841.
17. Install the spacer followed by the needle roller
bearing.
A Piston ring seal
18. Make sure that the space is installed first. B Clutch end bearing
19. Install the thrust washer 1 and thrust bearing 1. 21. Install new piston ring seals. Refer to Manual
Refer to Figure 841. Gearbox, Piston Ring Seal, Remove and Install
(PIL 27-03-45). Refer to Figure 842.
22. Do the step from 1 to 21 again, to assemble the
opposite side clutch.
23. Spacer is not installed on the opposite (Forward)
side clutch. Refer to step 17.
27 - 60 9813/7600-3 27 - 60
27 - Driveline
03 - Manual Gearbox
07 - Clutch - 2WD/4WD
07 - Clutch - 2WD/4WD Introduction

Introduction .................................................... 27-61 Refer to Driveline, Manual Gearbox, Clutch-
Component Identification ............................... 27-62 Forward/Reverse, Introduction (PIL 27-03-06).
Check (Condition) .......................................... 27-67
Check (Pressure) .......................................... 27-67
27 - 61 9813/7600-3 27 - 61
27 - Driveline
03 - Manual Gearbox
For: Pressure ON, SS700 MK2

................................................... Page 27-63
For: S1, SS700 MK2, Spring ON
................................................... Page 27-64
................................................... Page 27-65
27 - 62 9813/7600-3 27 - 62
27 - Driveline
03 - Manual Gearbox
(For: Pressure ON, SS700 MK2)
Figure 843. 2 and 4 Wheel Drive Clutch Assembly (Pressure ON)
V
W
X
W
Y
Z
R Q
U T S H
J
K
L
M
N
P
F
E D C B A
A Bolt B Output yoke

C Oil seal D 4WD (Four Wheel Drive) Case
E Bolt 1 F Bearing
G PTFE (Polytetrafluoroethylene) Piston ring seal H O-ring
27 - 63 9813/7600-3 27 - 63
27 - Driveline
03 - Manual Gearbox
J O-ring 1 K Piston
L Oil baffle M Spring
N Retainer plate P Circlip
Q Counter plate R Friction plate
S Pressure end plate T Shim
U Circlip 1 V Thrust washer
W Needle roller bearing X 4WD gear
Y Thrust washer 1 Z Bearing 1
(For: S1, SS700 MK2, Spring ON)
Figure 844. S1 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 2 J Pressure end plate
K Shim L Friction and counter plates
M Circlip 2 N Support washer
P Clutch drum Q Actuating sleeve
27 - 64 9813/7600-3 27 - 64
27 - Driveline
03 - Manual Gearbox
R Disc spring 3 S Piston

T Piston steel ring U O-ring 1
V O-ring 2 W Piston housing
X Shaft

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 (x2) 9B Disc spring 2 (x2)
10 Pressure end plate 11 Shim(s)
12 Friction plates and counter plates 13 Bearing 2
14 Thrust washer 3 15 Piston housing
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27 - Driveline
03 - Manual Gearbox
18 Piston 19 Spring steel ring
20 Disc spring 3 21 Actuating sleeve
22 Clutch drum 23 Shaft
27 - 66 9813/7600-3 27 - 66
27 - Driveline
03 - Manual Gearbox
Check (Condition) Check (Pressure)
Carry out a visual inspection of the friction and (For: SS700 MK2, Spring ON)
counter plates.
Special Tools
Counter plates Description Part No. Qty.
1. Light scoring or polishing is permissible, plates Test
that are not flat, worn or heavily marked or scored Pressure Test Adaptor 993/59300 1
must be replaced with a new set.
1. Assemble the 2 and 4 wheel drive clutch. Refer to
Friction plates the relevant Clutch- Disassemble and Assemble
procedure (PIL 27-03).
plates that are not flat, have friction material 2. Check the clutch pack end float and adjust
damage or scoring must be replaced with a new as required. Refer to the relevant Clutch -
set. Disassemble and Assemble procedure (PIL
27-03).
damaged or worn install a complete new set. 3. Use the service tool to insert the adaptor into
Note:Two different suppliers of the thinner friction the oil gallery in the end of the 2 and 4 wheel
plates (1.6 to 1.7 mm, 0.062 to 0.067 in approx.) drive clutch shaft as shown. Hold the adaptor in
have been used (identify as brown or green), do position with clamp.
not mix the different plates in the same clutch
pack. Special Tool: Pressure Test Adaptor (Qty.: 1)
3. Inspect the mating faces of the gearbox and 4WD 4. Use the hand pump to pressurise the clutch
casings for damage. assembly until the gear can be turned by hand.
Note the pressure gauge reading. Do not exceed
the given value.
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: 8.6–9.3bar (124.6–134.8psi)
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 - 67 9813/7600-3 27 - 67
27 - Driveline
03 - Manual Gearbox
Figure 846.
A Adaptor (Part of 993/59300)

B Clamp (Part of 993/59300)
27 - 68 9813/7600-3 27 - 68
27 - Driveline
03 - Manual Gearbox
For: Pressure ON, SS700 MK2 5. Remove all the bolts that attach the 4WD case to
................................................... Page 27-69 the gearbox. Lift off the 4WD case.
................................................... Page 27-74 6. Remove the 2WD and 4WD clutch from the
gearbox.
................................................... Page 27-76 7. If necessary only remove and replace the bearing
from the drive clutch assembly.
(For: Pressure ON, SS700 MK2)
8. Carefully remove the piston seal ring.
Special Tools
Description Part No. Qty. 9. If the piston ring seal is damaged or excessively
worn then check for burrs or damage on the shaft
groove.
Spanner
10. If necessary remove the burrs with a fine grade
Consumables abrasion paper and oil.
JCB Multi-Gasket 4102/1212 0.05L 11. Use a puller tool to remove the 4WD output gear
with its bearing 1, needle roller bearings and the
thrust washer 1.
Strength) 12. Remove the thrust washer. Note: the thrust
washer and thrust washer 1 are not
Before you disassemble the 2WD (Two Wheel Drive) interchangeable.
and 4WD (Four Wheel Drive) clutch units, drain the
gearbox oil. 13. Remove the circlip 1 and if installed remove the
shims. Keep the shims as an assembly set.
Disassembly 14. Remove the pressure end plate, the clutch pack
1. Use a spanner to hold the output yoke and friction plates and the counter plates. Keep them
remove the bolt. together in a set.
Special Tool: Drive Coupling Spanner (Qty.: 1) 15. Do not mix these plates with the plates from other
clutches.
2. Remove the output yoke.
16. If only the clutch pack is to be removed then do
3. Use the output yoke as a stand. the step 1 to 15 only.
4. Carefully remove and discard the oil seal. Make 17. Use a suitable press and a cut away tube as
sure that the seal housing is not damaged at the shown, to compress the spring and remove the
time of removal. circlip.
27 - 69 9813/7600-3 27 - 69
27 - Driveline
03 - Manual Gearbox
Figure 847.
AA
AA Cut away tube
18. Remove the spring retainer plate, spring and the Before assembly inspect the 2WD and 4WD clutch.
oil baffle.
Note: All bearings must be lightly oiled before
19. Remove the piston and then remove and discard assembly. Make sure that all components are
both the O-ring and O-ring 1. thoroughly clean and replace all O-rings.
The piston housing cannot be separated from the
shaft, as on some other types of 2WD and 4WD
clutches.
27 - 70 9813/7600-3 27 - 70
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03 - Manual Gearbox
Figure 848. Pressure ON
V
W
X
W
Y
Z
R Q
U T S H
J
K
L
M
N
P
F
E D C B A
A Bolt B Output yoke

C Oil seal D 4WD Case
E Bolt 1 F Bearing
G PTFE (Polytetrafluoroethylene) Piston ring seal H O-ring
J O-ring 1 K Piston
L Oil baffle M Spring
27 - 71 9813/7600-3 27 - 71
27 - Driveline
03 - Manual Gearbox
N Retainer plate P Circlip

Q Counter plate R Friction plate
S Pressure end plate T Shim
U Circlip 1 V Thrust washer
W Needle roller bearing X 4WD gear
Y Thrust washer 1 Z Bearing 1
27 - 72 9813/7600-3 27 - 72
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03 - Manual Gearbox
Assembly Figure 850.

following steps. AB
2. Install the new O-ring and O-ring 1 onto the
piston and the shaft. Lubricate the piston with oil
and press fully into the bore of the case.
3. Put the oil baffle, spring into the piston and set
the retainer plate over the spring.
4. Use a suitable press and a cut away tube as
shown, to compress the spring and install the
circlip.
AB
Figure 849.
AA
AB Screwdriver
10. If necessary, add or remove the shims to adjust
the end float.
11. Install the thrust washer, the 4WD gear, the
needle roller bearings and the thrust washer 1.
12. Push the bearing 1 onto the shaft to seat on the
thrust washer 1.
13. Make sure that you do not give any force on the
case i.e. rest the unit on the opposite shaft end,
not the case.
14. Install the two new piston ring seals. Refer
to Piston Ring Seal-Remove and Install (PIL
AA Cut away tube 27-12-45).
5. If only the clutch pack is to be assembled, then 15. If necessary, Install a new bearing on the 2WD
do the step 6 to step 25. and 4WD clutch. Make sure that you do not give
excessive force on the case.
6. Install the friction plates and counter plates
alternatively, starting with a counter plate and 16. Install the 2WD and 4WD clutch to the gearbox.
ending with a friction plate, to assemble the
clutch pack. 17. Apply a thin bead of JCB Multigasket to the 4WD
mating face of the gearbox front case. Install the
7. Install the pressure end plate, shims and the 4WD case on the gearbox.
circlip 1. Consumable: JCB Multi-Gasket
8. Use an air line to blow air into the oil inlet hole 18. Apply sealant to the bolts and secure the 4WD
and check the piston and clutch pack is free to case on the gearbox with bolt 1.
operate smoothly.
9. Use two screwdrivers as shown, to measure the (Medium Strength)
clutch pack end float. The end float should be in
the specified limit. 19. Tighten the bolt 1 to the correct torque value.
Dimension: 1–2.3mm 20. The 4WD clutch and its components are
manufactured using a "set right" system. If the
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27 - Driveline
03 - Manual Gearbox
components are assembled correctly, the shaft remove burrs with a fine grade abrasion
end float should be in be in the specified limit. paper and oil.
Dimension: 0.01–0.16mm 3. With a suitable puller, remove the 4WD gear
together with its bearing 2, thrust washer, and the
21. Rotate the shaft by hand and make sure that it
needle roller bearings (x2).
runs smoothly.
4. Use a suitable press and compress the disc
22. Pull the shaft up and down to find any excessive
springs to remove the circlip 1.
end float. If there is excessive end float or the
shaft runs roughly, disassemble the unit and 4.1. CAUTION: There is approximately 26700N
check for correct assembly. (6000lbf) clamping force acting on the
springs.
23. Install a new oil seal.
5. Remove the disc springs 1 (x2), disc springs 2
24. Install the Output yoke and then install the bolt.
(x2),pressure end plate and the shims.
6. Remove the clutch pack friction plates and
Table 315. Torque Values counter plates.
Item Description Nm 6.1. Keep them together in sets, do not mix the
A Bolt 395 plates with those from other clutches.
E Bolt 1 56 7. Remove the clutch drum retaining circlip 2 and
support washer.
(For: S1, SS700 MK2, Spring ON) 8. Remove the clutch drum and the actuating
sleeve.
Disassemble 9. Remove the disc spring 3.
1. Remove the bearing 1 from the shaft only if it is 10. Remove the piston and its spring steel ring.
to be replaced.
11. Remove and discard the piston O-ring 1 and O-
2. Carefully remove the piston ring seal. ring 2.
2.1. If the piston ring seal is damaged or 12. If necessary, remove the piston housing. The
excessively worn then check for burrs or piston housing is a press fit on the shaft.
damage on shaft grooves. If necessary
27 - 74 9813/7600-3 27 - 74
27 - Driveline
03 - Manual Gearbox
E F
L
F
D
C G N
M
U
H2
K
J
S
T
H1
Y
R
W
V

T Spring steel ring U O-ring 1
X Shaft Y Spacer
Assemble 2. Install the piston housing by pressing the shaft

squarely into the housing (make sure the housing
1. Lubricate the shaft. is securely supported).
3. Install the O-ring 1 and O-ring 2 onto the piston.
27 - 75 9813/7600-3 27 - 75
27 - Driveline
03 - Manual Gearbox
4. Lubricate the piston with oil and press fully into Figure 853.
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 3 into the housing.
7. Put the actuating sleeve onto the disc spring.
8. Install the clutch drum in the housing.
9. Install the support washer and drum retaining
circlip 2.
10. Build up the clutch pack. Install one friction plate
followed by one counter plate.
16. Measure the gap between the pressure end plate
10.1. Continue to install alternate counter and and the actuating sleeve.
friction plates, finish with the pressure
plate. 16.1. The gap should be within the range
specified.
11. Use the 4WD gear to align the clutch plate
splines. Make sure that all the plates are Length/Dimension/Distance: 0.75–1.5mm
engaged with the gear shaft splines. 16.2. If necessary, install a new shim to get the
12. Rotate the 4WD gear back and forth to create correct gap.
maximum backlash then remove the gear taking 16.3. The shim can be a combination of a
care not to disturb the pack. single counter plate, shim (thinner than the
counter plate) or both counter plate and
13. Put the first two disc springs 1 with their convex shim.
sides uppermost, onto the clutch pack. (There
are four disc springs, which are identical). Put the 16.4. Make sure that the clutch pack splines are
other two disc springs 2, with their convex sides still aligned.
down, onto the first two.
17. Install the two needle roller bearings into 4WD
Figure 852. gear.
18. Install the 4WD gear onto the shaft.
19. Install the thrust washer.
20. Apply gearbox oil on the clutch end bearing 2 and
press the bearing onto the shaft to seat on the
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 bearing1 into the
housing cover make sure you install the spacer.
14. Use a suitable press to compress the disc spring
24. Do an operational test of the clutch assembly.
and install the circlip 1.
15. Use levers to remove free play.
Disassemble
1. Carefully remove the piston ring seal from the
shaft.
1.1. If the piston ring seal is damaged or
excessively worn then check for burrs or
27 - 76 9813/7600-3 27 - 76
27 - Driveline
03 - Manual Gearbox
damage on the shaft grooves. If necessary 5. Remove the clutch pack friction plates and
remove burrs with a fine grade abrasion counter plates.
paper and oil.
5.1. Keep them together in sets, do not mix the
2. Use a suitable puller to remove the 4WD gear plates with those from other clutches.
with its related bearing 1, thrust washer 1, needle
roller bearing 1, and needle roller bearing 2. 6. Remove the thrust washer 2.
3. Use a suitable press to compress the disc spring 7. Use a suitable press on the output end of the
1 and remove the circlip. shaft and push the clutch drum with its related
bearing 2, thrust washer 3, piston housing, and
3.1. CAUTION: There is approximately 26700N actuating sleeve.
(6000lbf) clamping force acting on the
springs. 8. Remove the disc springs 3.
4. Remove the disc spring 1 (x2) disc spring 2 (x2), 9. Remove the piston and its spring steel ring.
pressure end plate and shim(s).
ring 2.
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03 - Manual Gearbox

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9A Disc spring 1 (x2) 9B Disc spring 2 (x2)
27 - 78 9813/7600-3 27 - 78
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03 - Manual Gearbox
Assemble 5.3. Put the disc spring 3 in position.
1. Install the needle roller bearing 1 and needle Figure 857.

roller bearing 2 to the 4WD gear in the correct
orientation.
1.1. One end of the bearing has a rounded
profile and the other end has a flat profile.
Figure 855.
AA
18 Piston
20 Disc spring 3
5.4. Put the actuating sleeve over the clutch
drum and then put the clutch drum in the
piston housing.
AB
AA Rounded profile Figure 858.
AB Flat profile
1.2. Install the needle roller bearings on the
4WD gear with the flat end profiles facing
out (nearest the ends of the shaft).
1.3. Use a suitable press to press the needle
roller bearings into the 4WD gear.
2. Install the O-rings 1 and O-rings 2 onto the
piston.
3. Lubricate the piston with oil and press fully into
the bore of the piston housing.
4. Install the spring steel ring onto the piston. Make 15 Piston housing
sure that the seal seats firmly in its groove. 20 Disc spring 3
21 Actuating sleeve
Figure 856. 22 Clutch drum
5.5. Put the shaft on the clutch drum and piston
housing.
Figure 859.
18 19
18 Piston
19 Spring steel ring
AC
5. Use a suitable press to assemble the shaft to the
piston housing and clutch drum as follows:
5.1. Place the thrust washer 3 on the press.
Arrange the press so that the shaft can
pass through the thrust washer a sufficient 22 Clutch drum
distance during assembly. 23 Shaft
5.2. Put the piston housing and piston assembly AC Splines
centrally on the thrust washer.
27 - 79 9813/7600-3 27 - 79
27 - Driveline
03 - Manual Gearbox
5.6. Hold the clutch drum and carefully rotate the Figure 861.
shaft until the splines engage.
5.7. The shaft will approximately drop to
the specified distance when the splines
engage.
Distance: 3mm
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 suitable bushing at the top of the shaft
and use the press to push the shaft fully
onto the piston housing and clutch drum. AE
Make sure that there are no splines visible. AE Cross hatching pattern
6. Install the thrust washer 2. Make sure that the 7.3. Install the shim or shims as applicable after
thrust washer 2 is positioned over the collar on you install the final counter plate.
the shaft correctly.
8. Install the pressure plate with its chamfer side
Figure 860. facing down.
9. Use the 4WD gear to align the clutch plate
splines.
9.1. Make sure that all the plates are engaged
with the gear shaft splines.
9.2. Rotate the 4WD gear back and forth to
create maximum backlash then remove the
gear taking care not to disturb the pack.
AD
10. Place the first two disc springs 1 with their convex
7 Thrust washer 2 sides uppermost, onto the clutch pack. (There
23 Shaft are four disc springs, which are identical).
AD Collar 11. Place the other two disc springs 2, with their
7. Build the clutch pack. Install one friction plate convex sides down, onto the first two.
followed by one counter plate. Figure 862.
7.1. Continue to install alternate counter and
friction plates.
7.2. Install the friction plates so that the cross
hatching pattern aligns with each adjacent
plate.
12. Use a suitable press to compress the disc springs

1 and install the retaining circlip.
13. Use levers to remove the free play.
27 - 80 9813/7600-3 27 - 80
27 - Driveline
03 - Manual Gearbox
Figure 863.
14. Measure the gap between the pressure end plate

and actuating sleeve.
14.1. The gap should be within the specified
range.
Distance: 0.75–1.5mm
14.2. If necessary install a new shim to achieve
the correct gap.
14.3. The shim can be a combination of a
single counter plate, shim (thinner than the
shim.
15. Make sure that the clutch pack splines are still
aligned and install the 4WD gear.
16. Install the thrust washer 1.
17. Apply oil on the bearing 1 and press the bearing
onto the shaft to seat on the thrust washer 1.
27 - 81 9813/7600-3 27 - 81
27 - Driveline
03 - Manual Gearbox
15 - Solenoid Control Valve
15 - Solenoid Control Valve Introduction

Introduction .................................................... 27-82 The solenoid control valve provides the switching for
Check (Condition) .......................................... 27-83 forward drive and reverse drive to select the direction
of travel.
27 - 82 9813/7600-3 27 - 82
27 - Driveline
03 - Manual Gearbox
Check (Condition)
If damage to any component or distortion of the

spool is evident the complete valve assembly must
be renewed. Great care should be taken when
dismantling and assembling the valve to avoid the
following:
• Contamination
• Damage to spools
• Damage to seal grooves
Any of the above may result in possible problems

with the operation of the valve.
27 - 83 9813/7600-3 27 - 83
27 - Driveline
03 - Manual Gearbox
16 - Check Valve
16 - Check Valve Introduction

Introduction .................................................... 27-84 Check Valves are unidirectional flow devices used
Remove and Install ....................................... 27-85 primarily in hydraulic systems to eliminate potential
damage caused by fluid back pressure.
27 - 84 9813/7600-3 27 - 84
27 - Driveline
03 - Manual Gearbox
16 - Check Valve
Remove and Install
Remove
1. Clean the area around the check valve and the
gearbox case. Do not allow particles of grit to fall
into the gearbox.
2. Unscrew and remove the check valve.
Figure 864.
A Check valve
B O-ring seal
C O-ring seal
Replacement is the opposite of the removal

procedure. During the replacement procedure do the
following work:
Install
1. Make sure that the O-ring seals are undamaged
and free from damage.
2. Tighten the check valve to the correct torque
value.

Item Nm
A 27
27 - 85 9813/7600-3 27 - 85
27 - Driveline
03 - Manual Gearbox
18 - Pressure Relief Valve
18 - Pressure Relief Valve Introduction

Introduction .................................................... 27-86 The pressure relief valve is a type of valve used to
Remove and Install ....................................... 27-87 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 - 86 9813/7600-3 27 - 86
27 - Driveline
03 - Manual Gearbox
Remove and Install 2. Renew the sealing washer.

3. Tighten the plug to the correct torque value.
There are two relief valves in the gearbox:
Cold Start
• Torque Converter
• Cold Start Remove
Torque Converter 1. Clean the area around the plug and the gearbox
case. Do not allow particles of grit to fall into the
Remove gearbox.
1. Clean the area around the plug and the gearbox 2. Undo the plug and remove the sealing washer,
case. Do not allow particles of grit to fall into the spring and ball.
gearbox.
Figure 866.
2. Undo the plug and remove the sealing washer,
spring and valve spool.
Figure 865.
A Plug
B Sealing washer
C Spring
D Ball
A Plug
B Sealing washer Install
C Spring
D Valve spool 1. The installation procedure is the opposite of the
Install steps.
1. The installation procedure is the opposite of the 2. Renew the sealing washer.
steps. 3. Tighten the plug to the correct torque value.
27 - 87 9813/7600-3 27 - 87
27 - Driveline
03 - Manual Gearbox

Item Nm
A 102
27 - 88 9813/7600-3 27 - 88
27 - Driveline
03 - Manual Gearbox
21 - Pressure Maintenance Valve (PMV)
21 - Pressure Maintenance Valve Install

(PMV) 1. Make sure that the O-ring seals are undamaged
and free from damage.
Remove and Install 2. Tighten the valve to the correct torque value.

Item Nm
1. Clean the area around the plug and the gearbox A 102
case. Do not allow particles of grit to fall into the
gearbox.
2. Undo the plug and remove the sealing washer,
spring and valve spool. Important: Some
gearboxes have two sealing washers. Record
the number of sealing washers to make sure that
the installation is correct.
Figure 867.
A Plug
B Sealing washer
C Spring
D Valve spool

following work:
27 - 89 9813/7600-3 27 - 89
27 - Driveline
03 - Manual Gearbox
24 - Oil Pump
24 - Oil Pump Check (Condition)

Check (Condition) .......................................... 27-90 Note: A pump which is worn or damaged may have
Remove and Install ....................................... 27-91 caused further damage to the gearbox.
If the existing pump is to be re-installed proceed as

follows:
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).
2. Carefully remove and discard the oil seal. Take
care not to damage the seal housing.
3. Install a new oil seal. Install the seal the correct
way around. Push the seal flush with the front of
the housing.
4. Re-assemble the pump.
5. Make sure that the pump and the mating face on
the gearbox front cover is clean and free from
surface damage.
Figure 868.
A
B
C
A Security screw
B Oil seal
C Housing
27 - 90 9813/7600-3 27 - 90
27 - Driveline
03 - Manual Gearbox
24 - Oil Pump
Remove
1. Clean the area around the pump. Do not allow
particles of grit to fall into the gearbox.
2. Remove the four fixing bolts and lift the pump
assembly off the input shaft.
3. Remove the four sealing washers and pump
sealing ring. Discard the washers and sealing
ring.
Figure 869.
C
B
A A Fixing bolts
C Sealing washers
D Sealing ring
F Position F

Item Nm
A Fixing bolts A 28
B Pump assembly
C Sealing washers
D Sealing ring
Inspect the pump for signs of damage, refer to

Manual Gearbox, Pump - Check Condition.
Install
1. Install a new sealing ring. Locate the pump over
the input shaft and align the bolt holes. Install
the bolts together with new sealing washers.
Progressively tighten the bolts to the correct
torque value.
2. Pour some clean, new, oil into the pump at
position F.
27 - 91 9813/7600-3 27 - 91
27 - Driveline
03 - Manual Gearbox
30 - Oil Pressure Sensor
30 - Oil Pressure Sensor Introduction

Introduction .................................................... 27-92 This sensor detects the fluid pressure inside the
Remove and Install ....................................... 27-93 gearbox. This is used for diagnostic purposes
to check the transmission fluid is at the correct
pressure.
27 - 92 9813/7600-3 27 - 92
27 - Driveline
03 - Manual Gearbox
Remove and Install 3. Tighten the pressure sensor to the correct torque
value.

Item Nm
1. Clean off all debris, dirt and grit from around the
A 16
pressure sensor. Do not allow particles of grit to
fall into the gearbox.
2. Unscrew the pressure sensor and remove the
sealing washer.
Figure 871.
A Pressure sensor
B Sealing washer

following work:
Install
1. The oil pressure sensor is a non serviceable
component. If it is faulty or damaged, it must be
renewed.
27 - 93 9813/7600-3 27 - 93
27 - Driveline
03 - Manual Gearbox
33 - Oil Temperature Sensor
33 - Oil Temperature Sensor Introduction

Introduction .................................................... 27-94 This sensor determines the fluid temperature inside
Remove and Install ....................................... 27-95 the gearbox. This is used for diagnostic purposes
to check the transmission fluid is at the correct
temperature.
27 - 94 9813/7600-3 27 - 94
27 - Driveline
03 - Manual Gearbox

Item Nm
A 16
Remove
temperature sensor. Do not allow particles of grit
to fall into the gearbox
2. Unscrew the temperature sensor and remove the
sealing washer.
Figure 872.
A Temperature sensor
B Sealing washer

following work:
Install
1. The oil temperature sensor is a non serviceable
renewed.
3. Tighten the temperature sensor to the correct
torque value.
27 - 95 9813/7600-3 27 - 95
27 - Driveline
03 - Manual Gearbox
45 - Piston Ring Seal
45 - Piston Ring Seal Introduction

Introduction .................................................... 27-96 A piston ring is a split ring that fits into a groove on
Remove and Install ....................................... 27-97 the outer diameter of a piston.
27 - 96 9813/7600-3 27 - 96
27 - Driveline
03 - Manual Gearbox
Remove and Install
Remove
1. Refer to the relevant Clutch- Disassemble and
Assemble procedure (PIL 27-03).
Install
1. Wind the PTFE (Polytetrafluoroethylene) piston
ring seal around your finger as shown, so that the
seal forms a coil.
Figure 873.
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 874.
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 - 97 9813/7600-3 27 - 97
27 - Driveline
03 - Manual Gearbox
47 - Oil Seal
47 - Oil Seal Introduction

Introduction .................................................... 27-98 Oil seals close spaces between components in
Remove and Install ....................................... 27-99 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 - 98 9813/7600-3 27 - 98
27 - Driveline
03 - Manual Gearbox
47 - Oil Seal
Remove and Install
Remove 2. Remove the oil seal. Do not damage the seal

housing.
1. Remove the drive yoke, refer to Drive Yoke -
Remove and Install (PIL 27-03).
Figure 875.
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. 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. refer to Drive Yoke- Remove and
Install (PIL 27-03).
27 - 99 9813/7600-3 27 - 99
27 - Driveline
03 - Manual Gearbox
52 - Driveshaft
52 - Driveshaft Introduction
Introduction .................................................. 27-100 The driveshaft is a mechanical component for
Remove and Install ..................................... 27-101 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 - 100 9813/7600-3 27 - 100

27 - Driveline
03 - Manual Gearbox
52 - Driveshaft
Remove and Install 3. The main hydraulic pump can be installed on the
gearbox at this stage or after the gearbox has
been installed to the machine.
Before Removal
After installation
1. Start the engine and check for any leakage.
Remove
1. Remove the main hydraulic pump from the
gearbox if it is not removed.
1.1. Support the pump.
1.2. Remove all the bolts.
1.3. Remove the pump from the gearbox.
2. Remove the circlip.
3. Remove the pump driveshaft with its bearing
4. Remove and discard the shaft sealing ring.
Figure 876.
A
C
B E
D
A Hydraulic pump
B Bearing
C Pump driveshaft
D Circlip
E Sealing ring
Install
1. Installation is the opposite of the removal
procedure.
2. At the time of installation, install a new sealing
washer.
27 - 101 9813/7600-3 27 - 101

27 - Driveline
03 - Manual Gearbox
54 - Main Shaft
54 - Main Shaft Introduction

Introduction .................................................. 27-102 The main shaft receives its power from the engine
Calibrate ...................................................... 27-103 and transmits the power to other components in the
Remove and Install ..................................... 27-103 gearbox.
Refer to Driveline, Semi-Automatic Gearbox, Output
Shaft, Introduction (PIL 27-06-58).
27 - 102 9813/7600-3 27 - 102

27 - Driveline
03 - Manual Gearbox
54 - Main Shaft
Calibrate Remove and Install

Special Tools
Refer to Manual Gearbox, Calibrate (For: SS750) Description Part No. Qty.
(PIL 27-03-00). Selector Shaft Lock 892/01077 1
Screw
Before removal
1. Remove the front and rear gear case. Refer
to Manual Gearbox, Front Case- Remove and
Remove
1. Remove the taper plug, spring and the detent ball
from the detent port 1 located on the front case.
Figure 877.
A
B
C
A Detent port 1
B Detent port 2
C Detent plug
D Spring
E Detent ball
F Shaft lock screw
2. Remove the selector shaft lock screw from the
detent port 2. Refer to Figure 877.
Special Tool: Selector Shaft Lock Screw (Qty.: 1)
3. Remove the selector fork retaining screw 1 and
the selector fork retaining screw 2. Refer to
Figure 878.
4. Remove the selector rod 1 and selector rod 2.
27 - 103 9813/7600-3 27 - 103

27 - Driveline
03 - Manual Gearbox
54 - Main Shaft
Figure 878. 9. Remove the needle roller thrust bearing 1 and

G the washer 1 from the idler shaft. Refer to Figure
H 880.
10. Lift off the idler gear and remove the needle roller
bearing. Refer to Figure 880.
Figure 880.
P
J
K
L
V U T
Q
S
R
P Input shaft
G Selector rod 1 Q 2WD/4WD clutch shaft
H Selector rod 2 R Needle roller thrust bearing 1 and washer 1
J Selector fork retaining screw 1 S Idler gear
K Selector fork retaining screw 2 T Needle roller thrust bearing 2 and washer 2
L Selector fork 1 U Idler shaft
M Layshaft V Needle roller bearing
5. Remove the selector fork 1. Refer to Figure 878. 11. Remove the needle roller thrust bearing 2 and
the washer 2 from the idler shaft. Refer to Figure
6. Lift off the layshaft. Refer to Figure 878. 880.
7. Remove the selector fork 2. Refer to Figure 879. 12. Lift out both the input shaft and the 2 wheel drive
(2WD)/4 wheel drive (4WD) clutch shaft. Refer to
Figure 879.
Figure 880.
N
13. Remove the main shaft bearing cup and the
spacer from the front gear case. Refer to Figure
881.
14. Remove the bearing cup 1, bearing cup 2,
bearing cup 3 from the front gear case. Refer to
Figure 881.
AH
N Main shaft
AH Selector fork 2
8. Lift out the main shaft. Refer to Figure 879.
27 - 104 9813/7600-3 27 - 104

27 - Driveline
03 - Manual Gearbox
54 - Main Shaft
W
W
X
Y Y
Z
AA
AA AD
AC
X
AB
Z
Q
W Main shaft bearing cup W Main shaft bearing cup

X Bearing cup 1 X Bearing cup 1
Y Spacer Y Spacer
Z Bearing cup 2 Z Bearing cup 2
AA Bearing cup 3 AA Bearing cup 3
AB Hole Q 2WD/4WD clutch shaft
AC Interlock plunger
AD Magnetic probe 2. Install the bearing cup 1, bearing cup 2, bearing
cup 3 from the front gear case. Refer to Figure
15. Make sure that you keep the bearing cups with 882.
their associated bearings. Refer to Figure 881.
3. Install the 2WD/4WD clutch assembly in the front
16. Use a magnetic probe to remove the interlock gear case. Refer to Figure 883.
plunger from the selector rod locating hole. Refer
to Figure 881. 4. Install the needle roller thrust bearing 2 and the
washer 2 on the idler shaft. Put some oil on the
Install bearing. Refer to Figure 883.
1. Install the spacer and then install the main shaft 5. Install the input shaft clutch assembly in the front
bearing cup. Refer to Figure 882. gear case. Refer to Figure 883.
27 - 105 9813/7600-3 27 - 105

27 - Driveline
03 - Manual Gearbox
54 - Main Shaft

L
P
AE
V U T
Q
S
R
P Input shaft L
N
Q 2WD/4WD clutch shaft
R Needle roller thrust bearing 1 and washer 1
S Idler gear
T Needle roller thrust bearing 2 and washer 2
U Idler shaft
V Needle roller bearing
L Main shaft
6. Install the needle roller bearing. Refer to Figure N Selector fork
883. AE Piston ring seal 1
7. Install the idler gear. Refer to Figure 883. 10. Install the main shaft in the front gear case. Make
sure that the piston ring seal 1 is not damaged.
8. Install the needle roller thrust bearing 1 and the
washer 1 on the idler shaft. Put some oil on the
bearing. Refer to Figure 883. 11. Locate the selector fork. Refer to Figure 884.
9. Make sure that the piston ring seal 1 is installed 12. Make sure that the piston ring seal 2 is installed
correctly. Refer to Figure 884. correctly. Refer to Figure 885.
27 - 106 9813/7600-3 27 - 106

27 - Driveline
03 - Manual Gearbox
54 - Main Shaft

AC G H
AG
AF J
M
K
N
M
A
E
D
M Layshaft A Detent port 1

AF Bore C Taper plug
AG Piston ring seal 2 D Spring
E Detent ball
13. Install the layshaft in the front gear case. Make G Selector rod 1
sure that the piston ring seal 2 is not damaged as H Selector rod 2
it is located on the layshaft bore. Refer to Figure J Selector fork retaining screw 1
885. K Selector fork retaining screw 2
14. Locate the selector fork and install the selector N Selector fork
rod 2. Refer to Figure 886. AC Interlock plunger
15. Put the inter lock plunger into its bore through the 17. Make sure that both the selector rods are
selector rod locating hole. Refer to Figure 886. engaged with the interlock plunger by pulling or
pushing both rods at the same time. The rods will
16. Install the selector rod 1. Refer to Figure 886. lock in position when they are correctly engaged.
18. Install the detent ball, spring and taper plug in the
detent port 1. Refer to Figure 886.
19. Install the selector fork retaining screw 1 and
selector fork retaining screw 2. Refer to Figure
886.
20. Tighten both screws to the correct torque value.
21. Let the output shaft gear mesh with the input
shaft when you assemble the rear gear case, it
is necessary to engage the 4th gear as follows.
21.1. Pull up selector rod 1so that the selector
fork engages with the 4th gear.
27 - 107 9813/7600-3 27 - 107

27 - Driveline
03 - Manual Gearbox
54 - Main Shaft
Figure 887.
G
B
F
B Detent port 2
F Shaft lock screw
G Selector rod 1
21.2. Install the selector shaft lock screw in
the detent port 2 to temporarily lock the
selector rod in position.
Special Tool: Selector Shaft Lock Screw
(Qty.: 1)
After install
1. Install the front and rear gear case. Refer to
Manual Gearbox, Front Case- Remove and

Item Description Nm
J Selector fork retaining 35
screw1
K Selector fork retaining 35
screw2
27 - 108 9813/7600-3 27 - 108

27 - Driveline
03 - Manual Gearbox
54 - Main Shaft
Before Disassembly 3. Use a suitable puller to remove bearing 2.
1. Remove the Main shaft. Refer to Manual 4. Remove the spacer and then remove the
Gearbox, Main shaft- Remove and Install (PIL synchroniser unit.
27-03-54).
5. Remove the gear.
Disassembly 6. Remove both needle roller bearings.
1. Carefully remove the piston ring seal. Note: All bearings must be lightly oiled before
assembly. Make sure all components are thoroughly
2. Use a suitable puller to remove the bearing 1 clean.
from the main shaft.
Figure 888.
3 4 5
6 7
2
8
1
1 Bearing 1 2 Spacer
3 Synchroniser unit 4 Needle roller bearing
5 Gear 6 Main shaft
7 Bearing 2 8 Piston ring seal
27 - 109 9813/7600-3 27 - 109

27 - Driveline
03 - Manual Gearbox
54 - Main Shaft
Assembly After Assembly

1. Install both needle roller bearings and put some 1. Install the Main shaft. Refer to Manual Gearbox,
oil on the bearings. Refer to Figure 889. Main shaft- Remove and Install (PIL 27-03-54).
Figure 889.
4 Needle roller bearing

5 Gear
2. Install the gear. Refer to Figure 889.
3. Install the synchroniser unit and the spacer.
Figure 890.
2 Spacer
3 Synchroniser unit
4. Use a suitable press to install the bearing 2 and
the bearing 1.
5. Install the piston ring seal.
27 - 110 9813/7600-3 27 - 110

27 - Driveline
03 - Manual Gearbox
56 - Layshaft
56 - Layshaft Introduction
Introduction .................................................. 27-111 The layshaft is an intermediate shaft within a gearbox
Remove and Install ..................................... 27-112 that carries gears, but does not transfer the primary
Disassemble and Assemble ........................ 27-113 drive of the gearbox either in or out of the gearbox.
27 - 111 9813/7600-3 27 - 111

27 - Driveline
03 - Manual Gearbox
56 - Layshaft
Remove and Install
Refer to Manual Gearbox, Main shaft- Remove and

27 - 112 9813/7600-3 27 - 112

27 - Driveline
03 - Manual Gearbox
56 - Layshaft
Before Disassembly 2. Carefully remove the piston ring seal.
1. Remove the layshaft. Refer to Manual Gearbox, 3. Use a suitable puller to remove bearing 2.
Main shaft- Remove and Install (PIL 27-03-54).
4. Remove the gear 1 and then remove the thrust
bearing 1 and the bevelled thrust washer 1.
Disassembly
5. Remove the gear 2.
1. Use a suitable puller to remove the bearing 1
from the layshaft.
Figure 891.
4 5 6 7
8 9
3
2
1
10
11
12
16 15 14
13
1 Layshaft 2 Bearing 1
3 Thrust bearing 2 4 Gear 3
5 Synchro assembly 6 Track ring
7 Gear 2 8 Thrust bearing 1
9 Gear 1 10 Bearing 2
11 Piston seal ring 12 Bevelled thrust washer 1
15 Needle roller bearing 3 16 Bevelled thrust washer 2
6. Remove the two needle roller bearing 1 and the 10. Remove the bevelled thrust washer 2 and the
track ring. thrust bearing 2.
7. Remove the synchro assembly. Note: All bearings must be lightly oiled before
assembly. Make sure all components are thoroughly
8. Remove the gear 3. clean.
9. Remove the needle roller bearing 2 and needle
roller bearing 3.
27 - 113 9813/7600-3 27 - 113

27 - Driveline
03 - Manual Gearbox
56 - Layshaft
Assembly
Figure 892.
4 5 6 7
8 9
3
2
1
10
11
12
A B
16 15 14
3 13 8
1 Layshaft 2 Bearing 1
3 Thrust bearing 2 4 Gear 3
5 Synchro assembly 6 Track ring
7 Gear 2 8 Thrust bearing 1
9 Gear 1 10 Bearing 2
11 Piston seal ring 12 Bevelled thrust washer 1
15 Needle roller bearing 3 16 Bevelled thrust washer 2
1. Install the bearing thrust washer 2. Refer to Figure 893.

Figure 893.
3 Thrust bearing 2
16 Bevelled thrust washer 2
27 - 114 9813/7600-3 27 - 114

27 - Driveline
03 - Manual Gearbox
56 - Layshaft
2. Put some oil on the thrust bearing 2 and then 8. Install both needle roller bearing 1 and put some
install the bevelled thrust washer 2. Refer to oil on them. Refer to Figure 895.
Figure 893.
9. Install the gear 2. Refer to Figure 896.
3. Make sure that the bevelled thrust washer 2
is orientated correctly with its inner diameter 10. Install the bevelled thrust washer 1 and then the
nearest to the thrust bearing 2. Refer to Figure thrust bearing 1. Refer to Figure 896.
892.
Figure 896.
4. Install the needle roller bearing 3 and then the
needle roller bearing 2. Refer to Figure 894.
Figure 894.
7 Gear 2
8 Thrust bearing 1
12 Bevelled thrust washer 1
4 Gear 3 11. Make sure that the bevelled thrust washer 1
14 Needle roller bearing 2 is orientated correctly with its inner diameter
15 Needle roller bearing 3 nearest to the thrust bearing 1. Refer to Figure
892.
5. Put some oil on both needle roller bearing 2 and
needle roller bearing 3, then install the gear 3. 12. Put some oil on the thrust bearing 1. Refer to
Refer to Figure 894. Figure 896.
6. Install the synchro assembly. Refer to Figure 13. Install the gear 1. Refer to Figure 897.
895.
14. Use a suitable press to install the bearing 2 and
7. Install the track ring. Refer to Figure 895. bearing 1. Refer to Figure 897.
2 Bearing 1
9 Gear 1
5 Synchro assembly
10 Bearing 2
6 Track ring
11 Piston seal ring
13 Needle roller bearing 1
27 - 115 9813/7600-3 27 - 115

27 - Driveline
03 - Manual Gearbox
56 - Layshaft
15. Install the PTFE (Polytetrafluoroethylene) piston

ring seal. Refer to Figure 897.
After Assembly
1. Install the layshaft. Refer to Manual Gearbox,
Main shaft- Remove and Install (PIL 27-03-54).
27 - 116 9813/7600-3 27 - 116

27 - Driveline
03 - Manual Gearbox
58 - Output Shaft
58 - Output Shaft Introduction

Introduction .................................................. 27-117 In the gearbox, the input and output shafts lie along
Remove and Install ..................................... 27-118 the same line, and are sometimes combined into a
single shaft within the gearbox. This single shaft is
called the main shaft.
The input and output ends of this combined shaft

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

of the main shaft can be locked together to create a
1:1 gear ratio, causing the power flow to bypass the
layshaft. The main shaft then behaves like a single,
solid shaft: a situation referred to as direct drive.
27 - 117 9813/7600-3 27 - 117

27 - Driveline
03 - Manual Gearbox
58 - Output Shaft

B A
Special Tools
Description Part No. Qty. C
Spanner D
E
Spacer Kit 921/53400 1 F
G
Before removal
1. Remove the front and rear gear case. Refer
to Manual Gearbox, Front Case- Remove and
Remove
1. Unstake the retaining nut. Refer to Figure 898.
2. Support the output shaft from inside the rear
3. Use a spanner to hold the output yoke and at H
J
the same time loosen the retaining nut. Refer to
Figure 898.
Special Tool: Drive Coupling Spanner (Qty.: 1)
A Retaining nut
4. It is necessary to get the help of an assistant as B Stepped washer
the retaining nut is very tight. Refer to Figure 898. C Output yoke
D Oil seal
5. Hold the output shaft from below. Refer to Figure
E Outer bearing
898.
F Spacer
G Rear gear case
H Bearing
J Output shaft
6. Remove the retaining nut and the stepped
washer. Refer to Figure 898.
7. Remove the output yoke. Refer to Figure 898.
8. Remove and discard the oil seal.Refer to Figure
898.
9. Make sure that the seal housing is not damaged.
10. Remove the output shaft with the bearing from
inside the rear gear case. Refer to Figure 898.
11. Remove the outer bearing and the spacer and
keep it for assembly. Refer to Figure 898.
12. If necessary, remove the main shaft bearing
outer cup from the centre of the output shaft
transfer gear. Refer to Figure 899.
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27 - Driveline
03 - Manual Gearbox
58 - Output Shaft
Figure 899. 16. Discard the oil baffle after removal. Refer to
Figure 900.
17. Normally it is not necessary to remove the oil
baffle. Refer to Figure 900.
Install
1. If the oil baffle is removed then install it. Refer to
Figure 901.
1.1. Install a new oil baffle from the inside of the
rear gear case.
K
1.2. Use a suitable mandrel and a soft faced
hammer to drive the baffle into the housing.
K Main shaft bearing outer cup Figure 901.
13. Use a suitable puller to remove the inner and P
outer bearing cups from the rear gear case. Refer
to Figure 900.
14. If necessary, remove the oil baffle. Refer to
Figure 900.
Figure 900.
L
M
R Q
M Oil baffle
P Bearing housing
Q Deformation of oil baffle
R Mandrel
1.3. Make sure that the outside diameter of the
baffle is flush with the bottom of the bearing
housing.
1.4. After installation of the oil baffle,
deformation is normal.
N 2. Use suitable mandrels and a soft faced hammer
to install the inner and outer bearing cups into the
rear gear case. Refer to Figure 902.
M
L Inner bearing cup
M Oil baffle
N Outer bearing cup
15. Use a suitable drift to remove the oil baffle. Refer
to Figure 900.
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27 - Driveline
03 - Manual Gearbox
58 - Output Shaft

B A
L
C
D
E
F
G
H
J
A Retaining nut
M B Stepped washer
C Output yoke
L Inner bearing cup D Oil seal
M Oil baffle E Outer bearing
N Outer bearing cup F Spacer
G Rear gear case
3. Lubricate the output shaft inner bearing. Refer to H Bearing
Figure 903. J Output shaft
4. Install the inner bearing on the output shaft. Refer 9. Temporarily install the output yoke. Refer to
to Figure 903. Figure 904.
5. Locate the output shaft in the rear gear case. 10. Temporarily install the stepped washer in correct
Refer to Figure 903. orientation, facing the retaining nut. Refer to
6. Install the service spacer (921/52627) in the Figure 904.
place of the original spacer. Refer to Figure 903. 11. Temporarily install the retaining nut. Refer to
Special Tool: Spacer Kit (Qty.: 1) Figure 904.
7. Lightly oil the outer bearing and temporarily

install it. Refer to Figure 903.
8. Make sure that you do not install the oil seal at
this stage. Refer to Figure 903.
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27 - Driveline
03 - Manual Gearbox
58 - Output Shaft
Figure 904. 17. Remove the retaining nut along with the stepped
washer and the output yoke. Refer to Figure 904.
C
18. Remove the outer bearing along with the service
spacer (921/ 52627). Refer to Figure 903.
19. Install the correct size original spacer and the
outer bearing. Refer to Figure 903.
20. Install a new oil seal. Before you install, lubricate
A the seal lips. Refer to Figure 904.
B
21. The seal is not attached to the back of the
housing. Refer to Figure 904.
D 22. Install the output yoke. Refer to Figure 904.
23. Install the stepped washer in the correct
orientation, facing the retaining nut. Refer to
Figure 904.
A Retaining nut 24. Instal a new retaining nut. Refer to Figure 904.
B Stepped washer
25. Tighten the nut to the correct torque value. Refer
C Output yoke
to Figure 904.
D Oil seal
26. Finally use a square ended staking tool to stake
12. Check the end float of the output shaft while
the retaining nut. Refer to Figure 904.
tightening the retaining nut to the specified torque
value. If there is no end float do the following Table 323. Torque Values
checks. Refer to Figure 904.
Item Description Nm
Torque: 50N·m
A Retaining nut 395
12.1. The bearing cups are pressed fully into the
case.
12.2. The correct bearings are installed.
12.3. The service spacer is installed.
output shaft end float. Pull and push the yoke to
move the output shaft in and out. Refer to Figure
904.
14. It is necessary to calculate the thickness of the
original spacer, to set the shaft end float or the
bearing pre-load within the specified limit. Refer
to Figure 904.
14.1. Maximum shaft end float is
Dimension: 0.03mm
14.2. Maximum bearing pre-load is
Dimension: 0.05mm
15. If the gearbox is assemble with its original
components is probable that the original spacer
will be the correct thickness. If it is necessary
to select a different thickness select the correct
spacer from spacer kit. Refer to Figure 903.
16. Support the output shaft from inside the rear
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27 - Driveline
03 - Manual Gearbox
74 - Synchromesh Gear 1 and 2
74 - Synchromesh Gear 1 and 2 Introduction

Introduction .................................................. 27-122 In a synchronised gearbox the gears are always
Component Identification ............................. 27-123 in mesh and rotating, but gears on one shaft can
Operation ..................................................... 27-124 freely rotate or be locked to the shaft. The locking
Check (Condition) ........................................ 27-127 mechanism for a gear consists of a collar on the shaft
which is able to slide sideways so that teeth on its
Disassemble and Assemble ........................ 27-127 inner surface bridge two circular rings with teeth on
their outer circumference, one attached to the gear,
one to the shaft. When the rings are bridged by the
collar, that particular gear is rotationally locked to
the shaft and determines the output speed of the
transmission.
The gearshift lever manipulates the collars using a

set of linkages, so arranged so that one collar may
be permitted to lock only one gear at any one time.
When shifting gears, the locking collar from one gear

is disengaged before that of another is engaged.
One collar often serves for two gears, sliding in one
direction selects one transmission speed, in the other
direction selects another.
In a synchromesh gearbox, to correctly match the

speed of the gear to that of the shaft as the gear is
engaged the collar initially applies a force to a cone-
shaped clutch attached to the gear, which brings the
speeds to match prior to the collar locking into place.
The collar is prevented from bridging the locking
rings when the speeds are mismatched by synchro
rings. The synchro ring rotates slightly due to the
frictional torque from the cone clutch. In this position,
the dog clutch is prevented from engaging. The brass
clutch ring gradually causes parts to spin at the same
speed. When they do spin at the same speed, there
is no more torque from the cone clutch and the dog
clutch is allowed to fall into engagement.
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27 - Driveline
03 - Manual Gearbox
Component Identification Figure 907.
Figure 905.
B C
E E Sleeve
F Ball
D G Poppet
H Spring
A Synchro hub J Wear indicator grooves
B Synchro rings
C Blocker pins
D Split energiser pins
E Synchro cups
Figure 906.
A Cone
B Cone
C Ring
D Ring
E Sleeve
J Wear indicator grooves
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03 - Manual Gearbox
A
The gearbox is installed with a Blocking Pin
synchromesh, comprising the following parts.
B
Synchro hub
Controls the operation of the synchromesh unit and
gear selection, the selector fork installed into the B C
outer groove. Internal splines link the selected gear
to the drive shaft. Through the synchro hub centre
are two sets of holes for the blocker pins and the split
energiser pins, spaced alternately.
Synchro rings
Synchro rings are rigidly joined by the blocker pins,
with the split energiser pins held, in counter bores,
between the two synchro rings.
Blocker pins
E
Blocker pins have a narrow neck in the centre,
against which the synchro hub transmits radial drive
during gear changes. The edges of the blocker
E
pin neck and their mating synchro hub holes are D
designed so that, as the radial loads are reduced,
the synchro hub can slide over the shoulder of the
A Synchro hub
blocker pin.
B Synchro rings
C Blocker pins
Split energiser pins D Split energiser pins
E Synchro cups
Split energiser pins take the initial axial load of the
synchro hub on the shoulder of the split energiser The diagram shows the gearbox with first gear
pin neck. As the axial load reaches approximately engaged. The synchro ring is in contact with the
40.8kg the internal springs allow the split energiser synchro cup and the synchro hub splines are linking
pin to collapse and the synchro hub to move axially. first gear to the shaft gear. In this position the split
energiser pins are collapsed. Refer to Figure 909.
Synchro cups
Synchro cups take the frictional drive from the
synchro ring on their inner faces. The synchro cups
are splined to drive their respective gears whilst
synchronisation is taking place.
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27 - Driveline
03 - Manual Gearbox
A
C
B
As the axial load on the synchro hub increases, the

split energiser pin collapses and the conical faces
of the blocking pin and synchro hub hole come into
E contact. Refer to Figure 911.
F
A Synchro hub
B Synchro rings
C Blocker pins
D Split energiser pins
E Synchro cups
When selecting second gear the synchro hub slides

along the split energiser pins until the pin recess
and the synchro hub flange are in line. At this point
the split energiser pins open and the synchro rings
are moved by the synchro hub pushing on the split
energiser pin shoulder.
Initial contact between the synchro ring and the

synchro cup starts to synchronise the speed of the
shaft and second gear. The rotational force of the
synchro ring is taken by the blocker pin against the
edge of the synchro hub hole. Refer to Figure 910.
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27 - Driveline
03 - Manual Gearbox
H
Further increases in the axial loads increase the
frictional grip of the synchro ring and the synchro
cup, causing the shaft and the gear speeds to
synchronise.
As the speeds are synchronised the radial load on

the blocker pin and the synchro hub is reduced.
This allows the synchro hub to slide freely along the
blocker pin and engage its splines with the second
gear. Refer to Figure 912.
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03 - Manual Gearbox
Check (Condition) Disassemble and Assemble
Ring and cone type synchroniser units must be Disassemble

checked for wear before assembly as follows:
1. Before dismantling the unit be aware that on re-
1. Inspect the mating faces of the cones and rings. assembly, the components must be kept in their
The wear indicator grooves must still be visible. original relationships.
2. Inspect the teeth on all cones and rings for 2. Dismantle the synchromesh unit by removing the
excessive wear or damage. If wear or damage is cones and rings. Push off the sleeve, take care
evident the synchromesh unit must be renewed. to retrieve the sets of balls, poppets and springs.
Figure 913.
A Cone
B Cone
C Ring
D Ring
E Sleeve
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03 - Manual Gearbox
Figure 914. 4. Inspect the teeth on all cones and rings for
excessive wear or damage. If wear or damage is
evident the unit must be renewed.
Assemble
1. Assemble the parts in the reverse order, make
sure that the components are kept in their original
relationships.
E Sleeve
F Ball
G Poppet
H Spring
3. Inspect the mating faces of the cones and
rings. The wear indicator grooves must still be
visible. As a further check, locate the cones
and rings together as shown and measure the
clearance between them using feeler gauges.
The clearance should be between the given
tolerance for both pairs. If either is outside these
limits then the complete synchromesh unit must
be renewed.
Figure 915.
K Cone and ring clearance
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27 - Driveline
03 - Manual Gearbox
76 - Synchromesh Gear 3 and 4 Introduction

Introduction .................................................. 27-129 Refer to Synchromesh Gear 1 and 2 - Introduction
Component Identification ............................. 27-130 (PIL 27-03-74).
Check (Condition) ........................................ 27-130
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27 - Driveline
03 - Manual Gearbox
Refer to Synchromesh Gear 1 and 2 - Component Refer to Synchromesh Gear 1 and 2 - Check
Identification (PIL 27-03-74). Condition (PIL 27-03-74).
27 - 130 9813/7600-3 27 - 130

27 - Driveline
03 - Manual Gearbox
Refer to Synchromesh Gear 1 and 2 - Disassemble

and Assemble (PIL 27-03-74).
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27 - Driveline
03 - Manual Gearbox
78 - Direct Shift Turret
78 - Direct Shift Turret Introduction

Introduction .................................................. 27-132 The gear lever turret connects the gear lever and the
Component Identification ............................. 27-133 gearbox.
27 - 132 9813/7600-3 27 - 132

27 - Driveline
03 - Manual Gearbox
(For: SS700 MK2)
Figure 916.
1 2 3 4 5 6
12 3
11
13
16
1
7 4
15 2
9 5
6
7
8
14
10 10
9 8
1 Circlip 2 Bush
3 Top lever 4 O-ring
5 Washer 6 Spring
7 Gear lever turret 8 Spring
9 Retainer 10 Lower lever
11 Worm drive clip 12 Worm drive clip
13 Gaiter 14 Retaining tabs
15 Turret peg 16 Turret peg
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27 - Driveline
03 - Manual Gearbox
4. Remove the circlip.

(For: SS700 MK2) 5. Slowly release the pressure from the top lever
and remove it, together with the bush, washer
Disassemble and spring 6.
1. Remove the gear lever. 6. Rotate the spring 8 so as to disengage from the
retaining tabs inside the gear lever turret. Be
2. Slacken the worm drive clips. Remove the rubber aware that the spring may suddenly disengage
gaiter. while still under pressure. Repeat this operation
until all the coils are disengaged and the spring
CAUTION! Beware of spring pressure acting on
can be removed.
the bush when the circlip is removed.
7. Remove the retainer and the lower lever.
3. Use a suitable press or clamp to carefully press
the top lever down to compress the spring 6, to
release pressure on the circlip 1.
Figure 917.
1 2 3 4 5 6
12 3
11
13
16
1
7 4
15 2
9 5
6
7
8
14
10 10
9 8
1 Circlip 2 Bush
3 Top lever 4 O-ring
5 Washer 6 Spring
7 Gear lever turret 8 Spring
9 Retainer 10 Lower lever
11 Worm drive clip 12 Worm drive clip
13 Gaiter 14 Retaining tabs
15 Turret peg 16 Turret peg
Replacement is the opposite of the removal Assemble

following work: 1. Lubricate liberally the working surfaces before
assembling.
27 - 134 9813/7600-3 27 - 134

27 - Driveline
03 - Manual Gearbox
2. Make sure that the O-ring is free from damage.

Install the O-ring correctly.
3. Locate the slots in the levers with the turret pegs.
4. After installing the spring 8, rotate it so that
the end of the bottom coil butts with the turret
retaining tabs.
27 - 135 9813/7600-3 27 - 135

27 - Driveline
03 - Manual Gearbox
79 - Remote Shift Turret
79 - Remote Shift Turret Component Identification

(For: SS700 MK2)
Figure 918.
Table 324.
Item Description
A Bolts 1
B Cover
C Gasket
D Bolts 2
E External lever 1
F Internal lever 1
G External lever 2
H Internal leve r2
J Housing
K Bushes
L Oil seals
X Cut out
27 - 136 9813/7600-3 27 - 136

27 - Driveline
03 - Manual Gearbox
5. Remove the external lever 1 and internal lever 1.

(For: SS700 MK2) 6. Hold the internal lever and pull the external lever
from the housing.
Disassembly
7. Remove the external lever 2 and internal lever 2
1. Remove the bolts 1. and do the step6 again.
2. Lift off the cover. 8. Check the bushes and seals for damage or
wear. Remove and discard any worn or damaged
3. Remove the gasket. components.
4. Remove the bolts 2.
Figure 919.
Item Description
Table 325. L Oil seals
X Cut-out
Item Description
A Bolts 1
Assembly
B Cover
C Gasket Assembly is the opposite of the disassembly
D Bolts 2 procedure. At the time of assembly do the following
steps.
E External lever 1
F Internal lever 1 1. If necessary, install new bushes to the housing.
G External lever 2
2. If necessary, install new oil seals. Use a press
H Internal lever 2
and any of the external levers as an assembly
J Housing tool.
K Bushes
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27 - Driveline
03 - Manual Gearbox
3. Make sure that the oil seals are correctly

installed.
4. Lubricate the seal lips.
5. Assemble the external levers to the correct sides
of the housings. Put the external lever 1 on the
side of the cut-out.
6. Assemble the internal levers correctly and put
them in their original position.
7. Make sure that the internal and external levers
are aligned. Refer to Figure 920.
Figure 920.
Y
Y
Y Maximum 1°
8. Tighten the bolts 2 to the correct torque value.
9. Install a new gasket.

Item Description Nm
A Bolts1 56
D Bolts2 28
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27 - Driveline
03 - Manual Gearbox
81 - Mount
81 - Mount
Check (Condition)
2. Get access to the mounting(s).
3. Make sure that the entire mounting(s) system is
in good condition.
3.1. Inspect brackets and casings for cracks,
damage and security.
3.2. Inspect rubber mountings (if installed) for
wear and tears and too much movement.
3.3. Make sure that all fastenings are there and
they are tightened to the correct torque.
Refer to (PIL 72).
4. Install new components if any are defective.
Refer to the correct section in the service manual
as necessary.
27 - 139 9813/7600-3 27 - 139

27 - Driveline
03 - Manual Gearbox
90 - Front Case
90 - Front Case Clean

Consumables
Clean ........................................................... 27-140
Check (Condition) ........................................ 27-141
Remove and Install ..................................... 27-141 - General purpose
solvent based parts
cleaner

servicing the gearbox. Observe the following:
1. Remove deposits of dirt, grit and oil from the

outer cases and components.
2. Prevent dirt, grit and debris falling into the
gearbox.
3. Cap all open ports, hoses, pipes and orifices.
27 - 140 9813/7600-3 27 - 140

27 - Driveline
03 - Manual Gearbox
90 - Front Case

Special Tools
Before you assemble the gearbox make sure that a Description Part No. Qty.
thorough inspection of all components is carried out. Selector Shaft Lock 892/01077 1
Remember that although a failed component may Screw
be easy to identify, the cause of that failure may be
less easy to trace. It is also possible that a failed Consumables
component may have caused damage to other areas
of the gearbox. Description Part No. Size
1. If the output shaft and bearing are removed they
must be installed. Lifting Equipment
Refer to: PIL 27-03. You can be injured if you use incorrect or faulty lifting
2. Make sure that the shaft assemblies are correctly be lifted then choose lifting equipment that is strong
assembled and free from defects. enough and suitable for the job. Make sure that lifting
3. Install new shaft piston ring seals. Make sure that local regulations.
they are installed correctly on the groove.
Refer to: PIL 27-03. Before removal
4. Carefully remove all traces of gasket compound 1. Make the machine safe. Refer to (PIL 01-03).
from components as follows:
2. Remove the oil filter. Refer to Manual Gearbox,
4.1. Front and rear case mating faces. Filter- Remove and Install (PIL 27-03-39).
4.2. Front case and torque converter housing
3. Remove the suction strainer. Refer to Manual
mating faces.
Gearbox, Suction stainer- Remove and Install
5. Clean the inside of the case using a suitable (PIL 27-03-40).
degreasing agent.
4. Remove the solenoid control valves. Refer
6. Carefully inspect all gears, bearings and shafts to Manual Gearbox, Solenoid control valve-
for signs of excessive wear or damage. If wear Remove and Install (PIL 27-03-15).
5. Remove the oil pressure sensor. Refer to Manual
replaced.
Gearbox, Oil pressure sensor- Remove and
7. Make sure that all oil way cross drillings in the Install (PIL 27-03-30).
cases, shafts and gears are clear and free from
6. Remove the oil temperature sensor. Refer
debris. Blocked oil ways are a common cause of
to Manual Gearbox, Oil temperature sensor-
bearing failure. Use an air line to blow through
cross drillings.
7. Remove the gear lever turret. Refer to Manual
8. Make sure that new cases are installed with the
Gearbox, Gear lever turret- Remove and Install
correct adaptors, plugs and orifice restrictors.
(PIL 27-03-14).
8. Remove the output drive yoke and oil seal. Refer
to Manual Gearbox, Oil seal- Remove and Install
(PIL 27-03-14).
9. Remove the park brake multi plate pack. Refer
to (PIL 24-18).
10. Remove the oil pump. Refer to Manual Gearbox,
Oil pump- Remove and Install (PIL 27-03-24).

servicing the gearbox. All precautions to prevent any
• Remove all the dirt, grit and oil from the outer
case and components.
27 - 141 9813/7600-3 27 - 141

27 - Driveline
03 - Manual Gearbox
90 - Front Case
• Prevent dirt, grit and debris falling into the Figure 922.
gearbox.
• Put caps on all the open ports, hoses, pipes and B
orifices.
Use a proper lifting equipment to locate the gearbox C

in a work cradle. Refer to Refer to Figure 921. .
Figure 921. D
A
B
A Work cradle
Do not try to dismantle the gearbox unless until it is

safely located on a work cradle. E C
B Jacking screw
Remove C Bearing retainer
1. Remove all the bearing retainer fixing screws. D Bearing retainer fixing screw (x6)
Refer to Figure 922. E Spacer
F Bearing outer cup
2. Remove the jacking screws. Refer to Figure 922.
3. Remove the bearing retainer. Refer to Figure
922.
4. Remove the spacer and then remove the bearing
outer cup. Refer to Figure 922.
5. To prevent the synchroniser from dis-
assembling, at the time of case removal do the
following steps. Refer to Figure 923.
5.1. Engage 4th gear by lifting the selector rod
and selector fork.
5.2. Remove the taper plug from the detent port
along with the spring and the ball.
27 - 142 9813/7600-3 27 - 142

27 - Driveline
03 - Manual Gearbox
90 - Front Case

P
R
H
L
K
J
S
N Rear case attaching bolt (x22)

P Rear case
Q Layshaft
R Transfer gear
S Taper roller bearing
M 7. Hold the layshaft so that taper roller bearing is

clear of the transfer gear and at the same time
G Selector fork use lifting equipment to carefully lift off the rear
H Detent port case. Refer to Figure 924.
J Taper plug
K Spring 8. Remove the bearing outer cup 1, bearing outer
L Detent ball cup 2 and the output shaft bearing outer cup.
M Selector Shaft Lock Screw Refer to Figure 925.
5.3. Temporarily Install the lock screw in the 9. The cups will be left on the bearings, or inside the
detent port to lock the selector rod in rear casing. Keep the cups with their associated
position. bearings. Refer to Figure 925.
Special Tool: Selector Shaft Lock Screw
(Qty.: 1)
6. Remove all the rear case attaching bolts. Refer
to Figure 924.
27 - 143 9813/7600-3 27 - 143

27 - Driveline
03 - Manual Gearbox
90 - Front Case
Figure 925. 4. Put new shaft piston ring seals. Make

sure that they are correctly installed in the
U shaft grooves. Refer to Manual Gearbox,
PTFE (Polytetrafluoroethylene) Piston ring seal-
• Do not try to assemble the gearbox unless until
it is safely located on a work cradle.
Figure 926.
T
A Cradle
T Bearing cup 1 Install

U Bearing cup 2
V Output shaft bearing cup 1. Remove the old sealing compound from the front
W O-ring and rear case mating surfaces.
10. Remove and discard the O-ring from the front 2. Make sure that the mating surfaces are free from
case. Refer to Figure 925. damage.
11. If it is necessary to remove the shafts, then 3. Apply a continuous bead of JCB Multigasket to
remove the lock screw from the detent plug the front case mating surface. Install O-ring on
mentioned in step 5.3. the front case mating surface. Refer to Figure
Special Tool: Selector Shaft Lock Screw (Qty.: 1) 927.
12. If the front and rear case are removed for the
sealing purpose only, then it is not necessary to
remove the shafts.
Before install
1. Check the condition of both the cases. Refer
to Manual Gearbox, Check (condition) (PIL
27-03-00).
2. If removed then install the output shaft and the
bearing. Refer to Manual Gearbox, Output shaft-
3. Make sure that the shaft assemblies are correctly
assembled and free from defects.
27 - 144 9813/7600-3 27 - 144

27 - Driveline
03 - Manual Gearbox
90 - Front Case
T R
Q Layshaft
R Transfer gear
S Taper roller bearing
W
7. Check the taper roller bearing for damage. Refer
to Figure 928.
8. If the rollers and cage are damaged at the time
case removal then replace the bearing. Refer
to Manual Gearbox, Layshaft- Disassemble
and assemble (PIL (Parts Identification List)
27-03-56). Refer to Figure 928.
T Bearing cup 1
U Bearing cup 2 9. Carefully lower the rear case. Refer to Figure
V Output shaft bearing cup 928.
W O-ring
10. Make sure that the input shaft engage with the
4. Lubricate the piston ring seals of the input shaft case first, followed by the 3rd/4th gear selector
and the 2 wheel drive(2WD)/ 4 wheel drive (4WD) rod. Refer to Figure 928.
clutch assembly. Refer to Figure 927.
11. Move and hold the layshaft to make sure that,
5. Make sure that the bearing cup 1 and bearing there should be a gap between the transfer gear
cup 2 are install on the rear case and the output and the taper roller bearing. Refer to Figure 928.
shaft bearing cup is installed on the output shaft.
Refer to Figure 927. 12. Do not give excessive force when installing the
rear case. Refer to Figure 929.
6. Make sure that 4th gear is selected and locked.
Refer to step 5 in disassembly procedure. Refer 13. Install all the rear case attaching bolts. Refer to
to Figure 928. Figure 929.
Figure 929.
P
N Rear case attaching bolt (x22)

P Rear case
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27 - Driveline
03 - Manual Gearbox
90 - Front Case
14. Tighten the bolts to the correct torque value. Figure 931.
Refer to Figure 929. L
15. Install the bearing outer cup on to the taper roller K H
16. Install the spacer. Refer to Figure 930. J
17. Install the bearing retainer. Refer to Figure 930.
Figure 930.
F E C
M
H Detent port
C J Taper plug
D K Spring
L Detent ball
M Selector Shaft Lock Screw
21. Install the detent ball, spring and the taper plug
at the detent port. Refer to Figure 931.
22. Tighten the taper plug to the correct torque value.
23. Check the shafts end float. Refer to Manual
Gearbox, Calibrate(For: SS750) (PIL 27-03-00).
C Bearing retainer Table 327. Torque Values
D Bearing retainer fixing screw (x6)
E Spacer Item Description Nm
F Bearing cup N Rear case attaching bolt 56
S Tapper roller bearing D Bearing retainer fixing screw 18
18. Secure the bearing retainer with the fixing J Taper plug 35
screws. Refer to Figure 930.
19. Tighten the screws to the correct torque value.
20. Remove the lock screw from the detent port.
Special Tool: Selector Shaft Lock Screw (Qty.: 1)
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27 - Driveline
03 - Manual Gearbox
91 - Rear Case
91 - Rear Case Clean

Clean ........................................................... 27-147 Refer to Front Case - Clean (PIL 27-03-90).
Check (Condition) ........................................ 27-148
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03 - Manual Gearbox
91 - Rear Case
Refer to Front Case - Check Condition (PIL Refer to Front Case - Remove and Install (PIL
27-03-90). 27-03-90).
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94 - Coupling Yoke
94 - Coupling Yoke Introduction

Introduction .................................................. 27-149 The drive yoke is an important component of a
Remove and Install ..................................... 27-150 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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03 - Manual Gearbox
94 - Coupling Yoke
Remove and Install
Special Tools 3. Use service tool 892/00812 to hold the yoke and
Description Part No. Qty. at the same time undo the nut. The nut is very
Drive Coupling 892/00812 1 tight, the help of an assistant will be required.
Spanner Discard the nut.
Remove 4. Remove the yoke and the washer.
5. If necessary remove the oil seal. Do not damage
2. Clean the area around the yoke. Do not allow the seal housing.
Figure 932.
A Yoke B Stake nut

C Oil seal D Oil seal interface
E Washer F Locking ring
Install 5. Install the stepped washer the correct way

around with the plan face facing the stake nut as
1. Make sure that the oil seal interface on the yoke shown.
6. Install a NEW stake nut. Tighten to the correct
2. If necessary install a new oil seal. Locate the seal torque value.
in the position shown, the seal does not locate to
the back of the housing. 7. Stake the nut to the shaft using a square ended
staking tool, as shown.
4. Install the yoke.
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94 - Coupling Yoke

Item Nm
B 395
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Contents Page No.
27-05-00 General ......................................................................................................................... 27-153

27-05-07 Clutch - 2WD/4WD ....................................................................................................... 27-186
27-05-19 Control Valve ................................................................................................................ 27-200
27-05-23 Motor ............................................................................................................................ 27-205
27-05-24 Oil Pump ...................................................................................................................... 27-211
27-05-27 Speed Sensor .............................................................................................................. 27-215
27-05-39 Filter ............................................................................................................................. 27-225
27-05-42 Dipstick ......................................................................................................................... 27-229
27-05-45 Piston Ring Seal .......................................................................................................... 27-230
27-05-47 Oil Seal ........................................................................................................................ 27-232
27-05-62 Clutch - Pump .............................................................................................................. 27-234
27-05-63 Clutch - Motor .............................................................................................................. 27-240
27-05-65 Clutch - Front (Output) ................................................................................................. 27-247
27-05-81 Mount ........................................................................................................................... 27-254
27-05-90 Front Case ................................................................................................................... 27-255
27-05-91 Rear Case .................................................................................................................... 27-257
27-05-93 Hose ............................................................................................................................. 27-259
27-05-95 Coupling Yoke .............................................................................................................. 27-261
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Introduction .................................................. 27-153 The JCB DTVT (Dual Technology Variable
Technical Data ............................................. 27-154 Transmission) is an innovative transmission
Component Identification ............................. 27-156 designed to provide the driver with the benefits of
Operation ..................................................... 27-162 hydrostatic or mechanical constant mesh gearboxes
when certain criteria is met.
Diagram ....................................................... 27-169
Fault-Finding ................................................ 27-175 To achieve this, the transmission can be considered
Drain and Fill ............................................... 27-176 to have two drive independent operating modes,
Check (Level) .............................................. 27-177 depending on the road speed of the machine. These
modes are independent of driver control and they are
Check (Pressure) ........................................ 27-177 not normally distinguishable in operation. Hydrostatic
Remove and Install ..................................... 27-178 drive is not engaged above the transition speed and
Disassemble and Assemble ........................ 27-179 the mechanical gearbox is not driving the machine
below this speed.
For road speeds up to the transition speed the

transmission operates in hydrostatic mode for
forward and reverse. The hydrostatic pump is
controlled by a swashplate to provide a constantly
variable ratio drive system giving excellent stop/start
and low speed controllability and efficient operation
up to the transition speed. Thus no fluid flywheel or
torque converter is required.
The transmission electronic control system allows

the mode to change smoothly from hydrostatic drive
to drive through the constant mesh gearbox at
speeds above the transition speed whilst maintaining
continuous operation. This means that the machine
can operate at higher speeds with 3 ratios using the
more "high speed efficient" mechanical gearbox.
Clutches
The clutches used in this transmission
are hydraulically actuated mechanical devices
consisting of a wet multi-plate clutch operated
by a hydraulic piston. The clutch is operated
by the transmission control valve block which is
itself controlled by the TCM (Transmission Control
Module). Depending on the application, clutches
may be either engaged by hydraulic pressure or
disengaged.
The 4WD (Four Wheel Drive) clutch is spring applied

and is released by hydraulic pressure.
Moving a Disabled Machine

To move a disabled machine, make sure you refer
to the instructions in the correct operators manual
before you attempt to move the machine.
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Technical Data
Table 329. Refer to driveline, hybrid gearbox, general, check

(pressure), (PIL 27-05-00).
Designation Dual Tech Variable
Transmission
Description Dual hydrostatic and
mechanical transmis-
sion. The transmission
switches between hydro-
static and mechanical
constant mesh torque
transmission when re-
quired.
Weight (dry) 500kg
Clutch solenoid current 0.85A
draw
Table 330. Transmission Clutch Pressures

Test Point Description Speed Mode Engine RPM Temp °C Specified
Pressure
H1 Hydrostatic 0–19km/h Power 2350 RPM 55–60°C 12–14.5bar
clutch (0.0–11.8mph) (Revolutions (130.9– (173.9–
M2 Powershift 16–23km/ Per Minute) 139.9°F) 210.1psi)
clutch h (9.9–
14.3mph)
M3 Powershift 23–32km/
clutch h (14.3–
19.9mph)
M4 Powershift 32–40km/
clutch h (19.9–
24.9mph)
4WD 4WD (Four 16–23km/
Wheel Drive) h (9.9–
Clutch 14.3mph)
Table 331. Hydrostatic Pressures

Test Point Description Speed Mode Engine Gear Temp °C Specified
RPM Selected Pressures
R Pump/motor 0km/h Power 2350 RPM Neutral 55–60°C 3bar
case drain (0.0mph) (130.9– (43.5psi)
MH Pump ser- 0km/h Neutral 139.9°F) 25bar
vice pres- (0.0mph) (362.3psi)
sure Minimum
MH
(2)
Pump max- Transmis- 1 470–485bar
imum pres- sion stall (6,811.6–
sure 7,029.0psi)
MH Hydrostat- 8–19km/ 1 Delta-P
ic transmis- h (5.0– = 70bar
sion 11.8mph) (1,014.5psi)
(1)
M1 Motor dis- 8–19km/ 1

placement h (5.0–
11.8mph)
(1) Delta P = MH-M1
(2) This measurement is carried out with the propshafts installed and the machine held in a stalled condition.
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Table 332. Transmission Supply and Lubrication Pressures

Test Point Description Speed Mode Engine Gear Temp °C Specified
RPM Selected Pressure
TF Transmis- 0km/h Power 2350 RPM Neutral 55–60°C 12–14.5bar
sion pump (0.0mph) (130.9– (173.9–
supply 139.9°F) 210.1psi)
TL Transmis- 0km/h TBA
sion lube (0.0mph)
BBL Bevel box 0–19km/ TBA
lube h (0.0–
11.8mph)
YST Charge 0km/h 27–30bar
pressure (0.0mph) (391.3–
434.8psi)
Table 333. DTVT Pressure Test Results

Test point Description Test Result
(1)
H1 Hydrostatic
clutch
M2 Powershift
clutch
M3 Powershift
clutch
M4 Powershift
clutch
4WD 4WD Clutch
- - -
R Pump/motor
case drain
MH Pump service
pressure
MH Pump maxi-
mum pressure
MH Hydrostatic
transmission
M1 Motor displace-
ment
- - -
TF Transmission
pump supply
TL Transmission
lube
BBL Bevel box lube
YST Charge pres-
sure
(1) Make sure the oil is at the correct temperature.
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D
E B A
S
L
G
K
H J T
A Bevel gearbox bell housing B Control valve block

D Mounting bracket E Priming tube- Hydrostatic system
F Hydrostatic filter G Hydrostatic motor
H Oil cooler manifold connections J Sensor
K Serial number plate L Park brake mechanism
S Solenoid T Hydraulic oil port (return to tank)
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C D
A
G S
D B
A Bevel gearbox bell housing B Control valve block

C Hydrostatic pump D Mounting bracket
G Hydrostatic motor L Park brake mechanism
R Hydrostatic filter mounting block S Solenoids
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E R
D B E
F
M
H Q
P
B Control valve block D Mounting bracket

E Priming tube- Hydrostatic system F Hydrostatic filter
G Hydrostatic motor H Oil cooler manifold connections
L Parkbrake mechanism M 4WD (Four Wheel Drive) Output flange (To front
axle)
N Gearbox oil filter (Mechanical) P Drive output flange to rear axle
Q Mounting flange for service hydraulic pump R Hydrostatic filter mounting block
(Pump not installed)
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640
650 500 530
550 470 520
270 10 460 720 130 670
400 140 560 710
360 150 510
410 160
110 480
300
390 370 690 260 490
380 610
170
450
660 600
680
340 160
120
350
330 310
320
310 280
630 100 220
620 70 190
440 100
430 590
420 170
570
580
700
90
30
50
200 260
80
230
40 240 540
60
180
210 250
290
270 280
Table 334.
Item Quantity Description
10 1 Casing-Front-Machining
20 1 Casing - Rear Machining
30 1 G.A. Clutch - Input DTVT
40 1 G.A. Clutch - Output Front DTVT
50 1 G.A. Clutch - Layshaft - DTVT
60 1 G.A. Clutch - Pump DTVT
70 1 G.A. Shaft - Motor DTVT
80 1 G.A. 4Wd Clutch - DTVT
90 1 Spacer Kit
100 4 Dowel
110 1 W.A. Pipe - Layshaft Clutch
120 1 W.A. Pipe - Layshaft Lube
130 1 W.A. Pipe - Bevel Lube
140 8 Copper Washer M12
150 4 Bolt - Banjo M12
160 11 Taper Plug - 1/8 BSP
170 15 Set Screw M10 X 30 G8.8
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180 1 Plate Carrier - 4Wd Output
190 1 Needle Roller Brg
200 3 Seal Ring
210 1 Cover - 4Wd
220 1 O Ring
230 1 Bearing-Ball
240 1 Circlip - Internal 80Mm
250 2 Seal - Triple Lip
260 12 Bolt M10 X 100 G8.8
270 2 Coupling Yoke - 1480 DTVT
280 2 Setscrew
290 1 Washer-M16-DTVT
300 1 Stake Nut M30 X 2
310 3 Plug-Relief Valve
320 3 Bonded Washer - 1/2" BSP
330 1 Ga Bevel Pinion & Carrier
340 1 Kit-Bevel Pinion & Gear-DTVT
350 1 Spacer Kit
360 1 Nut - Stake - M42 X 1.5
370 1 Shim Kit (Bevel Gearbox)
380 6 Verbus Ripp Bolt M10X1.5 25L
390 1 Ga Parkbrake - Ausco
400 2 Bolt M10 X 70 G8.8
410 5 Set Screw M10 X 40 G8.8
420 1 Suction Strainer
430 3 Set Screw M8 X 16 Encaps. G8
440 1 Gasket - Suction Strainer
450 1 DTVT Speed Sensor
460 1 Mtg Bracket M10 For Dt04
470 1 Tab Anti Rotation DTVT
480 1 Ga Valve Block DTVT
490 1 Gasket - Valve Block
500 14 Cap Screw M8 X 50 G12.9
510 1 Temp Sender
520 1 Switch - Oil Pressure
530 1 Bonded Washer 1/4"BSP
540 1 Washer
550 1 W.A. Bracket - DTVT Harness
560 2 Elbow Adaptor M/M
570 1 G.A. Oil Pump - DTVT
580 4 Cap Screw M6 X 40 G12.9
590 1 Filter Adaptor
600 1 Adaptor-Hose
610 1 Bonded Washer 10Mm
620 1 Adaptor G3/4A-G3/4A
630 1 Bonded Washer
640 1 Adaptor Male/Male
650 1 Bonded Washer
660 1 O Ring Seal
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670 1 Adaptor 90 M/F Swivel
680 4 Washer-Copper Sealing
690 2 Bolt - Banjo 1/4 BSP
700 0 Locking Sealant A/R
710 2 Pressure Test Point M10X1
720 1 Pressure Test Point 1/4" BSP
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Operation
Figure 937.
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
A Front axle B Hydrostatic drive pump

C Engine D Hydraulic services pump
E Rear axle F Hydrostatic drive motor
G Drive output to front axle H Drive output to rear axle
J Clutch/gear M4 K Clutch/gear M3
L Gear M Layshaft gear
N H1 Hydrostatic drive motor disconnect clutch P Hydrostatic drive motor pinion gear
Q 4WD (Four Wheel Drive) output clutch R Hydrostatic pump drive gear
S Gear T Gear
U Clutch/gear M2 V Sensor
W Bevel gear X Front differential
Y Rear differential Z Propeller shaft
1 Park brake 2 Wheels
Operation gearbox output sensor shifts the transmission into

mechanical only mode. The transmission will shift to
The engine transmits power through the bevel a mechanical gear to match the engine speed and
gearbox to the gearbox input shaft. the road speed. The transition from hydrostatic drive
to mechanical drive has been calibrated to be as
A transmission electronic control unit senses the smooth and seamless as possible.
speed of the engine and inputs from the operator
controls of the transmission. The solenoid control valves used to control
the oil flow to the clutches are controlled
When the transmission is engaged, initially it will shift by the transmission electronic control unit. The
into Hydrostatic speed (H1) until the transition road transmission electronic control unit uses a PWM
speed is reached. Refer to the operators manual. (Pulse Width Modulation) signal to progressively
energise or de-energise the clutch solenoids
At this point the transmission electronic control unit depending on the road speed and speed of the
which is calculating the machines speed from the
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27 - Driveline
05 - Hybrid Gearbox
00 - General
engine. The operator can also limit the highest gear from the hydrostatic motor to the transmission output
selected by the transmission ECU to allow for precise shaft. If required, the 4WD clutch can be engaged
operational requirements. (not shown- see 4WD). The machine can be driven
in hydrostatic mode up to the transition speed.
Clutch H1
Above the transition speed the transmission
Refer to Figure 938. electronic control unit disconnects the drive from the
hydrostatic motor to allow the mechanical clutches to
The engine drives the hydrostatic pump via two drive the geartrain.
constant mesh gears. The oil flows through a
hydraulic pipe to drive the hydrostatic motor and When the vehicle speed drops below the transition
returns via the other pipe. When starting to drive, speed, the electronically controlled mechanical gear
the H1 clutch is engaged which transfers the drive train clutches will be de-energised and the H1 clutch
will re-engage to drive the transmission.
Figure 938. Clutch H1
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Clutch M2 the 4WD clutch can be engaged (not shown- see

4WD).
Mechanical clutch M2 is engaged when the speed of 4WD is automatically engaged when the machine is
the machine is above the transition speed and will set in Auto mode. When the machine is in auto mode,
drive the transmission until a higher gear is selected. if 4WD is switched on, it is engaged for H1, M2, M3
and M4.
M2 is disengaged and the drive flows through the M3
engaged clutch gear to the output shaft. If required,
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05 - Hybrid Gearbox
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Figure 939. Clutch M2
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Clutch M3 Hydrostatic drive is disengaged and the drive flows

through the engaged clutch gear to the output shaft.
Refer to Figure 940. If required, the 4WD clutch can be engaged (not
shown- see 4WD). In auto mode, the 4WD clutch is
Mechanical clutch M3 is engaged when the speed of disconnected.
the machine is above a preset speed and will drive
the transmission until a higher gear is selected.
27 - 164 9813/7600-3 27 - 164

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05 - Hybrid Gearbox
00 - General
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Clutch M4 drive the transmission until the machine slows and a

lower gear or hydrostatic drive is required.
M3 is disengaged and the drive flows through the
Mechanical clutch M4 is engaged when the speed engaged clutch gear M4 to the output shaft. If
of the machine is above a preset speed the and will required, the 4WD clutch can be engaged (not
shown- see 4WD).
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05 - Hybrid Gearbox
00 - General
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Clutch 4X4 If required, the 4WD clutch can be engaged in all

gears.
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05 - Hybrid Gearbox
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Figure 942. Clutch 4X4
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
Parkbrake the layshaft and 2 constant mesh gears. 4WD is

disengaged and the park brake operates via the rear
Refer to Figure 943. axle.
All gears are deselected and the gearbox is in H1 clutch is engaged to prevent the transmission
neutral. The Park brake is engaged by the park brake from rolling backwards or forwards when the park
lever via a cable. The output shaft is locked via brake is applied.
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05 - Hybrid Gearbox
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Figure 943. Park brake
C
J
R
B X
A R E
J
S W
2 K 2
T
X X D
T
K
S U
Q L
X Z X
H Z Y
G
N L U
M
X
M 1
N V
P
F X
P
2 2
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Diagram
Figure 944. Dual Tech Variable Transmission, Hydraulic Schematic (TLG4330-D)..............Page 27-171
27 - 169 9813/7600-3 27 - 169

Notes:
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Page 27-172 Figure 944. Dual Tech Variable Transmission,

Hydraulic Schematic (TLG4330-D) Page 27-173
6
5
2
13
3 12
8 9 10
14
11
15
16
18
TLG4330-D
17
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Page Page
27-172 27-173
Figure 944. (Part 1 of 2)
Page 27-173
16
18
17
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Page Page
27-172 27-173

6
5
13
12
8 9 10
Page 27-172
14
11
15
16
TLG4330-D
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1 Control piston direction control 2 Cut-off valve

3 HP (High Pressure) valves 4 DTVT (Dual Technology Variable
Transmission) Pump (Case full)
5 Clutch supply pressure 14bar (202.9psi) 6 Clutch feeds
7 Charge pump 8 Pump drain (pump clutch)
9 Valve drain 10 Gearbox lubrication (maximum) pressure
3bar (43.5psi)
11 Oil filter 12 PMV (Pressure Maintenance Valve) Drain-
Bevel box
13 Valve block assembly 14 Bevel box lubrication
15 Transmission 16 Tank
17 Flushing valve 18 DTVT Motor (Case empty)
PT2 Pump drain PMT Pump drain to motor
R Air bleed MA HP Service line
MB HP Service line X1 Control pressure
X2 Control pressure S Suction
Fa Boost pressure inlet Fb Boost pressure outlet
Yst Pilot pressure MT2 Motor drain
M1 Pilot pressure A HP Service line
B HP Service Line
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Fault-Finding
Fault
Fault Finding Table 335. Page 27-175
Table 335. Fault Finding

Cause Remedy
Any suspected DTVT (Dual Technology Variable Refer to JCB Service for assistance
Transmission) faults
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Drain and Fill 3. Remove the access panel to gain access to the
underside of the gearbox. Refer to (PIL 06-06).
CAUTION Oil will gush from the hole when the
drain plug is removed. Keep to one side when you 4. Pace a suitable container below the gearbox
remove the plug. strainer.
5. Remove the gearbox strainer and gasket. Refer
Gearbox- Hydrostatic Drive System to (PIL 27-05-40).
The hydrostatic drive system is supplied from the 6. Drain the oil in to a suitable container for at least
machine main hydraulic oil system and this oil supply the specified time.
is separate from the mechanical part of transmission Duration: 6min
system.
7. Install the gearbox strainer. Refer to (PIL
To remove either the hydrostatic pump or motor you 27-05-40).
will need to drain the machine hydraulic system.
8. If necessary, install a new gearbox (mechanical)
Refer to hydraulic system, tank, (PIL 30-03-00). oil filter. Refer to (PIL 27-39).
Refill Refill
The hydrostatic pump system is installed with a 1. Get access to the gearbox dipstick/filler tube in
priming pipe located on the machine. When the the engine compartment. Refer to (PIL 06-06).
hydrostatic drive system is installed carry out the 2. Clean and remove the dipstick.
following: This procedure assumes the hydraulic
oil tank has already been drained and all safety 3. Fill the gearbox with the correct specification
procedures have been carried out. and quantity of oil to the maximum mark on the
dipstick. Refer to (PIL 75-00).
1. Make sure that all pipes and hoses are correctly
installed. 4. Make sure you do not overfill the gearbox.
2. Fill the machine hydraulic system (this will part 5. Install the dipstick.
fill the hydrostatic system). Make allowance for
the lift arm being raised. Refer to machine, 6. Operate the machine though all the gears for the
description, service point locations, refer to (PIL specified time.
01-09-15) and also (PIL 30-03-00). Duration: 1min
3. Clean the area around the priming tube cap to 7. Recheck the oil level and top up if required.
prevent the ingress of debris. Remove the cap.
8. Check for leaks.
4. Prime the hydrostatic system using the priming
tube. Refer to (PIL 06-06-10). 9. Install all access covers.
5. Make sure you use the same grade of hydraulic
fluid as the main hydraulic system. Refer to (PIL
75-00-00).
6. Install the cap and tighten to the correct torque.
7. Reconnect the battery and start the machine and
run for the specified time.
Duration: 60s
8. Recheck the hydraulic oil level
Gearbox- Mechanical Drive System

Drain
1. Make sure the gearbox is hot.
27 - 176 9813/7600-3 27 - 176

27 - Driveline
05 - Hybrid Gearbox
00 - General
Check (Level) Check (Pressure)

Special Tools
1. Make the machine safe with the boom lowered. Description Part No. Qty.
2. Start the engine and operate at low idle for few Adaptor 4WD Pressure 332/M7143 1
minutes. This allows the oil to fill the filter, pump, test tool
torque converter, oil cooler and hoses. Digital Hydraulic 998/11051 1
Duration: 4min Pressure Test Kit
3. Stop the engine. WARNING Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well
4. Remove the ignition key. clear of pressurised fluid and wear protective
glasses. If fluid penetrates your skin, get medical
5. Open the engine compartment cover. help immediately.
6. Before you complete a check of the oil level, WARNING Before disconnecting any propshaft,
you must wait as shown on the instructional make sure you block both sides of all wheels
label. The instructional label shows the time in to prevent machine movement. The park brake
seconds. will become ineffective or may only operate on 2
wheels (depending on machine specification).
7. Check the gearbox oil level on the dipstick. The
oil level must be between the end of the dipstick
To help with fault identification, record the test results
and maximum mark on the dipstick.
on a check list. The check list will help the engineer to
8. If necessary add oil through the dipstick tube. identify the cause of a gearbox fault and if needed it
can be sent to JCB Technical Service by email. Refer
to technical data, PIL (27-05-00).
1. Park the machine on a firm level surface.

3. Make sure the lift arm maintenance safety strut
is installed. Refer to PIL (06-69).
4. Remove the machine belly guard. Refer to PIL
(06-06-30).
5. The MH measurement is taken with the propeller
shafts installed and the machine in a stalled
condition by using a suitable method.
6. Remove the front and rear propeller shafts from
the machine. Refer to PIL (27-47 and 27-48).
6.1. Pressure tests must not be carried (except
the MH measurement) out unless the front
and rear propeller shafts are removed.
7. Remove the transmission control valve block
access plate. Refer to PIL (06-06-10).
8. Connect the test equipment as required to
complete the check list. Refer to control valve,
component identification PIL (27-05-19) and
hybrid gearbox, component identification PIL
(27-05-00).
Special Tool: Digital Hydraulic Pressure Test Kit
(Qty.: 1)
Special Tool: Adaptor 4WD Pressure test tool
(Qty.: 1)
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27 - Driveline
05 - Hybrid Gearbox
00 - General
9. When all testing is completed, install the Remove and Install

transmission control valve block access plate.
Refer to PIL (06-06-10).
Lifting Equipment
10. Install the front and rear propeller shafts to the You can be injured if you use incorrect or faulty lifting
machine. Refer to PIL (27-47 and 27-48). equipment. You must identify the weight of the item to
11. Install the machine belly guard. Refer to PIL enough and suitable for the job. Make sure that lifting
(06-06-30). equipment is in good condition and complies with all
12. Remove the maintenance safety strut and lower local regulations.
the lift arm. Refer to (PIL 01-03). CAUTION! You can be injured if you use incorrect or
faulty lifting equipment. You must identify the weight
13. Send the test results to JCB Technical Service of the item to be lifted then choose lifting equipment
for review. that is strong enough and suitable for the job. Make
sure that lifting equipment is in good condition and
complies with all local regulations.
Remove
2. Remove any attachments that may be installed.
4. Remove the transmission compartment access
covers. Refer to (PIL 06-06-10).
30-00-00).
6. Discharge the brake pressure. Refer to (PIL
24-03-00).
(PIL 06-06).
8. Remove the undershield. Refer to (PIL 06-06).
9. To drain the hydrostatic drive, drain the hydraulic
oil tank. Refer to (PIL 30-03).
10. Drain the gearbox mechanical transmission oil.
11. Remove the engine. Refer to (PIL 15-00).
12. Use a suitable method to support the gearbox
from underneath the machine.
13. Disconnect the propeller shafts. Refer to (PIL
27-47).
14. Disconnect all the hydraulic pipes, breather
pipe and electrical connections to the gearbox
including the following.
14.1. Hose from the valve block to the pump.
14.2. Hoses to the trailer brake valve.
14.3. Oil cooler hoses.
14.4. Gearbox mechanical system filling pipe.
Refer to (PIL 06-06-10) for identification.
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05 - Hybrid Gearbox
00 - General
14.5. Solenoid and sensor connections. Disassemble and Assemble

15. Remove the oil cooler hoses. Special Tools
Figure 945. Dual Tech Variable Transmission Description Part No. Qty.
A Clutch Lifter Tool 332/M5604 1
Push Pull Tool 332/M5714 1
Push Pull Adaptor M20 332/M5717 1
Push Pull Adaptor M8 332/M5718 1
A Push Pull Adaptor M16 332/M5719 1
Needle Bearing 332/M5883 1
Installation Tool
Bevel Gear Nut Socket 332/M6571 1
Bevel Gear Nut 459/M0155 1
Reaction Tool
Push Pull Lever Tool 998/M0041 1
Before following some of the procedures, remove

A the gearbox from its machine installation. Refer to
the correct machine service documentation. The
A Gearbox mounting locations following lists all the service procedures for the
16. Remove the gearbox mounts. gearbox. For some procedures it is necessary to do
other procedures first, these are shown below.
17. Manoeuvre the gearbox from the machine.
Disassemble
Install
1. Remove the oil cooler pipework. Seal the
1. The installation procedure is the opposite of the apertures to prevent the ingress of debris.
steps. 2. Remove the oil filter housing manifold.
1.1. Tighten all fastening and connections to the
correct torque value. Refer to (PIL 72-00). 3. Remove the hydrostatic motor and pump flexible
hoses. Refer to (PIL 27-05-93).
1.2. Make sure all hoses, pipes and electrical
wiring are routed correctly. 4. Remove the hydrostatic motor.
1.3. Fill the hydraulic system. Make sure that Refer to: PIL 27-05-23.
you allow space in the tank for oil to be
returned from the lift arm when it is lowered. 5. Remove the hydrostatic pump.
1.4. Bleed the hydrostatic drive system of the Refer to: PIL 30-13-00.
gearbox. Refer to (PIL 27-05-00).
6. Remove the speed sensor to allow the
1.5. Refill the gearbox mechanical system with transmission to fit in the cradle. Make sure the
the correct oil. Refer to (PIL 27-05-00). transmission is correctly retained in the cradle.
1.6. Check the hydraulic oil level and top up if Refer to: PIL 27-05-27.
7. Remove the park brake assembly. Refer to (PIL
1.7. Inspect the hydraulic system for leaks. 24-18-00 ).
8. Remove 4WD (Four Wheel Drive) cover and
clutch. Refer to (27-05-07).
9. Remove the plate carrier (4WD output). Refer to
(27-05-07).
9.1. Slacken the setscrew, inside the plate
carrier shaft and remove the shaft and
setscrew together. Make sure you discard
this bolt and install a new one.
27 - 179 9813/7600-3 27 - 179

27 - Driveline
05 - Hybrid Gearbox
00 - General
A Setscrew
9.2. Remove the needle roller bearing (renew
the setscrew).
Figure 947.
13. Before further disassembly, measure the motor
B shaft end float. Refer to Calibrate
Length: 0.01–0.11mm
Special Tool: Push Pull Tool (Qty.: 1)
Figure 949.
F E
C
D F
D Motor shaft end float

E Push/pull plate
F Screws
B Needle roller bearing 14. Use the push pull tool and relevant adaptor to
C Plate carrier shaft measure the motor shaft end float. Push down
using the specified force and zero DTI (Dial Test
10. Remove the union. Indicator).
11. Invert the stand and remove the shaft output Special Tool: Push Pull Lever Tool (Qty.: 1)
housing bolts and small valve block. Be careful Special Tool: Push Pull Adaptor M20 (Qty.: 1)
not to damage the small O-rings. Special Tool: Push Pull Adaptor M16 (Qty.: 1)
Special Tool: Push Pull Adaptor M8 (Qty.: 1)
12. Remove the transmission oil pump.
15. Then turn the torque wrench around and
Refer to: PIL 27-05-24. measure the deflection. The specified force is
Torque: 38N·m
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05 - Hybrid Gearbox
00 - General
18. Measure the pump clutch shaft end float.

Figure 953.
16. Reposition and use the same tools to measure

the layshaft end float.
Figure 951.
19. Use the special tool to lock off the bevel pinion
gear. Measure the bevel gear backlash. The tool
is installed the opposite side of the transmission
case.
17. Reposition and use the same tools to measure

the output shaft end float. The output shaft
bearing is preloaded and deflection should be
zero.
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05 - Hybrid Gearbox
00 - General
23. Position the reaction tool over the nut. Use the
20. Remove the output shaft yolk RWD (Rear Wheel tool to remove the bevel gear.
Drive). Special Tool: Bevel Gear Nut Reaction Tool (Qty.:
21. Remove bevel gear carrier and shim. 1)
Refer to: PIL 27-12. Figure 957.
Figure 955.
22. Remove the input shaft stake nut and 24. Remove the bevel gear assembly.
components. Make sure you de-stake the nut
or the shaft will be damaged. Use special
tools 332/M6571 and 459/M0155 (and setscrews
1314/0411Z).
Special Tool: Bevel Gear Nut Socket (Qty.: 1)
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05 - Hybrid Gearbox
00 - General
Figure 958. 27. Use the correct lifting equipment to remove the
bolts and separate the gear box housing. Take
care the bearing races are not an interference fit
and may drop out during this procedure.
28. Remove the gear train components:
28.1. Remove the pump clutch.
Figure 961.
25. Remove the spacer.

Figure 959.
E Pump clutch
28.2. Remove the pump shaft and bearing
races.
Figure 962.
Figure 960.
F Pump shaft
28.3. Use the special clutch lifter tool to
help to remove the remaining gear train
components.
26. Invert the transmission. Special Tool: Clutch Lifter Tool (Qty.: 1)
27 - 183 9813/7600-3 27 - 183

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05 - Hybrid Gearbox
00 - General
31. Disassemble the gearbox components as

required:
G Clutch lifter tool
31.1. Clutch-Input. Refer to (PIL 27-05-11).
29. Install the special tool on to the clutch assembly 31.2. Clutch-Output. Refer to (PIL 27-05-09).
and secure with the relevant screws. Remove the
clutch lifter with clutch assembly attached on to 31.3. Clutch-Layshaft. Refer to (PIL 27-05-08).
a clean workbench. 31.4. Clutch-Pump. Refer to (PIL 27-05-62).
30. Remove the clutch components sideways using 31.5. Clutch-Motor. Refer to (PIL 27-05-63).
the slots in the tool before removing the
remaining component vertically. Make sure that 31.6. Clutch-4WD. Refer to (PIL 27-05-07).
no components fall off the tool during this
32. Remove the transmission case components as
procedure.
required.
27 - 184 9813/7600-3 27 - 184

27 - Driveline
05 - Hybrid Gearbox
00 - General
Figure 965.
Assemble
following steps.
2. Make sure that all O-rings, seals and sealing
washers are renewed and lubricated with clean
new transmission oil.
3. Make sure the transmission and its components
are kept clean and free of debris.
4. Make sure that all lubrication paths are clean and
free of debris.
5. Make sure that all components are inspected. If
any are damaged they must be renewed.
6. Install the needle roller bearing (renew the
setscrew).
Special Tool: Needle Bearing Installation Tool
(Qty.: 1)
7. Make sure you check all end float measurements
during assembly. The end floats are not
adjustable and components or the transmission
will require replacement if the end floats are
incorrect. Refer to JCB service for advice.
27 - 185 9813/7600-3 27 - 185

27 - Driveline
05 - Hybrid Gearbox
07 - Clutch - 2WD/4WD Component Identification

Check (Condition) ........................................ 27-187
Check (Operation) ....................................... 27-187
Adjust .......................................................... 27-188
Figure 966. Clutch- 4WD

E B A J
D F M
C S
P N K
A Clutch drum M/C B Piston housing

C Shaft- 4WD (Four Wheel Drive) output D Seal ring
E Master- O-ring F Master- O-ring
G Sleeve- oil feed- 4WD shaft H Friction plate- 4WD
J Counter plate K Pressure plate
L Disc spring M Circlip 1
N Actuating sleeve 4WD clutch P Disc spring
Q Steel ring R Piston 4WD clutch
S Shim plate
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27 - Driveline
05 - Hybrid Gearbox
Do a visual check of the friction and counter plates Check the clutch pack operates smoothly by carrying
and gears: out an operation check using an airline. Apply the
specified pressure for the specified time and make
Counter plates sure there are no leaks. 10s at 3bar (43.5psi)
1. 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
1. The lubrication slots should be clearly visible,
one.
2. Do not change individual plates, if a plate is
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
an air line. Do not use a wire rod (or screwdriver) as
it can damage the valve seat.
Gears
1. Check the gear teeth for wear, cracking or
damage.
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27 - Driveline
05 - Hybrid Gearbox
Refer to driveline, hydrostatic gearbox, clutch The layshaft clutch, 2WD (Two Wheel Drive) / 4WD
2WD/4WD, disassemble and assemble. (PIL (Four Wheel Drive) clutch, reverse clutch, main shaft
27-05-07). clutch and forward / input clutch are all part of the
main shaft assembly.
1. Install a single shim plate if required to achieve
the specified dimension. Refer to the main shaft remove and install procedure.
Length/Dimension/Distance: 0.75–1.5mm Refer to (PIL 27-06-54).
Figure 967.
A
A Specified dimension
27 - 188 9813/7600-3 27 - 188

27 - Driveline
05 - Hybrid Gearbox
Disassemble and Assemble 9. Make sure the clutch plates have the correct
free movement and adjust if required. Refer to
CAUTION The spring (or springs) apply driveline, hydrostatic gearbox, clutch 2WD/4WD,
considerable force. Make sure you take care to Adjust, (PIL 27-05-07).
avoid damage or injury.
10. Make sure the clutch has the bolt, washer and
coupling yolk installed before doing the following:
Refer to Driveline, Hydrostatic gearbox, Clutch 2WD
(Two Wheel Drive)/4WD (Four Wheel Drive), (PIL 10.1. Check the clutch pack operates smoothly
27-05-07). by carrying out an operation check using
an airline. Apply the specified pressure for
Make a note of the fitted orientation of all the 10 seconds and make sure there are no
components to assist in installation. leaks.
Discard all o-rings and seals. Pressure: 3bar (43.5psi)
1. Remove bolt, washer and coupling yolk (If not

already removed).
2. Remove the oil feed sleeve.
3. Remove the piston housing.
4. Remove the circlip and remove the clutch
pressure, friction and counter plates in their
installed order.
5. Different clutches may have different
specification plates depending on the
application. Make sure that the plates are not
mixed up with plates from other clutches. You
may not be able to distinguish the difference if
the plates have been used.
Assemble
following steps.
2. Make sure all components are clean.
3. Install new seals and O-rings
4. Make sure all seals and O-rings are lubricated
but do not lubricate anything with grease. Make
sure you use transmission oil only, unless
otherwise stated in the procedure. Refer to (PIL
75).
5. Lightly lubricate all bearings and components
with the correct oil. Make sure you use
transmission oil only unless otherwise stated in
the procedure. Refer to (PIL 75).
6. Take care not to damage seals or o-rings during
assembly.
7. Install the first friction plate up against the clutch
drum.
8. On assembly of the splines, the friction plate
groove pattern is to be aligned.
27 - 189 9813/7600-3 27 - 189

27 - Driveline
05 - Hybrid Gearbox
11 - Clutch - Forward (Input)
11 - Clutch - Forward (Input) Component Identification

Check (Condition) ........................................ 27-192
Check (Operation) ....................................... 27-192
Adjust .......................................................... 27-193
Figure 968. Clutch- Input (Input Shaft With M3 Clutch)

J G P E F
Q
U A H
B C D
N R Y
V L
X K
T
M
W,X
459-m6574-1
A Gear 42T and plate carrier B Bearing- taper roller

C Gear 35T- input D Input shaft
E Plate- counter, clutch F Plate- friction, clutch
G Circlip- internal H Circlip- external
J Washer- spring retainer K Compression spring
L Oil baffle plate M Piston- clutch
N Circlip- external P Plate- pressure, clutch
Q O-ring R O-ring
S Seal ring T Spacer kit
U Bearing- deep groove ball V Disc spring
W Plate- pressure, clutch X Plate- shim, clutch
27 - 190 9813/7600-3 27 - 190

27 - Driveline
05 - Hybrid Gearbox
Y Bearing- taper roller
27 - 191 9813/7600-3 27 - 191

27 - Driveline
05 - Hybrid Gearbox
Carry out a visual inspection of the friction and Check the clutch pack operates smoothly by carrying
counter plates: out an operation check using an airline. Apply the

must be replaced with a new set.
Friction plates
set.
cracking. If in doubt install a new disc spring.
27 - 192 9813/7600-3 27 - 192

27 - Driveline
05 - Hybrid Gearbox
Clutch Pack End float Adjustment The layshaft clutch, 2WD (Two Wheel Drive) / 4WD
(Four Wheel Drive) clutch, reverse clutch, main shaft
1. Use a DTI (Dial Test Indicator) as shown, clutch and forward / input clutch are all part of the
measure the end float of the pressure (end) plate, main shaft assembly.
which should be within the specified tolerances.
Refer to the main shaft remove and install procedure.
Figure 969. For Illustration Purposes
2. If necessary, install a shim between the retaining

circlip and pressure (end) plate to correct end
float inaccuracies. Make sure the pressure plate
is installed with the flattest face against the
circlip.
3. Install the required pressure plate with either
the shim or counter plate installed between the
circlip and pressure plate as required to obtain
the correct end float. Refer to Table 336.
Table 336. Clutch Pack Adjustment

Item Size
Pressure plate 6
6.5
Plate- shim, clutch Sized as supplied
Plate- counter, clutch Sized as supplied
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27 - Driveline
05 - Hybrid Gearbox
Special Tools CAUTION The spring (or springs) apply

Description Part No. Qty. considerable force. Make sure you take care to
Input Shaft Drift 332/M5872 1 avoid damage or injury.
Spring Compressor 892/00916 1
Tool
Figure 970. Clutch- Input (Input Shaft With M3 Clutch)

J G P E F
Q
U A H
B C D
N R Y
V L
X K
T
M
W,X
459-m6574-1
A Gear 42T and plate carrier B Bearing 1- taper roller

C Gear 35T- input D Input shaft
E Plate- counter, clutch F Plate- friction, clutch
G Circlip 2- internal H Circlip- external
J Washer- spring retainer K Compression spring
L Oil baffle plate M Piston- clutch
N Circlip 1- external P Plate- pressure, clutch
Q O-ring R O-ring 1
S Seal ring 1 T Spacer kit
U Bearing 2- deep groove ball V Disc spring
W Plate- pressure, clutch X Plate- shim, clutch
27 - 194 9813/7600-3 27 - 194

27 - Driveline
05 - Hybrid Gearbox
Y Bearing 3- taper roller
Refer to driveline, hydrostatic gearbox, clutch Figure 971. For illustration only
forward (input), component identification. Refer to:
PIL 27-05-11. 11 11
Make a note of the fitted orientation of all the 12
components to assist in installation.
Discard all o-rings and seals.
1. Starting at the left side of the illustration.

13
2. Remove the seal rings 1 Y 13A

3. Remove the taper bearing 1 using the correct drift
tool.
Special Tool: Input Shaft Drift (Qty.: 1)
4. Remove the circlip 1.
5. Remove the 42T gear and plate carrier from the
shaft together with the ball bearings 2.
6. Remove the circlip 2 and remove the pressure
plate, clutch friction and counter plates in their
installed order.
11 Circlip
7. Different clutches may have different 12 Spring retaining plate
specification plates depending on the 13A Oil baffle plate
application. Make sure that the plates are not Y Cut-away tube
mixed up with plates from other clutches. You
may not be able to distinguish the difference if 9. Remove the washer, spring, and oil baffle
the plates have been used. together.
8. Position the clutch assembly in a press. Use a 10. Remove the O-ring 1 from the shaft.
cut-away tube to compress the piston spring then
remove the circlip. 11. Remove the 35T input gear.
Special Tool: Spring Compressor Tool (Qty.: 1) 12. Remove the taper bearing 3 using the correct drift
tool.
Special Tool: Input Shaft Drift (Qty.: 1)
13. Remove the clutch piston assembly from the
shaft.
14. Remove and discard the piston and shaft O-
rings.
Assemble
following steps.
but do not lubricate anything with grease. Make
sure you use transmission oil unless otherwise
stated in the procedure.
Refer to: PIL 75.
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27 - Driveline
05 - Hybrid Gearbox

transmission oil unless otherwise stated in the
procedure.
Refer to: PIL 75.
6. Take care not to damage seals or O-rings during
assembly.
7. Make sure the clutch pack pressure plate is
installed with the flattest face against the circlip
2. Refer to X. Refer to Figure 970.
8. Make sure the clutch plates have the
correct free movement and adjust if required.
Refer to driveline, Hydrostatic Gearbox, Clutch
2WD/4WD, Adjust,
9. Check the clutch pack operates smoothly by
carrying out an operation check using an airline.
Apply the specified pressure for 10 seconds and
make sure there are no leaks.
10. Carry out a pressure check.
27 - 196 9813/7600-3 27 - 196

27 - Driveline
05 - Hybrid Gearbox

Introduction .................................................. 27-197 The solenoid control valves provides the switching
Check (Condition) ........................................ 27-198 for forward drive and reverse drive to select the
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.
27 - 197 9813/7600-3 27 - 197

27 - Driveline
05 - Hybrid Gearbox
Check (Condition)

dismantling and assembling the valve to avoid the
following:
• Contamination

27 - 198 9813/7600-3 27 - 198

27 - Driveline
05 - Hybrid Gearbox
Introduction
The pressure relief valve is a type of valve used to

control or limit the pressure which can build up due

27 - 199 9813/7600-3 27 - 199

27 - Driveline
05 - Hybrid Gearbox
19 - Control Valve
19 - Control Valve Component Identification

Figure 972. Valve Block

F J
C M
H L
K
B D E
A
N
G
O
V R Q
U T S
P
A Oil pressure switch B Test point- H1

C Test point- Trans feed D Test point- 4WD (Four Wheel Drive)
E Test point- M3 F Test point- Tans lube
G Test point- M2 H Inlet elbow
J Breather (Hose not installed) K Test point- M4
L Outlet elbow M Cap screw (X14)
N Valve- PRV (Pressure Relief Valve) O Banjo bolt
P Valve- PMV (Pressure Maintenance Valve) Q Temperature sender
R Solenoid valve- proportional M4 S Solenoid valve- proportional M2
T Solenoid valve- proportional M3 U Solenoid valve- on/off valve 4WD
V Solenoid valve- proportional H1
27 - 200 9813/7600-3 27 - 200

27 - Driveline
05 - Hybrid Gearbox
19 - Control Valve
Remove and Install
Remove hoses and the pressure test points are remotely

located.
Before you start the removal procedure, pressure
wash all dirt and debris from the external case of the 4. Mark for correct replacement, remove the hoses
gearbox. Make sure that the electrical and hydraulic from the pressure points, plug the hoses and cap
connections are protected from any chemicals used the adaptors to prevent ingress of dirt.
in the wash equipment. 5. When you remove the capscrews, slacken
progressively and in a logical opposing sequence
1. Disconnect the wiring connectors from each of
to prevent distortion of the aluminium valve block.
the solenoid valves.
6. Remove and discard the gasket between the
2. Disconnect the hydraulic hose, plug the hose and
valve block and the gearbox case.
cap the adaptor.
7. Lift and remove the valve block.
3. The illustration shows self seal pressure test
points positioned on the valve, on some 8. Prevent ingress of debris to the mating face on
machines they may be replaced with microbore the transmission.
Figure 973.
G C
B D
F E
A
A Solenoid valve connections (x5) B Hydraulic hose connections (x2)

C Capscrews (x14) D Banjo bolt
E Oil pressure sender F Temperature sender
G Pressure test points (x7)
27 - 201 9813/7600-3 27 - 201

27 - Driveline
05 - Hybrid Gearbox
19 - Control Valve
Install
1. The Installation procedure is the opposite
of the removal procedure with the following
precautions.
2. Make sure that all surfaces and components are
clean and free of debris.
3. Position the new gasket on the case.
4. Position the valve block using a capscrew as a
guide.
5. Install the fixing screws into the remaining
positions.
6. Tighten in an opposing pattern from the
centre outwards to prevent the valve becoming
distorted.
7. Reconnect the hydraulic hoses to the pressure
test points (if required) in the correct positions as
marked on the removal.
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27 - Driveline
05 - Hybrid Gearbox
19 - Control Valve
Valve Block
The valve block is a single block type, The illustration
is intended as a guide to identify the components.
Be sure to note the location of all components when

you disassemble. Although some components may
appear to be identical, they are not interchangeable.
Make sure that components are assembled in their
original positions.
Great care should be taken when you disassemble

and assemble a valve to avoid the following:
• Contamination

Disassemble
1. Remove the valve block from the machine. Refer
to remove and install, (PIL 27-05-19).
2. Place the valve block on a suitable surface that
will not damage the valve.
3. Using the correct tools, remove the desired
components.
Assemble
1. The assembly procedure is the opposite of the
disassembly procedure.
2. When you assemble, also do the following steps:
2.1. Make sure that the components are
thoroughly clean before assembly.
2.2. Renew any seals or gaskets. Make sure
that the seals are not trapped or damaged.
2.3. Lubricate parts with the correct JCB
hydraulic fluid before assembling. Make
sure that all the parts move freely.
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27 - Driveline
05 - Hybrid Gearbox
21 - Pressure Maintenance Valve

(PMV)
Introduction
Refer to driveline, hydrostatic gearbox, general, (PIL

27-05-00).
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05 - Hybrid Gearbox
23 - Motor
23 - Motor Introduction
Introduction .................................................. 27-205 The axial piston variable motor converts hydrostatic
Component Identification ............................. 27-206 flow into mechanical rotation.
Operation ..................................................... 27-206
Fault-Finding ................................................ 27-208 The hydraulic flow to the motor can be reversed to
depending on the direction of travel required.
Bleed ........................................................... 27-209
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27 - Driveline
05 - Hybrid Gearbox
23 - Motor

Figure 974. Layout of the Axial Piston Unit The A6VM is a variable motor with axial piston rotary
group of bent-axis design, for hydrostatic drives in
open and closed circuits. For axial piston units with
bent axis design, the pistons are arranged askew to
the drive shaft. The pistons rest directly on the drive
B
shaft where they generate torque depending on the
A pressure and swivel angle. The specific torque and
displacement can be changed by adjusting the bent
axis.
Open Circuits (If Installed)

In an open circuit, the hydraulic fluid flows from
the reservoir to the hydraulic pump from where
G it is transported to the hydraulic motor. From the
C hydraulic motor, the hydraulic fluid flows directly back
to the reservoir. The output direction of rotation of the
F hydraulic motor can be changed, e.g. by a directional
E D valve.
A Drive shaft Closed Circuit (If Installed)

B Control piston
C Stroke piston In the closed circuit, the hydraulic fluid flows from
D Port plate the hydraulic pump to the hydraulic motor and
E Lens plate from there directly back to the hydraulic pump. The
F Cylinder output direction of rotation of the hydraulic motor is
G Piston changed, e.g. by reversing the flow direction in the
hydraulic pump.
Figure 975.
B
G
C
F
E D
A Drive shaft
B Control piston
C Stroke piston
D Port plate
E Lens plate
F Cylinder
G Piston
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27 - Driveline
05 - Hybrid Gearbox
23 - Motor
Motor Function
A hydraulic motor converts hydrostatic energy into
mechanical energy. Hydraulic fluid is directed via the
port plate and the lens plate to the cylinder bores.
The pistons in the cylinder bores execute a stroke
that is converted into rotary movement by the piston
on the drive shaft flange. During this process, the
pistons move the cylinder and generate an output
torque at the drive shaft. The output torque increases
with the pressure difference between the high- and
low-pressure sides and increasing displacement.
The output speed is proportional to the inward flow
and inversely proportional to the displacement of the
hydraulic motor.
Control
The swivel angle of the bent-axis rotary group is
steplessly variable. With two-point control (HZ, EZ),
the swivel angle can be switched from maximum
to minimum angle. Control of the swivel angle of
the bent-axis rotary group changes the piston stroke
and therefore the displacement. The swivel angle
is controlled hydraulically by the stroke piston. The
cylinder,including the piston and lens plate, is then
swiveled. The lens plate is mounted for easy motion
in a guideway. Increasing the swivel angle results
in an increase in the displacement and specific
torque; decreasing the swivel angle results in a
corresponding decrease of these values. The output
speed is dependent on the input flow and the
displacement of the hydraulic motor.
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27 - Driveline
05 - Hybrid Gearbox
23 - Motor
Fault-Finding
Fault
Motor Operation Is Noisy Under Load Table 337. Page 27-208
Motor Operation Is Noisy Without Load Table 338. Page 27-208
Motor Does Not Revolve Table 339. Page 27-208
Motor Sluggish Under Load Table 340. Page 27-208
Motor Revolves Irregularly Table 341. Page 27-208
Hydraulic Leak at Motor Table 342. Page 27-208
Table 337. Motor Operation Is Noisy Under Load

Cause Remedy
Excessive internal leaks. Replace the cylinder block and valving assembly.
Table 338. Motor Operation Is Noisy Without Load

Cause Remedy
Worn bearing support. Replace the motor bearing support.
Vibration- mountings and / or hydraulic piping has Torque tighten motor mountings and hydraulic piping.
become loose.
Table 339. Motor Does Not Revolve

Cause Remedy
No hydraulic fluid flow to the motor. Check the pump drive for correct operation and
pump outlet pressure.
The hydraulic circuit does not reach working Check the circuit for leaks.
pressure.
Brake remains engaged. Check the brake pilot circuit.
Table 340. Motor Sluggish Under Load

Cause Remedy
Low pump flow to the motor. Check the pump drive speed.
The hydraulic circuit does not reach working Check the circuit for leaks.
pressure.
Faulty replenishing (charge pressure) circuit. Check the replenishing circuit.
Table 341. Motor Revolves Irregularly

Cause Remedy
Irregular pump flow. Check the pump flow.
Table 342. Hydraulic Leak at Motor

Cause Remedy
Hydraulic pressure within the motor housing is too Check the drain circuit and filter for blockages.
high.
Deterioration / damage to seals. Replace seals.
Incorrect assembly of motor unit. Check the tightness of all bleed screws, mounting
screws and hydraulic fittings. Torque tighten where
required.
27 - 208 9813/7600-3 27 - 208

27 - Driveline
05 - Hybrid Gearbox
23 - Motor
Bleed Remove and Install

Refer to Driveline, Hybrid Gearbox, General, Drain be removed or handled using a suitable lifting
and Fill, (PIL 27-05-00). method and device.
Refer to driveline, hydrostatic gearbox, motor,

remove and install, (PIL 27-05-23).
Removal
1. Make the machine safe, refer to (PIL 01-03).
2. Vent the hydraulic system, refer to the machines
operator manual. Also refer to (PIL 30-00-00).
3. Isolate the machines battery, refer to (PIL
33-03-03).
4. Make the pump is cool enough to work on.
5. If required on your machine, seal the connection
to the tank to prevent loss of fluid.
6. Label and remove the hydraulic and electrical
connections. Use suitable containers to collect
the displaced fluid.
7. This component is heavy, make sure you
attach suitable lifting equipment and remove
the pump retaining bolts. Refer to hydraulic
system, hydrostatic pump, general, introduction,
technical data (PIL 30-13-00).
8. Empty the pump of fluid over a suitable container
and place the pump on a suitable surface.
9. Plug all openings to prevent the ingress of debris.
10. The pump may subsequently be moved by use
of a suitable eyebolt in the shaft.
Installation
Installation is the reverse of removal. In addition carry
out the following procedures:
1. Make sure the hydraulic fluid level is correct

when installation is complete.
2. Make sure all connections are correct according
to the labels made during removal.
3. Bleed the pump. Refer to hydraulic system,
general, bleed, (PIL 30-00-00).
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27 - Driveline
05 - Hybrid Gearbox
23 - Motor
Refer to JCB Service for advice.
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27 - Driveline
05 - Hybrid Gearbox
24 - Oil Pump
24 - Oil Pump Introduction

Introduction .................................................. 27-211 The oil pump supplies the mechanical gearbox
Component Identification ............................. 27-212 components of the transmission.
Check (Condition) ........................................ 27-212
Remove and Install ..................................... 27-213 It is not part of the hydrostatic drive system of the
transmission.
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27 - Driveline
05 - Hybrid Gearbox
24 - Oil Pump

Figure 976. Dual Tech Vari-
able Transmission Oil Pump
Check (Condition)
C D A pump which is damaged or worn can cause
B damage to the gearbox.
1. Remove the pump from the transmission. Refer

A to Driveline, Oil Pump, Remove and Install, (PIL
27-24).
2. Remove the pump assembly screws.
3. Separate the pump body.
4. 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.
C
E
F
A Transmission oil pump
B Hydrostatic pump mounting flange
C Dual Tech Variable Transmission
D Hydrostatic motor mounting flange
E Hydrostatic pump
F Hydrostatic motor
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27 - Driveline
05 - Hybrid Gearbox
24 - Oil Pump

A
C CAUTION This component is heavy. It must only
B method and device.
B
Remove
1. Remove the hydrostatic pump assembly. Refer
to Hydraulic System, Hydrostatic Pump, General,
Remove and Install, (PIL 30-13-00).
2. Remove the securing screws.
3. Use the jacking screw hole to remove the pump
from the transmission case.
4. Check the condition of the pump. Refer to
B Driveline, Hydrostatic Gearbox, Oil Pump, Check
(Condition), (PIL 27-24-00).
B
E
E D
A Oil pump body (front)
B Securing screw
C Jacking screw hole
D Oil pump body (rear)
E Oil pump assembly screw
5. Renew any gaskets or seals (if installed).
surface damage.

Item Nm
E 4
27 - 213 9813/7600-3 27 - 213

27 - Driveline
05 - Hybrid Gearbox
24 - Oil Pump
Figure 978. 6. Tighten all the bolts progressively in a criss-cross

A sequence, to the specified torque value until the
C final torque value is reached.
B 6.1. Specified torque value per tightening
B sequence
Torque: 5N·m
6.2. Specified torque final torque value to attain
Torque: 9.5–16.2N·m
7. Make sure the pump is free to rotate when it has
been installed.
8. Install the hydrostatic drive pump. Refer to
Hydraulic System, Hydrostatic Pump, General,
Remove and Install, (PIL 30-13-00).
B
B
E
E D
A Oil pump body (front)
B Securing screw (X4)
C Jacking screw hole (X1)
D Oil pump body (rear)
E Oil pump assembly screw
Install
1. If the existing pump is to be installed,
check the condition of the pump. Refer to
Driveline, Hydrostatic Gearbox, Oil Pump, Check
Condition, (PIL 27-05-24).
2. Lubricate the pump with the correct clean oil.
3. Make sure the pump is free to rotate before
installation. Do not install the pump if it is not free
to rotate.
4. Install the pump over the input shaft. Make sure
that the bolt holes are aligned.
5. Install the bolts and finger tighten.
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27 - Driveline
05 - Hybrid Gearbox
27 - Speed Sensor
27 - Speed Sensor Technical Data

Technical Data ............................................. 27-215 Table 344.
Type Magnetic gear tooth
Remove and Install ..................................... 27-216 sensor
Air gap 1.03–2.03mm
Output frequency 0–5Hz
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27 - Driveline
05 - Hybrid Gearbox
27 - Speed Sensor
Component Identification Remove and Install

Figure 979. Dual Tech Variable Trans-
mission- Transmission Speed Sensor
Remove
B
3. Refer to driveline, hydrostatic gearbox,
component identification.
4. Disconnect the electrical connector to the wiring
harness.
5. Remove the sensor retaining screw from the
transmission end of the sensor.
6. Withdraw the sensor from the transmission.
7. Make sure no debris can enter the transmission.
Install
steps.
2. Install a new o-ring seal if the sensor is to be re-
installed.
3. Tighten the sensor fasteners to the correct torque
value.
Torque: 11.3N·m
B
A
A Dual Tech Variable Transmission

B Dual Tech Variable Transmission speed sensor
27 - 216 9813/7600-3 27 - 216

27 - Driveline
05 - Hybrid Gearbox

Introduction .................................................. 27-217 This sensor detects the fluid pressure inside the
Technical Data ............................................. 27-218 gearbox. This is used for diagnostic purposes
Component Identification ............................. 27-218 to check the transmission fluid is at the correct
Remove and Install ..................................... 27-219 pressure.
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27 - Driveline
05 - Hybrid Gearbox
Table 345. Figure 980. Oil Pressure Switch

Switch contact closing 2.76 ± 0.69 (40.0 ± 10.0)
set pressure
(1)
Contacts Normally closed

Size of sensor body 24mm
(across flats)
(1) Falling pressure at the specified temperature.
20°C (68.0°F) B A
A Pin 1 (+ve)
B Pin 2 (-ve)
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27 - Driveline
05 - Hybrid Gearbox
Remove and Install
Remove 2. Unscrew the pressure sensor and remove the

sealing washer.
pressure sensor. Do not allow particles of grit to
fall into the valve block.
Figure 981.
A Pressure sensor B Sealing washer
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27 - Driveline
05 - Hybrid Gearbox
C Valve block
Install
steps:
2. The oil pressure sensor is a non-serviceable
renewed.
4. Tighten the pressure sensor to the correct torque
value.

Item Nm
A 16
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27 - Driveline
05 - Hybrid Gearbox

Introduction .................................................. 27-221 This sensor determines the fluid temperature inside
Technical Data ............................................. 27-222 the gearbox. This is used for diagnostic purposes
Component Identification ............................. 27-223 to check the transmission fluid is at the correct
Remove and Install ..................................... 27-224 temperature.
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27 - Driveline
05 - Hybrid Gearbox
Technical Data
Table 347.
Thread size 9/16-18 UNF
Table 348. Resistance vs Temperature

Temperature Resistance (Ohms)
-40°C (-39.9°F) 842.7Ω
-30°C (-22.0°F) 882.2Ω
-20°C (-4.0°F) 921.6Ω
-10°C (14.0°F) 960.9Ω
0°C (32.0°F) 1,000Ω
10°C (50.0°F) 1,039Ω
20°C (68.0°F) 1,077.9Ω
30°C (86.0°F) 116.9Ω
40°C (103.9°F) 1,155.4Ω
50°C (121.9°F) 1,194Ω
60°C (139.9°F) 1,232.4Ω
70°C (157.9°F) 1,270.7Ω
80°C (175.9°F) 1,308.9Ω
90°C (193.9°F) 1,347Ω
100°C (211.9°F) 1,385Ω
110°C (229.8°F) 1,422.9Ω
120°C (247.8°F) 1,460.6Ω
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27 - Driveline
05 - Hybrid Gearbox
Figure 982. Dual Tech Variable Transmission- Temperature Sensor
A B
1 2
A Pin 1 B Pin 2
C Temperature sensor D Valve block
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27 - Driveline
05 - Hybrid Gearbox
Remove and Install
Remove
Refer to driveline, hydrostatic gearbox, oil
temperature sensor, component identification, (PIL
27-05-33).
temperature sensor. Do not allow particles of grit
to fall into the gearbox
2. Unscrew the temperature sensor and remove the
sealing washer.
Install
following work:
1. The oil temperature sensor is a non serviceable

renewed.
3. Tighten the temperature sensor to the specified
torque value.
Torque: 16N·m
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27 - Driveline
05 - Hybrid Gearbox
39 - Filter
Introduction .................................................. 27-225 The transmission filter is designed to filter all the
Remove and Install ..................................... 27-226 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
05 - Hybrid Gearbox
39 - Filter
Special Tools
Oil Filter Removal Tool 892/00292 1
Consumables
JCB Transmission Fluid 4000/2601 5L
EP SAE 30 4000/2605 20L
4000/2603 200L
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. A
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.
A Gearbox filter
B Seal
Assemble
1. Smear the seal with transmission oil.
Consumable: JCB Transmission Fluid EP SAE
30
2. Screw the filter on until it just contacts the filter
head.
3. Turn the filter at least another 3/4 of a turn.
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27 - Driveline
05 - Hybrid Gearbox
40 - Suction Strainer
40 - Suction Strainer Introduction

Introduction .................................................. 27-227 The suction strainer is a component used for trapping
Remove and Install ..................................... 27-228 large and coarse particles entering the transmission
system.
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27 - Driveline
05 - Hybrid Gearbox

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 984.
A Strainer
B Bolts
D Gasket
Install
1. Install the strainer and a new gasket.
threads of the bolts. Tighten the bolts to the
(Medium Strength)
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27 - Driveline
05 - Hybrid Gearbox
42 - Dipstick
42 - Dipstick
Figure 985. Dual Tech Variable Transmission- Dipstick

C
A
B
A Engine B Dual Tech Variable Transmission

C Dipstick and dipstick tube
27 - 229 9813/7600-3 27 - 229

27 - Driveline
05 - Hybrid Gearbox

Introduction .................................................. 27-230 A piston ring is a split ring that fits into a groove on
Remove and Install ..................................... 27-231 the outer diameter of a piston
27 - 230 9813/7600-3 27 - 230

27 - Driveline
05 - Hybrid Gearbox
Remove and Install
Remove
1. Refer to the relevant Clutch - Disassemble and
Install
1. Wind the PTFE (Polytetrafluoroethylene) piston
ring seal around your finger as shown, so that the
seal forms a coil.
Figure 986.

Figure 987.

27 - 231 9813/7600-3 27 - 231

27 - Driveline
05 - Hybrid Gearbox
47 - Oil Seal

Introduction .................................................. 27-232 Oil seals close spaces between components in
Remove and Install ..................................... 27-233 mechanical systems, they are designed to:

system
system
27 - 232 9813/7600-3 27 - 232

27 - Driveline
05 - Hybrid Gearbox
47 - Oil Seal

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
2. Remove the yoke and the washer, refer to back of the housing.
Gearbox, Yoke- Remove and Install (27-06-95).
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 988.
torque value.
6. Stake the nut to the shaft using a square ended

Item Nm
B 400
A Yoke
B Stake nut
C Oil seal
D Oil seal interface
E Washer
F Locking ring
27 - 233 9813/7600-3 27 - 233

27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
62 - Clutch - Pump Component Identification

Check (Condition) ........................................ 27-237
Adjust .......................................................... 27-237
Figure 989. Clutch- Pump (Pump Shaft With M4 Clutch) (459/M7618-1)
Y
F
Q
G
A
N
W D
T
L
C
E
V
S B
M
K
U, Z H
P, X J
27 - 234 9813/7600-3 27 - 234

27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Item Description
M O-Ring
Table 351.
N G.A. Piston- Clutch
Item Description
P Plate-Pressure-Clutch
A Gear- 44T & Plate Carri-
Q Circlip 150mm- Internal
er
R Bearing- Needle Thrust
B Bearing-Taper Roller
Assembly S Seal Ring 50mm
C Washer- Thrust T Washer- Bevelled-
Thrust
D Gear 39T- Pump Drive
Shaft U Washer- Thrust
E Pump Drive Shaft V Compression Spring
F Plate-Counter-Clutch W Washer- Spring Retainer
G Plate-Friction-Clutch X Plate-Pressure-Clutch
H Oil Baffle Plate Y Plate-Shim-Clutch
J Circlip- External Z Washer- Thrust
K Bearing- Needle Roller
L O-Ring
Figure 990. Pump Clutch
20
40
50
130
110
60
80
120 140
240
230
150
70 200
210
90
190
160
180
100
170
180
160
30
250
20
10
459-M7618-1
27 - 235 9813/7600-3 27 - 235

27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Table 352.
10 Gear- 44T & Plate Carri-
er
20 Bearing-Taper Roller
Assembly
30 Washer- Thrust
40 Gear 39T- Pump Drive
Shaft
50 Pump Drive Shaft
60 Plate-Counter-Clutch
70 Plate-Friction-Clutch
80 Oil Baffle Plate
90 Circlip- External
100 Bearing- Needle Roller
110 O-Ring
120 O-Ring
130 G.A. Piston- Clutch
140 Plate-Pressure-Clutch A/
R 6mm
150 Circlip 150mm- Internal
160 Bearing- Needle Thrust
170 Seal Ring 50mm
180 Washer- Bevelled-
Thrust
190 Washer- Thrust
200 Compression Spring
210 Washer- Spring Retainer
R 6.5mm
240 Plate-Shim-Clutch A/R
250 Washer- Thrust A/R
3.53mm
27 - 236 9813/7600-3 27 - 236

27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Check (Condition) Adjust
Do a visual check of the friction and counter plates Refer to driveline- Hydrostatic Gearbox- Calibrate.
and gears: Refer to (PIL 27-05-00).
Counter plates If required, install a pressure plate of the specified

value along with a shim or counter plate. Install the
1. Light scoring or polishing is permissible, plates shim or counter plate between the circlip and the
that are not flat, worn or heavily marked or scored pressure plate.6–6.5mm
Make sure that the free movement on the clutch plate
is between the specified value. 1.9–2.5mm
Friction plates
one.

Gears
damage.
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27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Remove and Install Disassemble and Assemble

Special Tools
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD Description Part No. Qty.
(Four Wheel Drive) clutch, reverse clutch, main shaft Pump Shaft Drift 332/M5874 1
clutch and forward / input clutch are all part of the
main shaft assembly. Spring Compressor 892/00916 1
Tool
Refer to (PIL 27-06-54). CAUTION The spring (or springs) apply
considerable force. Make sure you take care to
Refer to driveline, hydrostatic gearbox, clutch pump,

component identification (PIL 27-05-62).
Make a note of the orientation of all the components

to assist in installation.
Discard all O-rings and seals.
1. Remove the taper roller bearing using the correct

tool from both the sides.
2. Remove the 39T gear from the pump drive shaft.
3. Remove the thrust washer 1.
4. Remove the needle thrust bearing and the
bevelled thrust washer use the correct drift tool.
Special Tool: Pump Shaft Drift (Qty.: 1)
shaft together with the needle roller bearing.
6. Remove the clutch pack retaining circlip.
7. If installed, remove the thrust washers 2.
8. Remove the clutch friction and counter plates in
their installed order.
8.1. Different clutches may have different
specification plates depending on the
application. Make sure that the plates
are not mixed up with plates from other
clutches. You may not be able to distinguish
the difference if the plates have been used.
10. Position the clutch assembly in a press. Use a
cutaway tube to compress the piston spring then
remove the external circlip.
27 - 238 9813/7600-3 27 - 238

27 - Driveline
05 - Hybrid Gearbox
62 - Clutch - Pump
Figure 991. For illustration only transmission oil only unless otherwise stated in
11 11
5. Take care not to damage seals or O-rings during
12 assembly.
6. Make sure that the 44T gear and plate carrier can
rotate freely on the assembly.
13 6.1. Make sure that the thrust washer is of the
thickest size.
Y 13A Length/Dimension/Distance: 3.7mm
6.2. If the 44T gear and plate carrier does
not rotate freely, install the thinner thrust
washer.
6.3. Recheck for free rotation.
installed with the flattest face against the circlip.
8. Make sure that the clutch plates have the correct
free movement and adjust if required. Refer to
11 Circlip driveline- hydrostatic gearbox- clutch pump, refer
12 Spring retaining plate to (PIL 27-05-62).
13A Oil baffle plate
Y Cut away tube 9. Check the clutch pack operates smoothly by
10.1. If no press is available, use the spring Apply the specified pressure for 10 seconds and
compressor tool. Position the feet of the make sure there are no leaks.
tool underneath the circlip. Install the C- Pressure: 3bar (43.5psi)
plate over the spring retaining plate, use
the two bolts to relieve spring tension and 10. Carry out a pressure check. Refer to (PIL
remove the circlip. 27-05-62).
Special Tool: Spring Compressor Tool
(Qty.: 1)
11. Remove the spring retainer washer, spring, and
oil baffle together.
12. Remove the shaft O-rings from the shaft.
Assemble
The assembly procedure is the opposite of the
disassembly procedure. When you assemble, do the
following steps also:

3. Make sure that all seals and O-rings are
lubricated but do not lubricate anything with
grease. Make sure you use transmission oil only
unless otherwise stated in the procedure. Refer
to (PIL 75).
4. Lightly lubricate all the bearings and components
27 - 239 9813/7600-3 27 - 239

27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
63 - Clutch - Motor Component Identification

Check (Condition) ........................................ 27-243
Check (Operation) ....................................... 27-243
Adjust .......................................................... 27-244
Figure 992. Clutch- Motor (Layshaft With H1 Clutch) (459/M5179-2)
Y,Z
K A
B Q
U L
R
C H,X E D
N
G
T
J
S
V F
M
W
Item Description
Table 353. G Bearing- Needle Thrust
Item Description H Washer- Thrust
A Gear- 48T & Plate Carri- J Circlip- External
er K Plate-Counter (2.5mm)
B Clutch Housing Layshaft L Plate-Friction-Clutch
C Bearing-Taper Roller M Circlip 150mm- Internal
Assy
N O-Ring
D Bearing-Taper Roller
P Seal Ring- Dia 35
Assy
Q Bearing- Needle Roller
E Layshaft
R O-Ring
F Washer- Bevelled-
Thrust S Compression Spring
27 - 240 9813/7600-3 27 - 240

27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
Item Description Item Description

T Oil Baffle Plate X Washer- Thrust
U Washer- Spring Retainer Y Plate-Pressure-Clutch
V Piston- Clutch Z Plate-Pressure-Clutch
W Plate-Shim-Clutch
Figure 993. Clutch- Motor (459/M5179-2)
40
50
140 10
80
70
60
160 130
60 100
70 110
80
90
210
190
200
280
270
240
170
220
20
250
30
150
459-M5179-2
70 Bearing- Needle Thrust

Table 354. 80 Washer- Thrust
10 Gear- 48T & Plate Carri- 90 Circlip- External
er 100 Plate-Counter (2.5mm)
20 Wa.Clutch Housing 110 Plate-Friction-Clutch
Layshaft HMH 130 Circlip 150mm- Internal
30 Bearing-Taper Roller 140 O-Ring
Assy 150 Seal Ring- Dia 35
40 Bearing-Taper Roller 160 Bearing- Needle Roller
Assy
170 O-Ring
50 Layshaft- HMH
190 Compression Spring
60 Washer- Bevelled-
Thrust 200 Oil Baffle Plate
27 - 241 9813/7600-3 27 - 241

27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
210 Washer- Spring Retainer

220 G.A. Piston- Clutch
240 Plate-Shim-Clutch
250 Washer- Thrust A/R
3.53mm
270 Plate-Pressure-Clutch
280 Plate-Pressure-Clutch
27 - 242 9813/7600-3 27 - 242

27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor

Friction plates
one.

Gears
damage.
27 - 243 9813/7600-3 27 - 243

27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
Clutch Pack End float Adjustment The layshaft clutch, 2WD / 4WD clutch, reverse
clutch, main shaft clutch and forward / input clutch
1. Use a DTI as shown, measure the end float of are all part of the main shaft assembly.
the pressure (end) plate, which should be within
the specified tolerances. Refer to the main shaft remove and install procedure.

circlip.

Item Size
Pressure plate 6
6.5
27 - 244 9813/7600-3 27 - 244

27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor
Disassemble and Assemble Figure 995. For illustration only
Special Tools 11 11
Spring Compressor 892/00916 1 12
Tool
CAUTION The spring (or springs) apply

considerable force. Make sure you take care to 13
Y 13A
Refer to Driveline, Hydrostatic Gearbox, Clutch
2WD (Two Wheel Drive)/4WD (Four Wheel Drive),
Component Identification. Refer to: PIL 27-05-07.
Make a note of the fitted orientation of all the

Discard all O-rings and seals. Always install new

ones.
1. Remove the taper bearing using the correct tool.

2. Remove the thrust washer.
11 Circlip
3. Remove the 53T gear and plate carrier from the 12 Spring retaining plate
shaft together with the needle roller bearing. 13A Oil baffle plate
Y Cut-away tube
4. Remove the needle thrust washer and washer
from the shaft (if not inside the 53T gear hub). 8. Remove the washer, spring, and oil baffle
together.
5. Remove the clutch pack retaining circlip and
remove the clutch friction and counter plates in 9. Remove the shaft O-rings from the shaft (X3).
specification plates depending on the 11. Remove the 47T output gear from the shaft using
application. Make sure that the plates are not moderate force to overcome the clutch piston
mixed up with plates from other clutches. You seal rings. The clutch piston assembly will remain
may not be able to distinguish the difference if on the shaft.
the plates have been used.
12. Remove the clutch piston assembly from the
7. Position the clutch assembly in a press. Use a shaft
cutaway tube to compress the piston spring then
13. Remove and discard the piston and shaft O-
remove the circlip.
rings.
Special Tool: Spring Compressor Tool (Qty.: 1)
Assemble
following steps.
3. Install new seals and O-rings.
but do not lubricate anything with grease.
Make sure you use transmission oil only unless
otherwise stated in the procedure.
Refer to: PIL 75.
27 - 245 9813/7600-3 27 - 245

27 - Driveline
05 - Hybrid Gearbox
63 - Clutch - Motor

the procedure.
Refer to: PIL 75.
assembly.
Refer to H.
rotate freely on assembly.
8.1. If the thrust washer 1 is renewed, make sure
it is the thickest size.
washer.
8.3. Re-check for free rotation.
9. Make sure the clutch plates have the correct
free movement and adjust if required. Refer
to Driveline, Hydrostatic Gearbox, Clutch
2WD/4WD, Adjust,
11. Carry out a pressure check.
27 - 246 9813/7600-3 27 - 246

27 - Driveline
05 - Hybrid Gearbox
65 - Clutch - Front (Output)
65 - Clutch - Front (Output) Component Identification

Check (Condition) ........................................ 27-250
Check (Operation) ....................................... 27-250
Adjust .......................................................... 27-251
Figure 996. Clutch- Output Front (Output Shaft With M2 Clutch) (459/M5180-2)
D E F G H J
K
C
L
M
A
B
B
P
W
N
V S
R
U T O
A Shaft- output B O-rings

C Bearing- taper roller assembly D Gear- 47T, output
E Compression spring F Washer- spring retainer
G Plate- pressure clutch H Circlip 150mm internal
27 - 247 9813/7600-3 27 - 247

27 - Driveline
05 - Hybrid Gearbox
J Washer- thrust K Bearing- needle thrust

L Washer- thrust M Bearing- taper roller
N Bearing- needle roller O Gear- 53 T and plate carrier
P Washer- bevilled thrust R Plate-shim, clutch
S Circlip- external T Plate- friction, clutch
U Plate- counter, clutch V Piston/clutch assembly
W Oil baffle plate
Figure 997. Clutch- Output Front (Output Shaft With M2 Clutch) (459/M5180-2)
30
10
60
230
70
140
50
160 170
250
90 240
100 150
260
200 210
220 110 80
120
190
130
40
270
20
220
459-M5180-2
Item Description
Table 356. 90 Washer- Spring Retainer
Item Description 100 Circlip- External
10 Gear- 53T & Plate Carri- 110 Compression Spring
er 120 Oil Baffle Plate
20 Bearing-Taper Roller 130 G.A. Piston- Clutch
Assy 140 Bearing- Needle Roller
30 Bearing-Taper Roller 150 Plate-Counter-Clutch
40 Gear 47T- Output 160 Plate-Friction-Clutch
50 Shaft- Output HMH 170 Plate-Pressure-Clutch A/
60 Washer- Bevelled- R 6mm
Thrust 190 O-Ring
70 Bearing- Needle Thrust 200 O-Ring
80 Washer- Thrust
27 - 248 9813/7600-3 27 - 248

27 - Driveline
05 - Hybrid Gearbox
Item Description
210 O Ring
220 O Ring
230 Washer- Thrust
240 Circlip 150mm- Internal
R 6.5mm
260 Plate-Shim-Clutch
270 Washer- Thrust
27 - 249 9813/7600-3 27 - 249

27 - Driveline
05 - Hybrid Gearbox

Friction plates
one.

Gears
damage.
27 - 250 9813/7600-3 27 - 250

27 - Driveline
05 - Hybrid Gearbox
Clutch Pack End float Adjustment The layshaft clutch, 2WD (Two Wheel Drive) / 4WD
1. Use a DTI as shown, measure the end float of clutch and forward / input clutch are all part of the
the pressure (end) plate, which should be within main shaft assembly.
the specified tolerances.

circlip.

Item Size
Pressure plate 6
6.5
27 - 251 9813/7600-3 27 - 251

27 - Driveline
05 - Hybrid Gearbox
Disassemble and Assemble Figure 999. For illustration only
Special Tools 11 11
Bearing Press 892/00179 1 12
CAUTION The spring (or springs) apply

avoid damage or injury. 13
Refer to driveline, hydrostatic gearbox, clutch front

Y 13A
(output), component identification Refer to: PIL
27-05-65.
Make a note of the fitted orientation of all the

Discard all o-rings and seals.

2. Remove the thrust washer.
shaft together with the needle roller bearing. 11 Circlip
12 Spring retaining plate
4. Remove the needle thrust washer and washer 13A Oil baffle plate
from the shaft (if not inside the 53T gear hub). Y Cut away tube
5. Remove the clutch pack retaining circlip and 8. Remove the washer, spring, and oil baffle
remove the clutch friction and counter plates in together.
9. Remove the shaft o-rings from the shaft (X3).
specification plates depending on the 10. Remove the taper bearing using the correct tool
application. Make sure that the plates are not
mixed up with plates from other clutches. You 11. Remove the 47T output gear from the shaft using
may not be able to distinguish the difference if moderate force to overcome the clutch piston
the plates have been used. seal rings. The clutch piston assembly will remain
on the shaft.
7. Position the clutch assembly in a press. Use a
cutaway tube to compress the piston spring then 12. Remove the clutch piston assembly from the
remove the circlip. shaft
Special Tool: Bearing Press (Qty.: 1) 13. Remove and discard the piston and shaft o-rings.
Assemble
Assembly is the reverse of dismantle, however carry
out the following:

2. Install new seals and o-rings
3. Make sure all seals and o-rings are lubricated but
do not lubricate anything with grease. Make sure
you use transmission oil only unless otherwise
stated in the procedure. Refer to (PIL 75).
27 - 252 9813/7600-3 27 - 252

27 - Driveline
05 - Hybrid Gearbox

assembly.
Refer to H.
rotate freely on assembly.
7.1. If the thrust washer 1 is renewed, make sure
it is the thickest size.
washer.
7.3. Recheck for free rotation.
8. Make sure the clutch plates have the correct
free movement and adjust if required. Refer
to driveline, hydrostatic gearbox, clutch front
(output), adjust,
27 - 253 9813/7600-3 27 - 253

27 - Driveline
05 - Hybrid Gearbox
81 - Mount
81 - Mount
Check (Condition)
in good condition.
Refer to (PIL 72).
as necessary.
27 - 254 9813/7600-3 27 - 254

27 - Driveline
05 - Hybrid Gearbox
90 - Front Case

Consumables
Clean ........................................................... 27-255
Check (Condition) ........................................ 27-256
- 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.
27 - 255 9813/7600-3 27 - 255

27 - Driveline
05 - Hybrid Gearbox
90 - Front Case
Check (Condition)
Consumables
Strength)
1. If the gearbox cases are to be renewed, be

sure to install blanking plugs and adaptors as
required. Inspect the original cases and identify
the blanking plug and adaptor positions. Transfer
the plugs and adaptors to the new cases. Apply
JCB Threadlocker and Sealer to the threads
before installation.
(Medium Strength)
27 - 256 9813/7600-3 27 - 256

27 - Driveline
05 - Hybrid Gearbox
91 - Rear Case

Check (Condition) ........................................ 27-258
27 - 257 9813/7600-3 27 - 257

27 - Driveline
05 - Hybrid Gearbox
91 - Rear Case
Refer to Front Case - Check Condition (PIL The front and rear case are separated at the same
27-06-90). time. Refer to the removal procedure of the front
case. Refer to (PIL 27-05-90).
27 - 258 9813/7600-3 27 - 258

27 - Driveline
05 - Hybrid Gearbox
93 - Hose
93 - Hose Introduction
Introduction .................................................. 27-259 Refer to hydraulic system, hose, general, (PIL
Remove and Install ..................................... 27-260 30-93-00).
27 - 259 9813/7600-3 27 - 259

27 - Driveline
05 - Hybrid Gearbox
93 - Hose
Remove and Install Figure 1000. Hydrostatic Hoses
CAUTION Make sure the hose is restrained A

sufficiently during this procedure. If the
hose clamps are released without sufficiently
restraining the hose, personal injury may occur
due to hose whip. E
B
Removal
1. This procedure assumes the transmission is F
already removed from the machine. Refer to
2. Make sure the transmission is correctly
restrained on a suitable work bench.
3. Label the hoses and ports to make sure they are
installed correctly later.
4. Make sure the areas around the hose and the D
hose itself are clean and free of debris. C
5. Position a suitable oil container and remove A Hose 1
clamp 1 on hose 1. B Hose 2
C Clamp 1 (left)
6. Using an assistant hold hose 1 very firmly whilst D Clamp 2 (right)
removing clamp 2. E Clamp 3 (left)
F Clamp 4 (right)
7. Carefully allow the hose to relax to its uninstalled
shape. Install
8. Plug the hose and ports. 1. Install hose 2 on to the pump body and tighten
9. Remove the clamps from the pump end of the the two clamps loosely to just allow the hose to
hose. be positioned.
10. Plug the hose and ports and store the hose 2. Install clamp 4 loosely on the motor and move
correctly. the hose so that the hose flange is engaged with
the clamp and the hose will stay in position. Make
11. Repeat steps 5 to 10 for hose 2 and clamps 3 sure the hose cannot become detached from the
and 4. clamp.
3. Install clamp 3 loosely.
4. Make sure the hose is seated correctly and
tighten clamp 4 and clamp 3 on the motor
sequentially to the correct torque.
Torque: 80N·m
5. Make sure the other end of hose 2 is seated
correctly and tighten the clamps on the pump
body to the correct torque.
Torque: 80N·m
6. Repeat steps 1 to 5 for hose 1 and clamps 1 and
2.
27 - 260 9813/7600-3 27 - 260

27 - Driveline
05 - Hybrid Gearbox
95 - Coupling Yoke
95 - Coupling Yoke Introduction

a driveshaft or PTO to flex or slip with their given
application. The drive yoke is also essential for
allowing u-joints to rotate properly with the driveshaft.
27 - 261 9813/7600-3 27 - 261

27 - Driveline
05 - Hybrid Gearbox
95 - Coupling Yoke
Special Tools
Spanner
Remove
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.
the seal housing.
A Yoke
B Stake nut
C Oil seal
E Washer
F Locking ring
Install
2. If necessary install a new oil seal. Locate the seal
the back of the housing.
5. Install the stepped washer the correct way
shown.
27 - 262 9813/7600-3 27 - 262

27 - Driveline
05 - Hybrid Gearbox
95 - Coupling Yoke

torque value.

Item Nm
B 400
27 - 263 9813/7600-3 27 - 263

27 - Driveline
06 - Semi-Automatic Gearbox
Contents Page No.
27-06-00 General ......................................................................................................................... 27-265

27-06-06 Clutch - Reverse .......................................................................................................... 27-343
27-06-07 Clutch - 2WD/4WD ....................................................................................................... 27-347
27-06-08 Clutch - Layshaft .......................................................................................................... 27-376
27-06-09 Clutch - Main Shaft ...................................................................................................... 27-396
27-06-10 Clutch - 6 Speed .......................................................................................................... 27-410
27-06-24 Oil Pump ...................................................................................................................... 27-441
27-06-27 Speed Sensor .............................................................................................................. 27-443
27-06-39 Filter ............................................................................................................................. 27-467
27-06-45 Piston Ring Seal .......................................................................................................... 27-471
27-06-47 Oil Seal ........................................................................................................................ 27-473
27-06-52 Driveshaft ..................................................................................................................... 27-475
27-06-54 Main Shaft .................................................................................................................... 27-478
27-06-56 Layshaft ........................................................................................................................ 27-481
27-06-57 Input Shaft .................................................................................................................... 27-482
27-06-58 Output Shaft ................................................................................................................. 27-483
27-06-81 Mount ........................................................................................................................... 27-493
27-06-85 Oil Feed Pipe ............................................................................................................... 27-494
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-495
27-06-90 Front Case ................................................................................................................... 27-496
27-06-91 Rear Case .................................................................................................................... 27-506
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-508
27 - 264 9813/7600-3 27 - 264

27 - Driveline
00 - General
Introduction .................................................. 27-265 Semi-automatic gearboxes are a hybrid form of
Technical Data ............................................. 27-266 transmission where an integrated control system
Component Identification ............................. 27-274 handles manipulation of the clutch automatically,
Operation ..................................................... 27-287 but the driver can still take manual control of gear
selection.
Fault-Finding ................................................ 27-314
Drain and Fill ............................................... 27-321 Many of these transmissions allow the driver to fully
Clean ........................................................... 27-322 delegate gear shifting choice to the control system,
Check (Condition) ........................................ 27-322 which then effectively acts as if it is an automatic
transmission. An automatic transmission uses a
Check (Level) .............................................. 27-323 torque converter instead of a straight friction clutch
Check (Pressure) ........................................ 27-324 to manage the connection between the transmission
Remove and Install ..................................... 27-337 gearing and the engine.
A typical JCB semi-automatic transmission is called
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:
• PS700
• PS750
• PS764
• PS766
Not all types of transmission are available on all

types of machine. Check the operators manual
or transmission identification label for the type of
transmission installed on your machine.
27 - 265 9813/7600-3 27 - 265

27 - Driveline
00 - General
Technical Data
For: PS750 MK4 ..................... Page 27-266

For: PS764 .............................. Page 27-268
For: PS766 .............................. Page 27-271
(For: PS750 MK4)

Table 359. PS 750 4- Speed 2/4 Wheel Drive
Designation PS 750 MkIV Powershift - ECU Control
Description Full electro-hydraulic transmission unit with input, reverse, layshaft and main-
shaft drive clutch packs giving 4 forward and 4 reverse speeds. ECU (Electron-
ic Control Unit) controlled gear selection. Permanent 4 wheel drive or selectable
2/4 wheel drive variants.
Weight (dry) 2/4 wheel drive 215kg
Permanent 4 wheel drive TBA
Clutch solenoid current draw 1.36A maximum (at 20°C (68.0°F))
Gearbox 'Limp Modes' (Powershift Mode Possible Reason

Electronic Control) Only 1st, 2nd and 3rd If the ECU does not de-
gears available. tect any input from the
When applicable, the gearbox ECU provides speed sensor it will pre-
restricted or modified gearbox operation if faults are vent selection of any
detected by the ECU. Typical 'limp mode' forms of gear above 3rd.
operation are shown here. Fault codes may also be
Limp Mode 4 (Repeating Error reading transmis-
displayed on the instrument panel. For fault codes
beeps until ECU power sion speed
refer to (PIL 33-57-90).
is reset)
On power up, the ECU will normally sound 3 beeps. Machine holds a gear If the ECU detects and
These beeps can be masked by other audible error with the speed
warnings on start up. sensor while operating,
it prevents autoshifting.
Table 360. Gearbox 'Limp
Modes' (Powershift Electronic Control). Stall Speed Combinations
Mode Possible Reason
The tests carried out at the factory record the correct
Limp Mode 1 (2 beeps Internal 'setup data'
engine r.p.m. (stall speed) when under maximum
at power up). ECU fault.
load from the transmission and hydraulic systems.
Machine autoshifts at If on power up the ECU
different road speeds detects an internal fault The figures relate to tests conducted at an ambient
than normal. with its 'set up' data, it temperature of 25°C (77.0°F) and barometric
will revert to use of a de- pressure of 1bar (14.5psi)at sea level. The changes
fault set of values. in ambient temperature, pressure and humidity and
Limp Mode 2 (1 beep at Error with ECU applica- fuel grade will affect engine power and hence the stall
power up). tion software. figures.
Machine remains in neu- If on power up, the ECU For example, at 10,000 ft the power reduction of a
tral at all times. detects an internal fault naturally aspirated engine could be 29% and for a
with its 'core operating turbo engine 8%.
software' it will prevent
operation of the gear- The figures apply to `bedded-in' engines, i.e. engines
box. that have done a minimum of 250 working hours.
Limp Mode 3 (Machine Error reading transmis- Therefore they should not be used for pre-delivery
will not autoshift). sion speed. inspection (PDI) checks.
All figures are recorded with the transmission oil

at 60°C (139.9°F) and the hydraulic oil at 55°C
(130.9°F). Figures achieved should be within +/- 100
27 - 266 9813/7600-3 27 - 266

27 - Driveline
00 - General
RPM (Revolutions Per Minute) from the figures given

in the table.
Table 361. Stall Speed Combinations

Engine Build Code SL SH
Engine Power 55kW 4 Speed PS750 (4 Speed 81kW 4 Speed PS750/PS764
SS700)
(1)
Model 531-70 5AA, 535-95 5AB, 541-70 531-70 5A(T)A, 535-95 5AB(TD),
5AD, 533-105 5AH, 540-140 536-60 5A(T)C, 541-70 5A(T)D,
5AL, 535-125 5AN, 535-140 5AP, 540-170 5AF, 550-140 5AG,
536-70 5AR, 526-56 5AS 533-105 5AH, 540-140 5AL,
550-1705AM, 535-125 5AN,
535-140 5AP, 536-70 5AR(TE),
526-56 5AS
Hydraulic System:
Gearpump
Variflow
Engine Stall Speeds RPM
Torque Converter Only
Hydraulics (MRV (Main Relief
Valve)) Only
Combined Converter + MRV
(2)
Combined Converter + LSRV

(Load Sense Relief Valve)
LSP (Load Sense Pump) Variflow
LSP Electro Servo
(1) 526-56 Machines only
(2) Combined stall tests on machines fitted with a hydraulic gearpump are performed with the crowd service
operated until the relief valve is lifted.
Gearbox Specifications
Table 362. Oil Pressures
Pressure
Converter pressure (in neutral)
Converter In at 50°C (121.9°F) 1000 RPM 1.5–4bar (21.7–58.0psi)
2000 RPM 5–7bar (72.5–101.4psi)
Converter Out at 50°C (121.9°F) 1000 RPM TBA
2000 RPM TBA
Converter inlet relief pressure 6.5bar (94.2psi)
(max.)
Lubrication pressure (in neutral)
Oil at 50°C (121.9°F) 1000 RPM 0.14–0.28bar (2.0–4.1psi)
2000 RPM 0.28–0.55bar (4.1–8.0psi)
Main Line Pressure (in neutral)
Oil at 50°C (121.9°F) 1000 RPM 11–13bar (159.4–188.4psi)
2000 RPM 12–14.5bar (173.9–210.1psi)
Clutch pressure All clutch pressures should be the same as mainline pressure to within
0.7bar (10.1psi).
27 - 267 9813/7600-3 27 - 267

27 - Driveline
00 - General
Flow Rates (in Flow Rate

neutral)
Table 363. Oil Flow Rates
Pump oil flow at 1000 RPM 11–15
Flow Rates (in Flow Rate 50°C (121.9°F)
neutral) 2000 RPM 22.5–29.5
Cooler oil 1000 RPM 8–13
flow at 50°C For new gearboxes (i.e. under 100 hours service),
(121.9°F) or gearboxes that have been fully serviced, the
2000 RPM 19–25 pressures will be slightly higher than those shown
(approximately 0.7–1bar (10.1–14.5psi)).
(For: PS764)
Table 364. PS 764 4- Speed 2/4 Wheel Drive
Designation PS 764 Powershift
Description Full electro-hydraulic transmission unit with input, reverse, layshaft and main-
shaft drive clutch packs giving 4 forward and 4 reverse speeds. ECU controlled
gear selection.
Weight (dry) Permanent 4 wheel drive 242kg
Clutch ratio solenoid types 3 way, 2 position, normally closed, with integral pro-
portional solenoid.
Clutch ratio solenoid current draw 0.85A for clutch pressure of 12bar (173.9psi)
Clutch ratio solenoid coil resistance 7.25Ω (at 20°C (68.0°F))
Clutch 4WD (Four Wheel Drive) solenoid type 3 way, 2 position, normally closed, with integral on/off
solenoid and suppression diode.
Clutch 4WD solenoid current draw 1.68A at 12V at 20°C (68.0°F)
Torque converter diameter 310mm
Torque converter identification W300
Torque multiplication at stall 2.02:1

Modes' (Powershift Electronic Control).
Table 365. Gear ratios
Gear (Forward) Ratio Limp Mode 1 (2 beeps Internal 'setup data'
1st 6.17:1 at power up). ECU fault.
2nd 3.32:1 Machine autoshifts at If on power up the ECU
3rd 1.86:1 different road speeds detects an internal fault
4th 1.00:1 than normal. with its 'set up' data, it
will revert to use of a de-
fault set of values.
Gearbox 'Limp Modes' (Powershift
Electronic Control) Limp Mode 2 (1 beep at Error with ECU applica-
power up). tion software.
When applicable, the gearbox ECU provides Machine remains in neu- If on power up, the ECU
restricted or modified gearbox operation if faults are tral at all times. detects an internal fault
detected by the ECU. Typical 'limp mode' forms of with its 'core operating
operation are shown here. Fault codes may also be software' it will prevent
displayed on the instrument panel. For fault codes operation of the gear-
refer to (PIL 33-57-90). box.
Limp Mode 3 (Machine Error reading transmis-
On power up, the ECU will normally sound 3 beeps. will not autoshift). sion speed.
These beeps can be masked by other audible
warnings on start up.
27 - 268 9813/7600-3 27 - 268

27 - Driveline
00 - General
Mode Possible Reason The figures relate to tests conducted at an ambient

Only 1st, 2nd and 3rd If the ECU does not de- temperature of 25°C (77.0°F) and barometric
gears available. tect any input from the pressure of 1bar (14.5psi)at sea level. The changes
speed sensor it will pre- in ambient temperature, pressure and humidity and
vent selection of any fuel grade will affect engine power and hence the stall
gear above 3rd. figures.
Limp Mode 4 (Repeating Error reading transmis- For example, at 10,000 ft the power reduction of a
beeps until ECU power sion speed naturally aspirated engine could be 29% and for a
is reset) turbo engine 8%.
Machine holds a gear If the ECU detects and
error with the speed The figures apply to `bedded-in' engines, i.e. engines
sensor while operating, that have done a minimum of 250 working hours.
it prevents autoshifting. Therefore they should not be used for pre-delivery
inspection (PDI) checks.
Stall Speed Combinations All figures are recorded with the transmission oil
The tests carried out at the factory record the correct (130.9°F). Figures achieved should be within +/- 100
engine r.p.m. (stall speed) when under maximum RPM from the figures given in the table.

Engine Build Code SH
Engine Power 81kW 4 Speed PS750/PS764
Model 531-70 5A(T)A, 535-95 5AB(TD), 536-60 5A(T)C,
541-70 5A(T)D, 540-170 5AF, 550-140 5AG, 533-105
5AH, 540-140 5AL, 550-1705AM, 535-125 5AN,
535-140 5AP, 536-70 5AR(TE), 526-56 5AS
Hydraulic System:
Gearpump
Variflow
Engine Stall Speeds RPM
Torque Converter Only
Hydraulics (MRV) Only
Combined Converter + MRV
(1)
Combined Converter + LSRV

LSP Variflow
LSP Electro Servo
(1) Combined stall tests on machines fitted with a hydraulic gearpump are performed with the crowd service
operated until the relief valve is lifted.
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27 - Driveline
00 - General
Engine Build SH DH
Code
Variflow
Engine Build SH DH
Code Engine Stall Speeds RPM
Engine Power 93kW 4 Speed 108kW 4 Speed Torque Convert-
PS764 PS764 er Only
Model 531-70 5A(T)A, 531-70 5A(T)A, Hydraulics
535-95 535-95 (MRV) Only
5AB(TD), 5AB(TD), Combined Con-
verter + MRV
(1)
536-60 5A(T)C, 536-60
541-70 5A(T)D, 5A(T)C, 541-70 Combined Con-
540-170 5AF, 5A(T)D, 536-70 verter + LSRV
550-140 5AG, 5AR(TE), LSP Variflow
540-140 5AL, 550-80
550-1705AM, 5AW(UW) LSP Electro
536-70 Servo
5AR(TE), (1) Combined stall tests on machines fitted with a
550-80 hydraulic gearpump are performed with the crowd
5AW(UW) service operated until the relief valve is lifted.
Hydraulic System:
Gearpump
Pressure
Converter pressure in neutral
Converter In at 50°C (121.9°F) 1000 RPM 1.4–2.2bar (20.3–31.9psi)
2000 RPM 5.8–6.9bar (84.1–100.0psi)
Converter In at 100°C (211.9°F) 1000 RPM 0.5–1.3bar (7.2–18.8psi)
2000 RPM 2.5–3.5bar (36.2–50.7psi)
Converter Out at 50°C (121.9°F) 1000 RPM 0.6–1.6bar (8.7–23.2psi)
2000 RPM 2.8–3.8bar (40.6–55.1psi)
Converter Out at 100°C (211.9°F) 1000 RPM 0.2–1bar (2.9–14.5psi)
2000 RPM 1–1.9bar (14.5–27.5psi)
Converter inlet relief pressure 7.1bar (102.9psi)
(max.)
2000 RPM 1.1–2.1bar (15.9–30.4psi)
2000 RPM 0.4–1.4bar (5.8–20.3psi)
Oil at 50°C (121.9°F) 1000 RPM 11–13bar (159.4–188.4psi)
2000 RPM 13–15.2bar (188.4–220.3psi)
2000 RPM 11.4–14.5bar (165.2–210.1psi)
Clutch pressure All clutch pressures should be the same as mainline pressure to within
0.7bar (10.1psi) and 4WD clutch pressure to be within 1.4bar (20.3psi)
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neutral)
Pump oil flow at 1000 RPM 11.5–15.6L/min
Flow Rates (in Flow Rate 100°C (211.9°F)
neutral) 2000 RPM 24–33L/min
Cooler oil 1000 RPM 8.5–11L/min
flow at 50°C For new gearboxes (i.e. under 100 hours service),
(121.9°F) or gearboxes that have been fully serviced, the
2000 RPM 17–25.1L/min pressures will be slightly higher than those shown
Cooler oil 1000 RPM 6.2–9.5L/min (approximately 0.7–1bar (10.1–14.5psi)).
flow at 100°C
(211.9°F)
2000 RPM 15–19.5L/min
(For: PS766)
Table 371. PS 766 6- Speed 4 Wheel Drive
Designation PS 766 Powershift
Description Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft,
6 speed and 4 wheel drive clutch packs giving 6 forward and 4 reverse speeds.
Electronically controlled gear selection. Integral wet multi-plate park brake.
Weight (dry) Permanent 4 wheel drive 285kg
Clutch solenoid types 3 way, 2 position, normally closed, integral suppres-
sion diode
Coil resistance 7.5Ω maximum (at 20°C (68.0°F))
Torque converter diameter 310mm
Torque converter identification W300 Lock up torque converter (LUC)
Torque multiplication at stall 2.52:1

Modes' (Powershift Electronic Control).
Table 372. Gear ratios
Gear (Forward) Ratio Limp Mode 1 (2 beeps Internal 'setup data'
1st 8.17:1 at power up). ECU fault.
2nd 4.90:1 Machine autoshifts at If on power up the ECU
3rd 3.62:1 different road speeds detects an internal fault
4th 2.25:1 than normal. with its 'set up' data, it
will revert to use of a de-
5th 1.35:1
fault set of values.
6th 1.00:1
Limp Mode 2 (1 beep at Error with ECU applica-
power up). tion software.
Gearbox 'Limp Modes' (Powershift
Machine remains in neu- If on power up, the ECU
Electronic Control) tral at all times. detects an internal fault
with its 'core operating
When applicable, the gearbox ECU provides software' it will prevent
restricted or modified gearbox operation if faults are operation of the gear-
detected by the ECU. Typical 'limp mode' forms of box.
operation are shown here. Fault codes may also be
displayed on the instrument panel. For fault codes Limp Mode 3 (Machine Error reading transmis-
refer to (PIL 33-57-90). will not autoshift). sion speed.
Only 1st, 2nd and 3rd If the ECU does not de-
On power up, the ECU will normally sound 3 beeps. gears available. tect any input from the
These beeps can be masked by other audible speed sensor it will pre-
warnings on start up. vent selection of any
gear above 3rd.
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Mode Possible Reason Table 374. Stall Speed Combinations

Limp Mode 4 (Repeating Error reading transmis- Engine Build SH DH
beeps until ECU power sion speed Code
is reset) Engine Power 93kW 6 Speed 108kW 6 Speed
Machine holds a gear If the ECU detects and PS766 PS766
error with the speed Model 531-70 5A(T)A, 531-70 5A(T)A,
sensor while operating, 535-95 535-95
it prevents autoshifting. 5AB(TD), 5AB(TD),
536-60 536-60
Stall Speed Combinations 5A(T)C, 541-70 5A(T)C, 541-70
5A(T)D, 536-70 5A(T)D, 536-70
The tests carried out at the factory record the correct 5AR(TE) 5AR(TE)
engine r.p.m. (stall speed) when under maximum Hydraulic System:
Gearpump
The figures relate to tests conducted at an ambient Variflow
temperature of 25°C (77.0°F) and barometric Engine Stall Speeds RPM
pressure of 1bar (14.5psi)at sea level. The changes
in ambient temperature, pressure and humidity and Torque Convert-
fuel grade will affect engine power and hence the stall er Only
figures. Hydraulics
(MRV) Only
For example, at 10,000 ft the power reduction of a Combined Con-
naturally aspirated engine could be 29% and for a verter + MRV
(1)
turbo engine 8%.

Combined Con-
The figures apply to `bedded-in' engines, i.e. engines verter + LSRV
that have done a minimum of 250 working hours. LSP Variflow
Therefore they should not be used for pre-delivery LSP Electro
inspection (PDI) checks. Servo
(1) Combined stall tests on machines fitted with a
All figures are recorded with the transmission oil
hydraulic gearpump are performed with the crowd
service operated until the relief valve is lifted.
(130.9°F). Figures achieved should be within +/- 100
RPM from the figures given in the table.
Pressure
Converter pressure (in neutral)
Converter In at 50°C (121.9°F) 1000 RPM 2–4.95bar (29.0–71.7psi)
2000 RPM 4–6.8bar (58.0–98.6psi)
Converter Out at 50°C (121.9°F) 1000 RPM 0.6–2.25bar (8.7–32.6psi)
2000 RPM 1.25–2.5bar (18.1–36.2psi)
Lock up torque converter inlet relief valve pressure (Maximum) 8.5bar (123.2psi)
Oil at 50°C (121.9°F) 1000 RPM 0.25–1bar (3.6–14.5psi)
2000 RPM 0.5–1bar (7.2–14.5psi)
2000 RPM 12.4–17bar (179.7–246.4psi)
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neutral)
Cooler oil 1000 RPM 14L/min
flow at 50°C
(121.9°F)
2000 RPM 17L/min
Pump oil flow at 1000 RPM 16L/min
50°C (121.9°F)
2000 RPM 34L/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 0.7–1bar (10.1–14.5psi)).
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For: PS750 MK4 ..................... Page 27-274 Figure 1002.

For: PS764, PS766 ................. Page 27-280
(For: PS750 MK4)
Unit Identification
unit identification plate as shown. When you make
details on the unit identification plate. In the case of
gear replacements, always check the part number
A Identification plate
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Figure 1003. External components
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Item Description
13 Oil pump
Table 377.
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
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00 - General
Figure 1004. 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 378.
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
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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
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00 - General
Figure 1005. Test Point
1 4
Test point Description

4 Forward high ratio clutch
Table 379.
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
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00 - General
Test point Description Clutch Control Solenoids

8 Layshaft clutch pressure
Figure 1006.
9 2/4 wheel drive clutch
pressure
3022
3021
3033
3041
3029
3040
Table 380.
Gear Clutches engaged Solenoids energised Refer to
Figure 1006.
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

(For: PS764, PS766) details on the unit identification plate. In the case of
gear replacements, always check the part number
Unit Identification
unit identification plate as shown. When you make
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00 - General
Figure 1007.
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Main component identification
Figure 1008.
H N
A
S J
B
C
D
R
Q
T
U
K L E
C
P
M V
Item Description
M Hose connection (to oil
Table 381.
cooler)
Item Description N Hose connection (from
A Torque converter oil cooler)
B Forward and input clutch P 6 speed assembly (if in-
C Reverse clutch stalled)
D Main shaft assembly Q Oil filter
E Layshaft assembly R Driveshaft (typically dri-
F 2 and 4 Wheel drive ves a hydraulic pump)
clutch S Gear drive to reverse
G Torque converter relief clutch
valve T Solenoid control valves
H Oil pressure mainte- U Transmission oil pres-
nance valve sure switch
J Transmission oil pump V Speed sensor
K Park brake actuator
L Park brake friction pack
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Sectional Drawing
Figure 1009.
1 2
23
22 3
21 4
17
18
20
12
16
14
15
13
11 5
10
9 19
7 6
8
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Item Description
13 Bearing end float control
Table 382.
spacer
Item Description 14 Oil seal
1 Rear case 15 Transfer gear and shaft
2 Front case 16 Yoke - drive shaft cou-
3 Torque converter hous- pling
ing 17 Auxiliary device mount-
4 Gearbox oil pump ing interface
5 Yoke - drive shaft cou- 18 Auxiliary device drive
pling shaft
6 Oil seal 19 Layshaft and layshaft
7 4WD (Four Wheel Drive) clutch assembly
case 20 Main shaft and clutch
8 4WD clutch assembly assembly
9 Integral park brake as- 21 Input shaft and forward
sembly cover (if in- clutch assembly
stalled) 22 Reverse shaft and clutch
10 Park brake friction plate assembly
pack (if installed) 23 6 speed shaft and clutch
11 Park brake actuator (if assembly (if installed)
installed)
12 Transfer gear shaft sup- The drawing is not a true sectional view. It is drawn
port bearings to show the main components as clearly as possible.
Clutch Control Solenoids

PS764
Figure 1010. PS764
A B C D
G F E
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Table 383.
Gear Clutches engaged Solenoids engaged Refer to Fig-
ure 1010.
1st gear forward Forward low A
Layshaft E
2nd gear forward Forward high B
Layshaft E
3rd gear forward Forward low A
Mainshaft F
4th gear forward Forward high B
Mainshaft F
1st gear reverse Reverse low C
Layshaft E
2nd gear reverse Reverse high D
Layshaft E
3rd gear reverse Reverse low C
Mainshaft F
4th gear reverse Reverse High D
Mainshaft F
PS766
Figure 1011. PS766
A B C D
G F E
Table 384.
ure 1011.
1st gear forward 6 speed E
Layshaft F
2nd gear forward Forward low A
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ure 1011.
Layshaft F
3rd gear forward Forward high B
Layshaft F
4th gear forward 6 speed E
Mainshaft G
5th gear forward Forward low A
Mainshaft G
6th gear forward Forward high B
Mainshaft G
1st gear reverse Reverse low C
Layshaft F
2nd gear reverse Reverse high D
Layshaft F
3rd gear reverse Reverse low C
Mainshaft G
4th gear reverse Reverse High D
Mainshaft G
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00 - General
Operation
For: PS764 .............................. Page 27-287 A gearbox mounted ground speed sensor detects
For: PS750 MK4 ..................... Page 27-295 the ground speed of the machine. Signals from the
sensor are connected to the transmission ECU via
For: PS766 .............................. Page 27-303
the machine control ECU and the CANbus. The ECU
responds by preventing ratio selection if the machine
(For: PS764) ground speed is not within pre-set values.
The gearbox system is controlled electronically. When the ratio up (plus) button is pressed the
Inputs from control devices are connected to various transmission ECU selects the next (higher) gear
ECU (Electronic Control Unit)s. The ECU’s energise ratio. When the ratio down (minus) button is pressed
the applicable electrical devices depending on the the transmission ECU selects the next (lower) gear
machine status. The ECU’s are connected to the ratio.
machine CAN (Controller Area Network)bus which
enables integrated control of all the main machine Park brake on
systems.
When the park brake is on, an electrical switch sends
For details of the ECUs installed on the machine refer a signal to the transmission ECU which sets the
to (PIL 33-45). transmission to neutral even if forward or reverse is
selected. A warning sound will be audible.
Start up
Transmission dump
Electrical interlocks prevent the engine being started,
unless the transmission is set to neutral. The A transmission dump switch on the hydraulic control
interlock is controlled by the ECU. lever sends a signal to the transmission ECU which
de-selects the transmission drive when the switch is
Direction Control operated.
A column switch controls the direction control, Foot Brake Control

forward, neutral or reverse. The switch is connected
to inputs on the ECU which in turn energise the When the foot brake operates a pressure transducer
applicable gearbox control solenoids. mounted in the hydraulic brake line detects the
change in brake system pressure. Input from
Joystick Direction Control the transducer is connected to the transmission
ECU. The transmission ECU selects neutral even
Drive direction can also be controlled with the joystick if Forward or Reverse is selected. The feature
direction control switch. Inputs from the switch are enables an increase in machine braking efficiency.
connected to the transmission ECU via the joystick An operator switch in the cab can be set to enable or
powerbase ECU and the CANbus. There is a logic disable the feature.
control for drive direction selection. Selection of
Forward or Reverse with the column switch disables
the joystick direction control switch. Both the joystick 2/4 Wheel drive select
and column switch must first be set to Neutral before
A cab mounted switch controls 2 or 4 wheel
the joystick switch is enabled.
drive selection. The switch provides an input to
the transmission ECU which in turn energises
Manual gear select the applicable gearbox control solenoid. The
transmission automatically selects 4 wheel drive
A rotating barrel switch controls selection of the gear when the service brakes are applied.
ratios (1,2,3 or 4). The switch is connected to inputs
on the ECU which energise the applicable gear box
control solenoids. Transmission Oil Pressure and
Temperature
Joystick Gear Selection
Oil pressure and temperature sensors are connected
Gear ratio selection can be controlled with the to the machine instrumentation which displays the
joystick ratio up (plus) and down (minus) buttons. pressure and temperature status. Warning displays
Inputs from the buttons are connected to the and fault codes are activated if the oil pressure or
transmission ECU via the machine control ECU and temperature is not within pre-set values.
the CANbus.
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Limp Modes Figure 1013. 2nd gear forward (4 wheel drive)
When necessary the transmission ECU will provide

alternative gear selection should faults occur. This
enables the machine to be moved (`limped') under its
own power. For limp mode details refer to Technical
Data (PIL 27-06).
U
Fault codes may also be displayed on the instrument
panel. For fault codes refer to (PIL 33-57-90).
Drive paths
Forward
Z
Figure 1012. 1st gear forward (4 wheel drive) S
T Table 386.
Clutches engaged Solenoids energised
Forward high ratio (U) 3021 (Us)
Layshaft (Z) 3029 (Zs)
2/4 wheel drive (spring -
applied) (S)
Z Figure 1014. 3rd gear forward (4 wheel drive)
Table 385.
Clutches engaged Solenoids energised T
Forward low ratio (T) 3022 (Ts) Y
applied) (S)
Table 387.
Forward low ratio (T) 3022 (Ts)
Mainshaft (Y) 3033 (Ys)
applied) (S)
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Figure 1015. 4th gear forward (4 wheel drive) Figure 1017. 2nd gear reverse
S S

Clutches engaged Solenoids energised Clutches engaged Solenoids energised
Forward high ratio (U) 3021 (Us) Reverse high ratio (V) 3040 (Vs)
Mainshaft (Y) 3033 (Ys) Layshaft (Z) 3029 (Zs)
2/4 wheel drive (spring - 2/4 wheel drive (spring -
applied) (S) applied) (S)
Reverse
Figure 1018. 3rd gear reverse
Figure 1016. 1st gear reverse
W
W
S
S
Table 391.
Table 389.
Clutches engaged Solenoids energised Reverse low ratio (W) 3041 (Ws)
Reverse low ratio (W) 3041 (Ws) Mainshaft (Y) 3033 (Ys)
Layshaft (Z) 3029 (Zs) 2/4 wheel drive (spring -
2/4 wheel drive (spring - applied) (S)
applied) (S)
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Figure 1019. 4th gear reverse torque is transferred from the converter assembly to
the clutch/gear assemblies through the input shaft on
the forward clutch assembly.
V
The forward clutch assembly contains two
hydraulically operated clutches: one clutch gives a
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
Y
either the forward low (solenoid 3022) or forward high
(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
S ratio drive and the other gives a reverse high ratio
drive. The reverse clutches are controlled by a
either the reverse low (solenoid 3041) or reverse high
Table 392.
Clutches engaged Solenoids energised Both the mainshaft and the layshaft assemblies have
Reverse high ratio (V) 3040 (Vs) a single clutch each. Both clutches are controlled
by a three position solenoid valve. When energised,
Mainshaft (Y) 3033 (Ys) solenoid 3029 directs pressurised oil to the layshaft
2/4 wheel drive (spring - clutch and solenoid 3033 directs pressurised oil the
applied) (S) mainshaft clutch.
Hydraulic operation and schematics When a gear is selected through the control switch in
the cab, two clutches are always engaged. When you
The engine directly drives the oil pump through the select different pairs of clutches different gear ratios
torque converter. are engaged. The hydraulic control ECU electrically
controls the solenoids. All the clutches work on the
Oil from the pump is fed through an internal passage same principle.
via the filter to the PMV (Pressure Maintenance
Valve), which maintains pressure to the solenoid The 2/4 wheel drive unit also has a single clutch.
valves for clutch selection. Excess oil from the In normal operation the clutch is spring loaded and
maintenance valve flows back through the case to therefore engaged to give 4 wheel drive. When
the torque converter. A relief valve controls pressure 2 wheel drive is selected, solenoid valve 3002 is
in the converter and dumps oil from the converter line energised and directs pressurised oil to the 2/4 wheel
back to the sump. drive clutch.
Oil from the torque converter flows out of the gearbox In the schematic, the gearbox is shown with 2nd
to the external oil cooler and again comes back to gear forward engaged. 2nd gear forward requires
the converter. Oil then flows through internal oil ways the forward low clutch T and layshaft clutch Z to
providing lubrication for clutches and bearings before be engaged. When the gear selection switch is
it goes back to the gearbox sump. moved to 2nd gear forward, the electrical control
system energises solenoid valves 3022 and 3029.
The torque converter is a fluid coupling bolted to Pressurised oil is diverted to the back of pistons
a drive plate which in turn is bolted to the engine in both clutches to engage the drive. At the same
driven bevel gearbox. As the engine starts to rotate, time all other solenoids are de-energised, diverting
the converter gives smooth power take off and oil from the back of the other clutch pistons to the
gradually increases the torque transmitted. This gearbox sump. The 4 wheel drive clutch 3002 is also
energised to give 2 wheel drive.
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Figure 1020.
H G
2 1 K X
2 3 3
3004 C
5 1 W V Q A
3021 J
3022 T U
1
3002
B
3041
Y
M
3040 z
L 6
3033
D
E S
3029
N F
P
Table 393.
Item Description
A Torque converter
B Forward clutch assembly
C Reverse clutch assembly
D Mainshaft assembly
E Layshaft assembly
F 2/4 wheel drive unit
G Torque converter relief valve
H Pressure maintenance valve
J Pump
L Park brake pack
M Hose connection - to oil cooler
N Hose connection - from oil cooler
P 6-Speed clutch assembly (if installed)
S Gear drive to reverse unit clutch assembly
Q Oil filter
T Forward low ratio clutch
U Forward high ratio clutch
V Reverse high ratio clutch
W Reverse low ratio clutch
X 6 speed clutch (PS766 only)
Y Mainshaft clutch
Z Layshaft clutch
1 Solenoid port 1
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Item Description
2 Solenoid port 2
3 Solenoid port 3
5 Solenoid valve control block
6 External oil cooler
Forward and Reverse Clutch Operation is then transmitted from the input shaft to the gear
1. Clutch for gear 2 is disengaged and no drive is
The forward and reverser clutch assembly transfers transmitted to gear 2 plate carrier. The gear is also
drive from the input shaft to either gear 1 or gear 2 free to rotate on the input shaft assembly.
depending on which of the two clutches is engaged,
giving forward or reverse drive. Actuation of the hydraulic pistons and is controlled
via three position solenoid control valve.
When neither clutch is engaged, neutral is selected.
When neutral is selected both solenoids are
The clutches are of the wet, multi plate type. deactivated and the flow of pressurised oil to the
clutches is blocked. The gear springs 1 and 2 move
The clutch housings and input shaft are a one piece the pistons away from the clutch plates and oil from
assembly. The assembly is permanently driven by both pistons is vented to the sump.
the engine via the torque converter.
When either forward or reverse is selected, the
Clutch counter plates are also permanently driven solenoid control valve diverts pressurised oil via
via meshing teeth inside the clutch housings. Clutch cross drillings inside the input shaft to the appropriate
friction plates are meshed with the gear plate clutch piston in the unit. Pressure from the other
carriers. clutch is vented to the sump via the solenoid valve
spool. Oil is prevented from leaking by seals on the
In the diagram, clutch for gear 1 is engaged. pistons and ring seals on the input shaft.
The counter plates and friction plates are pressed

together by a hydraulically actuated piston. Drive
27 - 292 9813/7600-3 27 - 292

27 - Driveline
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Figure 1021.
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
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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 1022.
B C
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
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27 - Driveline
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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 1023.
B C
A1
A
3 2
1
A2

C Piston D Springs
E Output yoke F Actuating sleeve
G Pressure plate
Drive direction and gear ratio are selected by means

(For: PS750 MK4) of electrical control switches (typically a steering
column mounted lever and swivel switch). Inputs
from control devices are connected to various ECUs.
Operation Overview The ECUs energise the applicable electrical devices
depending on the machine status. The ECUs are
The Powershift gearbox is an electro-hydraulic
connected to the machine CANbus which enables
transmission unit. Input from the engine is by
integrated control of all the main machine systems.
means of a torque converter. Gear shifting and
direction selection are controlled by engaging and For ECU details refer to (PIL 33-45).
disengaging multi-disc clutch packs.
Electric solenoid valves divert pressurised oil Start up

(provided by the gearbox oil pump) to the selected
clutch packs. Electrical interlocks prevent the engine being started,
unless the transmission is set to neutral.
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Drive Direction Control Transmission dump

A column switch controls the drive direction, forward, The input from the transmission `dump' switch on the
neutral or reverse. Inputs from the switch are joystick is connected to the transmission ECU. When
connected to the transmission ECU via the CANbus the switch is pressed the ECU selects Neutral even
which in turn energise the applicable gearbox control if Forward or Reverse is selected.
solenoids.
2/4 Wheel drive select
Joystick Direction Controls
A cab mounted switch controls 2 or 4 wheel drive
Drive direction can also be controlled with the joystick selection. Inputs from the switch are connected to
F / N / R (Forward / Neutral / Reverse) direction the machine control ECU which in turn energises
control switch. Inputs from the switch are connected the applicable gearbox control solenoid. The
to the transmission ECU via the joystick powerbase transmission automatically selects 4 wheel drive
ECU and the CANbus. There is a logic control for when the service brakes are applied.
drive direction selection. Selection of Forward or
Reverse with the column switch disables the joystick Transmission Oil Pressure and
direction control switch. Both the joystick and column
switch must first be set to Neutral before the joystick Temperature
direction control switch is enabled.
Oil pressure and temperature sensors are connected
to the machine instrumentation which displays the
Manual Gear Controls pressure and temperature status. Warning displays
and fault codes are activated if the oil pressure or
A rotating barrel switch controls selection of the temperature is not within pre-set values.
gear ratios (1,2,3 or 4). Inputs from the switch are
connected to the transmission ECU via the CANbus
which in turn energise the applicable gearbox control Drive paths
solenoids.
Forward
Joystick Gear Controls Figure 1024. 1st gear forward
Gear ratio selection can be controlled with the
joystick ratio up (plus) and down (minus) buttons. A
Inputs from the buttons are connected to the
transmission ECU via the machine control ECU and
the CANbus.
A gearbox mounted ground speed sensor detects

the ground speed of the machine. Signals from the E
sensor are connected to the transmission ECU via
responds by preventing ratio selection if the machine
ground speed is not within pre-set values.
When the ratio up (plus) button is pressed the

transmission ECU selects the next (higher) gear
ratio. When the ratio down (minus) button is pressed
the transmission ECU selects the next (lower) gear Table 394.
ratio
Park brake on Forward low ratio (A) 3022
Layshaft (E) 3029
When the park brake is ON the park brake switch
state changes. Inputs from the switch are connected
to the transmission ECU via the machine control
ECU and the CANbus. The ECU selects Neutral
even if Forward or Reverse is selected. An audible
warning sounds.
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27 - Driveline
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Figure 1025. 2nd gear forward Table 397.

B Forward high ratio (B) 3021
Mainshaft (F) 3033
Reverse
E Figure 1028. 1st gear reverse
E
Table 395.
Forward high ratio (B) 3021
Layshaft (E) 3029
Figure 1026. 3rd gear forward C
A
Table 398.
F
Reverse low ratio (C) 3041
Layshaft (E) 3029
Figure 1029. 2nd gear reverse
Table 396.
Clutches engaged Solenoids energised E
Forward low ratio (A) 3022
Mainshaft (F) 3033
Figure 1027. 4th gear forward

D
B
F Table 399.
Reverse high ratio (D) 3040
Layshaft (E) 3029
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Figure 1030. 3rd gear reverse 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 back to the sump.
F
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

a drive plate which in turn is bolted to the engine
C drive. As the engine starts to rotate, the converter
gives smooth power take off and gradually increases
the torque transmitted. This torque is transferred
Table 400. from the converter assembly to the clutch/gear
assemblies through the input shaft on the forward
Clutches engaged Solenoids energised clutch assembly.
Reverse low ratio (C) 3041
Mainshaft (F) 3033 The forward clutch assembly contains two
Figure 1031. 4th gear reverse high ratio drive. The clutches are controlled by a
F
The reverse clutch assembly is also similar to the
ratio drive and the other gives a reverse high ratio
either the reverse low (solenoid 3041) or reverse high
D Both the mainshaft and the layshaft assemblies have
a single clutch each. Both clutches are controlled
Table 401. solenoid 3029 directs pressurised oil to the layshaft
Clutches engaged Solenoids energised clutch and solenoid 3033 directs pressurised oil the
mainshaft clutch.
Reverse high ratio (D) 3040
Mainshaft (F) 3033 When a gear is selected through the control switch
in the cab, two clutches are always engaged. When
Hydraulic operation and schematics you select different pairs of clutches different gear
ratios are engaged. ECUs control the solenoids. All
The engine directly drives the oil pump through the the clutches work on the same principle.
torque converter.
Oil from the pump is fed through an internal passage

via the filter to the PMV, which maintains pressure
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Figure 1032.
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 402.
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
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Item Description
X Solenoid 3022
Y Solenoid 3029
Z Solenoid 3033
Forward and Reverse Clutch Operation The counter plates and friction plates are pressed
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.
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Figure 1033.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q

G1 Gear 1 G2 Gear 2
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Mainshaft and Layshaft Clutch Operation piston via a solenoid valve. The solenoid valve is
operated by a switch in the cab.
The mainshaft and layshaft units incorporate one
clutch and not two, as in the forward and reverse When the switch is in the 4WD position, the solenoid
units. The operation of the single clutches is the valve is de-energised. With the solenoid 1 de-
same as for one clutch in the forward or reverse units. energised, the valve spool moves under the force of
2 and 4 Wheel Drive Clutch Operation the same time oil vents from the back of the piston to
the sump via ports 1 and 2.
4 Wheel Drive Operation Because there is no pressure behind the piston, the
clutch friction/counter plates of the clutch pack are
This clutch is of the Spring-ON (4WD)/Pressure-OFF forced together by the disc springs, thus driving the
(2WD) type. output yoke.
The clutch is engaged and disengaged by
Figure 1034.
D B E
A A1
3 2
1
A2 C

C Piston D Springs
E Output yoke
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27 - Driveline
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Figure 1035.
D G B F E
A A1
3 2
1
A2

C Piston D Springs
G Pressure plate
Direction Control
(For: PS766)
A column switch controls the direction control,
The gearbox system is controlled electronically. forward, neutral or reverse. The switch is connected
Inputs from control devices are connected to various to inputs on the ECU which in turn energise the
ECUs. The ECU’s energise the applicable electrical applicable gearbox control solenoids.
devices depending on the machine status. The
ECU’s are connected to the machine CANbus which Joystick Direction Control
enables integrated control of all the main machine
systems. Drive direction can also be controlled with the joystick
direction control switch. Inputs from the switch are
For details of the ECUs installed on the machine refer connected to the transmission ECU via the joystick
to (PIL 33-45). powerbase ECU and the CANbus. There is a logic
control for drive direction selection. Selection of
Start up Forward or Reverse with the column switch disables
the joystick direction control switch. Both the joystick
Electrical interlocks prevent the engine being started, and column switch must first be set to Neutral before
unless the transmission is set to neutral. The the joystick switch is enabled.
interlock is controlled by the ECU.
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Manual gear select transmission to neutral even if forward or reverse is

selected. A warning sound will be audible.
When the machine is “Manual” transmission mode
(Transmission mode switch set to “Off”) the gears Transmission dump
can be selected manually. A rotating barrel switch
controls selection of the gear ratios (1,2,3 or 4). The A transmission dump switch on the hydraulic control
switch is connected to inputs on the ECU which lever de-selects the transmission drive when the
energise the applicable gear box control solenoids. switch is operated.
Joystick Gear Selection 2/4 Wheel drive select

Gear ratio selection can be controlled with the A cab mounted switch controls 2 or 4 wheel
joystick ratio up (plus) and down (minus) buttons. drive selection. The switch provides an input to
Inputs from the buttons are connected to the the transmission ECU which in turn energises
transmission ECU via the machine control ECU and the applicable gearbox control solenoid. The
the CANbus. transmission automatically selects 4 wheel drive
when the service brakes are applied.
A gearbox mounted ground speed sensor detects
the ground speed of the machine. Signals from the
sensor are connected to the transmission ECU via Foot Brake Control
responds by preventing ratio selection if the machine When the foot brake operates a pressure transducer
ground speed is not within pre-set values. mounted in the hydraulic brake line detects the
change in brake system pressure. Input from
When the ratio up (plus) button is pressed the the transducer is connected to the transmission
transmission ECU selects the next (higher) gear ECU. The transmission ECU selects neutral even
ratio. When the ratio down (minus) button is pressed if Forward or Reverse is selected. The feature
the transmission ECU selects the next (lower) gear enables an increase in machine braking efficiency.
ratio. An operator switch in the cab can be set to enable or
disable the feature.
Automatic gear select
Transmission Oil Pressure and
An operator switch in the cab can be set to enable Temperature
‘Auto mode’. The gearbox will automatically up shift
and down shift. The transmission ECU programme Oil pressure and temperature sensors are connected
selects the most economical gear for a given road to the machine instrumentation which displays the
speed and engine load. To enable up shifts the pressure and temperature status. Warning displays
accelerator pedal must be pressed, this prevents up and fault codes are activated if the oil pressure or
shifting when coasting down hill for example, thus temperature is not within pre-set values.
ensuring maximum machine control.
Lock up torque converter option
Kickdown operation
The lock up torque converter operates automatically
The column switch incorporates a kickdown switch between preset parameters when F5 or F6 gears are
which enables the operator to down shift to the selected. When field mode is selected the lock up
next lowest gear, depending on which `mode' is torque converter can be disabled.
selected. The transmission ECU checks to see if the
machine road speed is suitable before down shifting Limp Modes
the gearbox. If the road speed is too high a single
double beep is sounded. When necessary the transmission ECU will provide
alternative gear selection should faults occur. This
Pressing the kick down switch a second time causes enables the machine to be moved (`limped') under its
the transmission ECU to select the previous gear. An own power. For limp mode details refer to Technical
indicator light will illuminate until the operator selects Data (PIL 27-06).
another gear position using the column switch.
Fault codes may also be displayed on the instrument
Park brake on panel. For fault codes refer to (PIL 33-57-90).
When the park brake is on, an electrical switch sends

a signal to the transmission ECU which sets the
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Drive paths Table 404.

Forward Forward low ratio (T) 3022 (Ts)
Figure 1036. 1st gear forward (4 wheel drive) Layshaft (Z) 3029 (Zs)
X applied) (S)
Figure 1038. 3rd gear forward (4 wheel drive)
U
Z
S
Table 403.
6 speed (X) 3004 (Xs)
2/4 wheel drive (spring - Table 405.
applied) (S) Clutches engaged Solenoids energised
Figure 1037. 2nd gear forward (4 wheel drive) Layshaft (Z) 3029 (Zs)
applied) (S)
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Figure 1039. 4th gear forward (4 wheel drive) Table 407.

X
Forward low ratio (T) 3022 (Ts)
applied) (S)
Figure 1041. 6th gear forward (4 wheel drive)
Z
U
S
Y
Table 406.
6 speed (X) 3004 (Xs)
S
applied) (S)
Figure 1040. 5th gear forward (4 wheel drive) Table 408.

applied) (S)
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Reverse Table 410.
Figure 1042. 1st gear reverse Clutches engaged Solenoids energised

Reverse high ratio (V) 3040 (Vs)
applied) (S)
W
Figure 1044. 3rd gear reverse
S
Y
Table 409.
Clutches engaged Solenoids energised S
Reverse low ratio (W) 3041 (Ws)
applied) (S)
Table 411.
Figure 1043. 2nd gear reverse Clutches engaged Solenoids energised

Reverse low ratio (W) 3041 (Ws)
applied) (S)
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Figure 1045. 4th gear reverse torque is transferred from the converter assembly to
the clutch/gear assemblies through the input shaft on
the forward clutch assembly.
The forward clutch assembly contains two

V high ratio drive. The clutches are controlled by a
Y The reverse clutch assembly is also similar to the

ratio drive and the other gives a reverse high ratio
S either the reverse low (solenoid 3041) or reverse high
Both the mainshaft and the layshaft assemblies have

a single clutch each. Both clutches are controlled
Table 412. solenoid 3029 directs pressurised oil to the layshaft
Clutches engaged Solenoids energised clutch and solenoid 3033 directs pressurised oil the
Reverse high ratio (V) 3040 (Vs) mainshaft clutch.
Mainshaft (Y) 3033 (Ys) On 6-speed gearboxes, the 6-speed clutch X is
2/4 wheel drive (spring - controlled via solenoid valve 3004.
applied) (S)
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, which maintains pressure The 2/4 wheel drive unit also has a single clutch.
to the solenoid valves for clutch selection. Excess oil In normal operation the clutch is spring loaded and
from the maintenance valve flows back through the therefore engaged to give 4 wheel drive. When
case to the torque converter. A relief valve controls 2 wheel drive is selected, solenoid valve 3002 is
pressure in the converter and dumps oil from the energised and directs pressurised oil to the 2/4 wheel
converter line back to the sump. drive clutch.
Oil from the torque converter flows out of the gearbox In the schematic, the gearbox is shown with 2nd
to the external oil cooler and again comes back to gear forward engaged. 2nd gear forward requires
the converter. Oil then flows through internal oil ways the forward low clutch T and layshaft clutch Z to
providing lubrication for clutches and bearings before be engaged. When the gear selection switch is
it goes back to the gearbox sump. moved to 2nd gear forward, the electrical control
system energises solenoid valves 3022 and 3029.
The torque converter is a fluid coupling bolted to Pressurised oil is diverted to the back of pistons
a drive plate which in turn is bolted to the engine in both clutches to engage the drive. At the same
driven bevel gearbox. As the engine starts to rotate, time all other solenoids are de-energised, diverting
the converter gives smooth power take off and oil from the back of the other clutch pistons to the
gradually increases the torque transmitted. This gearbox sump. 4 wheel drive clutch 3002 is also
energised to give 2 wheel drive.
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Figure 1046.
H G
2 1 K X
2 3 3
3004 C
5 1 W V Q A
3021 J
3022 T U
1
3002
B
3041
Y
M
3040 z
L 6
3033
D
E S
3029
N F
P
Table 413.
Item Description
A Torque converter
B Forward clutch assembly
C Reverse clutch assembly
D Mainshaft assembly
E Layshaft assembly
F 2/4 wheel drive unit
G Torque converter relief valve
H Pressure maintenance valve
J Pump
L Park brake pack
M Hose connection - to oil cooler
N Hose connection - from oil cooler
P 6-Speed clutch assembly (if installed)
S Gear drive to reverse unit clutch assembly
Q Oil filter
T Forward low ratio clutch
U Forward high ratio clutch
V Reverse high ratio clutch
W Reverse low ratio clutch
X 6 speed clutch (PS766 only)
Y Mainshaft clutch
Z Layshaft clutch
1 Solenoid port 1
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27 - Driveline
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Item Description
2 Solenoid port 2
3 Solenoid port 3
5 Solenoid valve control block
6 External oil cooler
Forward and Reverse Clutch Operation is then transmitted from the input shaft to the gear
1. Clutch for gear 2 is disengaged and no drive is
The forward and reverser clutch assembly transfers transmitted to gear 2 plate carrier. The gear is also
drive from the input shaft to either gear 1 or gear 2 free to rotate on the input shaft assembly.
depending on which of the two clutches is engaged,
giving forward or reverse drive. Actuation of the hydraulic pistons and is controlled
via three position solenoid control valve.
When neither clutch is engaged, neutral is selected.
When neutral is selected both solenoids are
The clutches are of the wet, multi plate type. deactivated and the flow of pressurised oil to the
clutches is blocked. The gear springs 1 and 2 move
The clutch housings and input shaft are a one piece the pistons away from the clutch plates and oil from
assembly. The assembly is permanently driven by both pistons is vented to the sump.
the engine via the torque converter.
When either forward or reverse is selected, the
Clutch counter plates are also permanently driven solenoid control valve diverts pressurised oil via
via meshing teeth inside the clutch housings. Clutch cross drillings inside the input shaft to the appropriate
friction plates are meshed with the gear plate clutch piston in the unit. Pressure from the other
carriers. clutch is vented to the sump via the solenoid valve
spool. Oil is prevented from leaking by seals on the
In the diagram, clutch for gear 1 is engaged. pistons and ring seals on the input shaft.
The counter plates and friction plates are pressed

27 - 310 9813/7600-3 27 - 310

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Figure 1047.
B C D E F
A G1 G2
H H H
K J
N
M
R
Q

G1 Gear 1 G2 Gear 2
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27 - Driveline
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Mainshaft and Layshaft Clutch Operation piston via a solenoid valve. The solenoid valve is
operated by a switch in the cab.
The mainshaft and layshaft units incorporate one
clutch and not two, as in the forward and reverse When the switch is in the 4WD position, the solenoid
units. The operation of the single clutches is the valve is de-energised. With the solenoid 1 de-
same as for one clutch in the forward or reverse units. energised, the valve spool moves under the force of
2 and 4 Wheel Drive Clutch Operation the same time oil vents from the back of the piston to
the sump via ports 1 and 2.
4 Wheel Drive Operation Because there is no pressure behind the piston, the
clutch friction/counter plates of the clutch pack are
This clutch is of the Spring-ON (4WD)/Pressure-OFF forced together by the disc springs, thus driving the
(2WD) type. output yoke.
The clutch is engaged and disengaged by
Figure 1048.
B C
A1
3 2
1
A2

C Piston D Springs
E Output yoke
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27 - Driveline
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Figure 1049.
B C
A1
A
3 2
1
A2

C Piston D Springs
G Pressure plate
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Fault-Finding
Fault
Machine drives but lacks power in all gears. Gearbox oil may also be Table 414. Page 27-314
overheating.
Machine does not drive in any gear. Table 415. Page 27-315
Some gears fail to engage or lack power. Table 416. Page 27-316
Gearbox oil overheating. Table 417. Page 27-316
Noisy operation. Table 418. Page 27-317
Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch). Table 419. Page 27-317
Cannot engage 2WD (Spring ON clutch). Table 420. Page 27-317
Gearbox oil contaminated with water. Table 421. Page 27-318
Consequential Faults (Gearbox faults caused typically by water Table 422. Page 27-318
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 425. Page 27-319
(Lock-up torque converter variants only).
Gear shifts fail to function normally- Sychroshuttle gearboxes only. Table 426. Page 27-319
Gear shifts fail to function normally or shifts occur at the incorrect road Table 427. Page 27-319
speed.
The gear fails to autoshift (Note that on 6 speed gearboxes, 4th, 5th and Table 428. Page 27-319
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 414. 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.
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27 - Driveline
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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 415. 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.
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27 - Driveline
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Table 416. 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 417. 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.
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27 - Driveline
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Table 418. 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 419. 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 420. 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.
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27 - Driveline
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Table 421. 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 422. 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).
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Table 425. 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 426. Gear shifts fail to function normally- Sychroshuttle gearboxes only.
Cause Remedy
Cable shift mechanism faulty Adjust or replace gear shift cables as necessary.
Table 427. 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 428. 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.
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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.)
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27 - Driveline
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Drain and Fill 13. Continue this procedure for the specified
duration, if possible during machine operation.
Duration: 30min
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)
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: 5s
10.1. Do not stall the torque converter for
longer than the maximum duration or the
transmission oil will overheat.
Duration: 10s
11. Continue running the engine under normal
conditions for the specified duration.
Duration: 5min
12. Repeat step 10.
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Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4L JCB Threadlocker 4101/0250 0.01L
- General purpose and Sealer (Medium 4101/0251 0.05L
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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27 - Driveline
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5.4. Re-assemble the pump. Check (Level)

Figure 1050.
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: 4min
3. Stop the engine.
4. Remove the ignition key.
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)).
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 1057. • 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 - 324 9813/7600-3 27 - 324

27 - Driveline
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Figure 1051. Test points
A D
H
Item Description
F Reverse high ratio clutch
Table 429. 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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27 - Driveline
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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 1052.
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: 0–20bar (0.0–289.9psi) Figure 1052.
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 1052.
pressure gauge will show the main line pressure.
Refer to Figure 1052. 4. Stop engine and remove the test gauge. Refer to
Figure 1052.
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27 - Driveline
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Figure 1052. Pump flow test
A
L
X Y Z
P
Q
N
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27 - Driveline
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Special Tool: Flowmeter (Qty.: 1)
Table 430. 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 1052.
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 1052.
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 1052.
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 1052.
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 1052. 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 1052. 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 1053.
1052.
Pressure: 0–20bar (0.0–289.9psi)
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 1052. 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 1053.
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 1052. a pump flow test. Refer to Figure 1053.
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 1053.
to the correct torque value. Refer to Figure 2.3. Low pressure could be caused by a faulty
1052. pump or internal leakage. Refer to Figure
3.4. Type 'z': With the component parts 1053.
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 1053.
to Figure 1052.
3.5. Connect the flowmeter to the flow and
return adapters (shown with arrows). Refer
to Figure 1052.
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27 - Driveline
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Figure 1053. 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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27 - Driveline
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Converter relief (safety valve) pressure load valve and perform the test again, carefully
watch the pressure gauge. Refer to Figure 1053.
The purpose of the torque converter relief valve is
to protect the torque converter from excessive oil 6. If the converter relief valve opens at a pressure
pressure. Excessive oil pressure can be generated higher than specified then the valve is faulty.
when the transmission oil temperature is below 50°C Refer to Figure 1053.
(121.9°F) and/or the engine is run at over 2000 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 1053.
pressure.
9. Install hoses to their original position. Refer to
For this reason it is essential that the transmission oil Figure 1053.
should be more than 50°C (121.9°F) and the engine
should run between idle and 1000 RPM when you Bypassing the converter relief valve
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 1053.
following tests it will cause false results.
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 1053.
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 1053.
Pressure: 8.3bar (120.3psi) 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 1054.
should increase to the converter relief (safety)
valve pressure setting. Refer to Figure 1053. 2. Carefully remove the spring. Refer to Figure
1054.
5. The gauge pressure will fall, once the valve has
opened. This is normal relief valve operation and 3. Obtain a suitable plug, drill and tap the centre
does not indicate a fault. If necessary reset the then install a locking bolt. Refer to Figure 1054.
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27 - Driveline
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Figure 1054. 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 1054. 1054.
5. Do not damage the spool and its seat. Refer to Duration: 1min
Figure 1054.
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 1054. 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.
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27 - Driveline
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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 1055.
converter out line. Refer to Figure 1055.
4.1. A high pressure together with low flow could
Pressure: 0–20bar (0.0–289.9psi) 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 1055.
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 1055.
Figure 1055.
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 1055.
in neutral. Refer to Figure 1055.
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 1055.
Figure 1055. 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
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27 - Driveline
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 1055. 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 1055. record the pressure readings. Refer to Refer to
Table 431.
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 1055. 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 431.
the specified to the mainline pressure test point. 5.3. From the table we can see that the forward
Refer to Figure 1056. high clutch is used for selection of both 2nd
Pressure: 0–20bar (0.0–289.9psi) and 4th gear forward.
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 431.
Gear select Ratio clutch Mainshaft or layshaft Value (Examples Only)
clutch
1st Forward low Layshaft 9.65bar (139.9psi)
2nd Forward high Layshaft 8.62bar (124.9psi)
3rd Forward low Mainshaft 9.65bar (139.9psi)
4th Forward high Mainshaft 8.62bar (124.9psi)
27 - 333 9813/7600-3 27 - 333

27 - Driveline
00 - General
Figure 1056.
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 1056.
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 1056.
the specified to the mainline pressure test point.
Refer to Figure 1056. 7. Start engine and run at 1000 RPM, select 2nd
Pressure: 0–20bar (0.0–289.9psi) 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 1056.
to Figure 1056.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) 7.1. Stop the engine and interchange the
gauges. Refer to Figure 1056.
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 1056. the gauges is still greater than the specified
27 - 334 9813/7600-3 27 - 334

27 - Driveline
00 - General
value then disassemble the forward high 7.3. If after interchanging the gauges, the
clutch. Refer to Figure 1056. readings are different than the value
mentioned in step 7 then calibrate the
gauges and again do the check. Refer to
Figure 1056.
27 - 335 9813/7600-3 27 - 335

27 - Driveline
00 - General
Figure 1057. Transmission Technical Data Checklist
27 - 336 9813/7600-3 27 - 336

27 - Driveline
00 - General
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 1058.
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 - 337 9813/7600-3 27 - 337

27 - Driveline
00 - General
Figure 1059.
E C F
B D
A Frame B Cooler hose 1

C Cooler hose 2 D Drain pipe
E Oil filter pipes F Bolts
27 - 338 9813/7600-3 27 - 338

27 - Driveline
00 - General
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.
27 - 339 9813/7600-3 27 - 339

27 - Driveline
00 - General
For: PS750 MK4 ..................... Page 27-340 the correct machine service documentation. The
For: PS764, PS766 ................. Page 27-341 table lists all the service procedures for the gearbox.
For some procedures it is necessary to do other
procedures first, these are shown in the table.
(For: PS750 MK4)
Before following some of the procedures, remove
the gearbox from its machine installation. Refer to
Table 432. 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).
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).
27 - 340 9813/7600-3 27 - 340

27 - Driveline
00 - General
Serial No. Procedure Name Do these procedures first

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.
Figure 1060.
(For: PS764, PS766)
Special Tools
Gearbox Assembly 892/01082 1
Cradle
Note: The Disassembly and Assembly procedures

given below illustrate and describe the 6x4 gearbox.
Procedures for the 4x4 version of the gearbox
are identical in most respects. Where there are
differences, procedures are identified under the
heading 4x4 Gearbox.
With the gearbox removed from the machine, place

suitable wooden blocks to securely support the
assembly. If the gearbox is installed with an integral B
A
park brake the brake assembly must be removed
before you disassemble the gearbox. Refer to (PIL A Layshaft cover
27-06). B Bolt 1
Gearboxes compatible with a lock up torque 1.1. Remove the bolts.

converter are installed with a control valve and 1.2. Remove the cover.
interconnecting pipe. These components must be
removed before dismantling the gearbox. 1.3. Note: Unless the cases are to be replaced,
or the gearbox oil has been contaminated it
is not necessary to remove the cover.
Disassemble
2. Separate the front and rear case and remove the
1. If installed, remove the layshaft cover. Refer to
clutch shafts.
Figure 1060.
3. Do not attempt to disassemble the gearbox
further until it is safely positioned in a suitable
work cradle.
27 - 341 9813/7600-3 27 - 341

27 - Driveline
00 - General
4. Separate the front case and remove the clutch

shaft assemblies. Refer to (PIL 27-06).
5. Remove the transfer gear.
Install
1. Use suitable lifting equipment and put the rear
case of the gearbox in a work cradle.
Special Tool: Gearbox Assembly Cradle (Qty.: 1)
1.1. Clamp the gearbox at the three clamping
points on the rear case.
2. Do not attempt to assemble the gearbox further
until it is safely positioned in a suitable work
cradle.
3. Install the transfer gear.
4. Install the clutch shaft assemblies and the front
case. Refer to (PIL 27-06)
5. If applicable, install the layshaft cover as follows:
Figure 1061.
B
A
A Layshaft cover
B Bolt 1
5.1. Make sure that the case mating faces are
clean and not damaged.
5.2. Apply a thin bead of sealant to the rear case
and install the layshaft cover.
5.3. Install the bolts 1.
5.4. Tighten the bolts 1 to the correct torque
value.

Item Description Nm
B Bolt 56
27 - 342 9813/7600-3 27 - 342

27 - Driveline
06 - Clutch - Reverse
06 - Clutch - Reverse Introduction

Introduction .................................................. 27-343 A clutch is a mechanical device that engages and
Check (Condition) ........................................ 27-344 disengages drive, from driving shaft to driven shaft.
Check (Pressure) ........................................ 27-344
Remove and Install ..................................... 27-345 Each gear on the gearbox has an associated clutch
which is operated using the applicable solenoid.
When the solenoid is engaged fluid is applied to the
clutch to move it into position. When in position the
clutch connects the selected gear with the driven
shaft.
A combination of clutches is often used within the

gearbox to allow different gears to be engaged.
27 - 343 9813/7600-3 27 - 343

27 - Driveline

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
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
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).
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)
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.
Special Tool: Hand Pump Pressure Test (Qty.: 1)
5. If the pressure gauge reading is between
correctly and can be installed in the gearbox.
Pressure: 8.6–9.3bar (124.6–134.8psi)
6. If the pressure gauge reading is above the
27 - 344 9813/7600-3 27 - 344

27 - Driveline
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

main shaft assembly.

A Adaptor (Part of 993/59300)

B Clamp (Part of 993/59300)
27 - 345 9813/7600-3 27 - 345

27 - Driveline

For: PS750 MK4 ..................... Page 27-346
For: PS764, PS766 ................. Page 27-346
(For: PS750 MK4)

Refer to Clutch-Input, Disassembly and Assembly
(PIL 27-06-11).
(For: PS764, PS766)

Refer to Clutch-Input, Disassembly and Assembly
(PIL 27-06-11).
27 - 346 9813/7600-3 27 - 346

27 - Driveline
07 - Clutch - 2WD/4WD Introduction

Component Identification ............................. 27-348 disengages drive, from driving shaft to driven shaft.
Check (Condition) ........................................ 27-354
Check (Pressure) ........................................ 27-354 Each gear on the gearbox has an associated clutch
Disassemble and Assemble ........................ 27-359 When the solenoid is engaged fluid is applied to the
shaft.

27 - 347 9813/7600-3 27 - 347

27 - Driveline
For: PS750 MK4, PS764, PS766

................................................. Page 27-348
For: PS750 MK4, PS764, PS766
................................................. Page 27-349
For: PS764, PS766 ................. Page 27-351
(For: PS750 MK4, PS764, PS766)
Figure 1063. 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)
27 - 348 9813/7600-3 27 - 348

27 - Driveline
U O-ring 2 (Shaft)
(For: PS750 MK4, PS764, PS766)
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 - 349 9813/7600-3 27 - 349

27 - Driveline

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9A Disc spring 1 9B Disc spring 1
27 - 350 9813/7600-3 27 - 350

27 - Driveline
(For: PS764, PS766)
Figure 1066. S1 - 4WD Spring ON
U
M
L
F
E
C
B
A
Q
G
S
H
P
T
N W
V
J1
J2
A Piston ring seal B Taper roller bearing 1

C Thrust washer 1 D Gear and splined hub
E Needle roller bearings F Thick thrust washer
G Taper roller bearing 2 H Locknut
J1 Disc spring J2 Disc spring
K Friction and counter plates retaining circlip L Shims
M Pressure end plate N Friction plates
P Counter plates Q Pressure end plate
27 - 351 9813/7600-3 27 - 351

27 - Driveline
R Piston S O-ring 1
T O-ring 2 U O-ring 3
V Capscrew W Reaction pin

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

27 - 352 9813/7600-3 27 - 352

27 - Driveline

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9 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 - 353 9813/7600-3 27 - 353

27 - Driveline

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: 13.8bar (200.0psi)
If necessary clean the valve by blowing through with Special Tool: Hand Pump Pressure Test (Qty.: 1)
it can damage the valve seat. 5. If the pressure gauge reading is between
Gears correctly and can be installed in the gearbox.
Pressure: 8.6–9.3bar (124.6–134.8psi)
damage. 6. If the pressure gauge reading is above the
27 - 354 9813/7600-3 27 - 354

27 - Driveline

For: PS764, PS766 ................. Page 27-355
For: PS750 MK4 ..................... Page 27-358
(For: PS764, PS766)

Special Tools
Spanner
Remove
1. Remove the 4WD clutch assembly as follows:
Figure 1070.
B
D C
A Adaptor (Part of 993/59300) H

B Clamp (Part of 993/59300) E
A Output yoke
B Bolt 1 (If applicable)
C Thick washer (If Bolt 1 is installed)
D Nut
E Bolt 2
F Cover
G O-ring (If installed)
H Oil seal
J 4WD clutch and shaft assembly
1.1. Hold the output yoke with the tool.
27 - 355 9813/7600-3 27 - 355

27 - Driveline
Special Tool: Drive Coupling Spanner (Qty.: 1.1. Make sure that the inner bearing outer cup
1) is correctly installed in the front case.
1.2. Either remove the nut or the bolt1 along 1.2. Put the clutch and shaft assembly in the
with the thick washer. The nut or bolt is very housing.
tight and the help of a assistant would be
1.3. Make sure that the front and 4WD case
required.
mating faces are clean and not damaged.
1.3. Remove the yoke
1.4. If applicable install the O-ring to the front
1.4. Remove the bolts 2 (x8) and lift off the cover. case. The O-ring deforms to get positioned
in the recess.
1.5. Make sure to remove the bearing outer cup
from inside the cover. 1.5. For gearbox variants installed with an O-
ring apply a bead of Loctite 509 of the
1.6. If installed, remove the o-ring.
specified thickness to the front case at the
1.7. Remove the output shaft oil seal. Take care locations shown. Refer to Figure 1072.
not to damage the seal housing. Dimension: 3mm
1.8. Lift the 4WD clutch and shaft assembly from
the housing. Figure 1072.
1.9. Remove the inner bearing outer cup from

the case. P G
2. Remove the torque converter relief valve as
P
follows: Refer to Figure 1071.
Figure 1071.
K
L
M P
N
G O-ring
P Loctite 509
1.6. For gearbox variants not installed with O-
ring apply a bead of Loctite 509 of the
specified thickness on the front case at the
locations shown. Refer to Figure 1073.
Dimension: 3mm
K Plug
L Sealing washer
M Spring
N Poppet
2.1. Remove the plug.
2.2. Remove the sealing washer and the spring.
2.3. Remove the poppet.
Install
1. Install the 4WD clutch assembly as follows: Refer
to Figure 1074.
27 - 356 9813/7600-3 27 - 356

27 - Driveline

B
P
D C
P
A
H
P E
G
P
P Loctite509
J
1.7. Note that the bead is applied near the inner
or outer edge of the flange as applicable at
positions shown.
1.8. Make sure that the outer bearing outer cup
is correctly installed inside the cover.
1.9. Install the cover with the bolts 2 (x8).
1.10. Tighten the bolts 2 to the correct value.
A Output yoke
B Bolt 1 (If applicable)
C Thick washer (If Bolt 3 is installed)
D Nut
E Bolt 2
F Cover
G O-ring 3 (If installed)
H Oil seal
J 4WD clutch and shaft assembly
2. Measure the 4WD clutch shaft end float. as
follows:
2.1. The end float will be within limits provided
the components are installed correctly.
Rotate the shaft by hand, it should rotate
smoothly.
2.2. Install a bolt to the threaded hole in the end
of the shaft.
2.3. Pull up the bolt a to detect excessive end
float.
2.4. The end float must be within the range
specified.
3. Continue the installation of the 4WD clutch
assembly as follows:
27 - 357 9813/7600-3 27 - 357

27 - Driveline
3.1. Install a new oil seal. Make sure that the (For: PS750 MK4)
seal is positioned correctly in the housing.
3.2. Install the output yoke. The layshaft clutch, 2WD (Two Wheel Drive) / 4WD
(Four Wheel Drive) clutch, reverse clutch, mainshaft
3.3. As applicable install either the thick washer clutch and forward / input clutch are all part of the
and bolt 1 or the stake nut. mainshaft assembly.
3.4. Hold the yoke with the tool.
Refer to the mainshaft remove and install procedure.
Special Tool: Drive Coupling Spanner (Qty.: Refer to (PIL 27-06-54).
1)
3.5. Tighten the bolt or nut to the correct torque
value.
3.6. If the stake nut is installed, then stake the
nut with a square ended staking tool.
4. Install the torque converter relief valve as follows:
Figure 1075.
K
L
M
N
K Plug
L Sealing washer
M Spring
N Poppet
4.1. Install the poppet and the spring.
4.2. Use a new sealing washer and install the
plug.
4.3. Tighten the plug to the correct torque value.

Item Description Nm
B Bolt 1 400
D Nut 300
E Bolt 2 56
K Plug 56
27 - 358 9813/7600-3 27 - 358

27 - Driveline
For: PS750 MK4, PS764, PS766, Pressure

ON ........................................... Page 27-359
For: PS750 MK4, S1, Spring ON
................................................. Page 27-363
For: PS750 MK4, S2, Spring ON
................................................. Page 27-366
For: PS764, PS766 ................. Page 27-369
(For: PS750 MK4, PS764, PS766, Pressure ON)

Special Tools
Test
27 - 359 9813/7600-3 27 - 359

27 - Driveline
Disassemble
Figure 1076.
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 - 360 9813/7600-3 27 - 360

27 - Driveline
3. With a puller or press, remove the 4WD gear and Figure 1078.
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.
plates with those from other clutches.
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.
8.1. With a cut away tube compress the piston
spring and remove the circlip 2.
Assemble
Figure 1077.
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
install the circlip 2.
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.
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27 - Driveline
Figure 1079. 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.
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 - 362 9813/7600-3 27 - 362

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(For: PS750 MK4, S1, Spring ON)
Disassemble
Figure 1080.
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.
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27 - Driveline
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: 26,700N 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 1081.
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.
ring 2.
CAUTION! The spring (or springs) apply
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
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.
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27 - Driveline
Figure 1082. 16.3. The shim can be a combination of a

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.
23. Before pushing the outer cup of bearing 1 into the
16.2. If necessary, install a new shim to get the housing cover make sure you install the spacer.
correct gap.
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(For: PS750 MK4, S2, Spring ON)
Disassemble
Figure 1083.
8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9 Disc spring 1 (x4) 10 Pressure end plate
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27 - Driveline

23 Shaft
1. Carefully remove the piston ring seal from the Figure 1084.
shaft. AA
damage on the shaft grooves. If necessary
remove burrs with a fine grade abrasion
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: 26,700N 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 1085.
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.
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Figure 1086. 5.7. The shaft will approximately drop to

the specified distance when the splines
engage.
Distance: 3mm
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 1087.
Figure 1089.
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 1088. 7.2. Install the friction plates so that the cross
hatching pattern aligns with each adjacent
plate.
Figure 1090.
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
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27 - Driveline
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: 0.75–1.5mm
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
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 1091. 18. Install the thrust washer 2.
(For: PS764, PS766)

Special Tools
Test
CAUTION! The spring (or springs) apply Pressure Test Adaptor 993/59300 1
considerable force. Make sure you take care to Adaptor Spanner 998/10738 1
Consumables
12. Use a suitable press to compress the disc springs Description Part No. Size
1 and install the retaining circlip.
13. Use levers to remove the free play. and Sealer (Medium 4101/0251 0.05L
Strength)
Figure 1092.
Gearboxes can be installed with one of three clutch
types 4WD (Four Wheel Drive) Spring ON.
Disassembly
1. Carefully remove the piston ring seal from the
shaft.
damage on the shaft grooves. If necessary
remove burrs with a fine grade abrasion
paper and oil.
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27 - Driveline
2. Use a suitable puller or press to remove the 4WD 11.1. Match mark the piston and the clutch
gear and splined hub together with its taper roller housing, to make sure that the piston is
bearing 1, needle roller bearing and the thrust assembled in the same orientation when
washer 1. they are assembled again.
2.1. Remove the thick thrust washer. Figure 1093.
2.2. Note, the thick thrust washer and thrust
washer1 are not interchangeable.
3. Use a suitable puller or press to remove the taper
roller bearing 2.
4. Use an adaptor spanner and a 1/2" square drive
socket to remove the locknut.
Special Tool: Adaptor Spanner (Qty.: 1)
5. Use the 4WD output yoke secured in a vice as
a holding fixture, to support the clutch assembly
and prevent it from rotation when torque is
applied.
6. Lift off the disc springs.
11.2. If the piston does not loosen, then hand
7. Turn the assembly over and remove the friction pump air down the shaft oil inlet hole.
and counter plates retaining circlip. Special Tool: Hand Pump Pressure Test
8. Remove the pressure end plate 1 and shims, if (Qty.: 1)
installed. 12. Remove the piston.
9. Remove the friction plates and the counter 13. Remove and discard the O-ring 1 and O-ring 2
plates. from the piston.
9.1. Keep them together in sets, do not mix the 14. Remove and discard the O-ring 3 from the shaft.
15. If it is necessary to replace, remove the
10. Remove the pressure end plate 2. capscrews and the reaction pins.
11. Turn the assembly over and knock the clutch
shaft on a piece of aluminium (or wood) to loosen
the piston.
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27 - Driveline
U
M
L
F
E
C
B
A
Q
G
S
H
P
T
N W
V
J1
J2
A Piston ring seal B Taper roller bearing 1

C Thrust washer 1 D Gear and splined hub
E Needle roller bearings F Thick thrust washer
G Taper roller bearing 2 H Locknut
J1 Disc spring J2 Disc spring
K Friction and counter plates retaining circlip L Shims
M Pressure end plate N Friction plates
P Counter plates Q Pressure end plate
R Piston S O-ring 1
T O-ring 2 U O-ring 3
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27 - Driveline
V Capscrew W Reaction pin

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

27 - 372 9813/7600-3 27 - 372

27 - Driveline

8
6
4
12
5
3 7
2
11
10
9B 23
17
9A
18
19
20
21
22
13
14
15
16

9 Disc spring 1 10 Pressure end plate
23 Shaft
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27 - Driveline
Assembly the retaining circlip and the pressure end

plate2.
1. Assemble the reaction pins.
Figure 1097.
1.1. If removed then install the reaction pins to
the piston. do the steps below to make sure
that the pins are correctly aligned.
1.2. Put the piston into the bore of the clutch
housing. Do not install any O-rings at this
stage.
1.3. Install each reaction pin in turn from the
opposite end of the housing and secure to
the piston with a capscrew.
1.4. Apply JCB Threadlocker and Sealer to the
threads of the capscrews before you install
them.
Consumable: JCB Threadlocker and Sealer 7. Install the thick thrust washer.
(Medium Strength)
8. Carefully use a thin rod (or screwdriver) to align
1.5. When all four reaction pins are installed, the teeth of the clutch plates.
tighten the capscrews to the specified
torque value. 8.1. Install the 4WD gear, splined hub and the
needle roller bearings.
Torque: 10–12N·m
1.6. Match mark the piston and the clutch 9. Install the thrust washer1.
housing to make sure that the piston is 9.1. Apply gearbox oil to the taper roller bearing
assembled in the same orientation. 2 and press the bearing onto the shaft to
1.7. Temporarily remove the piston from the seat on the thrust washer1.
clutch housing and assemble the clutch
pack. 10. Turn the assembly over and install a new O-ring
3 to the shaft.
2. Install the pressure end plate 2.
10.1. Install a new O-ring 1 and O-ring 2 to the
3. Install one counter plate followed by one friction piston.
plate. 10.2. Lubricate the piston with gearbox oil and
3.1. Continue to install alternate counter and press fully into the bore of the clutch
friction plates, finishing with a friction plate. housing (note the match marks made at
the time of disassembly).
4. Install the pressure end plate 1 but do not install
the shim at this stage. 11. Install the first two disc springs with their concave
sides uppermost (there are four disc springs,
4.1. Make sure that the chamfered face of the which are identical).
pressure end plate faces the clutch pack.
11.1. Place the other two disc springs with their
4.2. Make sure the teeth are not aligned with the concave sides down, on top of the first two
lubrication slots in the housing. as shown.
5. Install the friction and counter plates retaining 12. Use an adaptor spanner and a 1/2" square drive
circlip. socket to install the locknut and tighten the nut to
6. Use a DTI to measure the end float of the
pressure end plate. It should be within the Special Tool: Adaptor Spanner (Qty.: 1)
specified limit.
12.1. Note that the locknut is assembled dry
Dimension: 4–5mm with no thread lockers or sealant on the
threads.
6.1. If it is necessary to adjust the end float to
bring it within the specified limit mentioned 13. Use the 4WD output yoke secured in a vice as
in step6, Install a 6.0mm (0.23in) or 6.5mm a holding fixture, to support the clutch assembly
(0.25in) pressure end plate1 together with and prevent it from rotation when torque is
a shim or an extra counter plate, between applied.
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27 - Driveline
14. Use the pressure test adaptor and clamp

assembly to check the operation of the clutch
assembly.
Special Tool: Pressure Test Adaptor (Qty.: 1)
14.1. Make sure that the clutch fully disengages
at the specified working pressure.
15. Apply gearbox oil to the taper roller bearing2 and
press the bearing onto the shaft.
16. Install the piston ring seal.

Item Description Nm
H Locknut 300
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27 - Driveline
08 - Clutch - Layshaft
08 - Clutch - Layshaft Introduction

Check (Condition) ........................................ 27-382
Calibrate ...................................................... 27-383 Each gear on the gearbox has an associated clutch
shaft.

27 - 376 9813/7600-3 27 - 376

27 - Driveline
For: PS750 MK4 ..................... Page 27-378

For: PS764, PS766 ................. Page 27-380
27 - 377 9813/7600-3 27 - 377

27 - Driveline
(For: PS750 MK4)
Figure 1098.
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
27 - 378 9813/7600-3 27 - 378

27 - Driveline
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
27 - 379 9813/7600-3 27 - 379

27 - Driveline
(For: PS764, PS766)
Figure 1099.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
Item Description
Table 436.
C Circlip 1
Item Description D 4 wheel drive transfer
A Piston ring seals gear
B Taper roller bearing 1
27 - 380 9813/7600-3 27 - 380

27 - Driveline
Item Description
E Gear and splined hub
F Thin thrust washers 1
G Thrust bearing 1
H Needle roller bearings
J1 Thin thrust washer 2
J2 Thin thrust washer 3
K Thrust bearing 2
L Thick thrust washer
M Taper roller bearing 2
N Friction and counter
plates retaining circlip
P Pressure end plate
Q Shim
R Friction plates
S Counter plates
T Circlip 2
U Spring retaining plate
V Spring
W Oil baffle
X Piston
Y O-ring 1
Z O-ring 2
27 - 381 9813/7600-3 27 - 381

27 - Driveline
Check (Condition)
Do a visual check of the friction and counter plates:
Counter plates
Friction plates
one.

27 - 382 9813/7600-3 27 - 382

27 - Driveline
Calibrate
.............................................. Page 27- Later clutch assemblies feature an additional thin

For: PS764, PS766 ................. Page 27-383 thrust washer. If any of the components listed below
are to be replaced, the end float of gear must be
measured and reset as required:
End float measurement
• Shaft assembly
1. Use a DTI (Dial Test Indicator) to measure the • Gear and plate carrier assembly
end float of the pressure end plate. • Thin thrust washers1
2. The end float should be within the specified limit. • Thin thrust washer2 and thin thrust washer3
• 4 wheel drive (WD) transfer gear or spacer as
Dimension: 1.9–2.5mm applicable
Figure 1100. Measure the end float as follows:
1. Temporarily install thick thrust washer, thin

thrust washer3, thrust bearing2 and thin thrust
washer2.
2. Install the needle roller bearing.
A
3. Temporarily install the gear and plate carrier
assembly.
4. Install the thin thrust washer1 and thrust bearing1
followed by the remaining thrust washer1.
5. Temporarily install the 4WD transfer gear 4 onto
the layshaft spline. Make sure that the gear is
installed in the correct orientation.
5.1. 2 wheel drive machines have a spacer
installed instead of a gear.
6. Install the circlip1.
A DTI 7. Make sure that the 4 wheel drive gear (or spacer)
is fully seated against circlip1.
3. If the end float is more than the specified value
then install a 6.0mm (0.23in) or 6.5mm (0.25in) 8. Measure the end float of gear.
thick pressure end plate, with either a shim or an
extra counter plate between the retaining circlip 9. The end float should be within the specified
and the pressure end plate. range.
clutch. 10. If the end float is to be adjusted select a suitable
thrust washer from the spacer kit and again
assemble the components given in steps 1 to 6.
(For: PS764, PS766) Special Tool: Thrust Washer Kit (Qty.: 1)
Special Tools
11. Measure the end float again and assemble the
clutch assembly.
Thrust Washer Kit 823/10420 1
12. Make sure you install the correct thick thrust
End Float Setting - Plate Carrier and Gear washer on final assembly.
Note: The following procedure is only applicable to

clutch assemblies fitted with thin thrust washer3.
27 - 383 9813/7600-3 27 - 383

27 - Driveline
Figure 1101.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
A Piston ring seals B Taper roller bearing1

C Circlip1 D 4 wheel drive transfer gear
E Gear and splined hub F Thin thrust washers1
G Thrust bearing1 H Needle roller bearings
J1 Thin thrust washer2 J2 Thin thrust washer3
K Thrust bearing2 L Thick thrust washer
M Taper roller bearing2 N Friction and counter plates retaining circlip
P Pressure end plate Q Shim
27 - 384 9813/7600-3 27 - 384

27 - Driveline
R Friction plates S Counter plates

T Circlip2 U Spring retaining plate
V Spring W Oil baffle
X Piston Y O-ring1
Z O-ring2
27 - 385 9813/7600-3 27 - 385

27 - Driveline
Remove and Install
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

(Four Wheel Drive) clutch, reverse clutch, mainshaft
mainshaft assembly.

27 - 386 9813/7600-3 27 - 386

27 - Driveline
For: PS750 MK4 ..................... Page 27-388

For: PS764, PS766 ................. Page 27-391
27 - 387 9813/7600-3 27 - 387

27 - Driveline
(For: PS750 MK4)
Disassemble
Figure 1102.
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 - 388 9813/7600-3 27 - 388

27 - Driveline
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 - 389 9813/7600-3 27 - 389

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 1104.
Figure 1103.
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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27 - Driveline
21.3. Use an air line to check the operation of puller, although it can damage the bearing
the clutch. cage which will require a new bearing.
22. Apply gearbox oil onto the taper roller bearing 1 8. Remove the friction and counter plates retaining
and install the bearing onto the shaft. circlip.
23. Install the new piston ring seals. 9. Remove the pressure end plate and shim, if
installed.
(For: PS764, PS766) 10. Remove the friction plates and the counter
plates.
Special Tools
Description Part No. Qty. 10.1. Keep them together in sets, do not mix the
Hand Pump Pressure 892/00223 1 plates with those from other clutches.
Test 11. Put the clutch assembly in a suitable press.
The illustration shows a main shaft assembly for a 6 11.1. With a cut away tube compress the piston
speed gearbox. The main shaft assembly for 4 speed spring and then remove the circlip 2.
gearboxes has some small differences. Procedures
are applicable for both 4 and 6 speed variants. Figure 1105.
Disassembly
1. Carefully remove the piston ring seals.
then check for burrs or damage on the shaft
grooves. If necessary remove burrs with a
2. Remove the taper roller bearing 1 with a suitable
puller and press.
3. Remove the circlip 1 and remove the 4 wheel
drive(4WD) transfer gear.
3.1. Make a note in which orientation the gear is
installed for assembly. 12. Lift off the spring retaining plate.
3.2. The 2 wheel drive (2WD) machines have a 13. Remove the spring and oil baffle.
spacer installed instead of a gear.
4. Remove the gear and the splined hub together shaft on a piece of aluminium (or wood) to loosen
with the thin thrust washer1 and thrust bearing1. the piston.
5. Remove the two needle roller bearing 14.1. If the piston does not loosen, then hand
assemblies. pump air down the shaft oil inlet hole.
5.1. 4-speed transmissions have only one Special Tool: Hand Pump Pressure Test
needle roller bearing installed. (Qty.: 1)
6. Remove the thin thrust washer 2, thrust bearing

2, thin thrust washer 3 (if installed) and thick
thrust washer 1.
7. Use a puller to remove the taper roller bearing 2.
7.1. It must be discarded and replaced.
7.2. This bearing would not normally be
removed unless it was damaged.
7.3. If a collet tool is not available, then it
is permissible to use a standard bearing
27 - 391 9813/7600-3 27 - 391

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Figure 1106. 15. Remove the piston.

16. Remove and discard the piston O-ring 1.
17. Remove and discard the shaft O-ring 2.
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Figure 1107.
L
J2
J1
F
K
H S
C
A
G
D
B
M
R
U
T
X Y Z
V W
Item Description
D 4 wheel drive transfer
Table 437.
gear
Item Description E Gear and splined hub
A Piston ring seals F Thin thrust washers 1
B Taper roller bearing 1 G Thrust bearing 1
C Circlip 1
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Item Description 7.1. Continue to install alternate counter and

H Needle roller bearings friction plates, finishing with a friction plate.
J1 Thin thrust washer 2 8. Install the pressure end plate. Make sure that the
J2 Thin thrust washer 3 chamfered face of the pressure end plate faces
K Thrust bearing 2 the clutch pack.
L Thick thrust washer 9. Make sure that the teeth are not aligned with the
M Taper roller bearing 2 lubrication slots in the housing.
N Friction and counter
plates retaining circlip 10. A spring disc is not installed in this clutch pack.
P Pressure end plate 11. Do not install the shim at this stage.
Q Shim
12. Install the friction and counter plate retaining
R Friction plates
circlip.
S Counter plates
T Circlip 2 13. Use a DTI to measure the end float of the
U Spring retaining plate pressure end plate. The value should be within
the specified range.
V Spring
W Oil baffle Dimension: 1.9–2.5mm
X Piston Figure 1109.
Y O-ring 1
Z O-ring 2
Assembly
2. Install the new O-ring 2 onto the shaft.
4. Install the oil baffle and piston spring. Make
sure that the spring is positioned correctly in the
piston. 14. If it is necessary to adjust the end float to
bring it within tolerance, there is a choice of
5. Install the spring retaining plate. installing a 6.0mm (0.23in) or 6.5mm (0.25in)
thick pressure end plate, with either a shim or an
6. Compress the spring with a cut away tube and extra counter plate between the retaining circlip
install the circlip 2. and the pressure end plate.
Figure 1108. 15. Use an airline to check the operation of the
clutch.
16. Install the thick thrust washer 1, thin thrust
washer 3, thrust bearing 2 and the thin thrust
washer 2.
17. Install the two needle roller bearing assemblies.
17.1. 4-speed transmissions have only one
needle roller bearing installed.
18. Carefully align the teeth of the clutch plates using
a thin rod (or screwdriver) and install the gear and
splined hub.
19. Install the thin thrust washer 1 and thrust bearing
1.
plate.
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20. Install the 4 wheel drive transfer gear onto

the layshaft spline. Make sure that the gear is
installed in the correct orientation.
20.1. 2 wheel drive machines have a spacer
installed instead of a gear.
20.2. Install the circlip 1.
21. Apply gearbox oil on the taper roller bearing
1 and taper roller bearing 2 then push both
bearings onto the shaft.
22. Install new piston ring seals.
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09 - Clutch - Main Shaft
09 - Clutch - Main Shaft Introduction

Check (Condition) ........................................ 27-402
Remove and Install ..................................... 27-402 Each gear on the gearbox has an associated clutch
shaft.

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For: PS750 MK4 ..................... Page 27-398

For: PS764, PS766 ................. Page 27-400
27 - 397 9813/7600-3 27 - 397

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(For: PS750 MK4)
Figure 1110.
M
N
P J
K
L
Q
G
B
A
27 - 398 9813/7600-3 27 - 398

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Item Description
H Counter plates
Table 438.
J Circlip 2
Item Description
K Spring retaining plate
A Piston ring seals
L Spring
B Taper roller bearing 1
M Oil baffle
C Taper roller bearing 2
N Piston
D Circlip 1
P O-ring 1 (Piston)
E Pressure plate
Q O-ring 2 (Shaft)
F Shim (if installed)
G Friction plates
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(For: PS764, PS766)
Figure 1111.
D
C
L
B M1
N
S
P
A Q
V R
T
M2
J
E
F
G
H

C Gear 1 D Gear 2
E Taper roller bearing 2 F Circlip 1
G Pressure end plate H Shim
J Friction plate K Counter plate
L Circlip 2 M1 Spring retaining plate (6 speed gearbox)
M2 Spring retaining plate (4 speed gearbox) N Spring
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P Oil baffle Q Piston

R Piston O-ring S Shaft O-ring
T Circlip 3 U Clutch housing
V O-ring 1
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Do a visual check of the friction and counter plates: The layshaft clutch, 2WD / 4WD clutch, reverse
clutch, mainshaft clutch and forward / input clutch are
Counter plates all part of the mainshaft assembly.
1. Light scoring or polishing is permissible, plates Refer to the mainshaft remove and install procedure.
that are not flat, worn or heavily marked or scored Refer to (PIL 27-06-54).
Friction plates
one.

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For: PS750 MK4 ..................... Page 27-403

For: PS764, PS766 ................. Page 27-406
(For: PS750 MK4)

Special Tools
Test
27 - 403 9813/7600-3 27 - 403

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Disassemble
Figure 1112.
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 - 404 9813/7600-3 27 - 404

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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 1114.
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 1113. 3. Lubricate the piston with oil and press fully into
that the spring is positioned properly in the piston.
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.
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27 - Driveline
11. Install the friction and counter plate retaining 6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
circlip 1. end plate, with either a shim or an extra counter
12. With a DTI (Dial Test Indicator) measure the end pressure end plate.
float of the pressure end plate. The value should
be within the specified range. 14. Use an airline to check the operation of the
Length/Dimension/Distance: 1.9–2.5mm clutch.
Figure 1115. 15. Apply gearbox oil to the taper roller bearings 1
and 2.
16. Install the bearings onto the shaft.
(For: PS764, PS766)

Special Tools
Test
The illustration shows a main shaft assembly for a 6

speed gearbox. The main shaft assembly for 4 speed
gearboxes has some small differences. Procedures
13. If it is necessary to adjust the end float to bring it are applicable for both 4 and 6 speed variants.
27 - 406 9813/7600-3 27 - 406

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Disassemble
Figure 1116.
D
C
L
B M1
N
S
P
A Q
V R
T
M2
J
E
F
G
H

C Gear 1 D Gear 2
E Taper roller bearing 2 F Circlip 1
G Pressure end plate H Shim
J Friction plate K Counter plate
L Circlip 2 M1 Spring retaining plate (6 speed gearbox)
M2 Spring retaining plate (4 speed gearbox) N Spring
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P Oil baffle Q Piston

R Piston O-ring S Shaft O-ring
T Circlip 3 U Clutch housing
V O-ring 1
1. Carefully remove the piston ring seals. 11. Turn the assembly over and knock the clutch
shaft on a piece of aluminium (or wood) to loosen
1.1. If the piston ring seals are excessively worn the piston.
then check for burrs or damage on shaft
grooves. If necessary remove burrs with a 11.1. If the piston does not loosen, then hand
fine grade abrasion paper and oil. pump air down the shaft oil inlet hole.
2. Use a puller or press to remove the taper roller Special Tool: Hand Pump Pressure Test
bearing 1. (Qty.: 1)
3. Remove gear 1 and gear 2. Before removal make Figure 1118.

a record of the orientation of the gears.
4. From the opposite end of the shaft remove the
taper roller bearing 2 with a suitable puller.
5. Remove the circlip 1 that retains the friction and
counter plates.
6. Remove the pressure end plate and the shims (If
applicable).
7. Remove the friction plates and counter plates.

considerable force. Make sure you take care to 12. Remove the piston.
13. Remove and discard the piston O-ring.
14. Remove and discard the shaft O-ring.
15. Remove the circlip 3 and the remove the clutch
spring and remove the circlip 2.
housing from the shaft.
Figure 1117.
16. Remove and discard the O-ring 1.
Assemble
1. Install the new O-ring 1.
2. Press the clutch housing onto the shaft spline
3. Install the new piston and shaft O-rings.
that the spring seats in the piston correctly.
6. Install the spring retaining plate. The 4 speed
9. Remove the spring retaining plate. The 4 speed transmissions have a different shaped spring
transmissions have a different shaped spring retaining plate installed.
retaining plate installed.
10. Remove the spring and oil baffle. install the circlip 2.
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27 - Driveline

plate.
9. Install the pressure end plate. Make sure that the
the clutch pack.
lubrication slots in the housing.
circlip 1.
13. Use a DTI to measure the end float of the
pressure end plate. The value should be within
the specified range.
Figure 1119.
14. If it is necessary to adjust the end float to bring it

6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
end plate, with either a shim or an extra counter
pressure end plate.
clutch.
16. Apply gearbox oil onto the taper roller bearing 2
and press the bearing onto the shaft.
17. At the opposite end of the shaft press gear 1 and
gear 2 onto the shaft spline.
18. Make sure that the gears are installed in their
correct orientation.
19. Apply gearbox oil onto the taper roller bearing 1
and press the bearing onto the shaft.
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10 - Clutch - 6 Speed
10 - Clutch - 6 Speed Introduction

Check (Condition) ........................................ 27-413
Disassemble and Assemble ........................ 27-414 Each gear on the gearbox has an associated clutch

shaft.

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Figure 1120.
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
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
27 - 411 9813/7600-3 27 - 411

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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 - 412 9813/7600-3 27 - 412

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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.

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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.
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27 - Driveline
Figure 1121.
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 - 415 9813/7600-3 27 - 415

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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 - 416 9813/7600-3 27 - 416

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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
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.
13. Install the clutch friction and counter plate
retaining circlip 1.
end float of the pressure end plate and it should
be within the specified limit.
Figure 1122.
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
and the pressure end plate.
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11 - Clutch - Forward (Input) Introduction

Clean ........................................................... 27-423
Check (Condition) ........................................ 27-423 Each gear on the gearbox has an associated clutch
shaft.

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For: PS750 MK4 ..................... Page 27-419

For: PS764, PS766 ................. Page 27-421
(For: PS750 MK4)
Figure 1123.
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
27 - 419 9813/7600-3 27 - 419

27 - Driveline
Table 439.
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
27 - 420 9813/7600-3 27 - 420

27 - Driveline
(For: PS764, PS766)
Figure 1124.
L
J X Y
W
C E
A
P
H
A K
G F V
D U
T R
S
A B
R
N
S
Y T
U
V H
J
Q P
W
M
L
M
N
Q Z
AB
AA
AC
AF
AD
AE
Item Description
Table 440. C Gear
Item Description D Thrust bearing 1
A Piston ring seal 1 (For- E Thin thrust washer 1
ward and reverse clutch F Gear and splined hub 1
only) G Needle roller bearing 1
B Clutch end bearing 1
27 - 421 9813/7600-3 27 - 421

27 - Driveline
Item Description
H Thick thrust washer 1
J Thrust bearing 2
K Thin thrust washer 2
L Friction and counter
plate retaining circlip
M Shim
P Friction plates
Q Counter plates
R Disc spring assembly
S Circlip 2
T Spring retaining plate
U Spring
V Oil baffle
W Piston
X Piston O-ring
Y Shaft O-ring
Z Piston ring seal 2
AA Clutch end bearing 2
AB Thick thrust washer 2
AC Thrust bearing 3
AD Thin thrust washer 3
AF Needle roller bearing 2
27 - 422 9813/7600-3 27 - 422

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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

faces. 1. Light scoring or polishing is permissible, plates
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.
27 - 423 9813/7600-3 27 - 423

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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 - 424 9813/7600-3 27 - 424

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For: PS750 MK4 ..................... Page 27-425

For: PS764, PS766 ................. Page 27-429
(For: PS750 MK4)

Special Tools Description Part No. Qty.
Description Part No. Qty. Spring Compressor 892/00916 1
Hand Pump Pressure 892/00223 1 Tool
Test
27 - 425 9813/7600-3 27 - 425

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Disassemble
Figure 1125.
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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27 - Driveline
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 1126.

grooves. If necessary remove burrs with a
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.
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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27 - Driveline
Figure 1127. 8. Install one counter plate followed by one friction

plate.
9. Install the pressure end plate. Make sure the
the clutch pack.
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: 1.9–2.5mm
17. To disassemble the opposite clutch, carefully Figure 1128.

remove the piston ring seals 2.
18. Remove the bearing 2 with a suitable puller.
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 8.1. Keep them together in sets, do not mix the
to 19. plates with those from other clutches.
23. Carefully align the teeth of the clutch plates using 9. If installed, remove the disc spring assembly.
a thin rod (or screwdriver) and install the gear and
splined hub 2. 10. Put the clutch assembly in a suitable press.
24. Install the needle roller bearing 2. 10.1. With a cut away tube compress the piston
spring and then remove the circlip 2.
25. Install the thrust bearing 3, thick washer 2, and
thin washer 3. Figure 1129.

install the gear and bearing 2 onto the shaft.
27. Install the new piston ring seals 2.
(For: PS764, PS766)

Special Tools
Test
This procedure is the same for the input and reverse

clutch assemblies. If there are any differences it will
be identified in the procedure. 11. Lift off the spring retaining plate.
Disassembly 12. Remove the spring and the oil baffle.
The illustrations show a reverse clutch assembly for 13. Turn the assembly over and knock the clutch
a 6 speed gearbox. 4 speed gearbox clutches have shaft on a piece of aluminium (or wood) to loosen
fewer friction and counter plates. Procedures are the piston.
applicable for both 4 and 6 speed variants.
13.1. If the piston does not loosen, then hand
1. Carefully remove the piston ring seals 1. pump air down the shaft oil inlet hole.
1.1. If the piston ring seals are excessively worn (Qty.: 1)
grooves. If necessary remove burrs with a Figure 1130.
1.2. The input shaft does not have piston ring
seals installed at this end of the shaft.
2. Use a suitable puller and press to remove the
clutch end bearing 1 and the gear.
3. Remove the thrust bearing 1 and thin thrust
washer 1.
6. Remove the friction and counter plates retaining
circlip. 14. Remove the piston.
7. If installed, remove the pressure end plate and 15. Remove and discard the piston O-ring 1.
shim. 16. Remove and discard the shaft O-ring 2.
8. Remove the friction plates and counter plates.
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17. To disassemble the opposite clutch, carefully 19. Remove the thrust bearing 3, thick thrust washer
remove the piston ring seals 2. 2 and thin thrust washer 3.
17.1. The input shaft has four piston ring seals 20. Remove the gear and splined hub 2 assembly
installed at this end of the shaft. with the needle roller bearing 2.
18. Loosen the clutch end bearing 2 and use a 21. Do the steps 5 to 16 to disassemble the opposite
suitable puller to remove it. side clutch assembly.
Figure 1131.
L
J X Y
W
C E
A
P
H
A K
G F V
D U
T R
S
A B
R
N
S
Y T
U
V H
J
Q P
W
M
L
M
N
Q Z
AB
AA
AC
AF
AD
AE
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7.1. Make sure that the disc spring is installed

Table 441. with the teeth towards the clutch pack.
Item Description 7.2. Make sure that the teeth are not aligned with
A Piston ring seal1 (For- the lubrication slots in the housing.
ward and reverse clutch
only) 7.3. In PS760 variant no disc spring is installed.
B Clutch end bearing 1 8. Install one counter plate followed by one friction
C Gear plate.
D Thrust bearing 1 8.1. Continue to install alternate counter and
E Thin thrust washer 1 friction plates, finishing with a friction plate.
F Gear and splined hub 1
G Needle roller bearing 1 9. Install the pressure end plate. Make sure the
H Thick thrust washer 1 the clutch pack.
J Thrust bearing 2
K Thin thrust washer 2 10. Make sure that the teeth are not aligned with the
L Friction and counter
plate retaining circlip 11. Do not install the shim at this stage.
M Shim
circlip.
P Friction plates
Q Counter plates 13. Use a DTI to measure the end float of the
R Disc spring assembly pressure end plate. For PS760 variant the value
should be within the specified range.
S Circlip 1
T Spring retaining plate Dimension: 1.9–2.5mm
U Spring Figure 1132.
V Oil baffle
W Piston
X Piston O-ring
Y Shaft O-ring
Z Piston ring seal 2
AA Clutch end bearing 2
AB Thick thrust washer 2
AC Thrust bearing 3
AD Thin thrust washer 3
AF Needle roller bearing 2
14. If it is necessary to adjust the end float to
Assembly bring it within tolerance, then you can choose
either 6.0mm (0.23in) or 6.5mm (0.25in) thick
1. Install the new piston O-ring onto the piston. pressure end plate, with either a shim or an extra
counter plate between the retaining circlip and
2. Install the new shaft O-ring onto the shaft. the pressure end plate.
3. Lubricate the piston with oil and push fully into 15. Use an airline to check the operation of the
the bore of the clutch housing. clutch.
4. Install the oil baffle and the piston spring. Make 16. Install the thick thrust washer 1, thin thrust
sure that the spring is positioned properly in the washer 2, and the thrust bearing 2.
piston.
17. Use a thin rod (or screwdriver) to carefully align
5. Install the spring retaining plate. the teeth of the clutch plates and install the gear
6. Compress the spring with a cut away tube and and splined hub 1.
secure with circlip 2. 18. Install the needle roller bearing 1.
7. Install the disc spring assembly.
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19. Install the thrust bearing 1 and thin thrust washer

1.
20. Apply gearbox oil on the clutch end bearing then
push the gear and the clutch end bearing 1 onto
the shaft.
21. Install the piston ring seals 1.
21.1. The input shaft does not have piston ring
seals installed at this end of the shaft.
22. To assemble the opposite side clutch do the
steps 1 to 15 again.
23. Use a thin rod (or screwdriver) to carefully align
the teeth of the clutch plates and install the gear
and splined hub 2.
24. Install the needle roller bearing 2.
25. Install the thrust bearing 3, thick thrust washer 2,
and thin thrust washer 3.
26. Apply gearbox oil on the clutch end bearing then
push the gear and the clutch end bearing 2 onto
the shaft.
27. Install the piston ring seals 2.
27.1. The input shaft has four piston ring seals
installed at this end of the shaft.
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Introduction .................................................. 27-433 The solenoid control valves provides the switching
Check (Condition) ........................................ 27-434 for forward drive and reverse drive to select the
Remove and Install ..................................... 27-434 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 27-434
For: PS764, PS766 ................. Page 27-436
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 20L
4000/2603 200L
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
prevent contamination.
7. Remove the valve stem from the gearbox case.
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Figure 1133. 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.
30
6. Use an extended socket to tighten the valve stem
to the correct torque value. Refer to Table 442.
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 442.
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 1134. Table 442. Torque Values

Item Nm
L F 6
J 27
K L 6
M
(For: PS764, PS766)
Remove
1. Put tags on the electrical harness connectors.
L
2. Disconnect the connectors from the solenoids.
3. Clean the area around the solenoid valve block.
Do not allow particles of dirt to fall into the
gearbox.
4. Remove the socket head cap screws along with
the washers and lift off the valve block assembly.
5. Do not use a screwdriver to lift the valve block,
the sealing faces will get damaged.
5.1. If it is difficult to remove the valve block,
lightly tap the manifold block with a soft
faced hammer.
N 6. If any of the individual solenoid valve cartridges
are to be removed, take care not to grip the unit
N by its electrical connector block. The connector
block is not designed as a leverage point.
N
7. Remove and discard the valve block sealing
K Electrical harness connector gasket.
L Retaining bolts
M Valve 7.1. The gasket may disintegrate on removal,
N O-ring seals make sure that all traces are removed and
discarded.
Install
steps.
2. Replace the O-ring seals.
3. Put some clean gearbox oil on the O-ring seals.
30
4. Install the solenoid in the correct orientation.
Refer to Table 442.
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Figure 1135. 6. If any of the individual solenoid valve cartridges

are to be replaced, take care not to grip the unit
by its electrical connector block. The connector
block is not designed as a leverage point.
B 7. Install the electrical harness connectors to the
solenoid valve cartridge connector block.
A Table 443. Torque Values
Item Nm
A 35
D
C
A Capscrews
B Solenoid valve block
C Valve cartridge
D Valve cartridge connector block
Install
1. Install two guide studs at the valve interface on
the front case.
2. Install a new valve block sealing gasket. Care is
needed as the gasket is thin.
Figure 1136.
A
177
/10
813
E Gasket
3. Put the valve block in position against the front
case.
4. Install the socket head capscrews and the
washers.
5. Progressively tighten the screws to the correct
torque value.
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Introduction
The pressure relief valve is a type of valve used to

control or limit the pressure which can build up due

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21 - Pressure Maintenance Valve

(PMV)
Remove and Install
2. Do not allow particles of grit to fall into the

(For: PS750 MK4) gearbox.
3. Remove the plug then the sealing washer, the
Remove spring and the valve spool.
1. Clean the area around the valve and the gearbox
case.
Figure 1137.
B
C
D
A Plug B Sealing washer

C Spring D Valve spool
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Install
At the time of installation do the following step.

Item Description Nm
A Plug 56
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24 - Oil Pump
24 - Oil Pump Check (Condition)

Check (Condition) ........................................ 27-441
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 1138.
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.
surface damage.
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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 0.05L 7. Put some clean, new, oil into the pump at the
Strength) location shown.

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 1139.
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.
4. Apply sealant to the threads of the bolts.
(Medium Strength)
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27 - Speed Sensor
27 - Speed Sensor Introduction

Introduction .................................................. 27-443 The sensor sends a varying frequency signal to
Component Identification ............................. 27-444 the Transmission ECU to determine the current
Operation ..................................................... 27-447 rotational speed of the input shaft or torque
Diagram ....................................................... 27-448 converter. The ECU uses the input shaft speed to
determine the slippage across the torque converter
Remove and Install ..................................... 27-450 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.
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27 - Speed Sensor
For: PS750 MK4 ..................... Page 27-444 (For: PS750 MK4)

For: PS764, PS766 ................. Page 27-445
Figure 1140. Location
A
A Ground speed sensor
Figure 1141. 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)
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27 - Speed Sensor
(For: PS764, PS766)
A Ground speed sensor B Input speed sensor
Figure 1143. 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)
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27 - Speed Sensor
Figure 1144. Input Speed Sensor
B A
A Earth B Power
C Signal output
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27 - Speed Sensor
Operation
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 - Speed Sensor
Diagram
For: PS750 MK4 ..................... Page 27-448 3 Signal A - output (white)

For: PS764, PS766 ................. Page 27-449 4 Signal B - power (orange)
5 Signal B- earth (brown)
6 Signal B - output (yellow)
(For: PS750 MK4)
Figure 1145. Ground Speed
Sensor Internal Schematic
1
5
R R 3
A 6
B 2
4
A Sensor element
B Diagnostic element
R Resistor
1 Signal A - power (red)
2 Signal A - earth (black)
Figure 1146. Speed Sensor Connections
ECU J1
ECU J2
6
3 1
5 4 F
ECU J5
2
B +
A Hydraulic control ECU (Electronic Control Unit) B Ground speed sensor

F Fuse
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27 - Speed Sensor
(For: PS764, PS766) 4 Signal B - power (orange)

5 Signal B- earth (brown)
Figure 1147. Ground Speed 6 Signal B - output (yellow)
1 Figure 1148. Input Speed
5
B
R
R R R
3 C
A 1
6
R
R
B 2
4 2
A
A Sensor element
B Diagnostic element
R Resistor
1 Signal A - power (red) A Earth
2 Signal A - earth (black) B Power
3 Signal A - output (white) C Signal output
R Resistor
1 Sensor element
2 Diagnostic element
Figure 1149. Speed Sensor Connections
ECU
A
A
B
C
D
ECU J2
6
3 1
5 4 F
ECU J5
2
C +
B
A Transmission ECU B Hydraulic control ECU

C Ground speed sensor D Input speed sensor
F Fuse
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27 - Speed Sensor
Remove and Install
For: PS750 Mk4, PS750 MK4 3. Do not allow particles of grit to fall into the
................................................. Page 27-450 gearbox.
For: PS764, PS766 ................. Page 27-451
4. Remove the screw 1.
(For: PS750 Mk4, PS750 MK4) 5. Remove the speed sensor 1 from the housing.
Speed sensors are installed depending on the Install

machine application. The gearbox has provision for
two speed sensors. 1. Installation is the opposite of the removal
procedure. At the time of installation do the
Speed sensor 1 following steps.
2. If the O-ring 1 is damaged replace it with a new
Remove one.
1. If connected, disconnect the speed sensor 3. Install the screw 1.
electrical connector.
4. Tighten the screw 1 to the correct torque value.
2. Clean the area around the speed sensor.
Figure 1150.
B
A
G B
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27 - Speed Sensor
5. Install the screw 2.
Table 446. 6. Tighten the screw 2 to the correct torque value.

Item Description Table 447. Torque Values
A Speed sensor 1
Item Description Nm
B Speed sensor 2
C Screw 1 28
C Screw 1
E Screw 2 12
D O-ring 1
E Screw 2
F O-ring 2 (For: PS764, PS766)
G Shims or spacers
Speed sensors are installed depending on the
Speed sensor 2 machine application. The gearbox has provision for
two speed sensors.
Remove
Speed sensor 1
1. If connected, disconnect the speed sensor
electrical connector. Remove
2. Clean the area around the speed sensor. 1. If connected, disconnect the speed sensor
gearbox. 2. Clean the area around the speed sensor.
4. Remove the screw 2. 3. Do not allow particles of grit to fall into the
gearbox.
5. Remove the speed sensor 2 from the housing.
4. Remove the screw 1.
6. If installed remove the shims or the spacers with
the sensor 2. 5. Remove the speed sensor 1 from the housing.
Install Install
1. Installation is the opposite of the removal 1. Installation is the opposite of the removal
procedure. At the time of installation do the procedure. At the time of installation do the
following steps. following steps.
2. If the O-ring 2 is damaged replace it with a new 2. If the O-ring 1 is damaged replace it with a new
one. one.
3. If the spacers or the shims were removed replace 3. Install the screw 1.
them correctly.
4. The speed sensor may be damaged or fail to
operate correctly if it is not at the correct distance
inside the housing.
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27 - Speed Sensor
Figure 1151.
B
A
G B

Table 448. gearbox.
Item Description 4. Remove the screw 2.
A Speed sensor 1 (Input
Speed) 5. Remove the speed sensor 2 from the housing.
B Speed sensor 2 (Ground
6. If installed remove the shims or the spacers with
Speed)
the sensor 2.
C Screw 1
D O-ring 1 Install
E Screw 2
1. Installation is the opposite of the removal
F O-ring 2
procedure. At the time of installation do the
G Shims or spacers following steps.
Speed sensor 2 2. If the O-ring 2 is damaged replace it with a new

one.
Remove 3. If the spacers or the shims were removed replace
them correctly.
1. If connected, disconnect the speed sensor
2. Clean the area around the speed sensor.
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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.

Item Description Nm
C Screw 1 28
E Screw 2 12
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Introduction .................................................. 27-454 The transmission pressure sensor is a form of switch
Component Identification ............................. 27-455 that closes an electrical contact when a certain
Remove and Install ..................................... 27-456 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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Component Identification (For: PS764, PS766)

For: PS750 MK4, SS700 MK2 Figure 1154. Location
................................................. Page 27-455
For: PS764, PS766 ................. Page 27-455 A
(For: PS750 MK4, SS700 MK2)

A Transmission Oil Pressure Switch

Figure 1153. Wires and Connectors
A B
2 1
A Instrument panel
B Transmission Oil Pressure Switch

A B
2 1
A Instrument panel
B Transmission Oil Pressure Switch
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For: PS750 MK4, SS700 MK2 1. Installation is the opposite of the removal
................................................. Page 27-456 procedure. At the time of installation do the
For: PS764, PS766 ................. Page 27-457 following steps.
2. The oil pressure switch is non serviceable. If it is
(For: PS750 MK4, SS700 MK2) faulty or damaged, it must be replaced with new
one.
Remove 3. Replace the sealing washer.
1. Clean off all debris, dirt and grit from around the 4. Tighten the pressure switch to the correct torque
pressure switch. value.
2. There must be no signs of debris, dirt or grit
inside the gearbox.
Item Description Nm
3. Remove the pressure switch and discard the
A Pressure switch 16
sealing washer.
4. Put caps on all the open ports of the gearbox.
Figure 1156.
A Pressure switch
B Sealing washer
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27 - Driveline
(For: PS764, PS766) 4. Disconnect the harness electrical connector from

the switch.
Remove 5. Remove the switch and discard the sealing
washer.
Figure 1157.
A
Install
B
steps.
2. The switch is non serviceable. If it is faulty or
damaged, it must be replaced with new one.
4. Tighten the switch to the correct torque value.
Refer to Table 451.

Item Nm
A 10

B Seal
C Transmission Oil Pressure harness electrical
connector
switch.
inside the gearbox.
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27 - Driveline

Introduction .................................................. 27-458 The transmission oil temperature sensor sends
Technical Data ............................................. 27-459 an analog signal to the instrument panel ECU
Component Identification ............................. 27-462 (Electronic Control Unit) to warn if the transmission
Remove and Install ..................................... 27-465 oil temperature is outside of specified limits.
The resistance of the sensor will change according

to the temperature of the oil - therefore the signal
to the ECU will change. The ECU will calculate the
resistance and the temperature that is sensed by the
sensor. For resistance and temperature values refer
to Technical Data (PIL 27-06-33).
If outside of the specified limits the instrument panel

ECU will broadcast a message on the machine
CAN (Controller Area Network)bus to other machine
ECUs and fault codes and displays will be triggered
to prevent damage to the transmission.
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Technical Data
For: PS750 MK4 ..................... Page 27-459

For: PS764, PS766 ................. Page 27-459
(For: PS750 MK4)

Table 452. Sensor Resistance Values
Temperature °C (°F) Sensor Resistance Ω
-40 89,665
-30 47,304
-20 26,017
-10 14,862
0 8,790
10 5,365
20 3,372
30 2,176
40 1,439
50 973
60 672
70 473
80 339
90 247
100 183
110 137
120 104
130 80
140 63
150 49
(For: PS764, PS766)
540-170 and 540-140 Machines

-40 89,665
-30 47,304
-20 26,017
-10 14,862
0 8,790
10 5,365
20 3,372
30 2,176
40 1,439
50 973
60 672
70 473
80 339
90 247
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27 - Driveline

100 183
110 137
120 104
130 80
140 63
150 49
Other Machines

-40 332,094
-35 239,900
-30 175,200
-25 129,287
-20 96,358
-15 72,500
-10 55,046
-5 42,157
0 32,554
5 25,339
10 19,872
15 15,698
20 12,488
25 10,000
30 8,059
35 6,535
40 5,330
45 4,372
50 3,605
55 2,989
60 2,490
65 2,084
70 1,753
75 1,481
80 1,256
85 1,070
90 915.4
95 786
100 677.3
105 585.7
110 508.3
115 442.6
120 386.6
125 338.7
130 297.7
135 262.4
140 231.9
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27 - Driveline

145 205.5
150 182.6
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27 - Driveline
For: PS750 MK4, SS700 MK2

................................................. Page 27-462
For: PS764, PS766 ................. Page 27-464
B A
A Transmission Oil Temperature Sender B Transmission Oil Cooler
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27 - Driveline
2 1
1 2
Figure 1160.
ECU
A Transmission ECU (Electronic Control Unit)

B Transmission Oil Temperature Sender
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(For: PS764, PS766)

A Transmission Temperature Sender

1 2
ECU
2
1
1 Transmission ECU
2 Temperature Sender
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Remove and Install
For: PS750 MK4, SS700 MK2

................................................. Page 27-465
For: PS764, PS766 ................. Page 27-466
Remove
Figure 1163.
C B
A Temperature Sender harness electrical B Temperature Sender

connector
C Transmission Oil Cooler
1. Make the machine safe. Refer to (PIL 01-03). Install

2. Access to the transmission oil cooler is made 1. The installation procedure is the opposite of the
easier if the engine cover base is removed. Refer removal procedure. Additionally do the following
to (PIL 06-06-06). steps.
3. Clean off all debris, dirt and grit from around the 2. The sender is non serviceable. If it is faulty or
sender. damaged, it must be replaced with new one.
4. Disconnect the harness electrical connector from 3. Replace the sealing washer.
the sender.
4. Tighten the sender to the correct torque value.
5. When removing the sender there may be some Refer to Table 455.
transmission oil spillage.
6. Remove the sender from the oil cooler.
Item Nm
7. Put caps on all the open ports of the cooler. B 27
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(For: PS764, PS766) 4. Disconnect the harness electrical connector from

the switch.
Remove 5. Remove the switch and discard the sealing
washer.
Figure 1164.
A
Install
B
steps.
2. The switch is non serviceable. If it is faulty or
damaged, it must be replaced with new one.
4. Tighten the switch to the correct torque value.
C Refer to Table 456.

Item Nm
A 16
A Temperature Switch
B Seal
C Temperature Switch harness electrical
connector
switch.
inside the gearbox.
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39 - Filter
Introduction .................................................. 27-467 The transmission filter is designed to filter all the
Remove and Install ..................................... 27-468 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 20L
4000/2603 200L
For draining the gearbox, refer to Gearbox, Drain and

Fill (PIL 27-06).
Remove
1. Clean the area around the filter. Do not allow
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 1165.
A Gearbox filter
B Seal
Assemble
1. Smear the seal with transmission oil.
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27 - Driveline

Remove and Install ..................................... 27-470 large and coarse particles entering the transmission
system.
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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 1166.
A Strainer
B Bolts
D Gasket
Install
1. Install the strainer and a new gasket.
threads of the bolts. Tighten the bolts to the
(Medium Strength)
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Introduction .................................................. 27-471 A piston ring is a split ring that fits into a groove on
Remove and Install ..................................... 27-472 the outer diameter of a piston
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Remove and Install
Remove
1. Refer to the relevant Clutch - Disassemble and
Install
1. Wind the PTFE piston ring seal around your
finger as shown, so that the seal forms a coil.
Figure 1167.

Figure 1168.

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27 - Driveline
47 - Oil Seal

Introduction .................................................. 27-473 Oil seals close spaces between components in
Remove and Install ..................................... 27-474 mechanical systems, they are designed to:

system
system
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27 - Driveline
47 - Oil Seal

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
2. Remove the yoke and the washer, refer to back of the housing.
Gearbox, Yoke- Remove and Install (27-06-95).
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 1169.
torque value.

Item Nm
B 400
A Yoke
B Stake nut
C Oil seal
E Washer
F Locking ring
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27 - Driveline
52 - Driveshaft
52 - Driveshaft Introduction
Remove and Install ..................................... 27-476 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.
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27 - Driveline
52 - Driveshaft
Remove and Install
1.2. Draw the pump away from the gearbox,

(For: PS764, PS766) disengage the drive shaft.
1.3. Lift the pump clear.
Remove
2. Remove the circlip and the bearing.
1. If the main hydraulic pump has not already been
removed proceed as follows: 3. Remove the driveshaft.
1.1. Support the pump, and remove the bolts. 4. Remove the sealing ring from the shaft.
Figure 1170.
A
A
B E
F
C
A Bolts B Pump
C Circlip D Ball bearing
E Driveshaft F Sealing ring
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52 - Driveshaft
Install
1. Install a new sealing ring to the shaft.
2. Apply clean oil to the sealing ring and install the
shaft inside the gearbox.
3. Apply clean oil to the ball bearing.
4. Install the bearing followed by the circlip.
5. Install the pump as follows:
5.1. Engage the pump with the driveshaft.
5.2. Support the pump and install the bolts.
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54 - Main Shaft
54 - Main Shaft Introduction

Introduction .................................................. 27-478 The main shaft receives its power from the engine
Check (Condition) ........................................ 27-479 and transmits the power to other components in the
Remove and Install ..................................... 27-479 gearbox.

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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)
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 1171.
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.
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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 1172.
P
V
K
V
M V
V
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
V Bearing outer cups 2
W Main shaft bearing outer cup
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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.
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57 - Input Shaft
57 - Input Shaft
Introduction

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27 - Driveline
58 - Output Shaft
58 - Output Shaft Introduction

Introduction .................................................. 27-483 In the gearbox, the input and output shafts lie along
Calibrate ...................................................... 27-484 the same line, and are sometimes combined into a
Remove and Install ..................................... 27-485 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.
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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 MK4 ..................... Page 27-485 Figure 1173.

For: PS764, PS766 ................. Page 27-489
B
A
(For: PS750 MK4)
Special Tools
Setting Tool Kit 892/00918 1
Flange Spanner 992/04800 1 D
End Float Setting Tool 993/70100 1 H E
Kit
(10-100Nm) J
Remove K
Before removing the output shaft and its bearings
remove all the clutch assemblies.
1. Remove the output shaft as follows: Refer to

Figure 1173.
1.1. Hold the brake disc (or output yoke) with the
service tool.
1.2. Remove the output shaft nut.
Special Tool: Flange Spanner (Qty.: 1)
1.3. Support the output shaft from inside the
case and remove the brake disc (or output
yoke). F
1.4. Remove the output shaft.
1.5. Remove and discard the oil seal. G
C
1.6. Remove the outer taper roller bearing.
1.7. Remove the spacer and keep for assembly.
1.8. Use a suitable puller to remove the output
shaft inner bearing.
A Brake disc
1.9. If required, the park brake bracket can B Output shaft nut
be removed at this stage. Before removal, C Output shaft
mark the position of the bracket with respect D Oil seal
to the case. E Outer taper roller bearing
1.10. Note: Due to different ratio options, some F Spacer
gearboxes may have a larger diameter G Inner taper roller bearing
output gear. When you remove the output H Bolt 1
shaft the gear may touch the gearbox J Park brake bracket
housing, preventing removal. Refer to K Rear case
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: Refer to Figure
1174.
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27 - Driveline
58 - Output Shaft
H E
M
J
L K
H Bolt1
J Park brake bracket
K Rear case
L 82mm
M 75mm
1.1. Put the bracket in position marked during
disassembly.
F
1.2. Attach the park brake bracket with the bolts
1.
1.3. Tighten the bolts to the correct torque value. C
1.4. Drill a hole of the specified diameter at the G
location shown to enable the installation of
the service tool for checking the end float.
Dimension: 12.5mm
C Output shaft
Special Tool: End Float Setting Tool Kit
D Oil seal
(Qty.: 1)
E Outer taper roller bearing
2. Pre-assemble the output shaft as follows: Refer F Service spacer
to Figure 1175. G Inner taper roller bearing
K Rear case
2.1. Apply oil on the inner bearing and cup and
install on the output shaft.
2.2. Install the bearing cups into the case.
2.3. Install the service spacer onto the output
shaft and install the output shaft into the
case.
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 1176.
Special Tool: Setting Tool Kit (Qty.: 1)
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27 - Driveline
58 - Output Shaft
3.2. Tighten the service tool nut to the correct Figure 1177.
torque value.
Torque: 50N·m S
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 1176.
Q T
S DTI
P T Torque wrench
3.7. Select the right size spacer based on the
N example given in the table. Refer to Table
459.
3.8. Note: If the measurement obtained is
outside the spacer kit range, then check the
assembly of the bearings.
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.
N Service tool sleeve
P Service tool nut Torque: 50N·m
Q Support pillar 3.12. Make sure that there is no end float and
R Bolt2 the rolling torque is less than the specified
3.5. Install the DTI (Dial Test Indicator). Refer to value.
Figure 1177. Torque: 1.5N·m
3.6. Set the torque wrench to the specified value 3.13. If the rolling torque exceeds the specified
and measure the end float while you rotate value then check that the output shaft is
the output shaft. installed correctly.
Torque: 35N·m 3.14. If the rolling torque is too high, install the
Special Tool: Torque Wrench (10-100Nm) next largest spacer.
(Qty.: 1)
3.15. If the rolling torque is too low, install the
next smallest spacer.
3.16. Remove the service tool nut and the
service tool sleeve.
4. Output shaft final assembly. Refer to Figure 1178.
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27 - Driveline
58 - Output Shaft
Figure 1178. 4.4. Install the brake disc (or output yoke) with
reference to the alignment marks made
A B during disassembly.
4.5. Note: Do not excessively hammer the disc
during assembly or damage to the shaft
bearings could occur. If necessary, press
D fit the parts. Fully support the shaft during
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.
A Brake Disc Torque: 2N·m
B Output shaft nut
F Oil seal 4.9. If the rolling torque is too high, install the
next largest spacer.
4.1. Lubricate the seal lips of a new oil seal.
4.10. If the rolling torque is too low, install the
4.2. Install the new oil seal. next smallest spacer.
4.3. Make sure that the seal is pushed square to 4.11. Stake the nut into the slot in the shaft with
the housing. a square ended staking tool.

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
H 166
Output Shaft Removal - Larger Diameter bearing inner cup and taper rollers will be forced
Gears partially up the output shaft, it will not be possible
to remove them at this stage.
In the event that the output gear fouls against the
2. Pull the output shaft up and position suitable
gearbox housing at position 1 when attempting to
spacers between the taper rollers and bearing
remove the output shaft, proceed as follows:
outer cup as shown.
Note: The following procedure will be required 3. Push the output shaft down again, the inner cup
when dismantling the gearbox, and also after initial and taper rollers will be forced further up the shaft
assembly, since the output shaft will need to be allowing them to be removed.
removed when setting the end float.
4. If the inner cup and taper rollers are still engaged
To enable the output shaft removal past the case at on the output shaft repeat steps 2 and 3 using
position 1, the bearing inner cup and taper rollers thicker spacers.
must first be removed from the output shaft.
5. With the bearing inner cup and taper rollers
1. Push the output shaft down until the gear removed, the output shaft and gear can be
contacts the housing at position 1, take care not lowered and tilted to one side, allowing the gear
to damage the housing or gear. Although the to clear the housing and the shaft to be removed.
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27 - Driveline
58 - Output Shaft
Figure 1179. Remove

1. Remove the pressure maintenance valve as
follows:
C C 1.1. Remove the plug.
1
1.2. Remove the spring and valve spool from the
2 rear case.
2. If required, remove the speed sensor as follows:
2.1. Remove the bolt 1.
2.2. Remove the sensor and its O-ring from the
3 rear case.
3. Hold the output yoke with the service tool.
A
4. Remove the bolt 2 and the thick washer.
4.1. The bolt is very tight, the help of an assistant
will be required.
B
1 Output shaft 5. Remove the yoke.
2 Taper rollers
3 Bearing outer cup 6. Remove and discard the oil seal. Make sure that
A Gear you do not damage the seal housing.
B Position 1
7. Support the transfer gear shaft assembly and
C Spacers
remove the gear from inside the rear case.
Note: If the output shaft is being removed after initial 8. The gear assembly will come down along with
assembly, typically to set the end float, take extreme the following components:
care to avoid damage to the bearing outer cup and
inner cup and taper rollers. Use only soft spacers 8.1. Inner taper roller bearing.
such as aluminium, Do not use hardened steel items
such as screwdrivers. 8.2. Inner taper bearing outer cup.
8.3. Solid spacer.
If the bearing is damaged a new bearing MUST be
installed. The tolerance difference between the new 9. Remove the outer taper rolling bearing and the
bearings is expected to be less than the difference outer bearing outer cup.
between the solid spacer sizes so changing a
bearing should not affect the end float. 9.1. Note: If the inner and outer taper roller
bearings are to be used again, keep the
bearings together with their respective outer
(For: PS764, PS766) cups in their original relationships.
Special Tools 9.2. Put tags on the bearings to make sure that
assembly of them in their original positions.
Drive Coupling 892/00812 1 9.3. If any of the two bearings is worn or
Spanner damaged, both the bearings must be
Transfer Gear 892/01083 1 replaced and a new solid spacer be
Assembly Tool selected and installed.
Bearing Assembly Tool 892/01084 1 10. Remove the layshaft bearing outer cup from the
rear case.
Before Removal
1. Remove the front case and the clutch shafts.
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27 - Driveline
58 - Output Shaft

F
G H
R
P
E
Q
D
R Layshaft bearing outer cup
C
M
B
N
A
L
K
A Plug
B Spring
C Spool
D Bolt 1
E Speed sensor
F Bolt 2
G Thick washer
H Yoke
J Oil seal
K Transfer gear shaft assembly
L Inner taper roller bearing
M Inner bearing outer cup
N Solid spacer
P Outer taper roller bearing
Q Outer bearing outer cup
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27 - Driveline
58 - Output Shaft
Install 3. Measure the transfer gear output shaft assembly

end float as follows: Refer to Figure 1183.
1. Install the layshaft outer bearing cup into the rear
case. Figure 1183.
2. Assemble the transfer gear output shaft as

follows:
2.1. Install the outer bearing outer cup into the Z
case. U
2.2. Apply oil onto the inner taper bearing. V
2.3. Push the inner bearing onto the transfer
gear/shaft. W
X
2.4. Install a service spacer of the specified
dimension. T
Dimension: 13.7mm
2.5. Install the inner bearing outer cup into the
case.
Y
2.6. Put the transfer gear assembly in position
against the case from inside. Z
2.7. Use the service tool to hold the transfer gear V
in position. Refer to Figure 1182.
Special Tool: Transfer Gear Assembly Tool
(Qty.: 1) X
Figure 1182.
S
K
T Service tool sleeve

U Service tool 1
V Service tool 2
W Bolt 3
X Support bracket
Y DTI
Z Torque wrench
3.1. Install the service tool sleeve over the
H Transfer gear transfer output shaft and secure with the
S Transfer gear retaining tool service tool 1.
3.2. Tighten the service tool 1 to the correct
2.8. If the gear is not held in position torque value.
the bearings may get damaged during
assembly. Torque: 50N·m
2.9. Apply oil onto the outer bearing. 3.3. Temporarily loosen the service tool sleeve.
2.10. Use the service tool to push the outer 3.4. Install the support bracket to the gearbox
bearing into the rear case. case.
Special Tool: Bearing Assembly Tool (Qty.: 3.5. Install the service tool 2 so that the fork end
1) engages in the groove of the service tool 1.
2.11. Do not install the oil seal at this stage. 3.6. Tighten the bolt 3 to secure the service tool
2 to the support bracket.
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27 - Driveline
58 - Output Shaft
3.7. Install a DTI to measure the end float of the 3.19. Remove the service tool 1 and the service
output shaft. tool sleeve.
3.8. Set the torque wrench to the specified 4. Transfer gear output shaft final assembly.
torque value and measure the end float
while you rotate the output shaft. 4.1. Use special tool to install a new oil seal.
Make sure the seal is pushed square to the
3.9. Select the right size spacer based on the
housing.
example given in the table. Refer to Table
461. 4.2. Install the yoke, the thick washer and the
bolt 2.
3.10. Note: If the measurement obtained is
outside the spacer kit range, then check 4.3. Hold the yoke with the tool.
the assembly of the bearings.
Special Tool: Drive Coupling Spanner (Qty.:
3.11. Disassemble the service tools and install 1)
the correct size spacer. Assemble the
4.4. Tighten the bolt to the correct torque value.
transfer gear output shaft.
4.5. The combined seal and bearing rolling
3.12. Install the service tool sleeve over the
torque should not exceed the specified
output shaft and secure with the service
value when fully torque tightened provided,
tool 1.
the correct size spacer has been selected.
3.13. Tighten the service tool 1 to the correct Torque: 2N·m
torque value.
Torque: 50N·m 5. If removed, install the speed sensor as follows:
3.14. Make sure that there is no end float and 5.1. Install the O-ring on the sensor. Make sure
the rolling torque is less than the specified that it is correctly installed.
value.
5.2. Attach the sensor with the bolt 1.
Torque: 1.5N·m
5.3. Tighten the bolt 1 to the correct torque
3.15. If the rolling torque exceed the specified value.
value then check that the output shaft is
installed correctly. 6. Install the pressure maintenance valve as
follows:
next largest spacer. 6.1. Apply oil to the spool and install to the case.
3.17. If the rolling torque is too low, install the 6.2. Install the spring.
next smallest spacer.
6.3. Use a new sealing washer and install the
3.18. Use the service tool to hold the transfer plug.
gear in position. Refer to Figure 1182.
6.4. Tighten the plug to the correct torque value.

Service spacer 13.7
Subtract end float obtained at step 3.7 0.41
Total 13.29
Subtract bearing tolerance and pre-load 0.12
Result 13.17
Use next smallest spacer i.e. 13.15
After Installation
1. Instal the clutch shafts and the front case.

Item Nm
A 56
D 28
F 300
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27 - Driveline
81 - Mount
81 - Mount
Check (Condition)
in good condition.
Refer to (PIL 72).
as necessary.
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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 1184.
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.

Item Description Nm
C Adaptor bolts 1 26.5
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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 1185.
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.

Item Description Nm
S Adaptor bolts 2 26.5
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27 - Driveline
90 - Front Case

Consumables
Clean ........................................................... 27-496
Check (Condition) ........................................ 27-497
Remove and Install ..................................... 27-497 - General purpose
solvent based parts
cleaner
1. Carefully remove all traces of gasket or gasket

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.
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90 - Front Case

Consumables For: PS750 MK4 ..................... Page 27-497
Description Part No. Size For: PS764, PS766 ................. Page 27-500
Strength)
(For: PS750 MK4)
Consumables
1. If the gearbox cases are to be renewed, be Description Part No. Size
sure to install blanking plugs and adaptors as JCB Multi-Gasket 4102/1212 0.05L
required. Inspect the original cases and identify
the blanking plug and adaptor positions. Transfer
the plugs and adaptors to the new cases. Apply Before removal
JCB Threadlocker and Sealer to the threads
before installation. Before splitting the front and rear case do the
following procedures.
(Medium Strength) • Remove the oil filter. Refer to (PIL 27-06-39).
• Remove the suction strainer. Refer to (PIL
27-06-40)
• Remove the solenoid control valves. Refer to
(PIL 27-06).
• Remove the 4WD (Four Wheel Drive) yoke and
seal. Refer to (PIL 27-06-95).
• Remove the speed sensors. Refer to (PIL
27-06-27).
• Remove the torque converter relief valve. Refer
to (PIL 27-14-09).
Cleanliness is of the utmost importance when you

service the gearbox. All precautions to prevent any
• 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.
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
cradle.
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27 - Driveline
90 - Front Case
Figure 1186. 2. Use lifting equipment to carefully lift off the rear
case.
3. Remove the shaft bearing outer cups. The cups
will be left on the bearings, or inside the front
case.
Figure 1188.
H
H
H H
A H
A Cradle
Remove the external oil feed pipe. Refer to (PIL

27-06-85).
J
Remove
J
Front and rear case
1. Remove all the case fixing screws. H Bearing outer cups
J O-ring seals
Figure 1187.
4. Keep the cups with their associated bearings.
5. Remove and discard the O-ring seals from the
front case.
F After removal
Remove the oil transfer pipe. Refer to (PIL 27-06-86).
Remove the clutch assemblies - refer to the following

procedures:
E • Mainshaft - (including layshaft clutch assembly,

2WD (Two Wheel Drive) / 4WD clutch
assembly, reverse clutch assembly, mainshaft
F clutch assembly and forward/input clutch
assembly) - refer to (PIL 27-06-54).
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)
G • Layshaft clutch - refer to (PIL 27-06-08)
• Mainshaft clutch - refer to (PIL 27-06-09)
E Case fixing screws (x22) • Forward / input clutch - refer to (PIL 27-06-11)
F Rear case
G Front case
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27 - Driveline
90 - Front Case
Before installation Figure 1190.

• If you remove the output shaft and bearing then
install them. Refer to (PIL 27-06-58).
• Make sure the clutch assemblies are correctly
J
assembled and are free from defects. Refer to
(PIL 27-06). J
• Replace the clutch shaft piston ring seals with
new ones. Make sure that the piston ring seals X
are correctly installed in the shaft grooves.
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 1189.
J O-ring seals
X Friction counter plates
Y JCB Multigasket
2. Apply a continuous bead of JCB Multigasket to
the front case mating face.
A 3. Use two small rods or screwdrivers to align all the
friction counter plates in the main shaft clutch.
4. Use suitable lifting equipment to carefully lower
A Cradle the rear case and to align the output gear splines
with the main shaft clutch friction plates.
Clean and check the condition of all components
before you install them.
Install the oil transfer pipe. Refer to (PIL 27-06-86).
Install the clutch shaft assemblies. Refer to (PIL

27-06).
Install the front and rear case

1. Install new O-ring seals in the front case.
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27 - Driveline
90 - Front Case
Figure 1191. The Disassembly and Assembly procedures given

illustrate and describe the 6x4 gearbox. Procedures
for the 4x4 version of the gearbox are identical
in most respects. Where there are differences,
procedures are identified under the heading 4x4
Gearbox.
F
With the gearbox removed from the machine, place
assembly. If the gearbox is installed with an integral
park brake the brake assembly must be removed
before you disassemble the gearbox. Refer to (PIL
27-06).
E
Gearboxes compatible with a lock-up torque
converter are installed with a control valve and
F interconnecting pipe. These components must be
removed before dismantling the gearbox.
Disassemble
1. Remove the main hydraulic pump and driveshaft.
2. Remove the solenoid control valve. Refer to (PIL
G 27-06-15).
E Case fixing screws (x22) 3. Use suitable lifting equipment to put the gearbox
F Rear case in a work cradle. Refer to Figure 1192.
G Front case Special Tool: Gearbox Assembly Cradle (Qty.: 1)
5. If necessary rotate the output shaft a small 3.1. Clamp the gearbox at the three clamping
amount to align the splines. points on the rear case.
6. Apply sealant to the threads of the case fixing Figure 1192.
bolts and install them.
After installation
Install the external oil feed pipe.

Item Description Nm A
E Case fixing screws 56
A Clamping points (x3)
(For: PS764, PS766) 4. Do not attempt to disassemble the gearbox

further until it is safely positioned in a suitable
Special Tools work cradle.
5. Remove the torque converter housing as follows:
Gearbox Assembly 892/01082 1 Refer to Figure 1193.
Cradle
Consumables
Strength)
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27 - Driveline
90 - Front Case
C F
D
F Front case
G Bolt 2
E
8.2. With suitable lifting equipment carefully lift
B Bolt1 the front case.
C Torque converter housing
8.3. Make sure you remove all the shaft bearing
D O-ring 1 (x5)
outer cups.
E O-ring 2 (x3): Only for lock-up torque converter
variants 8.4. The cups may be left on the bearings, or
inside the front case. Keep the cups with
5.1. Remove the bolts 1. their relative bearings.
5.2. Lift off the housing. 8.5. Remove and discard the sealing O-rings
5.3. Remove and retain the O-rings 1 (x5). from the front case.
5.4. For lock-up torque converter variants: 8.6. Remove the oil transfer pipes from the front
Remove and retain the O-rings 2 (x3). case only when they are damaged or the oil
is contaminated. Refer to Figure 1195.
6. Remove the gearbox oil pump. Refer to (PIL
27-06-24).
7. Remove the 4WD clutch assembly. Refer to (PIL
27-06-07).
8. Separate the front and rear cases as follows:
8.1. Remove the bolts 2 that attach the cases.
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27 - Driveline
90 - Front Case
Figure 1195. 9.3. Forward/Input clutch shaft.

9.4. Layshaft clutch.
H 9.5. Main shaft clutch.
10. Remove the bearing outer cups from the rear
case and centre of the transfer gear. Refer to
Figure 1197.
Figure 1197.
R
Q S
T
H Transfer pipes (x3)

9. Carefully remove the clutch shaft assemblies in
the sequence given below: Refer to Figure 1196.
Figure 1196.
L M K Q Bearing cups
N R Rear case
S Transfer gear
P T Layshaft bearing cup
11. The layshaft bearing cup cannot be removed until
the transfer gear output shaft has been removed.
12. Keep the bearings cups together with their
relative bearings.
Install
1. Make sure that the sealing rings (x4) on the
clutch pack shafts are in good condition and
lubricated with oil.
2. Install the bearing outer cups at their correct
positions in the rear case and centre of the
J transfer gear.
J O-rings 3 3. Install the clutch shaft assemblies in the
K 6 Speed clutch (not installed on 4x4 gearbox) sequence given below: Refer to Figure 1198.
L Reverse clutch unit
M Forward/Input clutch shaft
N Layshaft clutch
P Main shaft clutch
9.1. 6 Speed clutch (not installed on 4x4
gearbox).
9.2. Reverse clutch unit.
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27 - Driveline
90 - Front Case
Figure 1198. 5.1. Make sure that the O-rings are correctly
installed to the rear case. Refer to Figure
L M K 1198.
N 5.2. Apply a thin bead of sealant to the rear case
mating face as shown in the figure. Refer to
P
Figure 1200.
Figure 1200.
J O-rings 3 V
K 6 Speed clutch (not installed on 4x4 gearbox) V Sealant
L Reverse clutch unit
M Forward/Input clutch shaft 5.3. Make sure that the shaft bearing outer cups
N Layshaft clutch are correctly installed in the front case.
P Main shaft clutch 5.4. Carefully lower the front case over the
3.1. Main shaft clutch. clutch shafts until it mates with the rear
case. Do not use excessive force when you
3.2. Layshaft clutch. Take care not to damage install the case.
the rear bearing on the transfer gear teeth
when you install the layshaft clutch. 5.5. Install the bolts 2 that attach the cases
together. Refer to Figure 1201.
3.3. Forward/Input clutch shaft.
Figure 1201.
3.4. Reverse clutch unit.
3.5. 6 Speed clutch (not installed on 4x4 F
gearbox).
4. Before you install the rear case make sure that
the sealing rings (x4) on the clutch pack shafts
are in good condition and lubricated with oil.
Figure 1199.
U
G
F Front case
G Bolt 2
U Sealing rings (x4)
5. Assemble the front and rear cases as follows:
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27 - Driveline
90 - Front Case
6. Measure the end float of the clutch shafts except 7.2. The end float of the shaft should be within
the input shaft as follows: Refer to Figure 1202. the specified range.
6.1. For 4x4 gearbox: Remove the plug 1. Length/Dimension/Distance: 0.02–0.16mm
6.2. For 6x4 gearbox: Remove plug 1 and plug 8. Provided components are assembled correctly
2. the end float will be within the limits given. Check
that the shafts can be rotated by hand (turn the
6.3. Install a bolt to the threaded hole in the end input shaft and output yoke). The shafts should
of the shaft. rotate smoothly. The end floats can be checked
6.4. Pull the bolt to detect excessive end float. to confirm correct assembly.
Remove the bolt.
9. Install the 4WD clutch assembly.
6.5. The end float of the shafts should be within
the specified range. 10. Install the gearbox oil pump.
Length/Dimension/Distance: 0.02–0.16mm 11. Install the torque converter housing as follows:
6.6. Apply sealant to the plug 1 and plug 2 (for Refer to Figure 1203.
6x4 gearbox only).
11.1. Make sure that the front case and torque
Consumable: JCB Threadlocker and Sealer converter housing mating faces are clean,
(Medium Strength) dry and not damaged.
6.7. Tighten the applicable plugs to the correct 11.2. Install the O-rings 1 (x5) to the front case.
torque value.
11.3. For gearboxes installed with lock up
Figure 1202. torque converter: Install the O-rings 2 (x3)
to the front case.
L W X K
M N Figure 1203.
E
P
D Y
D O-ring 1 (x5)
E O-ring 2 (x3): Only for Lock up torque converter
variants
W Loctite 509
K 6 Speed clutch (not installed on 4x4 gearbox)
L Reverse clutch unit 11.4. Apply a bead of Loctite 509 of the specified
M Forward/Input clutch shaft thickness to the front case.
N Layshaft clutch Dimension: 3mm
P Main shaft clutch
W Plug 1 11.5. According to the gearbox configuration
X Plug 2 Install the 13 or 14 bolts 2. Refer to Figure
1204. or Refer to Figure 1205.
7. Measure the end float of the input shaft as
follows: Refer to Figure 1202.
7.1. Pull the input shaft to detect excessive end
float.
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27 - Driveline
90 - Front Case
Figure 1204. 13 Bolts Configuration

C
B Bolt 1 (x13)
Figure 1205. 14 Bolts Configuration
C
B Bolt 1 (x14)
11.6. Tighten the bolts to the correct torque
value.
12. Install the solenoid control valve.
13. Install the main hydraulic pump and driveshaft.

Item Description Nm
B Bolt 1 56
G Bolt 2 56
W-X Plug 102
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27 - Driveline
91 - Rear Case

Check (Condition) ........................................ 27-507
27 - 506 9813/7600-3 27 - 506

27 - Driveline
91 - Rear Case
Refer to Front Case - Check Condition (PIL (For: PS750 MK4)

27-06-90).
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

a driveshaft or PTO 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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27 - Driveline
Special Tools
Spanner
Remove
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.
the seal housing.
A Yoke
B Stake nut
C Oil seal
E Washer
F Locking ring
Install
2. If necessary install a new oil seal. Locate the seal
the back of the housing.
5. Install the stepped washer the correct way
shown.
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27 - Driveline

torque value.

Item Nm
B 400
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27 - Driveline
12 - Transfer Gearbox
Contents Page No.
27-12-00 General ......................................................................................................................... 27-513
27 - 511 9813/7600-3 27 - 511

Notes:
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27 - Driveline
00 - General
Introduction .................................................. 27-513 The transfer gearbox is a system of gears used in
Component Identification ............................. 27-514 4WD (Four Wheel Drive) vehicles, which transfers
Clean ........................................................... 27-517 torque from the transmission to the front and rear
Check (Condition) ........................................ 27-517 driveshafts or propshafts. Putting a transfer gearbox
in neutral disconnects the transmission from the
Calibrate ...................................................... 27-518 wheels.
Disassemble and Assemble ........................ 27-527 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.
27 - 513 9813/7600-3 27 - 513

27 - Driveline
00 - General

Unit Identification mentioned on the unit identification plate. In the case
of gear replacements, always check the part number
The gearbox serial number is stamped on the unit stamped on the gear, and the number of teeth.
identification plate as shown. When you make an
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27 - Driveline
00 - General
Figure 1207. 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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27 - Driveline
00 - General
Table 468.
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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27 - Driveline
00 - General

Consumables Consumables
Description Part No. Size Description Part No. Size
Cleaner/Degreaser 4104/1557 0.4L JCB Threadlocker 4101/0250 0.01L
- General purpose and Sealer (Medium 4101/0251 0.05L
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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27 - Driveline
00 - General
Calibrate
Figure 1208.
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
27 - 518 9813/7600-3 27 - 518

27 - Driveline
00 - General
C Pinion gear housing D Extraction holes

E Shim set 1 F Nut1
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 bearings1 and 2 must Figure 1210.
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 1209.
AQ M,AD
AR
AR 75mm
8. Pull the spring balance until the pinion gear
housing stops to rotate and then record the
reading.
Weight/Force: 6.9–19.6N
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 469. 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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27 - Driveline
00 - General
Figure 1211. Table 469. 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 1212.
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 1212.
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: 0.13–0.2mm
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
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2. With the gearbox under load, rotate the gears in Figure 1214.
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
1213. ) in mesh with the bevel gear do the
following:
Figure 1213.
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 1214. ) 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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Method B
Figure 1215.
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 470. 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 1215.
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 Constant +40
this event start by installing 0.5mm 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.
470. and Refer to Table 471.. When you note down Table 471. 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 470. AK Pinion assembly deviation 17
AL Pinion gear deviation +60
AP
(1)
=77
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Item Description Devia- Figure 1216.

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: 0.33mm
1.2. Compare the old and new dimension
measured during assembly. Refer to Table
472.
Table 472.
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 473.
Table 473.
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 1217.

deviations. Refer to Table 474.
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 474. - 27
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27 - Driveline
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Table 474.
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 1217.
If the case deviation markings are not visible it will Figure 1218.
not be possible to calculate shim stack adjustment.
In this event start by installing 0.5mm 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 475.
Old = 40.65
New = 40.32
Result = -0.33
Table 476.
AH Old (Pinion gear) = 30
AH New (Pinion gear) = 40
Difference = +0.1
Add difference from Refer to Table = -0.33
475.
Result = -0.23
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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 1219.
A Flywheel housing bolts
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Install
removal procedure.

Item Nm
A 70
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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: 55mm
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 0.5kg pinion gear. Make sure you also remove the
4003/2017 0.4kg bearing 1 and spacer 2.
4003/2006 12.5kg 1.8. Remove the triple-lip seal 1 and the O-ring
4003/2005 50kg 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: 0.01mm
Disassemble
Figure 1220.
Remove the gearbox from the machine, place
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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2.3. Remove the shim set 2 and put a label as Figure 1221.
'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: 46mm
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: 0.01mm
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Figure 1222. 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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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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Assemble Figure 1223.
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: 55mm
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: 0.5–2.5N·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 1224.
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: 55mm
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 1222.
Torque: 0.5–1.5N·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
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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: 0.5–2.5N·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 1222.
3.8. Tighten the nut 2 to the correct torque value
with a socket of the specified dimension. Table 478. Torques (Before 2011)
Dimension: 46mm 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
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 1225.
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: 46mm
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27 - Driveline
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Figure 1226. 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 1227.
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.
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Figure 1227. 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
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27 - Driveline
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Figure 1228. 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.
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27 - Driveline
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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 1227.
Figure 1228. and Refer to Figure 1227.
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 1229. 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 1228. and Refer to Figure 1227.
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.
Figure 1230.
1.12. If the seal drag is within limits, tighten the
setscrew to the specified torque value.
Torque: 395N·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: 395N·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.
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27 - Driveline
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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: 0.4–0.75N·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: 395N·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 1231.
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.
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27 - Driveline
14 - Torque Converter
Contents Page No.
27-14-00 General ......................................................................................................................... 27-539

27-14-06 Control Valve ................................................................................................................ 27-547
27-14-09 Relief Valve .................................................................................................................. 27-549
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Introduction .................................................. 27-539 The torque converter is a type of fluid coupling that
Component Identification ............................. 27-540 is used to transfer rotating power from the engine to
Operation ..................................................... 27-540 a rotating driven load.
Check (Operation) ....................................... 27-541
The torque converter normally takes the place of
Remove and Install ..................................... 27-545 a mechanical clutch in a vehicle with an automatic
transmission, allowing the load to be separated from
the power source.
It is usually located between the engine flywheel and

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

ability to multiply torque when there is a substantial
difference between input and output rotational
speed, thus providing the equivalent of a reduction
gear. Some torque converters are equipped with a
temporary locking mechanism which rigidly locks the
engine to the transmission when their speeds are
nearly equal, to avoid slippage and a resulting loss
of efficiency.
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27 - Driveline
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Figure 1232. 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
D 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.
A
The impeller is driven by the engine.
B 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

G C 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
F E 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.
H
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
A Impeller heat.
B Turbine
C Reaction member Because of the absence of a direct mechanical
D Drive plate (engine driven bevel gearbox) connection between the engine and the gearbox,
E Drive to gearbox input shaft the flexibility of the torque converter drive greatly
F Spline location for reaction member reduces wear on the transmission, absorbing shocks
G Direct drive from the engine to the gearbox oil and torsional vibration from the engine. The engine
pump cannot be stalled due to overload, as the fluid
H Direction of oil flow coupling slips.
For illustration refer to Component Identification (PIL

27-14-00).
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27 - Driveline
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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 1233.
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 - 541 9813/7600-3 27 - 541

27 - Driveline
00 - General
Figure 1233.
27 - 542 9813/7600-3 27 - 542

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 is 27-06).
above 50°C (121.9°F). Also make sure that the valve
block LSRV (Load Sense Relief Valve) pressure and Interpreting the Test Results
the variflow pump Delta P pressure are set correctly.
If all the engine speeds are below the stated figures
Before completing the following test, remove the either the engine is losing power and should be
transmission dipstick. If there is any sign of serviced/ overhauled or the torque converter reaction
smoke emitting from the dipstick tube stop the member clutch is slipping. To check the engine,
test immediately and dismantle the transmission for select neutral, open throttle fully and operate a
servicing. hydraulic service to 'blow off' the main relief valve.
Engine speed should fall to slightly below the
1. Check all engine fluid levels. Run the engine at maximum governed speed. Refer to (PIL 15-00). If
maximum speed and check the no load speed. engine speed is correct the torque converter reaction
Refer to Engine, General, General, Technical member clutch is slipping.
Data, (PIL 15-00-00).
If all the engine speeds are higher than the stated
2. Make sure that the engine and transmission are figures in all gears the torque converter safety relief
at normal working temperature (the transmission valve may be faulty. Alternatively there may be
oil must be above the specified temperature). internal oil leakage.
Run engine at maximum speed and check the
engine speed is correct (High Idle/ maximum If the engine speeds are higher than the stated
governed speed). Refer to engine- general, refer figures in some gears, check the transmission for
to (PIL 15-00). clutch slippage or internal leakage.
The example given below shows how the results can
3. Apply the park brake and foot brake firmly. be used to isolate a suspect clutch.
If necessary, set the machine against a fixed
obstruction.
27 - 543 9813/7600-3 27 - 543

27 - Driveline
00 - General
Table 479.
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 - 544 9813/7600-3 27 - 544

27 - Driveline
00 - General
Remove and Install
Consumables 2. Remove the gearbox. Refer to (PIL 27-06).

3. Prise out the access panel from the bevel
JCB Threadlocker 4101/0250 0.01L gearbox torque converter housing.
Strength) 4. Rotate the engine so as to gain access to the
torque converter retaining bolts (x4).
Remove
5. Support the torque converter. Loosen and
1. Due to the configuration of the engine and the remove the bolts (x4). Remove the torque
transmission mounting system, we recommend converter.
to remove the engine and the transmission as a
full assembly.
Figure 1234.
D
F
B
A Access panel B Retaining bolt

C Drive plate D Spigot
E Bolts F DTI (Dial Test Indicator)
27 - 545 9813/7600-3 27 - 545

27 - Driveline
00 - General
Install
steps.
1.1. Make sure that the drive plate and the
torque converter mating faces are perfectly
clean.
1.2. If removed, make sure that the drive plate
mating faces are clean and free from burrs
before you install it over the spigot on the
drive flange.
1.3. Install the bolts with JCB Threadlocker and
Sealer. Tighten to the correct torque value.
(Medium Strength)
1.4. Make sure that there are no burrs on the
torque converter spigot or to any of the
mating faces adjacent to the drive plate.
1.5. Install the torque converter spigot on the
recess in the bevel box output shaft.
1.6. Install a DTI.
1.7. Rotate the torque converter and measure
the run out of the drive shaft. Make sure that
the run out does not exceed the specified
value.

Item Nm
B 46
E 28
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27 - Driveline
06 - Control Valve
06 - Control Valve Figure 1235.

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.
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27 - Driveline
06 - Control Valve
6. Install the pipe and tighten the nuts to the correct

torque value.

Item Nm
A 56
D 9
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27 - Driveline
09 - Relief Valve
09 - Relief Valve
Remove and Install

(For: PS750 MK4) gearbox.
3. Remove the plug, sealing washer, spring and the
Remove poppet.
1. Clean the area around the valve and the gearbox
case.
Figure 1236.
B
C
A Plug B Sealing washer

C Spring D Poppet
27 - 549 9813/7600-3 27 - 549

27 - Driveline
09 - Relief Valve
Install
At the time of installation do the following step.

Item Description Nm
A Plug 56
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27 - Driveline
20 - Axle
20 - Axle
Contents Page No.
27-20-00 General ......................................................................................................................... 27-553

27-20-15 Breather ........................................................................................................................ 27-585
27-20-81 Mount ........................................................................................................................... 27-587
27 - 551 9813/7600-3 27 - 551

Notes:
27 - 552 9813/7600-3 27 - 552

27 - Driveline
20 - Axle
00 - General
00 - General Technical Data

Technical Data ............................................. 27-553 For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY], Dana 213 Series, Front
Component Identification ............................. 27-555 ................................................. Page 27-553
Drain and Fill ............................................... 27-561 For: 526-56 [T4F], 531-70 [5AA], 531-70
Check (Level) .............................................. 27-564 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
Remove and Install ..................................... 27-565 [5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Front
Disassemble and Assemble ........................ 27-580 ................................................. Page 27-553
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY], Dana 223 Series, Rear
................................................. Page 27-554
For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Rear
................................................. Page 27-554
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY], Dana 213 Series,
Front)
Table 483.
Designations
Series Dana 213
Type 3 piece steer drive pad
or trunnion mounted piv-
ot (sway) axle
Differential Standard or limited slip
Hubs Planetary reduction
Brakes Two internal hydraulical-
ly actuated oil immersed
service brake packs
Steering Power track rod with in-
tegral proximity switch
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Front)
Front Axle
Table 484. SD70 3 Piece Steer Drive Axle
Designations
Hubs 80 Series
Hub swivels and drive 55 Series
shafts
Drive head 80 Series 3 piece
Brakes 70 Series Integral
Brakes (3 piece axles)
Type JCB spiral bevel input
with epicyclic hub reduc-
tion
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27 - Driveline
20 - Axle
00 - General
Designations
Brakes Oil immersed multi-plate
discs, located in centre
section
Steering Steer rams
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY], Dana 223 Series,
Rear)
Table 485.
Designations
Series Dana 223
Type 3 piece steer drive pad
mounted pivot (sway)
axle
Differential Standard
Hubs Planetary reduction
Brakes Two internal hydraulical-
ly actuated oil immersed
service brake packs
Steering Power track rod with in-
tegral proximity switch
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Rear)
Rear Axle
Table 486. SD55 1 Piece Steer Drive Axle
Designations
Hubs 55 Series
Hub swivels and drive 55 Series
shafts
Drive head 55 Series 1 piece
Type JCB spiral bevel input
with epicyclic hub reduc-
tion
Steering Steer rams
27 - 554 9813/7600-3 27 - 554

27 - Driveline
20 - Axle
00 - General
For: 70/80-Series, Front .......... Page 27-555 The axle consists of a centre casing (drivehead) and
For: Dana 223 Series .............. Page 27-555 two axle arms and swivel wheel hubs.
For: 55-Series, 70-Series ........ Page 27-557 The drivehead houses the differential gearing and
For: 70/80-Series, Rear ........... Page 27-557 two oil immersed disc brake units. The axle arms
For: 55-Series ......................... Page 27-560 house the driveshafts. Specially shaped spider gears
in the differential provide torque proportioning, which
make sure drive power will be kept on one wheel if
(For: 70/80-Series, Front) the other is slipping. The wheel hubs are connected
to the driveshafts through universal joints which drive
3 Piece Axle sun-and-planet gears inside the hubs.
The illustration shows a typical 3 piece steer drive The drive yoke, pinion, crownwheel and differential
front axle. unit are all components of the drivehead.
Figure 1237.
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: Dana 223 Series)
Unit Identification
The axle serial number is stamped on the unit
identification plate as shown.
Make sure that the correct ratio axle in relationship

to the gearbox ratio is fitted to the machine. Do not
fit a new axle with a different ratio to the axle being
replaced.
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27 - Driveline
20 - Axle
00 - General
Figure 1238. Dana 223 Axle
A Unit identification plate
Figure 1239. Dana 223 Axle
A
B
C
D E
F
G
H
J
K
T L
S Q
R P
N
M
A Lock stop B Axle arm

C Brake piston hydraulic port D Power track rod proximity switch
E Drive head casing F Breather
G Brake piston hydraulic port H Axle arm
J Steer swivel trunnion bearings K Wheel stud and nut
27 - 556 9813/7600-3 27 - 556

27 - Driveline
20 - Axle
00 - General
L Planetary wheel hub M Steering swivel

N Steering link arm P Plug- oil fill / level / inspection
Q Power track rod R Trunnion assembly
S Propshaft connecting yoke T Pinion nut
SD55 1 Piece Steer Drive Axle

(For: 55-Series, 70-Series)
The illustration shows a typical steer drive rear axle.
SD80 3 Piece Steer Drive Axle- Integral The axle has a single piece case which houses the
Brakes differential and half shafts. The rear axle is pivot
mounted to the chassis.
For SD80 3 piece steer axle, refer to (PIL 20-00).
Figure 1240.
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
The axle has a single-piece casing which houses the

(For: 70/80-Series, Rear) differential and driveshafts.
The axle is mounted to the chassis with a pivot pin to

1 Piece Axle allow the machine to sway.
The illustration shows a typical 1 piece steer drive
rear axle.
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27 - Driveline
20 - Axle
00 - General
Figure 1241.
A B
F
G
J
K
C
D
E
H

J Axle pivot K Oil filler / level plug
27 - 558 9813/7600-3 27 - 558

27 - Driveline
20 - Axle
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 1242.
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
27 - 559 9813/7600-3 27 - 559

27 - Driveline
20 - Axle
00 - General
(For: 55-Series)
Figure 1243. 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
27 - 560 9813/7600-3 27 - 560

27 - Driveline
20 - Axle
00 - General
Drain and Fill
axle for your machine. Refer to Figure 1244.

(For: 55-Series, 70/80-Series) and Refer to Figure 1245.
Notice: The oil level must be checked with the 1.2. Then make sure you identify the correct
machine level, otherwise a false indication of the plug for your machine.
amount of oil will be given. 1.3. Then use the related torque information for
Notice: It is not recommended that the machine the drain plug. Refer to Table 487. and Refer
be driven with the axle partially filled with oil. to Table 488.
2. Remove the hexagonal fill/level plug with its
Remove sealing washer (if installed) or the tapered plug.
1. Make the machine safe. Refer to (PIL 01-03). 3. Fill with the specified oil until oil is level with the
bottom of the hole. Refer to (PIL 75-00).
2. Get access to the axle drain plug.
4. Clean the fill/level plug.
3. Clean the area around the drain plug.
5. Install the fill/level plug with its sealing washer (if
4. Drain the oil. installed) or the tapered plug.
4.1. Place a container of suitable size beneath 6. Tighten the fill/level plug to the correct torque
drain plug to catch the oil. value.
4.2. Remove the hexagonal drain plug and its 6.1. To Make sure you use the correct torque
washer (if installed) or the tapered plug. tightening information, identify the correct
Allow oil to drain out. Wipe it clean (metallic axle for your machine. Refer to Figure 1244.
particles should be carefully removed). and Refer to Figure 1245.
6.2. Then make sure you identify the correct
Install plug for your machine.
1. Install the drain plug (and sealing washer- if 6.3. Then use the related torque information for
installed), tighten to the correct torque. the fill/level plug. Refer to Table 487. and
Refer to Table 488.
1.1. To Make sure you use the correct torque
tightening information, identify the correct
Figure 1244. JCB Axle (Inboard Brakes)
C
A
B
C
A Axle fill/level plug B Axle drain plug

C Hub drain plug
27 - 561 9813/7600-3 27 - 561

27 - Driveline
20 - Axle
00 - General
Figure 1245. JCB Axle (Braked Hubs)

F
D
E
D Axle fill/level plug E Axle drain plug

F Hub drain plug
Figure 1246. Hexagonal Plug and Seal- Figure 1247. Taper Plug
ing Washer (Prior to January 2011) (January 2011 Onwards)
Table 487. JCB Axles With Inboard Brakes

Function of Plug Installed Description Torque (Nm)
Axle drain plug with hexagonal Hex head plug and washer (3/4 in 90
head and bonded washer BSP)
Axle drain plug with tapered plug Taper plug (3/4 in BSP) 80
Axle fill plug with hexagonal head Hex head plug and washer (3/4 in 90
and bonded washer BSP)
Axle fill plug with tapered plug Taper plug (3/4 in BSP) 80
Table 488. Axles With Braked Hubs

Axle drain plug with hexagonal Hex head plug and washer (3/4 in 90
head and bonded washer BSP)
Axle drain plug with tapered plug Taper plug (3/4 in BSP) 80
27 - 562 9813/7600-3 27 - 562

27 - Driveline
20 - Axle
00 - General

Axle fill plug with hexagonal head Hex head plug and washer (3/4 in 90
and bonded washer BSP)
Axle fill plug with tapered plug Taper plug (3/4 in BSP) 80
Also refer to hub, general, drain and refill, (PIL

27-00).
27 - 563 9813/7600-3 27 - 563

27 - Driveline
20 - Axle
00 - General
Check (Level)
Notice: The oil level must be checked with the
machine level, otherwise a false indication of the
amount of oil will be given.
Notice: It is not recommended that the machine
be driven with the axle partially filled with oil.

2. Get access to the axle fill/level plug.
3. Clean the area around the fill/level plug.
4. Remove the plug with its sealing washer.
5. Make sure the oil is level with the bottom of the
hole.
6. If necessary add the correct new oil. Refer to (PIL
75-00).
7. Clean the fill/level plug.
8. Install the plug with its sealing washer.
27 - 564 9813/7600-3 27 - 564

27 - Driveline
20 - Axle
00 - General
Remove and Install
For: 70-Series, 80-Series, Front 2. Install the safety strut. Refer to (PIL 06-69).
................................................. Page 27-565
For: 550-80 [5AW], 550-80 [5UW], 560-80 3. Shims may have been installed on the axle
[5AY], 560-80 [5UY], Dana 213 Series mounts. Make sure to note the position and
................................................. Page 27-567 quantity of these shims before removal. There
For: Dana 223 Series, Rear ..... Page 27-573 may be an uneven number of shims on each side
of the axle as they are used to adjust the machine
For: 55-Series, Rear ................ Page 27-575 height and make it level.
For: 80-Series, Rear ................ Page 27-577
4. Make sure to collect the shims and replace them
in the correct position when you replace the axle.
(For: 70-Series, 80-Series, Front)
Consumables 5. If installed, remove the front stabilisers. Refer to
(PIL 06-42-00).
Special HP Grease 4003/2020 0.5kg 6. Remove the bolt 1 and disconnect the propshaft
4003/2017 0.4kg coupling from the axle.
4003/2006 12.5kg 7. Disconnect the hydraulic feed hoses from the
4003/2005 50kg steer rams (one hose on each ram). Cap the
open ports and hoses to prevent contamination.
Raised Machine
8. Loosen the front road wheel retaining nuts then
Never position yourself or any part of your body raise and support the front end of the machine
under a raised machine which is not correctly on support stands or blocks positioned under the
supported. If the machine moves unexpectedly you chassis. Refer to (PIL 27-29.
could become trapped and suffer serious injury or be
killed. 9. Remove the front road wheels.
WARNING! A raised and badly supported machine
10. If installed, remove the front fenders. Refer to
(PIL 06-54).
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on the 11. Disconnect the brake hose. Cap the open ports
machine hydraulics or jacks to support the machine and hoses to prevent contamination.
when working under it. Disconnect the battery, to
prevent the machine being started while you are 12. Remove the bolt 2 and then remove the pivot pin
beneath it. 1.
WARNING! Before disconnecting any propshaft, 13. Support the axle on a trolley jack.
make sure you block both sides of all wheels to
prevent machine movement. The park brake will 14. Remove the bolt 3 and then remove the pivot pin
become ineffective or may only operate on 2 wheels 2.
(depending on machine specification).
15. Remove the axle from the machine.
Remove
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27 - Driveline
20 - Axle
00 - General
Figure 1248. SD80 Pivot sway axle
A B
F
C
Install
Table 489. 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
27 - 566 9813/7600-3 27 - 566

27 - Driveline
20 - Axle
00 - General
1.6. Apply grease on the axle pivot. Refer to (PIL Make sure you retain the shims and install them in
75-06-00). the correct position when you install the axle. There
may be an uneven number of shims between each
side of the axle as the shims are used to adjust the
Table 490. Torque Values machine height and make it level.
Item Description Nm Remove

G Pivot pin 2 118
1. Slacken off the road wheel retaining nuts. Refer
to (PIL 27-29).
(For: 550-80 [5AW], 550-80 [5UW], 560-80 2. Raise and support the front end of the machine
[5AY], 560-80 [5UY], Dana 213 Series) on axle stands or blocks positioned under the
chassis. Remove the front road wheels.
WARNING A raised and badly supported
machine can fall on you. Position the machine 3. Remove the bolts and remove the access plate
on a firm, level surface before raising one end. from the chassis.
Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks 4. Remove the bolts 2 and the straps and
to support the machine when working under it. disconnect the propshaft from the axle.
Disconnect the battery, to prevent the machine
being started while you are beneath it. 5. Put a label on the steer hoses and the brake
hoses for correct installation.
WARNING Make sure that the blocks and
towing vehicle will prevent the machine from 6. Disconnect the steering hydraulic hoses from the
moving because when the driveshafts have been power track rod connectors. Plug all the open
disconnected the park brake cannot prevent ports and hoses to prevent contamination.
the machine from moving. It is necessary
to work under the machine to remove the 7. Remove the retaining nuts at the steering
driveshafts. This job should be done by a qualified trunnions and remove the mudguard bracket.
mechanic. Anyone working underneath, or near
the machine, could be killed or seriously injured if 8. Disconnect the brake hoses from the axle.
the machine moves. Plug all the open ports and hoses to prevent
contamination.
Fixed Axle 9. Disconnect the steer proximity switch electrical

connector (if installed).
If the lift arm is raised, make sure to install the
maintenance strut. Refer to (PIL 06-69). 10. Support the axle on a trolley jack.
11. Remove the nuts and bolts 1.
Follow the care and safety procedures. Refer to (PIL
01-03). 12. Remove the load spreader plate, spacer and
lower support plate from the axle and the bracket.
Some machines may have shims installed on the
axle mounts. Make sure to note the position and 13. Lower the axle from the machine.
quantity of these shims before you remove them.
27 - 567 9813/7600-3 27 - 567

27 - Driveline
20 - Axle
00 - General
Figure 1249.
B
A
Q R
G
H
L
F
N M
A Steer hoses B Electrical connector

C Brake hoses D Mudguard bracket
E Retaining nuts F Access plate
G Bracket H Spreader plate
J Bolts 1 K Spacer
L Axle M Lower support plate
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27 - Driveline
20 - Axle
00 - General
N Nuts P Propshaft
Q Bolts 2 R Straps
27 - 569 9813/7600-3 27 - 569

27 - Driveline
20 - Axle
00 - General
Install on axle stands or blocks positioned under the

chassis.
removal procedure. Additionally do the following 2. Remove the front road wheels. Refer to (PIL
steps. 27-29).
1.1. Replace the road wheels. Refer to (PIL 3. Remove the bolts and the access plate from the
27-29). chassis.
1.2. Tighten the steer hose and the brake hose 4. Remove the bolts 4 and straps and disconnect
to the specified torque values. Refer to the propshaft from the axle.
Table 491.
5. Put a label on the steer hoses and the brake
1.3. Tighten the propshaft retaining bolt 2 to the hoses to assist with correct installation.
correct torque value. Refer to Table 491.
6. Disconnect the steering hydraulic hoses from the
2. Before you drive the machine do the following power track rod connectors. Plug all the open
steps: ports and hoses to prevent contamination.
2.1. Bleed and check the operation of the brake 7. Remove the retaining nuts at the steering
system. Refer to (PIL 24-03). trunnions and remove the mudguard bracket.
2.2. Bleed and check the operation of the
steering system. Refer to (PIL 25-00). 8. Disconnect the brake hoses from the axle.
Plug all the open ports and hoses to prevent
2.3. Re-phase the steering system. Refer to (PIL contamination.
25-00).
9. Disconnect the steer proximity switch electrical
Sway Axle connector (if installed).
10. Support the axle on a trolley jack.
If the lift arm is raised, make sure you install the
maintenance strut. Refer to (PIL 06-69). 11. Loosen the bolt 1 and remove the pivot pin.
Follow the care and safety procedures. Refer to (PIL 12. Loosen the sway ram pivot bracket mounting
01-03). bolts 2. Lift the bracket away.
Remove 13. Remove the nuts and bolts 3 from the trunnion.
1. Slacken off the road wheel retaining nuts then 14. Lower the axle from the machine.
raise and support the front end of the machine
27 - 570 9813/7600-3 27 - 570

27 - Driveline
20 - Axle
00 - General
Figure 1250.
B
A
G P
J
H
Q R
N
N
L L
K M
M
A Steer hoses B Electrical connector

C Brake hoses D Fender bracket
E Retaining nuts F Pivot pin
G Bolt 1 H Bolts 2
J Bracket K Access plate
L Trunnions M Nuts
27 - 571 9813/7600-3 27 - 571

27 - Driveline
20 - Axle
00 - General
N Bolts 3 P Propshaft
Q Bolts 4 R Straps
27 - 572 9813/7600-3 27 - 572

27 - Driveline
20 - Axle
00 - General
Install to support the machine when working under it.

Disconnect the battery, to prevent the machine
1. The installation procedure is the opposite of the being started while you are beneath it.
removal procedure.
WARNING You could be killed or injured if the
2. When you install, do the following steps also: boom drops while you are working under it. Install
the boom maintenance strut as instructed before
2.1. Replace the road wheels. Refer to (PIL doing any maintenance work with the boom
27-29). raised. Keep people away from the machine while
you install or remove the boom maintenance strut.
2.2. Tighten the steer hose and the brake hose
to the specified torque values. Refer to WARNING Before disconnecting any propshaft,
Table 491. make sure you block both sides of all wheels
to prevent machine movement. The park brake
2.3. Tighten the propshaft retaining bolt 4 to the
will become ineffective or may only operate on 2
correct torque value. Refer to Table 491.
3. Before you drive the machine, do the following
steps: Remove
3.1. Bleed and check the operation of the brake 1. Slacken off the road wheel retaining nuts then
system. Refer to Service brake, General. raise and support the front end of the machine
Refer to (PIL 24-03). on axle stands or blocks positioned under the
3.2. Bleed and check the operation of the chassis.
steering system. Refer to Steering system,
General. Refer to (PIL 25-00). 2. Remove the front road wheels. Refer to (PIL
27-29).
3.3. Re-phase the steering system. Refer to
Steering system, General. Refer to (PIL 3. Remove the bolts 2 and the straps to disconnect
25-00). the propshaft from the axle.
Table 491. Torque Values 4. Put a label on the steer hoses and brake hoses
to help installation.
Item Description Nm
A Fixed Axle- Steer hoses 47 5. Disconnect and plug the hydraulic hoses 2 to the
C Fixed Axle- Brake hoses 35 window power track rod.
Q Fixed Axle- Bolts 2 70 6. Plug all the open ports and hoses to prevent
A Sway Axle- Steer hoses 47 contamination.
C Sway Axle- Brake hoses 35
7. Remove the retaining nuts at the steering
Q Sway Axle- Bolts 4 70 trunnions and remove the fender bracket.
8. Disconnect the brake hoses 1 from the axle.
(For: Dana 223 Series, Rear)
Consumables contamination.
10. Disconnect the steer proximity switch electrical
Special HP Grease 4003/2020 0.5kg connector (if installed).
4003/2017 0.4kg
4003/2006 12.5kg 11. Disconnect the LLMI (Longitudinal Load Moment
Indicator) electrical connector.
4003/2005 50kg
12. Support the axle on a trolley jack.
machine can fall on you. Position the machine 13. Remove the bolts 1.
on a firm, level surface before raising one end.
Ensure the other end is securely chocked. Do 14. Lower the axles down from the machine.
not rely solely on the machine hydraulics or jacks
27 - 573 9813/7600-3 27 - 573

27 - Driveline
20 - Axle
00 - General
Figure 1251.
B
A
A
B
B
G
H
A Hose 1 B Bolts 1
C Hose 2 D LLMI Electrical connector
27 - 574 9813/7600-3 27 - 574

27 - Driveline
20 - Axle
00 - General
E Fender bracket F Retaining nuts

G Straps H Bolts 2
J Propshaft
Install 2. Install the safety strut. Refer to (PIL 06-69).
1. The installation procedure is the opposite of the 3. Follow the general health and safety procedures.
removal procedure. Additionally do the following Refer to (PIL 01-03).
steps.
4. Remove the bolts 1 and disconnect the propshaft
1.1. Install the road wheels. Refer to (PIL 27-29). coupling from the axle. Refer to (PIL 27-48).
1.2. Tighten the hoses A and C to the correct 5. Disconnect and install caps on the hydraulic feed
torque value. hoses to the steer rams (one hose on each ram).
1.3. Tighten the propshaft retaining bolts H to 6. Remove the rear fenders (if installed).
7. Slacken off the rear road wheel retaining nuts
2. Before driving the machine: and then raise and support the rear end of the
machine on axle stands or blocks positioned
under the chassis. Remove the rear road wheels.
braking system. See (PIL 24-03).
steering system. See (PIL 25-00). 8. Support the axle on a trolley jack.
2.3. Grease the trunnion. 9. Remove the bolt 2 securing the axle pivot pin and
Consumable: Special HP Grease the drive out the pivot pin towards the rear of the
machine.
2.4. Calibrate the LLMI/ LLMC (Longitudinal
Load Moment Control) system (if installed). 10. Lower the axle away from the mounting yoke and
Refer to (PIL 33-66). remove from the machine.
2.5. Re-phase the steering system. Refer to (PIL Install
25-00).
Table 492. Torque Values removal procedure. Additionally do the following
Item Nm steps.
A 35 1.1. Install the road wheels and do the tightness
C 47 checks. Refer to (PIL 27-30).
H 70
2. Before you drive the machine, do the following
steps.
(For: 55-Series, Rear)
SD55 1 Piece Steer Drive Axle

Remove
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27 - Driveline
20 - Axle
00 - General
Figure 1252. 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 493. Torques table

Item Nm
C 118
27 - 576 9813/7600-3 27 - 576

27 - Driveline
20 - Axle
00 - General
(For: 80-Series, Rear) during removal or installation. During pin

removal, make sure that the cut out is
SD80 3 Piece Steer Drive Axle- Integral aligned with the crownwheel. If you do not
align the pivot pin, the pin will damage the
Brakes crownwheel.
Remove Figure 1253.
B
4. Remove the bolts 1 and disconnect the propshaft A
coupling from the axle. Refer to (PIL 27-48).
5. Disconnect and install the caps on the hydraulic
feed hoses to the steer rams (one hose on each
ram).
C
6. Slacken off the rear road wheel retaining nuts
and then raise and support the rear end of the A 5/8 UNF Thread
machine on axle stands or blocks positioned B Rear axle pivot pin
under the chassis. Remove the rear road wheels. C Cutout
12. Lower the axle away from the mounting yoke and
7. Remove the rear fenders (if installed). Refer to remove from the machine.
(PIL 06-54).
Install
8. Disconnect the brake hose. Install caps on the
open connections. 1. The installation procedure is the opposite of the
9. Support the axle on a trolley jack. steps.
10. Remove the bolt 2 and take out the right side 1.1. Install new seals on the pivot pin.
RAS (Rear Axle Stabilization) ram pivot pin.
Repeat the procedure for the left side RAS ram 1.2. Make sure the axle pivot pin cut out is
pivot. correctly aligned to allow it to pass the
crownwheel.
11. Remove the bolt 3 securing the axle pivot pin 1.3. Install the road wheels. Refer to (PIL 27-29).
and remove the pivot pin towards the rear of the
machine. 2. Before you drive the machine do the following
steps.
11.1. The axle pivot pin has a cut out on one
end to allow it to clear the crownwheel
27 - 577 9813/7600-3 27 - 577

27 - Driveline
20 - Axle
00 - General
Figure 1254. 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
27 - 578 9813/7600-3 27 - 578

27 - Driveline
20 - Axle
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 494. Torques table

Item Nm
F 118
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27 - Driveline
20 - Axle
00 - General
12. Make sure that you do not install new plates

(For: 70-Series) individually.
Consumables 13. Remove all the three reaction pins and check
Description Part No. Size them for damage.
JCB Gear Oil HP 4000/0505 20L 14. In the controlled retraction piston type, If new
4000/0503 200L brake and friction plates are installed then a new
JCB Multi-Gasket 4102/1212 0.05L brake back off pin 1 and tension bushes also
JCB Threadlocker 4101/0250 0.01L need to be installed. Failure to do so could result
and Sealer (Medium in the brake being permanently on.
4101/0251 0.05L
Strength)
Brake piston and seals- Controlled
Disassembly retraction type
Make sure that only one side at a time is
It is recommended that axle must be removed from
disassembled to prevent damage to the bearings and
the machine while you disassemble the rear axle
preserve the crownwheel and the backlash settings.
brake.
Before you remove the brake housing and the piston
Before you disassemble the rear axle brakes, it is
assembly make sure that you support the differential
mandatory to mark the components for alignment
with the driveshaft or any other suitable support.
and to identify the right hand and left hand side, to
make sure that it is correctly assembled at the time 1. Mark the brake piston housing and the
of assembly. drivehead.
Brake pack 2. Remove the capscrews.
1. Use a heavy duty (6 point) socket to remove the 3. Remove the brake housing and the piston
bolt 1. assembly.
2. Carefully remove the axle arm from the 4. Make sure that you do not turn the nut, if it is
drivehead. turned then the bearing pre-load needs to be
reset.
3. If necessary, tap the case with a soft faced
hammer and remove all traces of the old sealant 5. Remove the six reaction pin assemblies.
from the mating faces.
5.1. Remove the circlip 2.
4. The brake pack consist of five friction plates and
six counter plates. There are two counter plates, 5.2. Remove the back off pins 1.
one at each end of the brake pack, which are not 5.3. Remove the tension bushes and the spring
attached to the plate carrier. 1.
5. If it is necessary to install the plates again 6. Remove the brake piston from the brake housing.
then make a note of their position and correct
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 9. Nicks or cuts in the seals may be the reason for
then make a note of their original position before loss of brake fluid.
you remove them.
Brake Piston and Seals- Positive retraction
8. The wear limit of friction plates is to the depth of type
the cross hatching.
Make sure that only one side at a time is
9. Check all plates for flatness and damage. disassembled to prevent damage to the bearings and
10. Scoring of the counter plates to a certain limit is do the preservation procedure for the crownwheel
permissible. and the backlash settings.
11. Install a new brake pack, if it is damaged.
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27 - Driveline
20 - Axle
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.
27 - 581 9813/7600-3 27 - 581

27 - Driveline
20 - Axle
00 - General
Figure 1255.
E J
L
K
M
N Q R
T
B
B
C D
Item Description
Table 495. 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
27 - 582 9813/7600-3 27 - 582

27 - Driveline
20 - Axle
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 496. 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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27 - Driveline
20 - Axle
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 496.
Table 496. 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
15 - Breather
15 - Breather
Check (Condition)
For: 550-80 [5AW], 550-80 [5UW], 560-80 Figure 1257. Rear Axle
[5AY], 560-80 [5UY], Front ....... Page 27-585
Otherwise ................................ Page 27-585 A
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY], Front)
Axle Breather (Braked Axles)- Inspection

Breathers are fitted to axles to relieve pressure build
up, due to braking and prolonged roading.
If breathers are not kept clear, seal leakage and

brake problems can result due to pressure build up.
Most axles are fitted with a long stem breather.
Make sure there is adequate clearance around the

breather.
There is only one breather per axle. The front axle

has a blanking plug on the opposite side to the
breather connector. A Long Stem Breather
Figure 1256. Front Axle (Otherwise)

A Breathers are installed to axles to release the
pressure build up due to braking and prolonged
roading.
If the breathers are blocked, there can be oil leakage

past seals and brake problems due to pressure
build up. Most of the axles are have long stem type
breather.
Make sure that there is sufficient clearance around

the breather.
If the breather is dislodged or removed, make sure

that it is installed again with the hole pointing towards
the wheel.
B
Make sure that the breather is installed on the
opposite side of the crownwheel (in less turbulent oil
A Long Stem Breather areas) to avoid oil seepage.
B Blanking Plug
Make sure that the plug is installed on the
crownwheel side.
27 - 585 9813/7600-3 27 - 585

27 - Driveline
20 - Axle
15 - Breather
Figure 1258.
A Long stem breather B Plug

C Hole
27 - 586 9813/7600-3 27 - 586

27 - Driveline
20 - Axle
81 - Mount
81 - Mount
Check (Condition)
in good condition.
Refer to (PIL 72).
as necessary.
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27 - Driveline
22 - Drivehead
22 - Drivehead
Contents Page No.
27-22-00 General ......................................................................................................................... 27-589

27-22-06 Crownwheel .................................................................................................................. 27-590
27-22-09 Pinion Gear .................................................................................................................. 27-592
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27 - Driveline
22 - Drivehead
00 - General
00 - General
Introduction
The axle drivehead transmits drive from the input

coupling yoke to the driveshafts through the
differential unit.
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27 - Driveline
22 - Drivehead
06 - Crownwheel
06 - Crownwheel Introduction
Introduction .................................................. 27-590 A crown wheel is a rotating gear wheel with teeth set
Check (Operation) ....................................... 27-591 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 1261.
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 1259.
2. Pinion too deeply in mesh. Move the crown wheel

towards the pinion to correct the backlash.
Figure 1260.
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 .................................................. 27-592 A pinion gear is a small gear that meshes with a
Calibrate ...................................................... 27-593 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 the bearing before measurement. Make sure

that the bearing cup is square and measure
and record the height. The bearing cups and
(For: 55-Series, 70/80-Series) rollers are matched sets. Always keep the
bearing assemblies together. Make sure that you
Special Tools measure only the inner bearing.
Shim Kit 921/M0229 1 Figure 1264.
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
Shim Size Calculation Example
and the deviation figure on the drivehead
housing. Both figures are in units of 0.01 mm. Table 497. Calculation 1.
Note: The pinion depth may be etched on the Actual Drivehead Case Size
gear face or on the rear of a gear tooth.
Item Typical Fig- Description
Special Tool: Shim Kit (Qty.: 1) ures
Figure 1262. A 187.6 mm Nominal drive-
head case size,
D 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 498. Calculation 2. -

Actual Pinion and Bearing Size
Item Typical Fig- Description
ures
C 150.0 mm Nominal pinion
D Pinion depth length, fixed at
the factory
Figure 1263. 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 499. 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
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27 - Driveline
24 - Differential
24 - Differential
Contents Page No.
27-24-00 General ......................................................................................................................... 27-595

27-24-09 Pinion Gear .................................................................................................................. 27-619
27 - 594 9813/7600-3 27 - 594

27 - Driveline
24 - Differential
00 - General
Introduction .................................................. 27-595 A differential is a particular type of simple planetary
Component Identification ............................. 27-597 gear train.
Check (Condition) ........................................ 27-598
Remove and Install ..................................... 27-598 The differential couples the drive shaft to half-shafts
that connect to the rear driving wheels. The purpose
Disassemble and Assemble ........................ 27-610 of the differential is to allow a speed differential
between the inner and outer wheel while being driven
by the input shaft. In its most common form, the
differential consists of a pinion and ring and planetary
bevel gears to connect the output shafts.
The axle can have the following type of differentials.
1. Open Differential.
2. LSD (Limited Slip Differential).
Open Differential
A standard differential, or what is referred to as an
open carrier. A conventional open differential always
supplies close to equal (because of limited internal
friction) torque to each side. The differential gearing
allows the outer drive wheel to rotate faster than the
inner drive wheel during a turn. This is necessary
when the vehicle turns, making the wheel that is
travelling around the outside of the turning curve roll
farther and faster than the other.
In a standard [open type] differential, the rotational

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

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

In the most basic sense, a LSD equalizes the
difference in either speed between output shafts or
applied torque between output shafts to maintain
traction in adverse or performance conditions. The
benefits of installing an LSD are:
1. Enhanced traction in snow, gravel, and sand.
27 - 595 9813/7600-3 27 - 595

27 - Driveline
24 - Differential
00 - General
2. More predictable handling at the limits of grip.
This type behaves as an open differential unless one

wheel begins to spin and exceeds that threshold.
The LSD will remain open unless enough torque is
applied to cause one wheel to lose traction and spin,
at which point it will engage.
An LSD can use clutches when engaged, or may

also be a solid mechanical connection like a locker
or spool. It is called limited slip because it does just
that; it limits the amount that one wheel can slip.
27 - 596 9813/7600-3 27 - 596

27 - Driveline
24 - Differential
00 - General
Figure 1265. 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 - 597 9813/7600-3 27 - 597

27 - Driveline
24 - Differential
00 - General

For: 550-80 [5AW], 550-80 [5UW], 560-80
1. For JCB axles only: measure and note the [5AY], 560-80 [5UY], Front ....... Page 27-598
thickness of the friction plates, the result must not
For: 550-80 [5AW], 550-80 [5UW], 560-80
be less than the specified dimension. [5AY], 560-80 [5UY], Rear ....... Page 27-603
Dimension: 1.25mm
2. Check the condition of the friction material, which (For: 550-80 [5AW], 550-80 [5UW], 560-80
should be even over both surfaces. If in doubt, [5AY], 560-80 [5UY], Front)
discard the set (friction and counter plates). Consumables
Strength)

method and device.
Safety Precautions
2. During all operations, the axle should be
fastened onto a trestle, while the other parts
mentioned should rest on supporting benches.
3. When you remove one of the arms, put an anti-
tilting safety trestle under the other arm.
4. When you work on an arm that is installed on the
machine, make sure that the supporting trestles
are correctly positioned and that the machine is
locked lengthways.
5. Make sure that only weak solvents are used
for cleaning purposes. Avoid using turpentine,
dilutants and toluol-xylol based or similar
solvents. Use light solvents such as kerosene,
mineral spirits or water based, environment
friendly solvents.
6. For the sake of clarity, the parts that do not
normally need to be removed have not been
reproduced in some of the diagrams.
Left Side, Right Side

The terms right and left in this section refer to the
position of the operator facing the axle from the side
opposite the drive.
27 - 598 9813/7600-3 27 - 598

27 - Driveline
24 - Differential
00 - General
Figure 1266. DANA 213 Front Axle Figure 1269.
A B
1
A Left side
B Right side
Remove
1 Ring nuts
1. Remove the entire arms. Refer to Figure 1267.
5. If necessary, using the Dana tool T12, loosen and
Figure 1267. remove the ring nuts. Refer to after sales- non
JCB tools. Refer to (PIL 78-94). Refer to Figure
1270.
Figure 1270.
2. If necessary, mark the position of the ring nuts.

3. Remove the screws and the ring nut locking tab.
Refer to Figure 1268. 1 Ring nuts
Figure 1268. 6. Remove all traces of sealant from the threads of

the ring nuts and intermediate covers.
1 7. Tighten two safety M16 studs in the main body.
2 8. Loosen and remove the check screws of the
3 intermediate cover 1 on gear ring side. Refer to
Figure 1271.
1 Ring nuts
2 Locking tab
3 Screws
4. If necessary, heat the ring nuts uniformly to the
specified temperature. Refer to Figure 1269.
27 - 599 9813/7600-3 27 - 599

27 - Driveline
24 - Differential
00 - General
Figure 1271. 12. Remove the outer thrust blocks of the bearings
from intermediate cover 1 and intermediate cover
5 2 for bearing installation. Refer to Figure 1274.
Figure 1274.
4
9 10
4 Intermediate cover 1
5 Check screws
9. Support the differential unit and separate the
intermediate cover 1 from the main body and 9 Bearings
remove the cover. Refer to Figure 1272. 10 O-rings
Figure 1272. 13. Carefully check the O-rings for defects.
14. Remove the snap ring and the cap. Refer to
Figure 1275.
Figure 1275.
12
11
4
6
6 Main body
10. Remove the differential unit and place it on a
clean work bench. Refer to Figure 1273.
11 Snap ring
Figure 1273. 12 Cap
15. Make sure you replace the cap when you
disassemble each time.
Install
T13 1. If the bearings are replaced, put the thrust
blocks into the intermediate cover 1 and the
intermediate cover 2. Refer to Figure 1276.
7 Differential unit
T13 Dana tool T13
11. Use the Dana tool T13 to ease removal. Refer to
after sales- non JCB tools. Refer to (PIL 78-94).
27 - 600 9813/7600-3 27 - 600

27 - Driveline
24 - Differential
00 - General
T13
4, 8
9
4 Intermediate cover 1 7 Differential unit

8 Intermediate cover 2 T13 Dana tool T13
9 Bearings
6. Tighten the two safety studs into the main body.
2. Install the non-gear ring side of the main body
complete of pinion with intermediate cover. Lock 7. Install the intermediate cover. Lock the cover with
the cover with check screws coated with JCB check screws coated with JCB sealant and with
sealant and with two service screws (M16 x 50) two service screws (M16 x 50) tightened to the
tightened to the same torque. same torque value.
Consumable: JCB Threadlocker and Sealer Consumable: JCB Threadlocker and Sealer
(Medium Strength) (Medium Strength)
3. Tighten the screws to the specified torque value. 8. Tighten the screws to the specified torque value.
4. Check the condition of the O-ring. Refer to Figure
1277. 9. Check the condition of the O-ring.

V V
6
10
4
8
6 10
V
C
5
V 5
V Service screws C Safety studs

5 Check screws V Service screws
6 Main body 4 Intermediate cover 1
8 Intermediate cover 2 5 Check screws
10 O-ring 6 Main body
10 O-ring
5. Use the Dana tool T13 to position the differential
unit into the main body. Refer to after sales- non 10. If the differential clearance and the pre-load
JCB tools. Refer to (PIL 78-94). Refer to Figure adjustment ring nuts have been removed, tighten
1278. the ring nuts by approximately 3 turns. Apply JCB
Locking Fluid- Low Strength and tighten in the
relative intermediate covers.
11. Tighten the ring nut on the gear ring side until
there is no clearance between the pinion and the
27 - 601 9813/7600-3 27 - 601

27 - Driveline
24 - Differential
00 - General
gear ring. Then loosen by about 1/4 to 1/2 turn. Figure 1282.
Figure 1280.
TM
TM Torque meter
15. Use a dial gauge with a long probe through the
hole provided for the cap. Refer to Figure 1283.
1 Ring nuts
16. Position the tracer on the side of a tooth of the
12. If the ring nuts have been removed, pre-load the gear ring approximately at the specified distance
bearings with ring nut on the non-gear ring side in from the outer rim.
order to increase the torque of the pinion. Refer Length/Dimension/Distance: 5mm
to Figure 1281. In case of used bearings, check
the thrust torque. In case of new bearings, check 17. Pre-load by 1 mm and zero the comparator.
the continuous torque.
Figure 1283.
Figure 1281.
1
A
14
A Dial gauge
1 Ring nuts 14 Gear ring
13. Attach the torque meter to the pinion nut and 18. Hold the pinion in position and move the gear
check that torque will increase by the specified ring manually in both directions to check the
value as a result of differential bearing pre-load. clearance between the pinion and the gear ring.
The clearance must be as specified.
14. Adding the pinion and differential torque gives
the specified torque value. Refer to Figure 1282. 18.1. Important: The difference between the
minimum and maximum clearance for the
Torque: 1.4–1.7N·m whole circumference must not exceed the
specified value.
19. If the torque value and/or pinion-gear ring
clearance is not within tolerance values and the
ring nuts have not been removed, mark the
position of the ring nuts and remove the locking
tabs. Refer to Figure 1284.
27 - 602 9813/7600-3 27 - 602

27 - Driveline
24 - Differential
00 - General

3
1 1
2
3
2
1 Ring nuts 1 Ring nuts

2 Locking tab 2 Locking tab
3 Screws 3 Screws
20. Adjust the clearance between the pinion and 23. Install the brake cylinders and the axle arm. Refer
gear ring as follows: to Figure 1287.
1 T12 T12 1
1 Ring nuts
T12 Dana tool T12
20.1. To increase: Loosen the ring nut on gear Item Description Nm
ring side and tighten the ring nut on non-
gear ring side by the same measure. V Service screws 137
3 Screws 9
20.2. To decrease: Do the same operations
inversely. To rotate ring nuts, use the Dana 5 Check screws 137
special wrench T12. Refer to after sales-
non JCB tools. Refer to (PIL 78-94). Refer
to Figure 1285. (For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY], Rear)
21. Install the stops for the ring nuts. Engage locking
tabs in the slot next to the holes provided for the Consumables
check screws. Description Part No. Size
22. Apply JCB sealant on the screws and tighten to and Sealer (Medium
the correct torque value. Refer to Figure 1286. 4101/0251 0.05L
Strength)
(Medium Strength) Remove
1. Sling the arm to be removed and connect it to a
hoist.
27 - 603 9813/7600-3 27 - 603

27 - Driveline
24 - Differential
00 - General
2. Loosen and remove the screws and nuts. Refer Figure 1291.
to Figure 1288.
Figure 1288. DANA 223 Axle
2,26
T14
T14 Dana tool T14

2 Ring nut 1
26 Ring nut 2
6. Loosen the stud bolt 1 and the stud bolt 2 and
3. Remove the screw 1. Refer to Figure 1289.
remove the two of them. Refer to Figure 1292.
Figure 1289.
Figure 1292.
35
27
41
27 Screw 1
35 Stud bolt 1
4. Uniformly heat the ring nuts up to the specified 41 Stud bolt 2
temperature. Refer to Figure 1290.
7. Remove the crown side intermediate cover 2.
Temperature: 80°C (175.9°F) Refer to Figure 1293.
38
5. Using the Dana tool T14, mark the position of the 8. Remove the cover and the studs. Refer to Figure
ring nut 1 and the ring nut 2. Refer to Figure 1291. 1294.
27 - 604 9813/7600-3 27 - 604

27 - Driveline
24 - Differential
00 - General
25
25 Bearing 2
9. Remove the whole differential unit. Refer to
Figure 1295. 3. Position a shim with adequate diameter in order
to engage the internal ring of the bearing with out
Figure 1295. engaging the cage.
4. Only if the bearings are replaced, insert the
thrust blocks of the bearings into the intermediate
covers. Refer to Figure 1298.
Figure 1298.
Install
1. Put the differential unit under a press and, using a
driver with an adequate diameter, install the first
5. Thoroughly check the condition of the O-ring 1
Figure 1296. and the O-ring 2. Refer to Figure 1299.
Figure 1299.
3 Bearing 1
2. Turn the unit upside down and install the second
27 - 605 9813/7600-3 27 - 605

27 - Driveline
24 - Differential
00 - General
6. Install the intermediate cover 1 on the opposite Figure 1302.

side of the ring gears. Lock the cover with stud
bolt 1 coated with JCB sealant.
Consumable: JCB Threadlocker and Sealer C
(Medium Strength)
7. Tighten the stud bolts to the specified torque
Figure 1300.
38
35
C Safety screws
28 Main body
28 11. If the ring nuts have been removed, tighten

the ring nut 1 on the gear ring side until the
clearances between pinion and gear ring are
zeroed. Then, loosen by about 1/4 turn. Refer to
33 Figure 1303.
28 Main body
33 Intermediate cover 1 Figure 1303.
35 Stud bolt 1
8. Position the differential unit in the central body
with the help of a bar and install the middle cover.
Figure 1301.
T14
2
T14 Dana tool T14
2 Ring nut 1
12. If the ring nuts have been removed, preload the
bearings with the ring nut 2 on the non-gear ring
side in order to increase the torque of the pinion.
9. Tighten the two safety screws into the main body

and install the intermediate cover.
10. Tighten the safety screws to the specified torque
27 - 606 9813/7600-3 27 - 606

27 - Driveline
24 - Differential
00 - General
T14
26
T14 Dana tool T14 A Dial gauge

26 Ring nut 2
18. As you hold the pinion in position, move the
13. In the case of used bearings, check the thrust gear ring manually in both directions to check
torque. In the case of new bearings, check the clearance between pinion and gear ring. Make
continuous torque. Refer to Figure 1305. sure that the clearance is of the specified value.
14. Attach the torque meter to the pinion nut and
check that torque will increase by the specified Length/Dimension/Distance: 0.25–33mm
value as a result of differential bearing preload. Figure 1307.
Figure 1305.
TM
19. If the torque and/or pinion gear ring clearance is

TM Torque meter not within tolerance values and the ring nuts have
not been removed, mark the position of the ring
14.1. Example: Pinion torque: 120-130 Ncm. nut 2 and remove the screws 1. Refer to Figure
Pinion + Differential torque: 140 - 170 Ncm 1308.
15. Introduce a dial gauge with a long tracer through

the hole provided for the cap.
16. Position the tracer on the side of a tooth gear ring,
approximately at the specified distance from the
outer rim.
17. Preload by specified value and zero the dial
gauge. Refer to Figure 1306.
27 - 607 9813/7600-3 27 - 607

27 - Driveline
24 - Differential
00 - General
27 27
26
26 Ring nut 2 27 Screws 1

27 Screws 1
23. Install the top plug after applying re-positionable
20. Adjust the clearance between the pinion and jointing compound for seals to the rims. Refer to
the gear ring. To rotate ring nuts, use the Dana Figure 1311.
special wrench T14. Refer to Figure 1309.
Figure 1311.
Figure 1309.
T14
T14 Dana tool T14

24. Install the snap ring. Refer to Figure 1312.
20.1. To Increase: Loosen the ring nut on gear
ring side and tighten the ring nut on non- Figure 1312.
gear ring side by the same measure.
20.2. To Decrease: Tighten the ring nut on gear
ring side and loosen the ring nut on non-
gear ring side by the same measure.
21. Engage the screws 1 in the slot next to the holes
provided for the check screws.
22. Coat screws 1 with JCB threadlocker and sealer
and tighten to the specified torque value. Refer
to Figure 1310.
(Medium Strength)
25. Install the complete arm. Refer to Figure 1313.
27 - 608 9813/7600-3 27 - 608

27 - Driveline
24 - Differential
00 - General
Figure 1313.
26. Make sure that the torque wrench setting is of

the specified value. Tighten using the criss-cross
method. Refer to Figure 1314.
Torque: 283–312N·m
Figure 1314.

Item Description Nm
C Safety screws 140
27 Screws 1 26
35 Stud bolt 1 140
41 Stud bolt 2 140
27 - 609 9813/7600-3 27 - 609

27 - Driveline
24 - Differential
00 - General
For: 55-Series, 80-Series, Front, Limited Slip 2. Remove the crownwheel.

Differential (LSD) ..................... Page 27-610
For: 550-80 [5AW], 550-80 [5UW], 560-80 3. Put marks on the two halves of the differential
[5AY], 560-80 [5UY], Rear ....... Page 27-613 housing before disassembly to make sure of
correct assembly.
(For: 55-Series, 80-Series, Front, Limited 4. Remove the capscrews.
Slip Differential (LSD))
5. Disengage the two halves of the differential and
The numerical sequence shown on the illustration is remove the following components:
intended as a guide for disassembly. 5.1. Trunnion pins.
The number of friction and counter plates shown in 5.2. Side gears.
the illustration is typical only. The actual number of
5.3. Bevel gears.
plates is determined by the axle variant.
5.4. Spherical washers.
Important: The crownwheel and pinion are matched
and should be renewed as a pair if either one is 5.5. Pressure plates.
damaged or excessively worn. The two halves of 5.6. Counter plates.
the differential housing are also matched as are the
differential side gears and bevel gears, do not use 5.7. Friction plates.
unmatched halves or gears. 5.8. Shims.
Disassemble 6. Make a note of the relative positions of the

friction plates, counter plates and spacers before
1. Use a heavy duty socket to remove the verbus- disassembly, they must be installed in the same
ripp bolts. Discard the bolts. positions.
Figure 1315. Limited Slip Differential (LSD)
E
F
H
J
K
N P
A M
G K
C J
H
G
27 - 610 9813/7600-3 27 - 610

27 - Driveline
24 - Differential
00 - General
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 - 611 9813/7600-3 27 - 611

27 - Driveline
24 - Differential
00 - General
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.
1.2. Side gears with pressure plates.
4. Use a DTI (Dial Test Indicator) (or feeler gauges),
1.3. Counter plates.
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.
Figure 1316.
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 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.
27 - 612 9813/7600-3 27 - 612

27 - Driveline
24 - Differential
00 - General

Item Nm
1
(1)
94
1
(2)
200
3 56
(1) The torque value is applicable for the 55 Series drivehead.
(2) The torque value is applicable for the 80 Series drivehead.
4. If the bearings must be replaced, extract the

(For: 550-80 [5AW], 550-80 [5UW], 560-80 external thrust blocks of the bearing 1 and
[5AY], 560-80 [5UY], Rear) bearing 2 from the middle cover 1 and middle
cover 2.
Consumables
Description Part No. Size 5. Accurately check the O-ring 1 and O-ring 2. Refer
to Figure 1319.
JCB Threadlocker and 4101/0550 0.01L
Sealer (High Strength) 4101/0552 0.2L Figure 1319.
Disassemble 3,25
1. Remove the differential unit. Refer to driveline-

rear differential, refer to (PIL 27-25).
2. Remove the snap ring. Refer to Figure 1317.
Figure 1317.
36,37 33,38
3 Bearing 1
25 Bearing 2
30 33 Middle cover 1
36 O-ring 2
37 O-ring 1
38 Middle cover 2
6. If required, remove and replace the bearing 1.
30 Snap ring Refer to Figure 1320.
3. Remove the cap. Refer to Figure 1318. Figure 1320.
Figure 1318. 3
29 3 Bearing 1
29 Cap
27 - 613 9813/7600-3 27 - 613

27 - Driveline
24 - Differential
00 - General
7. If required, remove and replace the bearing 2 10. Remove the screws 2 joining the differential to
from the differential carrier. Refer to Figure 1321. the half box. Refer to Figure 1324.
24
25
23
23 Differential carrier 24 Screws 2

25 Bearing 2
11. Using a plastic hammer, split the upper half box
8. Remove the fitting screws 1 of the crown. Refer and the lower half box. Refer to Figure 1325.
to Figure 1322.
Figure 1325.
Figure 1322.
13
4 5
5 Lower half box

4 Screws 1 13 Upper half box
9. Remove the spacer and the crown. Refer to 12. Note down the coupling marks.
Figure 1323.
13. Remove the upper half box. Refer to Figure 1326.
Figure 1323.
Figure 1326.
42
13
6 Crown
42 Spacer 13 Upper half box
27 - 614 9813/7600-3 27 - 614

27 - Driveline
24 - Differential
00 - General
14. Remove the shoulder ring 1 and the sun wheel Figure 1329.
1. Refer to Figure 1327.
Figure 1327.
22 17
21 10,12
16,9
9 Spherical shoulder washer 3

10 Planet wheel 3
12 Planet wheel 4
21 Sun wheel 1 13 Spherical shoulder washer 4
22 Shoulder ring 1 17 Shafts 2
15. Remove shafts 1, complete with the planet wheel 17. Remove the sun wheel 2 and the shoulder ring
1, planet wheel 2, spherical shoulder washer 1 2. Refer to Figure 1330.
and spherical shoulder washer 2. Refer to Figure
1328. Figure 1330.
Figure 1328.
15,19 8
18
14,20
5
5 Lower half box
7 Shoulder ring 2
14 Spherical shoulder washer 1 8 Sun wheel 2
15 Planet wheel 1
18 Shaft 1 Assemble
19 Planet wheel 2
20 Spherical shoulder washer 2 1. Install the shoulder ring 2 and the sun wheel 2
into the lower half box. Refer to Figure 1331.
16. Remove shafts 2, complete with planet wheel 3,
planet wheel 4, spherical shoulder washer 3 and
the spherical shoulder washer 4. Refer to Figure
1329.
27 - 615 9813/7600-3 27 - 615

27 - Driveline
24 - Differential
00 - General

15,19
18
8
14,20
5
5 Lower half box 14 Spherical shoulder washer 1
7 Shoulder ring 2 15 Planet wheel 1
8 Sun wheel 2 18 Shaft 1
19 Planet wheel 2
2. Install the planet wheel 3, planet wheel 4, 20 Spherical shoulder washer 2
spherical shoulder washer 3 and the spherical
shoulder washer 4 onto the shafts 2. 6. Install the sun wheel 1 and the shoulder ring 1.
3. Install the planetary set. Refer to Figure 1332.
Figure 1334.
Figure 1332.
22
21
17
10,12
16,9
21 Sun wheel 1
9 Spherical shoulder washer 3 22 Shoulder ring 1
10 Planet wheel 3
12 Planet wheel 4 7. Mount the upper half box on to the lower half box.
16 Spherical shoulder washer 4 Refer to Figure 1335.
17 Shafts 2
Figure 1335.
4. Install the planet wheel 1, planet wheel 2,
spherical shoulder washer 1 and the spherical
shoulder washer 2 onto the shafts 1. 13
5. Install the planetary set. Refer to Figure 1333.
5 Lower half box

13 Upper half box
27 - 616 9813/7600-3 27 - 616

27 - Driveline
24 - Differential
00 - General
8. Install and lock both the half boxes with screws Figure 1338.
2 coated with JCB sealant. 42
(High Strength)
9. The match marks on the two half-boxes must
align. Use only new screws. Refer to Figure
1336.
Figure 1336.
6
24
6 Crown
42 Spacer
13. Fasten the crown to the differential box with
screws 1. Use only new screws. Refer to Figure
1339.
Figure 1339.
24 Screws 2
10. Install the complete differential carrier unit in a
vice and tighten the screws 2 to the specified
torque value holding the two half boxes together.
Refer to Figure 1337. 4
6
Figure 1337.
24
4 Screws 1
6 Crown
14. Lock the crown by tightening the screws 1 to the
15. Use the alternate and criss cross tightening
method. Refer to Figure 1340.
24 Screws 2
11. Tighten screws using the alternate and criss-
cross method.
12. Install the spacer and the crown. Refer to Figure
1338.
27 - 617 9813/7600-3 27 - 617

27 - Driveline
24 - Differential
00 - General
Figure 1340.
4 Screws 1
6 Crown
16. Install the differential unit. Refer to driveline- rear
differential, refer to (PIL 27-25).

Item Description Nm
4 Screws 1 150
24 Screws 2 80
27 - 618 9813/7600-3 27 - 618

27 - Driveline
24 - Differential
09 - Pinion Gear
09 - Pinion Gear Component Identification

Component Identification ............................. 27-619 For: Dana 213 Series, Front .... Page 27-619
Remove and Install ..................................... 27-621 For: Dana 223 Series, Rear ..... Page 27-620
(For: Dana 213 Series, Front)
Figure 1341.
L
F
G
H
C J
A Nut B Pinion
C O-ring D Flange
E Seal ring F Main body
G Shims 1 H Distance piece
27 - 619 9813/7600-3 27 - 619

27 - Driveline
24 - Differential
09 - Pinion Gear
J Outer bearing K Inner Bearing

L Shims 2
Figure 1342. Pinion Gear- Dana 223 Axle
4
7
8 15
3 14
9
2
10
11
1
16
12
1 Pinion nut 2 Guard

3 External bearing 4 Shim washers
5 Pinion 6 Internal bearing
7 Shim S1 8 Distance piece
9 Sealing ring 10 Flange
11 O-ring 12 Main body
14 Cap 15 Snap ring
16 Drain plug
27 - 620 9813/7600-3 27 - 620

27 - Driveline
24 - Differential
09 - Pinion Gear
Remove and Install Refer to after sales- non JCB tools, refer to (PIL
78-94). Refer to Figure 1345.
Figure 1345.
Consumables
JCB Gear Oil LS Plus 4000/3901 5L
4000/3905 20L 1
4000/3903 200L
Sealer (High Strength) 4101/0552 0.2L
Remove
01-03). 1 Nut
2. Remove the axle arms. Refer to Figure 1343. 5. If necessary, heat the nut with a heat gun to
Figure 1343. approximately the specified temperature.
6. Remove the nut and the O-ring. Refer to Figure
1346.
Figure 1346.
3. Put match marks across the joint seam between

the nut and pinion. Attach a reaction bar to the
main body. Refer to Figure 1344.
Figure 1344. 1 Nut
3 O-ring
1
7. If the nut is heated to assist removal, then the O-
ring must be replaced.
A 2
8. Using a puller, pull out and remove the flange.
A Reaction bar
1 Nut
2 Pinion
4. With the Dana tool, wrench T15, hold the pinion
tight. Loosen the nut using a socket wrench.
27 - 621 9813/7600-3 27 - 621

27 - Driveline
24 - Differential
09 - Pinion Gear
4 Flange 2 Pinion
9. Replace only the seal ring of pinion. Pull the seal 15. Remove the seal ring of the pinion and outer
out using a screwdriver or a lever. Do not damage bearing. Refer to Figure 1350.
the ring seal and pinion. Refer to Figure 1348.
Figure 1350.
Figure 1348.
5 2
2 Pinion
2 Pinion 5 Seal ring
5 Seal ring
16. Using a puller for inner parts, remove the thrust
10. Apply Arexons rubber cement to the outer cup of the outer bearing. Refer to Figure 1351.
surface of the new seal ring. Install the seal ring
using the Dana tool T18. Refer to after sales- non Figure 1351.
JCB tools, refer to (PIL 78-94).
11. Apply JCB sealant to the pinion thread and
tighten the nut up to the marks across the joint
9
seam between nut and the pinion.
(High Strength)
12. Apply small blocks T16 to the main body and,
using a puller, pull out the entire pinion. Refer to
after sales- non JCB tools, refer to (PIL 78-94).
13. Outer bearing and thrust blocks remain in the
main body.
9 Bearing 1
14. Remove the pinion, the shims and the distance
piece. Refer to Figure 1349. 17. Using a punch of soft material, pull out the thrust
block of the inner bearing and the shims. Refer
to Figure 1352.
27 - 622 9813/7600-3 27 - 622

27 - Driveline
24 - Differential
09 - Pinion Gear
11
DG
10
10 Bearing 2 DG Dial gauge 1

11 Shims
1.3. Bring the inner bearing complete with the
18. Using a separator and a press, remove the inner thrust cup under the dial gauge 1.
bearing from the pinion. Refer to Figure 1353.
1.4. Calculate the total thickness of the bearing
Figure 1353. by checking deviation compared with
dimension of the block.
1.5. Press the thrust block centrally and carry
out several measurements by rotating the
thrust cup. Example: 43 - 0.62 = 42.38 =
2 Total thickness. Refer to Figure 1355.
Figure 1355.
9
DG
2 Pinion D
9 Bearing 1
Install
10
1. Calculate the pinion centre distance:
1.1. Using a faceplate, reset a dial gauge 1 on a D Total thickness
calibrated block of the specified thickness. DG Dial gauge 1
Length/Dimension/Distance: 43mm 10 Bearing 2
1.2. Preload the dial gauge 1 by the specified 2. Check the nominal dimension as marked on
value. Refer to Figure 1354. the pinion. Add up to subtract from the nominal
Length/Dimension/Distance: 3mm dimension the variation to obtain the actual
centre distance. Example: Actual centre distance
= 153-0.2 = 152.8. Refer to Figure 1356.
27 - 623 9813/7600-3 27 - 623

27 - Driveline
24 - Differential
09 - Pinion Gear

S
X Nominal dimension S Shims

Y Variation
5. Mount the driver T20A thrust cup of inner bearing
3. Calculate shims for insertion under the thrust cup and pack of shims onto the tension bar T20B.
of the inner bearing using the following formula: Install the tension bar into the main body and
mount the thrust cup of outer bearing and the
3.1. Shims = 196 - (Actual pinion centre distance driver T20C. Refer to after sales- non JCB tools,
+ Total bearing thickness) where 196 = refer to (PIL 78-94).Refer to Figure 1359.
Fixed dimension.
Figure 1359.
3.2. Example: Shims = 196 - (152.8 + 42.38) =
0.82 mm. Refer to Figure 1357.
10
Figure 1357.
196
K D S
10
9
11
11
9 Bearing 1
10 Bearing 2
11 Pack of shims
D Total bearing thickness 6. Apply grease on the shims to hold them in
K Actual pinion centre distance position.
S Shims
7. Connect the tension bar to the press and push
4. Subtract 0.05 to 0.07 mm from the resulting the thrust cup of bearing 1 and bearing 2 into their
shims value, until the value is rounded off to seats.
the lower 0.05 mm. Example: Shims = 0.75 mm.
Make up the pack of shims. Refer to Figure 1358. 8. Disconnect from the press and remove tension
bar and drivers. Refer to Figure 1360.
27 - 624 9813/7600-3 27 - 624

27 - Driveline
24 - Differential
09 - Pinion Gear
DDG
DDG
T17
T17
DDG Dial gauge 2

T17 Dana tool T17
9. Calculate the pinion bearing rolling torque.
9.4. Remove the dial gauge 2 and take out tool
9.1. Install the Dana tool T17 complete with the
and bearing kits from the main body.
bearing 1 and bearing 2 into the main body.
Tighten by hand until a rolling torque is 9.5. Reinstall every part, also installing a
definitely obtained. Refer to after sales- non distance piece between the bearing 1 and
JCB tools, refer to (PIL 78-94). Refer to bearing 2. Tighten the entire pack by hand.
Figure 1361. Refer to Figure 1363.
10
9
9
10
8
6
6 Main body 8 Distance piece

9 Bearing 1 9 Bearing 1
10 Bearing 2 10 Bearing 2
9.2. Insert the probe of a dial gauge 2 into either 9.6. Insert the probe of the dial gauge 2 in the
side hole of the Dana tool T17. Refer to after Dana tool T17 and measure the deviation
sales- non JCB tools, refer to (PIL 78-94). from the previous reset. Example: Deviation
= 1.19 mm. Refer to after sales- non JCB
9.3. Reset the dial gauge 2 with a preload of the tools, (PIL 78-94).
specified value. Refer to Figure 1362.
9.7. The deviation must be added to a set value
of 0.12 to 0.15 mm to make up the pack
of shims (7) for insertion between the inner
bearing and the distance piece.
9.8. Addition of the pack of shims must be
rounded off to the higher 0.05 mm.
Example: Shim pack = Deviation + Nominal
dimension = 1.19 + (0.12 to 0.15) = 1.31 to
1.34 mm.
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27 - Driveline
24 - Differential
09 - Pinion Gear
10. Heat the inner bearing to the specified value and Figure 1366.
install it to the pinion.
9
Figure 1364.
2
10
2 Pinion
9 Bearing 1
14. Lightly lubricate the bearing 2.
2 Pinion Consumable: JCB Gear Oil LS Plus
10 Bearing 2
15. Install the flange and the nut. Refer to Figure
11. Once the bearing has cooled down, lightly 1367.
lubricate the bearing 2.
Figure 1367.
Consumable: JCB Gear Oil LS Plus
12. Install the pinion, the shims and the distance
piece in the main body. Make sure you install the
thinner shims between the thicker ones. Refer to 4
Figure 1365.
Figure 1365.
6
1 Nut
8 4 Flange
7
2 16. Do not mount the seal ring and the O-ring at this
stage.
2 Pinion
6 Main body 17. If necessary, use a plastic hammer to key the
7 Shims flange.
8 Distance piece
18. From the main body, remove the small reaction
13. Heat the external bearing to the specified blocks T16 for pinion extraction and install
temperature and install it on to the pinion so as reaction bar. Refer to after sales- non JCB tools,
to complete the pack. Refer to Figure 1366. refer to (PIL 78-94). Refer to Figure 1368.
27 - 626 9813/7600-3 27 - 626

27 - Driveline
24 - Differential
09 - Pinion Gear
1 4
A Reaction bar 1 Nut

2 Pinion
19. Engage the Dana tool T15 on the flange and 4 Flange
tighten the nut to the specified torque value.
Refer to after sales- non JCB tools, refer to (PIL 27. Apply Arexons rubber cement to the outer
78-94). surface of the new seal ring and install the ring in
the main body using the Dana driver T18. Refer
20. Attach a torque meter onto the pinion nut and to after sales- non JCB tools, refer to (PIL 78-94).
check pinion torque. Torque should be of the Refer to Figure 1370.
specified value.
Figure 1370.
21. If torque exceeds maximum value, increase the
shims thickness (7) between the bearing 2 and
the distance piece. If the torque does not reach 6
the set value, increase the tightening torque
of the nut. Do this in several stages until the 5
maximum specified torque value reached.
22. If torque does not reach minimum value, reduce
the shims thickness.
23. In order to be able to calculate increase or
reduction on shims thickness, it should be taken
into account that for every 0.01 mm variation in
shim thickness, the pinion torque varies by the 5 Seal ring
specified value. 6 Main body
Torque: 0.6N·m 28. Oil seal ring lips and install flange.
24. Before you complete the installation of the pinion 29. Mount the O-ring and apply JCB sealant to the
and relative seals, install the differential unit. pinion tang. Refer to Figure 1371.
25. Make positional marks across the nuts and the Consumable: JCB Threadlocker and Sealer
pinion tang. (High Strength)
26. Remove nut and flange. Refer to Figure 1369.
27 - 627 9813/7600-3 27 - 627

27 - Driveline
24 - Differential
09 - Pinion Gear
Figure 1371. Disassemble and Assemble

4 Consumables
JCB Gear Oil LS Plus 4000/3901 5L
4000/3905 20L
4000/3903 200L
3 and Sealer (Medium 4101/0251 0.05L
1 Strength)
1 Nut Disassemble
3 O-ring
4 Flange 1. Remove both axle arms. Refer to Figure 1373.
30. Tighten the nuts until the match marks line up. Figure 1373.
Figure 1372.
2. If it is difficult to remove the pinion nut of

1 Nut the flange, heat it to the specified temperature.
Heating will aid the release of the threadlocker.
Figure 1374.
10
1 Pinion nut
10 Flange
3. Position the Dana tool T12, so as to avoid pinion
rotation. Refer to Figure 1375.
27 - 628 9813/7600-3 27 - 628

27 - Driveline
24 - Differential
09 - Pinion Gear
T12
9
T12 Dana tool t12 9 Sealing ring
4. Loosen and remove the pinion nut. Also remove 7. Attach the Dana tool T15 and, with the help of a
the O-ring. Refer to Figure 1376. puller remove the pinion complete with the inner
bearing, the distance piece, and the shims. The
Figure 1376. thrust cups of the bearings remain in the central
body. Refer to Figure 1379.
Figure 1379.
10
11
1
1 Pinion nut
2 Guard 5
10 Flange
11 O-ring T15
5 Pinion
5. Remove the flange complete with the guard. T15 Dana tool T15
8. Refer and keep to the positions marked during
Figure 1377. disassembly. Refer to Figure 1380.
Figure 1380.
10
2
2 Guard
10 Flange
6. Remove the sealing ring. Refer to Figure 1378.
27 - 629 9813/7600-3 27 - 629

27 - Driveline
24 - Differential
09 - Pinion Gear
9. Using a puller and a press, remove the Inner Figure 1384.

bearing from the pinion. Refer to Figure 1381.
6
Figure 1381.
4
4 Shim washers
6 Internal bearing
5 Pinion 13. Remove the snap ring. Refer to Figure 1385.
6 Internal bearing
Figure 1385.
10. Remove the thrust cup of the external bearing.
Figure 1382.
15
15 Snap ring
14. Remove the cap. Refer to Figure 1386.
3 External bearing Figure 1386.
11. Insert a drift in the appropriate holes. Refer to

Figure 1383.
Figure 1383.
14
14 Cap
Assemble
Calculating the pinion center distance
12. Remove the thrust cup of the Inner bearing as 1. Using a faceplate, reset a dial gauge on a
well as the shim washers. Refer to Figure 1384. calibrated block (whose known thickness is
27 - 630 9813/7600-3 27 - 630

27 - Driveline
24 - Differential
09 - Pinion Gear
42mm). Preload the dial gauge by the specified Figure 1389.

Figure 1387.
DG
I Actual pinion centre distance

42 mm M5 Match part number
Y Variation
DG Dial gauge 4.1. EXAMPLE: Nominal dimension, I = 135 -

0.1 = 134.9
2. Bring the inner bearing, complete with its thrust
cup, under the dial gauge. Refer to Figure 1388. 5. Calculate shims for insertion under the thrust cup
of the inner bearing using the following formula:
Figure 1388.
Figure 1390.
D Total bearing thickness

M5 Match part number
3. Press the thrust block centrally and carry out
several measurements by rotating the thrust cup. 5.1. Shims, S = 178 - I + D where: 178 = fixed
dimension, I =actual pinion centre distance,
3.1. EXAMPLE: 42 +0.5 = 42.5 = Total bearing D = Total bearing thickness.
thickness, D.
5.2. EXAMPLE: S = 178 - (134.9 + 42.5) = 0.6
4. Check the nominal dimension as marked on the mm. Refer to Figure 1390.
pinion. Add up to or subtract from the nominal
6. Using the Dana special tool T10, partially insert
dimension the variation to obtain the actual
the thrust cup of the bearing 1, bearing 2 and the
centre distance. Refer to Figure 1389.
shims. Refer to Figure 1391.
27 - 631 9813/7600-3 27 - 631

27 - Driveline
24 - Differential
09 - Pinion Gear
12
4
3 T11
T10 6
T10 Dana tool T10 T11 Dana tool T11
3 External bearing 3 External bearing
4 Shim washers 6 Internal bearing
6 Internal bearing 12 Main body
7. Connect the tension rod to the press and move 2. Introduce the probe of a dial gauge into either
the thrust cups of the bearing 1 and bearing 2 side hole of the Dana tool T11.
into the seats.
3. Reset the dial gauge with a preload of the
8. Disconnect the press and remove the tension specified value. Refer to Figure 1394.
rod. Refer to Figure 1392.
Figure 1392.
Figure 1394.
A
A T11 DG
T11
DG Dial gauge
9. Before starting the next stage, make sure that the T11 Dana tool T11
bearing thrust cup has been completely inserted
into its seat. 4. Remove the dial gauge and take out tool and
bearing kits from the main body.
Calculating pinion bearings rolling torque 5. Reinstall every part. Also introduce a distance
piece between the bearing 1 and bearing 2.
1. Introduce the Dana tool T11 complete with
Tighten the entire pack by hand. Refer to Figure
bearing 1 and bearing 2 into the main body.
1395.
Tighten by hand until a rolling torque is definitely
obtained. Refer to Figure 1393.
27 - 632 9813/7600-3 27 - 632

27 - Driveline
24 - Differential
09 - Pinion Gear
6 3
3 External bearing
6 Internal bearing 8.1. EXAMPLE: S1 = Deviation, H + Set value,
X = 1.19 + 0.12 to 0.13 = 1.32 to 1.33.
6. Introduce the dial gauge in the Dana tool T11 and
measure the deviation from the previous reset. 8.2. Use a shim thickness of the specified value.
Figure 1396.
B 1. Heat the inner bearing to the specified

temperature and install it to the pinion. Refer to
Figure 1398.
B
Figure 1398.
T11
5
T11 Dana tool T11 6
6.1. EXAMPLE: Deviation, H = A - B = 1.19 mm.

7. Add deviation to the specified set value to make
up the pack of shims (4) for insertion between the
inner bearing and the distance piece. 6
Length/Dimension/Distance: 0.12–0.13mm 5 Pinion
6 Internal bearing
8. The dimension of shims S1 must be rounded up
to the nearest 0.05 mm. 2. Once the inner bearing has been cooled down,
lightly lubricate it.
3. Make sure that the inner bearing is well set. Refer
to Figure 1399.
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27 - Driveline
24 - Differential
09 - Pinion Gear
8
12 6
6 Internal bearing 6 Internal bearing
8 Distance piece
4. Refer and keep to the positions marked during 12 Main body
disassembly. Refer to Figure 1400.
6. Heat the external bearing to the specified
Figure 1400. temperature and install it on to the pinion so as
to complete the pack. Refer to Figure 1402.
7 Temperature: 100°C (211.9°F)
7. Once the outer bearing has been cooled down,
lightly lubricate it.
5
11
11 66
44 Figure 1402.
8
3
9
2
10
1
3
1 Pinion nut
2 Guard
3 External bearing
4 Shim washers
5 Pinion
6 Internal bearing
7 Shim S1
8 Distance piece
9 Sealing ring 3 External bearing
10 Flange
8. Install the flange onto the pinion without sealing
11 O-ring
ring. Refer to Figure 1403.
5. Install the pinion, shim S1 and distance piece in
the main body. Make sure to place the thinnest
shims between the thicker ones.
27 - 634 9813/7600-3 27 - 634

27 - Driveline
24 - Differential
09 - Pinion Gear
10
10 Flange
9. Attach wrench to the pinion nut and bar-hold the 12. If the torque does not reach the minimum value,
Dana tool, T12 to the pinion. then the size of the shims S1 must be reduced.
When you calculate the increase or decrease in
10. Lock the Dana tool, T12 and rotate the pinion size of shim S1, make a note that a variation of
using a suitable torque wrench, up to a minimum shim S of 0.01 mm corresponds to a variation of
required torque of the specified range. Refer to the specified value in the torque of the pinion.
Figure 1404. Torque: 0.6N·m
Torque: 800–1,000N·m
13. Make positional marks across the pinion nut and
Figure 1404. the pinion tang. Remove the pinion nut and the
flange. Refer to Figure 1406.
Figure 1406.
T12 1
T12 Dana tool T12

10
11. If the torque does not reach the set value,
increase the torque setting of the pinion nut in 1 Pinion nut
different stages to obtain the maximum specified 5 Pinion
value.Refer to Figure 1405. 10 Flange
Torque: 800–1,000N·m 14. Apply Arexons rubber cement to the outer
surface of the new seal ring and install the ring
in the main body using the Dana tool, T13. Refer
to Figure 1407.
27 - 635 9813/7600-3 27 - 635

27 - Driveline
24 - Differential
09 - Pinion Gear
12
9 T13 10 11 1
T13 Dana tool T13 1 Pinion nut
9 Sealing ring 10 Flange
12 Main body 11 O-ring
15. Install the safety flange. Refer to Figure 1408. 18. Tighten the pinion nut until the match marks line
up. Refer to Figure 1410.
Figure 1408.
Figure 1410.
2 Guard
16. Oil seal the ring lips and install flange.
17. Mount the O-ring and apply JCB sealant to the
pinion tang. Tighten the pinion nut. Refer to
Figure 1409.
(Medium Strength)
27 - 636 9813/7600-3 27 - 636

27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ......................................................................................................................... 27-639

27-27-03 Upper Trunnion ............................................................................................................ 27-653
27-27-60 Swivel ........................................................................................................................... 27-655
27-27-66 Wheel Stud ................................................................................................................... 27-663
27 - 637 9813/7600-3 27 - 637

Notes:
27 - 638 9813/7600-3 27 - 638

27 - Driveline
27 - Hub
00 - General
Introduction .................................................. 27-639 The hub is the part of the axle where the wheel
Component Identification ............................. 27-640 is mounted and where the axle shaft (if installed)
Drain and Fill ............................................... 27-642 passes through.
Calibrate ...................................................... 27-645
Some hubs are not driven and rotate due to motion
Disassemble and Assemble ........................ 27-645 of the machine and some driven hubs may also have
reduction gearing installed.
The hub may also be designed to allow steering of

the wheels and/or incorporate brakes.
27 - 639 9813/7600-3 27 - 639

27 - Driveline
27 - Hub
00 - General

(For: 55-Series, 70-Series)
Figure 1413.
Unit Identification
G H
The axle serial number is stamped on the unit
identification plate as shown. When you make an
mentioned on the unit identification plate. In the case
of gear replacements, always check the part number A
Figure 1411. B
K
A D
E L
Figure 1412. F M
Table 504.
Item no Description
A Annulus ring
B Planet gear assembly
(x3)
C Thrust pad
D Sun gear
E Planet gear carrier
F Wheel stud (x5)
G Bearing carrier
A Identification plate H Hub swivel
J Driveshaft
K Oil seal
L Wheel bearing (inner)
M Wheel bearing (outer)
27 - 640 9813/7600-3 27 - 640

27 - Driveline
27 - Hub
00 - General
Sectional Drawing
Figure 1414.
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 505. 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)
27 - 641 9813/7600-3 27 - 641

27 - Driveline
27 - Hub
00 - General
Drain and Fill
4. Apply the park brake.

(For: 55-Series, 70/80-Series) 5. Set the transmission to the neutral position.
Check the hub oil level of one wheel at a time. 6. Lower the attachments to the ground.
Complete the steps below to check the hub oil.
8. Clean the area around the hub plug.
2. Set the machine level with the wheels above the
ground. 9. Remove the hub plug.
2.1. Use suitable lifting equipment to lift the 10. Check the oil level of the hub.
machine axles to the same level.
10.1. The hub oil level must be level with the
3. Set the hub oil level mark to the horizontal bottom surface of the plug hole.
position.
10.2. If necessary, add the correct axle oil. Refer
3.1. Turn the wheel manually to get the hub oil to (PIL 75).
level mark to the horizontal position.
11. Clean the plug before you install it.
3.2. The specified tolerance is permitted above
or below the oil level mark horizontal 12. Install the hub plug and tighten to the correct
position. torque.
Length/Dimension/Distance: 5mm 12.1. To Make sure you use the correct torque
tightening information, identify the correct
Figure 1415. axle for your machine. Refer to Figure
A 1416. and Refer to Figure 1417.
12.2. Make sure you identify the correct plug
B for your machine. Then use the related
torque information. Refer to Figure 1418.
and Refer to Figure 1419.
D C
A Wheel
B Hub
C Plug
D Level mark
E Tolerance 5mm
27 - 642 9813/7600-3 27 - 642

27 - Driveline
27 - Hub
00 - General
Figure 1416. JCB Axles With Inboard Brakes (If installed)
A
B
A Axle drain plug 1 location
Table 506. JCB Axles With Inboard Brakes

Type of Differential Plug In- Hub Plug Installed Hub Plug Torque (Nm)
stalled on Your Machine
Axle drain plug 1 with hexagonal Taper plug (3/4 in NPSF) 50
head and bonded washer
Axle drain plug 1 with tapered plug Taper plug (3/4 in BSP) 80
Figure 1417. JCB Axles With Braked Hubs (If installed)

D
D Drain plug E Axle drain plug 2 location
Table 507. Axles With Braked Hubs

Type of Differential Plug In- Hub Plug Installed Hub Plug Torque (Nm)
stalled on Your Machine
Axle drain plug 2 with hexagonal Plug (M22) 37.5
head and bonded washer
Axle drain plug 2 with tapered plug Taper plug (3/4 in BSP) 80
Figure 1418. Hexagonal Head Plug and

Bonded Washer (Prior to January 2011)
27 - 643 9813/7600-3 27 - 643

27 - Driveline
27 - Hub
00 - General
Figure 1419. Taper Plug (If in-

stalled) (January 2011 Onwards)
27 - 644 9813/7600-3 27 - 644

27 - Driveline
27 - Hub
00 - General
Calibrate Disassemble and Assemble
Refer to the relevant Disassemble and Assemble (For: Dana 223 Series, Rear)
Consumables
JCB High Strength 4102/0551 0.05L
Threadlocker
Strength)
Dismantle
1. Remove check screws from the planetary gear
carrier cover.
Figure 1420.
1 Screw
2. Insert a lever in the slots provided and prise to
remove the planetary gear carrier.
Figure 1421.
2 Planet gear carrier

3 Hub carrier
3. Remove the complete planet gear carrier.
27 - 645 9813/7600-3 27 - 645

27 - Driveline
27 - Hub
00 - General
2 Planet gear carrier

4. Loosen and remove the nuts that lock the gear 7. Partially draw out the wheel hub by using a
ring flange plastic hammer.
4 nuts 7 Wheel hub

5 Gear ring flange
8. Remove the external bearing.
5. Remove the safety flange
Figure 1427.
Figure 1424.
8 External bearing
6 Safety flange
9. Draw out the wheel hub.
6. Remove the complete gear ring flange by using a
puller and applying counter pressure to the studs.
27 - 646 9813/7600-3 27 - 646

27 - Driveline
27 - Hub
00 - General
10 Planetary gears
10. Take out the pins and remove the steering case. 13. Remove the snap ring of the gear ring.
For more information see Driveline, Rear Hub,
Swivel (PIL 27-28-60) Figure 1432.
Figure 1429.
12 Snap ring
13 Gear ring
3 steering case
14. Remove the gear ring flange.
11. Remove the snap rings.
Figure 1433.
Figure 1430.
14 Gear ring flange.

9 Snap ring
15. Remove the seal ring from the wheel hub. Make
12. Using a puller, remove the planetary gears. sure you mark the seal ring position.
27 - 647 9813/7600-3 27 - 647

27 - Driveline
27 - Hub
00 - General
Figure 1434. 18. Using a puller, remove seal ring from steering
case. Make sure you note down the seal ring
orientation.
Figure 1437.
15 Seal ring
16. Remove the bearing.
Figure 1435. 17 Seal ring
19. Using the Dana service tool, extract the guide
bushing of the twin U-joint.
20. Remove the defective studs, which will need to
be replaced.
Figure 1438.
16 Bearing
17. Remove the outer thrust cups of both bearings
by inserting and hitting a pin-driver in the slots
provided on the hub. Make sure you drive the
bearing races evenly to avoid damage.
Figure 1436.
T5 Dana service tool
Assemble
1. Install the bushing in the steering case using the
Dana service tool.
7 Hub
8 Bearing outer race
16 Bearing outer race
27 - 648 9813/7600-3 27 - 648

27 - Driveline
27 - Hub
00 - General
18 Bush 16 Bearing (outer race)

T6 Dana service tool T8 Dana service tool
2. Apply a coat of AREXONS rubber cement to the 5. Install the bearing.
outer metal surface of the seal ring.
6. Apply Arexons seal rubber cement to the outer
3. Position the seal ring and, using tool the Dana surface of seal ring.
service tool, install it in the appropriate seat.
Make sure the direction of installation is correct. 7. Position the seal ring in the hub. Make sure you
check the seal ring orientation carefully.
Figure 1440.
Figure 1442.

17 Seal ring 7 Hub
15 Seal ring
4. Position the wheel hub under a press; lubricate 16 Bearing outer race
the outer seat of bearing and, using the Dana
service tool, install the thrust block of bearing. 8. Position tool the Dana service tool and press the
seal ring into its seat.
27 - 649 9813/7600-3 27 - 649

27 - Driveline
27 - Hub
00 - General
15 Seal ring 12 Snap ring

T9 Dana service tool 13 Gear ring
14 Flange
9. Turn the hub cover, lubricate bearing seat and
use the Dana service tool to install the thrust 11. Mount the gears onto the pins of the planetary
block of the bearing. cover. To insert gears, use tool the Dana service
tool. Make sure the radiused part of the bearings
Figure 1444.
inner ring must faces the bottom of the pin.
Figure 1446.
7 Hub cover
10. Install the flange in the gear ring and lock into 2 Planetary cover
position with the snap ring. Make sure that the 9 Snap rings
snap ring is fully inserted in the slot of the gear 10 Gears
ring. T21 Dana service tool
12. Lock the gears into position by installing the snap
rings.
27 - 650 9813/7600-3 27 - 650

27 - Driveline
27 - Hub
00 - General
9 Snap ring 3 Steering hub

10 Gear 7 Wheel hub
13. Oil the seal ring and bushing. Slip the steering 17. Install the outer bearing. Make sure you push the
case onto the twin U-joint, install the pivot pins bearing as far as it will go by tapping with a plastic
and connect the steering link arm. hammer all around the rim.
3 Steering case 8 Outer bearing

14. For more information see Driveline, Rear Hub, 18. Install the complete gear ring flange. To engage
Swivel (PIL 27-28-60). the flange, use a plastic hammer and hit
alternately at several equally spaced points.
15. If studs have been removed, apply a coat of JCB
Locking Fluid to the fastened end of the studs Figure 1452.
and apply Tecnolube 101 to ground nut end;
tighten the studs as far as they will go
Figure 1449.
19 Stud 5 Flange
16. Install the wheel hub onto the steering case. 19. Make sure that faces are thoroughly clean, and
then mount the safety flange.
27 - 651 9813/7600-3 27 - 651

27 - Driveline
27 - Hub
00 - General
6 Safety flange 2 Planetary gear cover

14 Flange 7 Wheel hub
20. Apply JCB Locking Fluid to the studs and tighten 23. Lock the planetary cover with the screw and
nuts. tighten to the specified torque.
Consumable: JCB Threadlocker and Sealer Torque: 40–50N·m
(Medium Strength)
Figure 1456.
21. Tighten the nuts in two stages using the criss-
cross method using the specified torques.
Figure 1454.
1 Screw
2 Planetary gear cover
4 Nuts
21.1. Initial tightening torque:
Torque: 250N·m
21.2. Final tightening torque:
Torque: 460–465N·m
22. Install the planetary cover on the wheel hub.
Make sure you check the condition and position
of the O-ring.
27 - 652 9813/7600-3 27 - 652

27 - Driveline
27 - Hub
03 - Upper Trunnion
03 - Upper Trunnion Figure 1459.
Disassembly
Figure 1457.
3. Position the trunnion support under a press and

remove the complete bushing.
D Figure 1460.
C
B
A
A Cap
B Grease nipple
C Trunnion support (x2)
D Bush
1. Remove the trunnion support.
2. Remove the trunnion support on the side

opposite the drive. Assembly
1. If the bushing is worn and needs replacing, note
down the assembly side of the connection notch.
27 - 653 9813/7600-3 27 - 653

27 - Driveline
27 - Hub
03 - Upper Trunnion

E
C
E Notch
2. Position the trunnion support under a press and
insert the complete bushing.
Figure 1463.
3. Install the trunnion support.

Figure 1464.
4. Install the trunnion support on the side opposite

the drive.
27 - 654 9813/7600-3 27 - 654

27 - Driveline
27 - Hub
60 - Swivel
60 - Swivel Figure 1467.
Remove and Install

For: Dana 213 Series, Front .... Page 27-655
For: Dana 223 Series, Rear ..... Page 27-660
3
2
Consumables
Moly Grease 4003/1326 12.5kg
JCB Threadlocker 4101/0250 0.01L 2 Screws 1
and Sealer (Medium 4101/0251 0.05L 3 Lower pivot pin
Strength)
4. Insert a screwdriver or lever alternately in the
Remove slots provided and prise the lower pivot pin along
with the dust ring 1. Refer to Figure 1468.
1. Disconnect the pivot of the steering link arm from
Figure 1468.
the steering swivel.
2. Sling the whole unit and connect it to a hoist.
Slightly tension the sling rope. Refer to Figure
1466.
Figure 1466.
1
3 Lower pivot pin

5. Make sure you replace the dust ring 1 when you
disassemble each time.
6. Loosen and remove the screws 2 of the upper
1 Steering link arm pivot pin. Refer to Figure 1469.
3. Loosen and remove the screws 1 of the lower Figure 1469.

pivot pin. Refer to Figure 1467.
5
6
5 Screws 2
6 Upper pivot pin
27 - 655 9813/7600-3 27 - 655

27 - Driveline
27 - Hub
60 - Swivel
7. Insert a screwdriver or lever alternately in the Figure 1472.

slots provided and prise the upper pivot pin along
with the dust ring 2.
8. Make sure you replace the dust ring 2 when you
disassemble each time. Refer to Figure 1470.
Figure 1470.
12
6 8
7
11
11 Upper bushing
12 Lower ball bushing
11. When the bushings are pulled out, the distance
pieces are removed as well.
12. Remove the dust ring 1 from the lower pivot pin.
6 Upper pivot pin Refer to Figure 1473.
7 Shims
8 Dust ring 2 Figure 1473.
9. Remove the complete steering swivel by drawing

it out from the twin joint. Refer to Figure 1471. 4
Figure 1471.
4 Dust ring 1
13. Note down direction of installation. Refer to
10 Figure 1474.
9 Steering swivel
10 Twin joint
10. Using a puller for inner parts, remove the upper
bushing and the lower ball bushing. Refer to
Figure 1472.
27 - 656 9813/7600-3 27 - 656

27 - Driveline
27 - Hub
60 - Swivel
6 12
4
12
4
3
3 Lower pivot pin 3 Lower pivot pin
4 Dust ring 1 12 Lower ball bushing
6 Upper pivot pin
12 Lower ball bushing 2. Install a new dust ring 1 onto the lower pivot pin.
Make sure you check the orientation carefully.
14. If the round cap needs replacement, remove the Refer to Figure 1477.
round cap from the lower pivot pin. Refer to
Figure 1475.
4
12
3 4 Dust ring 1
3 Lower pivot pin 3. Lubricate the upper bushing and the round
12 Lower ball bushing lower bushing. Install them in the fulcrum holes
provided on the arm, using a suitable tool. Refer
to Figure 1478.
Install
Figure 1478.
1. If the pivot pin has been disassembled, put the
lower pivot pin under a press and install the round
cap. Refer to Figure 1476.
12
11
11 Upper bushing
12 Lower ball bushing
27 - 657 9813/7600-3 27 - 657

27 - Driveline
27 - Hub
60 - Swivel
4. Install distance pieces using the same tools. Figure 1481.

Figure 1479. 6
13
6 Upper pivot pin

13
8. Temporarily lock the upper pivot pin complete
13 Distance piece with the dust ring 2, but with out shims with four
screws 2. Refer to Figure 1482.
5. Lubricate the end part of twin U-joint and mount
the steering swivel. Make sure you do not Figure 1482.
damage the seal ring of the twin joint. Refer to
Figure 1480.
Figure 1480. 6
10 6 Upper pivot pin

9. Fill the seat of the lower pivot pin with grease and
insert the complete lower pivot pin.
9 Steering swivel Consumable: Extreme Performance Moly
10 Twin joint Grease
6. Make sure that the holes for the upper and lower 10. Apply JCB sealant to the screws 1 and tighten
fulcrum pins are aligned. until the lower pivot pin is secured.
7. Install the upper pivot pin. Refer to Figure 1481. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
11. Loosen upper pivot pin screws 2 by the specified
value.
12. Tighten the screws 1 to the specified torque
using the criss-cross tightening method. Refer to
Figure 1483.
27 - 658 9813/7600-3 27 - 658

27 - Driveline
27 - Hub
60 - Swivel
3 Lower pivot pin

13. Tighten the screws 2 of the upper pivot pin with 17. Remove the upper pivot pin along with the dust
the crisscross method until you notice a slight ring 2.
increase in the torque of the steering swivel.
18. Fill the seat of the upper pivot pin with grease.
14. Using a feeler gauge, check clearance between Consumable: Extreme Performance Moly
the upper pivot flange and the steering swivel. Grease
Check at several points. Refer to Figure 1484.
19. Position the pack of shims previously calculated.
Figure 1484.
20. Reinstall the upper pivot pin along with the dust
ring 2.
6 5
21. Apply JCB sealant to the screws 2.
(Medium Strength)
22. Tighten the screws 2 to the specified torque value
using the criss-cross tightening method. Refer to
Figure 1486.
9 Figure 1486.
5 Screws 2
6 Upper pivot pin 6 7
9 Steering swivel
15. Calculate the average of measurements taken 8
and subtract the specified value from the
resulting measure until you have rounded off to
the lower decimal figure.
Length/Dimension/Distance: 0–0.1mm
16. Make up the pack of shims choosing among the
available shims. Refer to Figure 1485.
6 Upper pivot pin
7 Shims
8 Dust ring 2
23. Check that the steering swivel is free to rotate
and has no vertical clearance. If necessary,
recalculate shims as described earlier. Refer to
Figure 1487.
24. Thoroughly lubricate the two pivot pins with
grease.
27 - 659 9813/7600-3 27 - 659

27 - Driveline
27 - Hub
60 - Swivel
Consumable: Extreme Performance Moly Figure 1489.

Grease
Figure 1487.
10
19
10 Sealing ring
19 Bottom articulation pin
5 Screws 2 3. Using two levers, remove the top articulation pin
complete with the front seal and the shims. Refer
Table 508. Torque Values to Figure 1490.
Item Description Nm
Figure 1490.
2 Screws 1 136
5 Screws 2 136
(For: Dana 223 Series, Rear) 4
Remove
9
1. Loosen and remove the installed screw 1 and
screw 2 from the bottom actuation pin and the top
actuation pin. Refer to Figure 1488.
Figure 1488.
3
3 Shims
4 Top articulation pin
9 Front seal
4
4. Take care not to damage the surfaces.
5. Remove the complete steering case. Refer to
8 Figure 1491.
Figure 1491.
15 19
1
8 Screw 2
15 Screw 1
19 Bottom articulation screw
2. Remove the bottom articulation pin complete
with the front sealing ring. Refer to Figure 1489.
1 Steering case
27 - 660 9813/7600-3 27 - 660

27 - Driveline
27 - Hub
60 - Swivel
Install Figure 1494.
1. Lubricate the terminal of the U-joint and install

the steering case. Refer to Figure 1492.
Figure 1492. 4
3
3 Shims
1 8. Lubricate the unit in the steering case. Refer to
Figure 1495.
1 Steering case
Figure 1495.
2. Take care not to damage the dust cover rings and
the sealing rings.
3. Install a series of shims of the specified thickness
under the top articulation pin. Refer to Figure
1493.
Figure 1493.
4
9. Install the bottom articulation pin in the steering

case.
10. Position the screws 2 and tighten to a necessary
torque.
3 11. Check for the correct assembly side of the

sealing ring. Refer to Figure 1496.
3 Shims
4. Install a new seal on to the top articulation pin.
5. Lubricate and install the unit in the steering case.
6. Position the screws 2 and tighten to the specified
torque value.
7. Check the correct assembly side of the seal.
27 - 661 9813/7600-3 27 - 661

27 - Driveline
27 - Hub
60 - Swivel
12
10
19
1
1 Steering case
10 Sealing ring 15. The torque of the bottom and top articulation pins
12 Bearing should be of the specified value.
19 Bottom articulation pin
16. If the preliminary measured value is too high,
12. Tighten the new installed screws 1 of the top and increase the shims.
bottom articulation pins to the specified torque
value. Refer to Figure 1497. Figure 1499.
Figure 1497.
15
15 Screws 1 Table 509. Torque Values

13. Using a lever check for the vertical gap. Item Description Nm
4 Top articulation pin 60
14. If there is any gap, determine the width and
8 Screw 2 140
reduce it by removing the shims. Refer to Figure
1498. 15 Screws 1 140
19 Bottom articulation pin 60
27 - 662 9813/7600-3 27 - 662

27 - Driveline
27 - Hub
66 - Wheel Stud
66 - Wheel Stud Figure 1501.

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 1500.
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 - 663 9813/7600-3 27 - 663

27 - Driveline
29 - Wheel
29 - Wheel
Contents Page No.
27-29-00 General ......................................................................................................................... 27-665
27 - 664 9813/7600-3 27 - 664

27 - Driveline
29 - Wheel
00 - General
Introduction .................................................. 27-665 On new machines, and whenever a wheel has been
Health and Safety ........................................ 27-666 removed, check the wheel nut torques every two
Remove and Install ..................................... 27-666 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 - 665 9813/7600-3 27 - 665

27 - Driveline
29 - Wheel
00 - General
Health and Safety Remove and Install

WARNING If, for whatever reason, a wheel stud
is renewed, all the studs for that wheel must be (For: 550-80 [5AW], 550-80 [5UW], 560-80
changed as a set, since the remaining studs may [5AY], 560-80 [5UY])
have been damaged.
WARNING Wheels and tyres are heavy. Take WARNING Whenever a wheel has been
care when lifting or moving them. Store with care changed, check the nut torques every two hours.
to ensure that they cannot fall and cause injury. When the nuts stay tight for 8h, the interval for
checking can revert to the period stated in the
WARNING An exploding tyre can kill. Inflated servicing schedule.
tyres can explode if over-heated or over-inflated.
Follow the instructions given when inflating the WARNING Run flat inserts are installed in the
tyres. Do not cut or weld the rims. Use a tyre/ rear wheels. These must remain installed to the
wheel specialist for all repair work. rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre.
WARNING Deflate the tyre you wish to change
before removing the wheel from the machine.
Air pressure in the tyres can cause the tyre and Remove (One Wheel)
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner 1. Make the machine safe. Refer to (PIL 01-03).
and outer wheel halves together when there is air 2. Follow the general health and safety procedures.
pressure in the tyre. Always wear safety glasses. Refer to (PIL 01-03).
WARNING Wheels installed with semi-solid tyres
are heavy. Removing and installing them requires 3. Put chocks 1 under the rear wheels.
special equipment and training. Have the work
4. Loosen the five wheel nuts by half a turn.
carried out by your JCB dealer or a tyre specialist.
WARNING Do not install pneumatic tyres on a 5. Put a jack under the axle arm. Use the correct
wheel made for a solid tyre. Do not install a solid jack.
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for 6. Use the jack to lift the machine until the front
your machine, contact your local JCB dealer or a wheel is off the ground.
trained specialist. 7. Put chocks 2 under the axle arm.
DANGER Run flat inserts may be installed in the
rear wheels. These must remain installed to the 8. Hold the wheel and remove the wheel nuts.
rear wheels to ensure machine stability is not
9. Remove the wheel.
compromised in the event of a deflated tyre.
Make sure that all tyres are inflated to the correct
pressure and have run flat inserts as required.
Where run flat inserts have been specified for use,
ensure that replacement wheels also have run flat
inserts to ensure the machine stability.
27 - 666 9813/7600-3 27 - 666

27 - Driveline
29 - Wheel
00 - General
Figure 1502.
E
C
D
B
A Chocks 1
B Wheel nuts
C Jack
D Front wheel
E Chocks 2
Install
steps.
1.1. Make sure that the mating surfaces of the
wheel and axle hub are clean.
1.2. Tighten the wheel nuts to the correct torque
value.

Item Torque value
B 650N·m
27 - 667 9813/7600-3 27 - 667

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-669
27 - 668 9813/7600-3 27 - 668

27 - Driveline
33 - Tyre
00 - General
Introduction .................................................. 27-669 Tyres provide a flexible cushion that absorb shocks,
Health and Safety ........................................ 27-670 while keeping the wheel in close contact with the
Check (Condition) ........................................ 27-670 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 - 669 9813/7600-3 27 - 669

27 - Driveline
33 - Tyre
00 - General

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

make sure it is correctly installed on the machine
or installed in a tyre inflation cage.
27 - 670 9813/7600-3 27 - 670

27 - Driveline
33 - Tyre
00 - General
Figure 1503.
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 - 671 9813/7600-3 27 - 671

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-673
27 - 672 9813/7600-3 27 - 672

27 - Driveline
47 - Propshaft
00 - General

Check (Condition) ........................................ 27-673 1. Make the machine safe. Refer to (PIL 01-03).
Lubricate ...................................................... 27-674
2. Check the propshaft tube for damage or cracks.
3. Check the centre bearing (if installed) for
security, cracks or damage.
4. Check the universal joints for security, cracks
or damage. Make sure that there is no play in
the joint and that grease points are present (if
installed).
5. Check the sliding joints for security, cracks or
damage. Make sure that there is no play in
the joint and that grease points are present (if
installed).
6. Check any sensor or sensor ring for security,
cracks or damage (if installed).
7. Make sure the correct fasteners are installed and
tightened to the correct torque.
8. Renew any defective component as needed.
27 - 673 9813/7600-3 27 - 673

27 - Driveline
47 - Propshaft
00 - General
Lubricate
2. Make sure you have the correct grease.
3. Use a grease gun to lubricate the universal joint
grease points until fresh grease appears past the
seals of all four bearings in each joint.
3.1. If grease does not appear, push the
propshaft away from the bearing that
grease does not appear from and grease
again.
3.2. If grease still does not appear, remove and
examine the bearing. Renew if necessary.
4. Remove any excess grease.
27 - 674 9813/7600-3 27 - 674

27 - Driveline
47 - Propshaft
00 - General
Remove and Install
For: Front, HM560 Variable Transmission, Description Part No. Size

Rear ........................................ Page 27-675 Special MPL-EP 4003/1501 0.4kg
For: Front, Rear ...................... Page 27-676 Grease 4003/1506 12.5kg
4003/1510 50kg
(For: Front, HM560 Variable Transmission,
Rear) WARNING Before disconnecting any propshaft,
make sure you block both sides of all wheels
Consumables to prevent machine movement. The park brake
Description Part No. Size will become ineffective or may only operate on 2
JCB Threadlocker 4101/0250 0.01L wheels (depending on machine specification).
Strength)
Remove
Figure 1504.
A
A Chassis B Front propeller shaft

C Rear propeller shaft D Dual Tech Variable Transmission
27 - 675 9813/7600-3 27 - 675

27 - Driveline
47 - Propshaft
00 - General
E Bolts F Strap
1. Make the machine safe with the lift arm raised. Figure 1505.
2. Install the maintenance strut. Refer to (PIL X
06-69).
3. Remove the central access panels. refer to (PIL
06-06).
4. Put marks on all propshaft joints and the
sliding joints before removal to help during the Y
replacement procedure.
5. Support the propshaft.
6. Remove the bolts and straps to disconnect the
propshaft from the axles.
Install Z

At the time of installation follow the steps below.
1. Lubricate the sliding joints with the specified X Same plane (correct)
grease only, then align the shafts against Y Right angle (not correct)
identification marks previously made or, in Z Intermediate angle (not correct)
the case of a shaft being replaced use the 5. Tighten the bolts to the correct torque value.
manufacturer's alignment markings.
Consumable: Special MPL-EP Grease Table 511. Torque Values
2. Apply sealant to the threads of all the flange Item Description Nm

bolts. A Bolts 1 70
(Medium Strength)
(For: Front, Rear)
3. Straps must always be replaced with new ones.
Consumables
4. The propshaft must have both ends exactly on Description Part No. Size
the same plane as shown below. Refer to Figure JCB Threadlocker 4101/0250 0.01L
1505. and Sealer (Medium 4101/0251 0.05L
Strength)
4.1. The yokes must not be at right angles or
Special MPL-EP 4003/1501 0.4kg
at an intermediate angle. Refer to Figure
Grease 4003/1506 12.5kg
1505.
4003/1510 50kg
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
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).
2. Remove the central access panels. refer to (PIL
06-06).
27 - 676 9813/7600-3 27 - 676

27 - Driveline
47 - Propshaft
00 - General
3. Put marks on both propshaft companion flanges 4.2. Remove the nuts and the bolts 1 to
and the sliding joints before removal to help disconnect the propshaft coupling from the
during the replacement procedure. transmission.
4. Machines without RAS (Rear Axle Stabilization): 4.3. Remove the bolts 2 and straps to
disconnect the propshaft form the axles.
4.1. Support the propshaft.
5. Machines with RAS:
Figure 1506.
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
B axle.
Consumable: Special MPL-EP Grease
A
A Bolts 1
B Bolts 2
C Strap
27 - 677 9813/7600-3 27 - 677

27 - Driveline
47 - Propshaft
00 - General
Figure 1507.
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 1508.
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 1508.
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 - 678 9813/7600-3 27 - 678

27 - Driveline
47 - Propshaft
00 - General
Figure 1508.
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 - 679 9813/7600-3 27 - 679

27 - Driveline
51 - Driveshaft
51 - Driveshaft
Contents Page No.
27-51-00 General ......................................................................................................................... 27-681

27-51-15 Shaft Hub Side ............................................................................................................. 27-689
27 - 680 9813/7600-3 27 - 680

27 - Driveline
51 - Driveshaft
00 - General
Check (Condition) ........................................ 27-682 transmitting torque and rotation, usually used to
Lubricate ...................................................... 27-682 connect other components of the driveline that
Remove and Install ..................................... 27-683 cannot be connected directly because of distance
or the need to allow for relative movement between
Disassemble and Assemble ........................ 27-687 them.
27 - 681 9813/7600-3 27 - 681

27 - Driveline
51 - Driveshaft
00 - General
Check (Condition) Lubricate
(For: 55-Series, 70/80-Series) (For: 55-Series, 70/80-Series)

1. Make the machine safe. Refer to (PIL01-03). 1. Make the machine safe. Refer to (PIL 01-03).
2. Check the joint for damage, cracks or play. 2. Make sure you have the correct grease. Refer to
(PIL 75-00).
3. Renew any defective component as needed.
3. Use a grease gun to lubricate the universal joint
grease points until fresh grease appears past the
seals of all four bearings in each joint.
3.1. If grease does not appear, push the
driveshaft away from the bearing that
grease does not appear from and grease
again.
3.2. If grease still does not appear, remove and
examine the bearing. Renew if necessary.
4. Remove any excess grease.
27 - 682 9813/7600-3 27 - 682

27 - Driveline
51 - Driveshaft
00 - General
Remove and Install 4. The twin U-joint can only be removed once
the steering swivel has been removed. Refer to
For: Dana 213 Series, Front .... Page 27-683 driveline- front hub, refer to (PIL 27-27).
For: Dana 223 Series, Rear ..... Page 27-685 5. Introduce compressed air at specified pressure
into the service brake line to hold brake discs in
(For: Dana 213 Series, Front) position.
Consumables Pressure: 7bar (101.4psi)
Description Part No. Size 6. Remove the snap ring 1 of the bushing kit. Refer
JCB Threadlocker 4101/0250 0.01L to Figure 1511.
Strength) Figure 1511.
Remove
1. Loosen and remove the check nut of the dowel.
Remove the dowel. Refer to Figure 1509.
Figure 1509. 4
1 2
4 Snap ring 1
5 Bushing
7. Put the U-joint under a press and remove the
complete bushing. Refer to Figure 1512.
Figure 1512.
1 Check nut
2 Dowel
2. Remove the driveshaft and the twin U-joint. Refer
to Figure 1510.
Figure 1510. 5
5 Bushing
8. Remove the snap ring 2 of the bearing.
3 9. Remove the O-ring and, using a puller for inner
parts, remove the bearing and the seal ring. Note
down the direction of installation of the seal ring.
3 U-joint
3. If required, use a plastic hammer or lever to ease
extraction of the twin U-joint.
27 - 683 9813/7600-3 27 - 683

27 - Driveline
51 - Driveshaft
00 - General
6 7
6 7
9
8
6 Snap ring 2 6 Snap ring 2

7 Bearing 7 Bearing
8 O-ring
9 Seal ring 3. Install the complete bushing onto the twin U-joint
and set the bushing into position with a plastic
hammer.
Install
4. Make sure you tap around the whole rim. Refer
1. Using the Dana tools T3 and T4, put the seal
to Figure 1516.
ring and the bearing into the bushing. Check the
direction of installation of the seal carefully. Refer Figure 1516.
to Figure 1514.
Figure 1514.
5
T3 T4
5 Bushing
5. Install the snap ring of the bushing kit. Put the O-
T3 Dana tool T3 ring also in position. Refer to Figure 1517.
T4 Dana tool T4
5 Bushing Figure 1517.
2. Install the snap ring to the bearing. Refer to

Figure 1515.
4 Snap ring 1
5 Bushing
27 - 684 9813/7600-3 27 - 684

27 - Driveline
51 - Driveshaft
00 - General
6. Install the twin U-joint into the arm and lock into (For: Dana 223 Series, Rear)
position with the dowel coated with JCB sealant.
Consumables
Consumable: JCB Threadlocker and Sealer Description Part No. Size
(Medium Strength)
7. Tighten the dowel to the specified torque value. and Sealer (Medium 4101/0251 0.05L
Refer to Figure 1518. Strength)
Figure 1518. Remove

1. Remove the steering swivel. Refer to driveline-
rear hub, refer to (PIL 27-28).
2 2. Removal is carried out with the axle arm resting
on the bench.
3. Introduce compressed air of the specified
pressure into the service brakingline to hold the
3 brake discs in position.
4. Loosen and remove the check nut of the dowel.
2 Dowel 5. Remove the dowel. Refer to Figure 1520.

3 U-joint
Figure 1520.
8. Apply JCB sealant to the protrusion position of
the dowel and tighten the nut.
(Medium Strength)
A B
9. Tighten the nut to the specified torque value while
holding the dowel in position. Refer to Figure
1519.
Figure 1519.
1 2
1,2 A Check nut

B Dowel
6. Pull out the whole driveshaft together with the
twin U-joint. Refer to Figure 1521.
Figure 1521.
1 Check nut
2 Dowel

Item Description Nm
A Check nut 65
B Dowel 15 C
C U-joint
27 - 685 9813/7600-3 27 - 685

27 - Driveline
51 - Driveshaft
00 - General
7. If necessary use plastic hammer or lever to pull Table 514. Torque Values
out the twin U-joint.
Item Description Nm
A Check nut 70
Install
B Dowel 15
1. Insert the twin U-joint into the axle arm and lock
into position with the dowel coated with JCB
sealant.
(Medium Strength)
2. Tighten the dowel to the specified torque value.
Figure 1522.
2 Dowel
3 U-joint
3. Apply JCB sealant to the protruding portion of the
dowel.
(Medium Strength)
4. Hold the dowel in position and tighten the nut to
the specified torque value. Refer to Figure 1523.
Figure 1523.
A
B
A,B
A Check nut
B Dowel
27 - 686 9813/7600-3 27 - 686

27 - Driveline
51 - Driveshaft
00 - General
Disassemble
1. Remove the rear driveshaft. Refer to driveline-
rear driveshaft, refer to (PIL 27-52).
C D
2. Remove the snap ring 1 from the bushing kit. F
Refer to Figure 1524. E
Figure 1524.
C Snap ring
D Bearing
E O-ring
F Seal ring
A Assemble
1. Using the Dana tool T3 and the Dana tool T4,
install the seal ring and the bearing into the
bushing.
2. Check the direction of installation of the seal.
B Refer to Figure 1527.
A Snap ring 1 Figure 1527.
B Bushing kit
3. Place the U-joint under a press and remove the
complete bushing. Refer to Figure 1525.
Figure 1525.
T3 T4
3. Install the snap ring 2 of the bearing. Refer to

Figure 1528.
4. Remove the snap ring 2 of the bearing.

5. Remove the O-ring.
6. Using a puller remove the bearing and the seal
ring.
7. Mark the direction of installation of the seal ring.
27 - 687 9813/7600-3 27 - 687

27 - Driveline
51 - Driveshaft
00 - General
Figure 1528.
C D
4. Install the complete bushing onto the twin U-

joint. Set the bushing into position with a plastic
hammer. Refer to Figure 1529.
Figure 1529.
5. Tap around the whole rim.

6. Install the snap ring 1 on the bushing kit. Position
the O-ring. Refer to Figure 1530.
Figure 1530.
7. Install the rear driveshaft. Refer to driveline- rear

driveshaft, refer to (PIL 27-52).
27 - 688 9813/7600-3 27 - 688

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
15 - Shaft Hub Side 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 1532.
Remove and Install
Figure 1532. 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: 98N·m 11. Tighten the bolts to the specified torque value.
4. Install the top trunnion and finger tighten the top Torque: 98N·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 1531. mentioned in the step 5.
Figure 1531. Measuring the swivel turning force Table 515. Example of
shim thickness calculation
Gap 1.55mm
Subtract 1mm
Shim Thickness 0.55mm
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 - 689 9813/7600-3 27 - 689

Notes:
27 - 690 9813/7600-3 27 - 690

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-03 Smooth Ride System (SRS) .......................................................................................... 30-38
30-00-09 Levelling System ............................................................................................................ 30-44
30-00-49 Schematic Symbols ........................................................................................................ 30-52
30-00-50 Schematic Circuit ........................................................................................................... 30-56
30-03 Tank
30-03-00 General ......................................................................................................................... 30-167
30-04 Filter
30-04-00 General ......................................................................................................................... 30-177
30-04-03 Main .............................................................................................................................. 30-178
30-04-09 Return Line ................................................................................................................... 30-180
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-187
30-11 Gear Pump
30-11-00 General ......................................................................................................................... 30-193
30-12 Variable Displacement Pump
30-12-00 General ......................................................................................................................... 30-205
30-13 Hydrostatic Pump
30-13-00 General ......................................................................................................................... 30-219
30-15 Cylinder / Ram
30-15-00 General ......................................................................................................................... 30-229
30-15-06 Lift Arm ......................................................................................................................... 30-241
30-15-07 Lift Extension ................................................................................................................ 30-247
30-15-08 Lift Compensating ........................................................................................................ 30-258
30-15-11 Lift Arm Crowd ............................................................................................................. 30-263
30-15-34 Steering ........................................................................................................................ 30-274
30-15-63 Sway ............................................................................................................................. 30-277
30-15-99 Seal Kit ......................................................................................................................... 30-280
30-18 Accumulator
30-18-00 General ......................................................................................................................... 30-285
30-18-06 Smooth Ride System (SRS) ........................................................................................ 30-291
30-21 Oil Cooler
30-21-00 General ......................................................................................................................... 30-301
30-30 Manifold
30-30-00 General ......................................................................................................................... 30-311
30-51 Lift Arm Control Valve Block
30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-313
30-51-06 Auxiliary Relief Valve (ARV) ......................................................................................... 30-314
30-51-21 Load Sense Relief Valve .............................................................................................. 30-317
30-51-24 Flow Regulator ............................................................................................................. 30-320
30-53 Servo System Control Valve Block
9813/7600-3
2018-02-25
30-53-00 General ......................................................................................................................... 30-325
30-53-27 Pressure Compensator Valve ...................................................................................... 30-356
30-53-36 Load Hold Check Valve ............................................................................................... 30-359
30-53-80 Spool ............................................................................................................................ 30-360
30-54 Parallel Circuit Control Valve Block
30-54-00 General ......................................................................................................................... 30-365
30-60 Directional Control Valve
30-60-00 General ......................................................................................................................... 30-391
30-60-12 Electro Proportional Control ......................................................................................... 30-393
30-60-15 Joystick ......................................................................................................................... 30-406
30-60-18 Shuttle .......................................................................................................................... 30-415
30-60-27 Auxiliary Circuit ............................................................................................................ 30-416
30-60-82 Sway ............................................................................................................................. 30-417
30-60-90 Flow Regulator ............................................................................................................. 30-421
30-61 Counterbalance Valve
30-61-00 General ......................................................................................................................... 30-423
30-61-06 Lift Arm ......................................................................................................................... 30-431
30-63 Hose Burst Check Valve
30-63-00 General ......................................................................................................................... 30-435
30-70 Pilot Pressure Supply Valve
30-70-00 General ......................................................................................................................... 30-439
30-93 Hose
30-93-00 General ......................................................................................................................... 30-451
30-93-03 Lift Arm ......................................................................................................................... 30-464
30-96 Pipe
30-96-03 Lift Arm ......................................................................................................................... 30-467
30-97 Connectors
30-97-03 Quick Release Coupling .............................................................................................. 30-469
30-97-09 Adaptor ......................................................................................................................... 30-471
30-97-24 Push Lock Fitting ......................................................................................................... 30-473
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-474
9813/7600-3
2018-02-25
Acronyms Glossary
ARV Auxiliary Relief Valve

BSP British Standard Pipe
Transmission
HBCV Hose Burst Check Valve
HVCS Hydraulic Variable Control Solenoid
Valve
LED Light Emitting Diode
LS Load Sense
LSD Limited Slip Differential
LSRV Load Sense Relief Valve
MRV Main Relief Valve
PRV Pressure Relief Valve
QRC Quick Release Coupling
SAE Society of Automotive Engineers
TBV Trailer Brake Valve
9813/7600-3
2018-02-25
Notes:
9813/7600-3
2018-02-25
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-03 Smooth Ride System (SRS) .......................................................................................... 30-38
30-00-09 Levelling System ............................................................................................................ 30-44
30-00-49 Schematic Symbols ........................................................................................................ 30-52
30-00-50 Schematic Circuit ........................................................................................................... 30-56
30 - 1 9813/7600-3 30 - 1
Notes:
30 - 2 9813/7600-3 30 - 2
00 - General
00 - General
Introduction ...................................................... 30-3
Health and Safety ........................................... 30-5
Technical Data ................................................. 30-6
Operation ....................................................... 30-17
Operation (Hydraulic) .................................... 30-23
Diagram ......................................................... 30-24
Fault-Finding .................................................. 30-27
Discharge and Pressurise ............................. 30-29
Clean ............................................................. 30-32
Check (Level) ................................................ 30-33
Check (Pressure) .......................................... 30-34
(For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY],
JCB Tier 4F Engine 4 Cyl)
Table 516. Valve Block and Pump Options

Machine Valve Block Options Hydraulic Pump Options
526-56
Agri Electro servo - Gear -
Agri Plus Electro servo - Gear -
531-70
Agri Manual lever Electro servo Gear
(1)
Variable
Agri Plus Electro servo - - Variable
Agri Super Electro servo - - Variable
Agri Extra NGE - - Variable
Agri Pro Electro servo - - Variable
535-95
(1)
Variable
536-60
Agri Electro servo - - Variable
536-70
(1)
Variable
536-70LP
Agri Electro servo - - Variable
541-70
30 - 3 9813/7600-3 30 - 3
00 - General
00 - General
Machine Valve Block Options Hydraulic Pump Options

(1)
Variable
550/80
560/80
(1) Manual lever only.
30 - 4 9813/7600-3 30 - 4
00 - General
00 - General
Health and Safety

Hydraulic Pressure
removing hoses. Make sure the machine cannot be
WARNING! Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well clear of
pressurised fluid and wear protective glasses. If fluid
penetrates your skin, get medical help immediately.
WARNING! Take care when disconnecting hydraulic
hoses and fittings as the oil will be hot.
WARNING! Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not use
the machine if a hose or hose fixture is damaged.
Notice: Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component
has been disconnected, always install protective
caps and plugs to prevent dirt ingress.Failure to
follow these instructions will lead to dirt entering the
system. Dirt in the system will seriously damage
the systems components and could be expensive to
repair.
CAUTION! The temperature of the hydraulic oil will
be high soon after stopping the machine. Wait until it
cools before beginning maintenance.
30 - 5 9813/7600-3 30 - 5
00 - General
00 - General
Technical Data
For: 550-80 [5AW], 550-80 [5UW], 560-80 Circuit Restriction Relief Valve
[5AY], 560-80 [5UY] .................... Page 30-6 Setting
For: 526-56 [T4F] ........................ Page 30-7 Neutral Circuit Sway Circuit 220bar
For: 535-95 [5AB], 535-95 [5TB] limited by the (3,188.4psi)
..................................................... Page 30-8 ARV
For: 536-60 [5AC], 536-60 [5TC] Lift End The lift circuit 260bar
..................................................... Page 30-9 is limited to the (3,768.1psi)
For: 536-70 [5AE], 536-70 [5TE], 541-70 MRV pressure
[5AD], 541-70 [5TD] .................... Page 30-9 Lift End The extension 260bar
For: 531-70 [5AA], 531-70 [5TA] circuit is limit- (3,768.1psi)
................................................... Page 30-11 ed to the MRV
pressure
(For: 550-80 [5AW], 550-80 [5UW], 560-80 Lift End The tilt circuit 260bar
[5AY], 560-80 [5UY]) is limited to the (3,768.1psi)
MRV pressure
during normal
Table 517. System Pressures operation and
the parallel lift
Circuit Restriction Relief Valve function when
Setting the tilt ram end
Neutral Circuit Pressure lim- 260bar stops is limited
ited by main (3,768.1psi) by the ARV
valve block Auxiliaries / Auxiliary circuit 220bar
MRV (Main Re- Hitch is limited by the (3,188.4psi)
lief Valve) ARV
Neutral Circuit Fan Motor Cir- 230bar Steer Circuit Steer circuit is 175bar
cuit limited by (3,333.3psi) limited by the (2,536.2psi)
the ARV (Aux- ARV
iliary Relief
Valve)
Neutral Circuit Trailer Brake 145bar
Circuit limited (2,101.4psi)
by the ARV
30 - 6 9813/7600-3 30 - 6
00 - General
00 - General
Figure 1533.
A B 4
A B 3
A B 2
A B 1
P T
332/H5263-2
1 Spool 1, lift arm, electric control 2 Spool 2, tilt, electric control

3 Spool 3, lift arm extend / retract, electric control 4 Spool 4, auxiliary, electric control
Circuit Restriction Relief Valve

(For: 526-56 [T4F]) Setting
Lift End The tilt circuit 260bar
Gear Pump Machines is limited to the (3,768.1psi)
MRVpressure
Table 518. System Pressures during normal
(Gear Pump)T4 EN15000 operation and
Circuit Restriction Relief Valve the parallel lift
Setting function when
the tilt ram end
Neutral Circuit Pressure limited 260bar stops is limited
by main valve (3,768.1psi) by the ARV to
block MRV
Auxiliaries / Auxiliary circuit 180bar
Neutral Circuit Fan motor cir- 230bar Hitch is limited by the (2,608.7psi)
cuit limited by (3,333.3psi) ARV to
the ARV
Steer Circuit Steer circuit is 190bar
Neutral Circuit Trailer brake 150bar limited by the (2,753.6psi)
circuit limited by (2,173.9psi) ARV to
the ARV
Lift End The lift circuit 260bar
is limited to the (3,768.1psi)
MRV pressure
Lift End The extension 260bar
circuit is limit- (3,768.1psi)
ed to the MRV
pressure
30 - 7 9813/7600-3 30 - 7
00 - General
00 - General
(For: 535-95 [5AB], 535-95 [5TB]) Circuit Restriction Relief Valve

Setting
Gear Pump Machines Neutral Circuit Trailer Brake 150bar
Double Pump Machines by the ARV to
Neutral Circuit Sway Circuit 220bar
Table 519. System Pressures (Gear limited by the (3,188.4psi)
Pump- 2 Section) EN15000 Multi Lever ARV to
Circuit Restriction Relief Valve Lift End The lift circuit is 240bar
Setting limited to MRV (3,478.2psi)
Neutral Circuit Pressure limited 240bar pressure
by main valve (3,478.2psi) Lift End The extension 240bar
block MRV circuit is limit- (3,478.2psi)
Neutral Circuit Fan Motor Cir- 230bar ed to the MRV
cuit limited by (3,333.3psi) pressure
the ARV Lift End The tilt circuit is 240bar
Neutral Circuit Trailer Brake 150bar limited to MRV- (3,478.2psi)
Circuit limited (2,173.9psi) pressure dur-
by the ARV to ing normal op-
eration and
the parallel lift
limited by the (3,188.4psi)
function when
ARV to
the tilt ram end
Lift End The lift circuit is 240bar stops is limited
limited to MRV (3,478.2psi) by the ARV to
pressure
Lift End The extension 240bar Hitch is limited by the (3,188.4psi)
circuit is limited (3,478.2psi) ARV to
to MRV pres-
sure
Lift End The tilt circuit is 240bar ARV to
limited to MRV (3,478.2psi)
pressure dur-
ing normal op- Variable Pump Machines
eration and
the parallel lift
Table 521. System Pressures (Variable Pump)
function when
the tilt ram end Circuit Restriction Relief Valve
stops is limited Setting
by ARV to Neutral Circuit Pressure limited 240bar
Auxiliaries / Auxiliary circuit 220bar by main valve (3,478.2psi)
Hitch is limited by the (3,188.4psi) block MRV
ARV to Neutral Circuit Fan Motor Cir- 230bar
Steer Circuit Steer circuit is 190bar cuit limited by (3,333.3psi)
limited by the (2,753.6psi) the ARV
ARV to Neutral Circuit Trailer Brake 150bar
Triple Pump Machines by the ARV to
Table 520. System Pressures (Gear
Pump- 3 Section) EN15000 Single Lever
ARV to
Circuit Restriction Relief Valve Lift End The lift circuit is 240bar
Setting limited to MRV (3,478.2psi)
Neutral Circuit Pressure limited 240bar pressure
by main valve (3,478.2psi) Lift End The extension 240bar
block MRV circuit is limited (3,478.2psi)
Neutral Circuit Fan Motor Cir- 230bar to MRV pres-
cuit limited by (3,333.3psi) sure
the ARV
30 - 8 9813/7600-3 30 - 8
00 - General
00 - General
Circuit Restriction Relief Valve Circuit Restriction Relief Valve

Setting Setting
Lift End The tilt circuit is 240bar Auxiliaries / Auxiliary circuit 220bar
limited to MRV (3,478.2psi) Hitch is limited by the (3,188.4psi)
pressure dur- ARV to
ing normal op- Steer Circuit Steer circuit is 190bar
eration and limited by the (2,753.6psi)
the parallel lift ARV to
function when
the tilt ram end
stops is limited
by ARV to (For: 536-70 [5AE], 536-70 [5TE], 541-70
Auxiliaries / Auxiliary circuit 220bar [5AD], 541-70 [5TD])
Hitch is limited by the (3,188.4psi)
ARV to Gear Pump Machines
limited by the (2,753.6psi) Double Pump Machines
ARV to
Table 523. System Pressures (Gear
Pump- 2 Section) EN15000 Multi Lever
(For: 536-60 [5AC], 536-60 [5TC]) Circuit Restriction Relief Valve
Setting
Neutral Circuit Pressure limited 260bar
Table 522. System Pressures (Gear Pump- 2 by main valve (3,768.1psi)
Section - double pump) EN15000 Multi Lever block MRV
Circuit Restriction Relief Valve Neutral Circuit Fan Motor Cir- 230bar
Setting cuit limited by (3,333.3psi)
Neutral Circuit Pressure limited 260bar the ARV
by main valve (3,768.1psi) Neutral Circuit Trailer Brake 150bar
block MRV Circuit limited (2,173.9psi)
Neutral Circuit Fan Motor Cir- 230bar by the ARV
cuit limited by (3,333.3psi) Neutral Circuit Sway Circuit 220bar
the ARV limited by the (3,188.4psi)
Neutral Circuit Trailer Brake 150bar ARV
Circuit limited (2,173.9psi) Lift End Pressure limited 260bar
by the ARV to by main valve (3,768.1psi)
Neutral Circuit Sway Circuit 220bar block MRV set
limited by the (3,188.4psi) at
ARV to Lift End Pressure limited 260bar
Lift End The lift circuit is 260bar by main valve (3,768.1psi)
limited to MRV (3,768.1psi) block MRV set
pressure at
Lift End The extension 260bar Lift End The tilt circuit is 138bar
circuit is limited (3,768.1psi) limited to MRV (2,000.0psi)
to MRV pres- pressure dur-
sure ing normal op-
eration and
Lift End The tilt circuit is 140bar the parallel lift
limited to MRV (2,029.0psi) function when
pressure dur- the tilt ram end
ing normal op- stops is limited
eration and by the ARV to
the parallel lift
function when Auxiliaries / Auxiliary circuit 220bar
the tilt ram end Hitch is limited by the (3,188.4psi)
stops is limited ARV to
by the ARV to Steer Circuit Steer circuit is 190bar
ARV to
30 - 9 9813/7600-3 30 - 9
00 - General
00 - General
Triple Pump Machines Circuit Restriction Relief Valve

Setting
Table 524. System Pressures (Gear Neutral Circuit Trailer Brake 150bar
Pump- 3 Section) EN15000 Single Lever Circuit limited (2,173.9psi)
by the ARV
Setting Neutral Circuit Sway Circuit 220bar
Neutral Circuit Pressure limited 260bar
ARV
by main valve (3,768.1psi)
block MRV Lift End The lift circuit is 260bar
Neutral Circuit Fan Motor Cir- 230bar
pressure
cuit limited by (3,333.3psi)
the ARV Lift End The extension 260bar
circuit is limited (3,768.1psi)
Neutral Circuit Trailer Brake 150bar
to MRV pres-
sure
by the ARV
Lift End The tilt circuit is 140bar
pressure dur-
ARV
ing normal op-
Lift End The lift circuit is 260bar eration and
limited to MRV (3,768.1psi) the parallel lift
pressure function when
Lift End The extension 260bar the tilt ram end
circuit is limited (3,768.1psi) stops is limited
to MRV pres- by the ARV to
sure Auxiliaries / Auxiliary circuit 220bar
Lift End The tilt circuit is 138bar Hitch is limited by the (3,188.4psi)
limited to MRV (2,000.0psi) ARV to
pressure dur- Steer Circuit Steer circuit is 190bar
ing normal op- limited by the (2,753.6psi)
eration and ARV to
the parallel lift
function when
the tilt ram end A536-70L Machine Agri Plus / Super
stops is limited
by the ARV to Table 526. System Pressures
Auxiliaries / Auxiliary circuit 220bar (Variable Pump) Agri Plus / Super
ARV to Circuit Restriction Relief Valve
Setting
limited by the (2,753.6psi) Neutral Circuit Pressure limited 260bar
ARV to by main valve (3,768.1psi)
block MRV
Variable Pump Machines Neutral Circuit Fan Motor Cir- 230bar
cuit limited by (3,333.3psi)
the ARV
A536-70L Machine (Not Agri Plus / Super /
Xtra) Neutral Circuit Trailer Brake 150bar
by the ARV
Table 525. System Pressures (Variable
Pump) Not Agri Plus / Super / Xtra)
Circuit Restriction Relief Valve ARV
Setting Lift End The lift circuit is 260bar
Neutral Circuit Pressure limited 260bar limited to MRV (3,768.1psi)
by main valve (3,768.1psi) pressure
block MRV Lift End The extension 260bar
Neutral Circuit Fan Motor Cir- 230bar circuit is limited (3,768.1psi)
cuit limited by (3,333.3psi) to MRV pres-
the ARV sure
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Setting (For: 531-70 [5AA], 531-70 [5TA])
limited to MRV (2,029.0psi) Valve 25/411600 Mechanical Lever
pressure dur- Control, (Non SRS).
ing normal op-
eration and Figure 1534.
the parallel lift F
function when
the tilt ram end
stops is limited
by the ARV to B
ARV to A
limited by the (2,753.6psi) 1 2 3 4
ARV to
A536-70L Machine Agri Xtra

Table 527. System Pressures C
(Variable Pump) Agri Xtra
Setting
Neutral Circuit Pressure limited 260bar D
by main valve (3,768.1psi) E
block MRV 1 Lift spool (double acting)
Neutral Circuit Fan Motor Cir- 230bar 2 Extend spool (double acting)
cuit limited by (3,333.3psi) 3 Tilt spool (double acting)
ARV 4 Auxiliary spool (double acting)
Neutral Circuit Trailer Brake 150bar A Port A
Circuit limited (2,173.9psi) B Port B
by the ARV C Top outlet section
- - - D Linkage assemby
E MRV position
Lift End The lift circuit is 260bar
F Top inlet
pressure
Lift End The extension 260bar Table 528.
circuit is limited (3,768.1psi)
to MRV pres- MRV pressure 241.3bar (3,497.1psi)
sure
pressure dur-
ing normal op-
eration and
the parallel lift
function when
the tilt ram end
stops is limited
by the ARV to
ARV to
ARV to
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Valve 25/407900 Mechanical Single Lever

Control, (Non SRS).
Figure 1535.
K L M
1 2 3 4 C
F
A
E
D
1 Lift spool (double acting)
2 Tilt spool (double acting)
3 Extend spool (double acting)
4 Auxiliary spool (double acting)
A Port A
B Port B
C Top outlet section
D Solenoid operated pilot section
E Port restrictors
F Accumulator port
G Top outlet (plugged)
H 10bar (144.9psi) pilot generating inlet section
J Top inlet
K MRV position
L Accumulator port
M Port restrictors
Table 529.
MRV pressure 241.3bar (3,497.1psi)
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For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................... Page 30-13
For: 526-56 [T4F] ...................... Page 30-15
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
Figure 1536.
G B
A
E
F
A1 A2 A3
K N
L P
M
K Oil from pump section 1 L Oil from pump section 2

M Oil suction line from the tank to the pump N Return to tank
sections
P Oil from pump section 3
30 - 13 9813/7600-3 30 - 13
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Item Description Notes

D Hydraulic tank -
Table 530.
E Fan motor Driven by pump
Item Description Notes section 2
A Pump assembly Two or three F Hydraulic oil Oil from pump
section cooler section 2 flows
gearpump through the oil
A1 Pump section 1 - cooler
A2 Pump section 2 - G Single lever -
A3 Pump section 3 - control
B Control valve Parallel valve
block block
C Hydraulic oil fil- Positioned in
ter the return line
to tank
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(For: 526-56 [T4F])
Figure 1537.
G H
J C
A
E
Q
A1
A3
A2
K N
L P
M
K Oil from pump section 1 L Oil from pump section 2 (if installed)
M Oil suction line from the tank to the pump N Return to tank
sections
P Oil from pump section 3
Item Description
Table 531. A3 Pump section 3 -
Item Description (if installed
A Pump assembly Two or three B Control valve Parallel valve
section block block
gearpump C Hydraulic oil fil- Positioned in
A1 Pump section 1 - ter the return line
A2 Pump section 2 - to tank
(if installed) D Hydraulic tank -
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Item Description
E Fan motor Driven by pump
section 2
Q Hydraulic oil Oil from pump
cooler section 2 flows
through the oil
cooler
30 - 16 9813/7600-3 30 - 16
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Operation
flows through the priority valve and joins with the flow
(For: 526-56 [T4F], 531-70 [5AA], 531-70 from pump section 1 to feed the control valve block.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 Pump section 3 is dedicated to driving the cooling
fan. Oil from pump section 3 flows directly to the
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 cooling fan hydraulic motor. On sway machines a
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 changeover valve switches oil supply between the
[5AW], 550-80 [5UW], 560-80 [5AY], sway ram service and the fan motor.
560-80 [5UY])
Some smaller machines may have a hydraulic pump
with only two sections, in this case the larger pump
Hydraulic pump section 1 has the integral priority valve, and operates
in the same way as section 2.
Oil is drawn from the hydraulic tank by the hydraulic
pump assembly. The pump assembly is mounted on In neutral circuit conditions (i.e. no service selected),
the rear of the bevel gearbox and is driven by the the oil flows through the control valve block neutral
engine. gallery into the return or exhaust line and back to the
tank through an in-tank filter.
The pump has three sections, Oil from the larger
pump section 1 flows direct to the control valve block. Some machine variants also have a hydraulic oil
Pump section 2 has an integral priority valve which cooler in the return line from the fan hydraulic motor,
always gives priority demand to the steer circuit. to cool the system hydraulic oil as it is continually
With the steering in the straight ahead position (i.e. circulated around the cooling fan circuit.
with no steering demand), oil from pump section 2
30 - 17 9813/7600-3 30 - 17
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Figure 1538.
G H
C
J
A
E
Q
A1 A2 A3
K N
L P
M
Item Description
Table 532. E Fan motor Driven by pump
section 2
Item Description
Q Hydraulic oil Oil from pump
A Pump assembly Two or three cooler section 2 flows
section through the oil
gearpump cooler
A1 Pump section 1 -
A2 Pump section 2 -
Table 533. Hydraulic connections colour key
A3 Pump section 3 -
B Control valve Parallel valve Item Description
block block K Oil from pump section 1
C Hydraulic oil fil- Positioned in L Oil from pump section 2
ter the return line M Oil suction line from the
to tank tank to the pump sec-
D Hydraulic tank - tions
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Item Description spools. A third lever operates the auxiliary service

N Return to tank spool. The levers operate the spools via mechanical
linkages. For machines with stabilisers two more
P Oil from pump section 3 levers are installed to operate the stabiliser service
spools (6 spool control valve).
Control valve block
Single lever control
The control valve block controls the boom hydraulic
services. For machines with stabilisers, the valve has Machines with single lever control use a lever which
two more spools to control the stabiliser hydraulic moves in two axis and operates two service spools
services. via mechanical linkages. Buttons on the control lever
operate solenoid valves on the remaining two spools.
When the control valve spools are actuated, oil from
the pump passes into the service ports, operating the
relevant hydraulic ram.
Parallel lift
The parallel lift system is used to make sure that
The control valve contains MRV (Main Relief Valve)
when the boom raise/lower or extend/retract services
and ARV (Auxiliary Relief Valve). These valves
are operated, the forks remain parallel to the ground.
prevent the hydraulic pressure increasing to a
level which would cause damage to the hydraulic
components and pipework. Boom regenerative valve (3 stage
booms)
The control valve block inlet section also includes
valves which are used for the LLMC (Longitudinal The regenerative valve is installed to the outer
Load Moment Control) system. extension ram to increase the speed of the boom
during the extend cycle, under light load conditions.
Dual lever control Hydraulic oil is displaced from the rod side of the
inner extension ram to supplement the pump flow to
Machines with dual lever control use two control the head side of the outer extension ram. The speed
levers for operation of the three loader service of the extending boom is increased.
Figure 1539.
Q S
R
Q Outer extension ram HBCV (Hose Burst Check R PRV (Pressure Relief Valve)
Valve)
S Pilot operated check valve T Non-return valve
The only servicing possible in the event of external Boom extend cycle
oil leakage is the renewal of oil seals, or the renewal
of a faulty screw-in cartridge. Light load (Regenerative cycle)
As the boom extends with the forks lightly loaded,

oil from the valve block flows through the outer
30 - 19 9813/7600-3 30 - 19
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extension ram HBCV to the head side of the outer to the head side of inner extension ram. The inner
extension ram. extension ram starts to extend and oil is displaced
from the rod side of the cylinder. A PRV prevents oil
Oil is displaced from the rod side of outer extension leaving the regenerative valve block and returning to
ram and passes through inner extension ram HBCV tank.
Figure 1540.
U1
Y
V U
Z
U Inner extension ram U1 Counterbalance valve

V Outer extension ram W Outer extension ram HBCV
X PRV Y Pilot operated check valve
Z Check valve
A pilot operated check-valve opens to allow the oil to ram HBCV to the head side of the outer extension
supplement the main pump flow through the check ram.
valve and the speed of extension.
Oil is displaced from the rod side of outer extension
Heavy load ram and passes through the inner extension ram
HBCV to the head side of inner extension ram.
As the boom extends, oil under high pressure closes The inner extension ram starts to extend and oil
the check valve. Oil flows through the outer extension is displaced from the rod side of the cylinder. Pilot
pressure opens the PRV.
30 - 20 9813/7600-3 30 - 20
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Figure 1541.
W
U1
V
Y
U
Z

Z Check valve
Oil displaced from the rod side of the inner Boom retract cycle
extension ram now passes through the extension
spool and back to tank. This oil is prevented from As the boom is retracted, oil flows through the PRV to
supplementing the main pump flow by the pilot the rod side of inner extension ram. Oil is prevented
operated check-valve. from entering the regenerative valve block by the
pilot operated check-valve. Oil is displaced from the
The boom will extend slower, but with more force head side of inner extension ram through the HBCV
than the regenerative cycle. and back to tank through the extension spool. Oil
cannot flow through the regenerative valve because
the check valve is closed.
Figure 1542.
U1
V
Y
U
Z
30 - 21 9813/7600-3 30 - 21
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Z Check valve
30 - 22 9813/7600-3 30 - 22
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Operation (Hydraulic) and leakage and can lead to major problems. The
main contaminants can be classified as follows:
The hydraulic system is a power transmission system 1. Solid Particles - Sand, fibres, metallic particles,
that uses the force of flowing liquids to transmit power welding scale, sealing materials and wear
to specific components in a machine. particles etc.
To help you trace specific hydraulic problems to a 2. Liquid - Usually water and incompatible oils and
faulty unit (valve, actuator, ram etc.), refer to Fault greases.
finding. Refer to: PIL 30-00-00.
3. Gases - Air, sulphur dioxide etc. which can create
Once you have traced the faulty unit, refer to corrosive compounds if dissolved in the fluid.
the relevant section for removal, disassembly and
checking instructions. These contaminants can appear during
manufacture, assembly and operation.
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 - 23 9813/7600-3 30 - 23
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Diagram
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
Neutral
Figure 1543.
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
Colour code Description

AC Exhaust
Table 534. Colour codes
for oil flow and pressure AD Servo
AE Load sense line
AA Full Pressure
AB Neutral
30 - 24 9813/7600-3 30 - 24
00 - General
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One service operated
Figure 1544.
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
for oil flow and pressure AD Servo
AE Load sense line
AA Full Pressure
AB Neutral
30 - 25 9813/7600-3 30 - 25
00 - General
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Main system pressure relief
Figure 1545.
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 - 26 9813/7600-3 30 - 26
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Fault-Finding
Fault
One service fails, or is slow to operate. Table 537. Page 30-27
The engine tends to stall when hydraulics are under load. Table 538. Page 30-27
Forks creep down Table 539. Page 30-28
Parallel lift faulty Table 540. Page 30-28
Ram creep Table 541. Page 30-28
Table 537. 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 538. 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 - 27 9813/7600-3 30 - 27
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Table 539. 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 540. 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 541. 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 - 28 9813/7600-3 30 - 28
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Discharge and Pressurise amount of stored accumulator pressure available

for venting.
For: 526-56 [T4F] ...................... Page 30-29
4. Depending on your machines specification, other
For: 531-70 [5AA], 531-70 [5TA], 535-95 systems will require additional venting such
[5AB], 535-95 [5TB], 536-60 [5AC], as SRS (Smooth Ride System), refer to (PIL
536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1], 30-18-00).
541-70 [5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 5. Clean the top of the tank around the filler cap.
[5UY], JCB T4F 4.4 over 55kw Electronic 6. Slowly remove filler cap to allow the system
Dieselmax Turbocharged Aftercooled Engine
................................................... Page 30-30 to vent fully and to prevent the oil from being
forced out of the filler neck. The filler cap has a
side mounted barrel lock and is operated by the
(For: 526-56 [T4F]) ignition key. Refer to Figure 1546.
WARNING Depending on your machines 7. Make sure that the seal is in good condition and
specification, other hydraulic systems will require installed correctly in the cap. Replace the seal if
additional venting. These may include (but not necessary.
limited to) SRS, refer to (PIL 30-18-00) and power
brakes, refer to (PIL 24-03-00). Figure 1546. Hydraulic tank filler
cap (526-56 machines only)
2. Operate the controls to remove the hydraulic
pressure from the service hose lines.
2.1. For manually operated services, operate
the controls several times of the service to A
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 B
be disconnected.
2.3. For machines installed with an auxiliary 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. While the vent switch is on, a
buzzer will sound and the venting symbol
will be displayed on the dash. Refer to
Figure 1547.
2.4. For 526-56 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. Refer to Figure 1548.
The specified duration is A Filler cap
Duration: 2–3s B Ignition key
3. Make sure that the pressure is vented correctly.

Electrical and pilot services have a limited
30 - 29 9813/7600-3 30 - 29
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Figure 1547. Vent switch (If installed) (For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC],
536-60 [5TC], 536-70 [5AE], 536-70 [5TE],
536-70LP [5A1], 536-70LP [5T1], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY], JCB T4F 4.4 over 55kw Electronic
Engine)
WARNING Depending on your machines
specification, other hydraulic systems will require
additional venting. These may include (but not
limited to) SRS, refer to (PIL 30-18-00) and power
brakes, refer to (PIL 24-03-00).
CAUTION Do not run the machine with the
hydraulic tank filler cap removed.
CAUTION Allow the hydraulic fluid temperature to
cool before removing the hydraulic tank filler cap.
Open the cap slowly to prevent oil being forced
out of the filler neck.

2. Operate the controls to remove the hydraulic
1 Position 1- Off pressure from the service hose lines.
2 Position 2- Vent position, hold switch down
for on position (battery connected, isolator on, 2.1. For manually operated services, operate
ignition switch set to on, engine off) the controls several times of the service to
be disconnected.
Figure 1548. Auxiliary Vent
Knob (526-56 machines only) 2.2. For 550-80 machines without hydraulic
venting switch - 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 lift arm raise and
lower controls several times. On 550-80
machines the lift arm lower and retract
service are still operative when the engine
is not running until the hydraulic pressure
is fully released. Make sure that the lift arm
is lowered or supported fully on the safety
strut.
2.3. For electrical and servo operated services,
make sure the battery is connected and
ignition key to the on position and operate
the controls several times of the service to
be disconnected.
2.4. For machines installed with a vent switch,
A make sure the battery is connected and
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 Auxiliary vent knob while the vent switch is set to on. While the
vent switch is on, a buzzer will sound and
30 - 30 9813/7600-3 30 - 30
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the venting symbol will be displayed on the Figure 1550. Hydraulic tank filler cap -
dash. machines without external sight gauge
Figure 1549. Vent switch (If installed) A
A Filler cap
Figure 1551. Hydraulic tank filler cap
- machines with external sight gauge
1 Position 1- Off
2 Position 2- Vent position, hold switch down
for on position (battery connected, isolator on,
ignition switch set to on, engine off) A Filler cap
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. These
may include (but not limited to) SRS, refer to
(PIL 30-18-00) and power brakes, refer to (PIL
24-03-00).
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.
6.1. Some filler caps have a side mounted barrel
lock, operated by the ignition key. Your
machine may differ from the one shown.
7. Make sure that the seal is in good condition and
installed correctly in the cap. Replace the seal if
necessary.
30 - 31 9813/7600-3 30 - 31
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Clean • Red Blood Cell = 8 microns (0.008 mm,

0.000315 in)
Special Tools • Human Hair = 70 microns (0.07 mm, 0.00275
Description Part No. Qty. in)
Hydraulic Flushing Rig 892/01255 1 • Grain of Salt = 100 microns (0.1 mm, 0.00394
in)
Cleaning Operation The smallest particle visible to the naked eye is
40 microns (0.00157) approximately. Standards will
The purpose of cleaning oil is to remove often be quoted to ISO (International Standards
contaminants of all types and sludge by filtering Organisation) for which literature can be obtained.
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.
Figure 1552.
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 - 32 9813/7600-3 30 - 32
00 - General
00 - General
Check (Level)
2. Machines may be installed with a sight tube or a
dipstick for hydraulic fluid level display.
Machines with a Sight Tube

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 - 33 9813/7600-3 30 - 33
00 - General
00 - General
Check (Pressure)
Figure 1554. Test Point (Typical Triple Pump)

(For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
Special Tools
Digital Hydraulic 998/11051 1
Pressure Test Kit
Testing MRV Pressure

A
30-00).
3. Connect the digital hydraulic pressure test kit to
the pressure test point. A Pressure test point
(Qty.: 1) Testing ARV's Set Lower than the MRV
4. Start the engine and bring the hydraulic system 1. Make the machine safe. Refer to (PIL 01-03).
to the specified working temperature.
Temperature: 50°C (121.9°F) 2. Discharge the hydraulic pressure. Refer to (PIL
30-00).
5. Select the lift arm lower service and hold the ram
fully closed. 3. Connect the digital pressure test kit to the
pressure test point.
6. Gradually increase the engine speed to 2200
RPM (Revolutions Per Minute) while checking 4. Start the engine and bring the hydraulic system
the maximum gauge reading. Refer to (PIL to the specified working temperature.
30-00). Temperature: 50°C (121.9°F)
Figure 1553. Test Point (Typical Double Pump) 5. Set the engine to idle RPM and operate the
relevant service to full travel. Hold and check
the maximum gauge reading. Refer to Technical
Data (PIL 30-00).
6. Make sure that the engine is not run at the
maximum speed as a significant increase in
pressure will be recorded.
7. If the pressure is not correct, adjust the relevant
ARV (Auxiliary Relief Valve).
A Pressure test point
30 - 34 9813/7600-3 30 - 34
00 - General
00 - General
Figure 1555. Test Point (Typical Double Pump) tilt ram ARVs. Because the tilt ram is smaller than the
lift ram, higher hydraulic pressure is required on one
side of the tilt ram to prevent the load tilting the forks
forward.
Check the pressure setting and the ARV location for

the applicable machine.

2. Raise the lift arm and install the safety strut.
3. Tilt the forks fully forward.
4. Follow the general safety precautions for the
hydraulic system. Refer to (PIL 30-00).
A
30-00).
A Pressure test point 6. Locate the hydraulic line for the high pressure
side of the tilt ram. Refer to Figure 1557. , Refer
Figure 1556. Test Point (Typical Triple Pump)
to Figure 1558. and Refer to Figure 1559.
7. Install a tee piece in the hydraulic line. Connect
the digital pressure test kit to the tee piece.
8. Locate a connection in the tilt ram circuit at the
rear of the lift arm.
9. Start the engine and tilt the forks fully back.
10. Remove the safety strut and slowly lower the
lift arm. As the lift arm is lowered, the pressure
gauge will show the ARV pressure, which should
be as stated. Refer to Technical Data (PIL 30-00).
A
11. If the pressure is incorrect, adjust the ARV. Refer
to (PIL 30-00).
WARNING! Take care when disconnecting

A Pressure test point hydraulic hoses and fittings as the oil will be hot.
12. After you complete the test, fully lower the

Testing ARV's Set Higher than the MRV lift arm. Switch off the engine and release
(P1) the hydraulic pressure. Disconnect the pressure
gauge and connect the tilt ram hose again.
Some ARVs are set at a higher pressure than the
MRV (Main Relief Valve). This is usually one of the
30 - 35 9813/7600-3 30 - 35
00 - General
00 - General
Figure 1557. Tilt ram hose at the rear lift arm bulkhead bracket
A Hose B Connector
Figure 1558. Tilt ram hose forward of the lift arm pivot
A Hose B Connector
30 - 36 9813/7600-3 30 - 36
00 - General
00 - General
Figure 1559. Tilt ram hose on the displacement ram hose, lift arm underside
A Hose B Connector
30 - 37 9813/7600-3 30 - 37
00 - General
03 - Smooth Ride System (SRS)
03 - Smooth Ride System (SRS) Operation

Operation ....................................................... 30-38 For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
Diagram ......................................................... 30-41 [5TC], 536-70 [5AE], 536-70 [5TE], 541-70
Discharge and Pressurise ............................. 30-43 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80
[5UW] ........................................ Page 30-38
For: 526-56 [T4F] ...................... Page 30-39
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW])
WARNING Do not attempt to use the boom to
raise the front of the machine. With the Smooth
Ride System activated, the machine will drop
suddenly when the control lever returns to the
neutral position. Switch off SRS before working
on the machine.
The SRS (Smooth Ride System) enhances the

comfort of the ride by damping the forces imposed
on the machine by the movement of the boom as
the machine travels over uneven surfaces. This is
achieved by connecting the head side of the lift
ram to pressurised piston type accumulator. This is
achieved by connecting the head side of the lift ram
to pressurised piston type accumulator.
Piston type accumulators operate as a liquid springs

absorbing displaced fluid from the lift ram. The
system is controlled by the hydraulic control ECU
(Electronic Control Unit).
To activate the SRS system, the pressure in the lift

ram must be less than 20bar (289.9psi), typically
when the boom is fully lowered. This is sensed by the
pressure transducer E which is mounted on the SRS
valve block.
30 - 38 9813/7600-3 30 - 38
00 - General
Figure 1560.
A
A/M
E
D
G
A SRS switch B Accumulator solenoid valve

C Drain solenoid valve D SRS valve block
E Pressure transducer F Accumulators
G Lift ram
The SRS mode is selected using the operator switch

in the cab. When Auto SRS is on, the SRS system (For: 526-56 [T4F])
will become active when the machine is travelling
at speeds over 4km/h (2.5mph). It will de-activate The SRS enhances the comfort of the ride by
when the machine is travelling at speeds below 2km/ damping the forces imposed on the machine by the
h (1.2mph). movement of the boom as the machine travels over
uneven surfaces. This is achieved by connecting the
When the switch is in the “manual” position the SRS head side of the lift ram to pressurised piston type
will become active when the machine is travelling at accumulators.
speeds over 4km/h (2.5mph). It will not deactivate
until the switch is set to off position or the ignition key Piston type accumulators operate as liquid springs,
is turned to off. absorbing displaced fluid from the lift ram.
When SRS is active the accumulator solenoid valve To activate the SRS system, the pressure in the lift
is energised and connects the piston head side of ram must be less than 40bar (579.7psi), (typically
the lift ram with the accumulators. The drain solenoid when the boom is fully lowered). This is sensed
valve will also energise and connect the rod side of by the pressure switch. Pushing the SRS switch in
the lift ram to the valve block return line to make up the cab will then energise the accumulator solenoid
or dissipate oil as required. valve and will connect the piston head side of the lift
ram with the accumulators. The drain solenoid valve
If the pressure in the lift ram is greater than the (chassis mounted) will also energise and connect the
specified limit when the SRS is active, the system rod side of the lift ram to the valve block return line
will not be activated (the solenoid valves will not to make up or dissipate oil as necessary.
energise).
Once the SRS system is activated, the boom can

then be raised to the travelling position as required.
30 - 39 9813/7600-3 30 - 39
00 - General
Figure 1561.
A
B C
H
G
F D
A Lift ram B Piston type accumulators

C Accumulator solenoid valve D Control valve block
E Drain solenoid valve F Return line
G Pressure switch H HBCV (Hose Burst Check Valve)
J SRS switch
If the pressure in the lift ram is greater than 40bar

(579.7psi), when the SRS switch is pushed, then the
system will not be activated (the solenoid valves will
not energise).
Once the SRS system is activated, the boom can

then be raised to the travelling position as necessary.
Service spool sensors

On machines with parallel hydraulic systems, spool
sensors are installed to the control valve block.
These inform the hydraulic control ECU when the
SRS service is selected.
30 - 40 9813/7600-3 30 - 40
00 - General
Diagram
For: 526-56 [T4F] ...................... Page 30-41

For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................... Page 30-42
(For: 526-56 [T4F])
Figure 1562.
H A
D
G
C
E
F
B
A Lift ram B Accumulators

C Accumulator solenoid valve D Control valve block
E Drain solenoid valve (chassis mounted) F Valve block return line
G Pressure switch H Hose burst check valve
30 - 41 9813/7600-3 30 - 41
00 - General
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80
[5UW], 560-80 [5AY], 560-80 [5UY])
Figure 1563.
A
D
V2
B
G
C
V1
A Control valve block B Lift ram

C Pressure transducer D Accumulator solenoid
E Drain solenoid F Accumulators
G Pilot operated lift counterbalance valve
30 - 42 9813/7600-3 30 - 42
00 - General
Refer to Hydraulic System, Accumulator, Smooth

Ride System (SRS), (PIL 30-18-06).
30 - 43 9813/7600-3 30 - 43
00 - General
09 - Levelling System
Operation
For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................... Page 30-44
For: 526-56 [T4F] ...................... Page 30-49
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70LP [5A1], 536-70LP [5T1], 541-70 [5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY])
Table 542. 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) Figure 1564.
Ram operation
D
The schematic diagrams show a typical system.
Your system may be different. Refer to the relevant
machine schematic diagram, (PIL 30-00-50).
The parallel lift system operates when the boom lifts

or lowers.
E
A C
A C
A Displacement ram
C Boom ram
D Tilt ram
E Forks
When the boom ram lifts or lowers the boom, the

displacement ram extends or retracts. The ram
displaces oil, then oil flows to the tilt ram which will
30 - 44 9813/7600-3 30 - 44
00 - General
extends or retracts and will keep the forks parallel Oil is forced out of the head side of displacement
with the ground. ram as the boom lifts. The oil cannot flow past the tilt
spool, as the spool is not selected. Instead, it flows
Boom raise cycle to the head side of tilt ram. Oil displaced from the
rod side of the tilt ram increases pilot pressure in the
When the spool is in the lift position, the neutral HBCV (Hose Burst Check Valve). This allows oil to
circuit is blocked and oil feeds to the pilot operated feed back to the rod side of the displacement ram.
counterbalance valve. Check valve1 opens and
supplies oil to the head side of the boom lift ram.
Figure 1565.
Q
H J
R
S
K
L P
N
F
F Spool G Counter balance valve

H Pilot valve J Boom lift ram
K Displacement/lift link valve L HBCV
M Displacement ram N Tilt ram
P Tank Q Check valve 1
R Check valve 2 S Check valve 3
The displacement/lift link valve is installed between accidentally leak back into the circuit when a load
lift service and tilt service lines. The function of this is on the boom. The lower service will only operate
valve is to allow a restricted flow of oil into the tilt when there is sufficient pilot pressure provided by the
circuit to increase the lift force available by utilising hydraulic pump or stored in the pilot accumulator. If
the displacement ram. there is no pilot pressure the pilot valve will not open
and the boom will not lower.
Boom lower cycle
Check valve 3 creates a circuit when the ram return
When the lift spool is selected, the neutral line is in cavitation.
circuit is blocked and oil feeds the pilot operated
counterbalance valve. The pilot pressure used to As the boom lowers, oil is forced from the rod side of
operate the spool acts upon the pilot valve. The pilot the displacement ram. The oil cannot flow past the tilt
valve allows a return to tank via check valve 2 and spool, as the spool is not selected. Instead, it flows
the valve block which enables the boom to lower. through the free flow direction of the HBCV to the rod
This is to make sure that the ram pressure cannot side of the tilt ram.
30 - 45 9813/7600-3 30 - 45
00 - General
Figure 1566.
Q
H J
R
S
G
K
L P
N
F
F Spool G Pilot operated counter balance valve

Displaced oil from the displacement ram closes the

check valve in displacement/lift link valve.
The circuit created between the displacement ram,

lift ram and tilt ram prevents cavitation/vacuum.
Parallel lift (S2)

Ram operation
The schematic diagrams show a typical system.

or lowers.
30 - 46 9813/7600-3 30 - 46
00 - General
Figure 1567. When the boom ram lifts or lowers the boom, the
D displaces oil, then oil flows to the tilt ram which will
extends or retracts and will keep the forks parallel
B with the ground.
Machines have a single or twin displacement rams,

dependant on the machine variant.
E
Boom raise cycle
A C The illustration below shows twin displacement rams.
The operation is similar on machines with single
D displacement rams.
When the spool is in the lifted position, the neutral

B circuit is blocked and oil feeds to the pilot operated
counterbalance valve. Check valve 1 opens and
supplies oil to the head side of the boom lift ram.
E
Oil is forced out of the rod side of displacement ram
as the boom lifts. The oil cannot flow past the tilt
A C spool, as the spool is not selected. Instead, it flows
A Boom ram to the head side of the tilt ram. Oil displaced from the
B Boom pivot rod side of the tilt ram increases pilot pressure in the
C Displacement ram HBCV. This allows oil to feed back to the head side
D Tilt ram of the displacement ram.
E Forks
Figure 1568.
Q
J
R H
S
G
K
L
P
F N

30 - 47 9813/7600-3 30 - 47
00 - General
Displaced oil from the displacement ram closes the counterbalance valve. The pilot pressure used to
check valve in displacement/lift link valve is installed operate the spool acts upon the pilot valve. The
between lift service and tilt service lines. The function pilot valve allows oil to return to the tank via the
of this valve is to allow a restricted flow of oil into the check valve 2 and the valve block which enables
tilt circuit to increase the lift force available by utilising the boom to lower. This is to make sure that the
the displacement ram. ram pressure cannot accidentally leak back into
the circuit when a load is on the boom. The lower
Boom lower cycle service will only operate when there is sufficient pilot
pressure provided by the hydraulic pump or stored in
The illustration below shows twin displacement rams. the pilot accumulator. If there is no pilot pressure the
The operation is similar on machines with single valve will not open and the boom will not lower.
displacement rams.
When lift spool is selected, the neutral circuit line is in cavitation.
is blocked and oil feeds to the pilot operated
Figure 1569.
Q
H
J
R
S
G
K
L
P
N
F
M7

As the boom lowers, oil is forced from the rod side of The circuit created between the displacement ram,
the displacement ram. The oil cannot flow past the tilt lift ram and tilt ram prevents cavitation/vacuum.
through the free flow direction of the HBCV to the rod
side of the tilt ram.

30 - 48 9813/7600-3 30 - 48
00 - General
(For: 526-56 [T4F]) When the boom ram lifts or lowers the boom, the
Parallel lift (S2) displaces oil, then oil flows to the tilt ram which will
extends or retracts and will keep the forks parallel
with the ground.
Ram operation
Machines have single or twin displacement rams,
The schematic diagrams show a typical system. dependant on the machine variant.
Boom raise cycle
The illustration below shows twin displacement rams.
or lowers.
The operation is similar on machines with single
Figure 1570. displacement rams.
D When the spool is in the lifted position, the neutral

circuit is blocked and oil feeds to the pilot operated
counterbalance valve. Check valve 1 opens and
B supplies oil to the head side of the boom lift ram.
Oil is forced out of the rod side of displacement ram

E as the boom lifts. The oil cannot flow past the tilt
to the head side of the tilt ram. Oil displaced from the
A C rod side of the tilt ram increases pilot pressure in the
HBCV. This allows oil to feed back to the head side
of the displacement ram.
D
A C
A Boom ram
B Boom pivot
C Displacement ram (System may have 1 or 2
installed)
D Tilt ram
E Forks
30 - 49 9813/7600-3 30 - 49
00 - General
Figure 1571.
Q
J
R H
S
G
K
L
P
F N

M Displacement ram (System may have 1 or 2 N Tilt ram
installed)
Displaced oil from the displacement ram closes the counterbalance valve. The pilot pressure used to
check valve in displacement/lift link valve is installed operate the spool acts upon the pilot valve. The
between lift service and tilt service lines. The function pilot valve allows oil to return to the tank via the
of this valve is to allow a restricted flow of oil into the check valve 2 and the valve block which enables
tilt circuit to increase the lift force available by utilising the boom to lower. This is to make sure that the
the displacement ram. ram pressure cannot accidentally leak back into
the circuit when a load is on the boom. The lower
Boom lower cycle service will only operate when there is sufficient pilot
pressure provided by the hydraulic pump or stored in
The illustration below shows twin displacement rams. the pilot accumulator. If there is no pilot pressure the
The operation is similar on machines with single valve will not open and the boom will not lower.
displacement rams.
When lift spool is selected, the neutral circuit line is in cavitation.
is blocked and oil feeds to the pilot operated
30 - 50 9813/7600-3 30 - 50
00 - General
Figure 1572.
Q
H
J
R
S
G
K
L
P
N
F
M7

As the boom lowers, oil is forced from the rod side of

the displacement ram. The oil cannot flow past the tilt
through the free flow direction of the HBCV to the rod
side of the tilt ram.

The circuit created between the displacement ram,

lift ram and tilt ram prevents cavitation/vacuum.
30 - 51 9813/7600-3 30 - 51
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction .................................................... 30-52 Complex hydraulic components and circuits can
Diagram ......................................................... 30-53 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 - 52 9813/7600-3 30 - 52
00 - General
Diagram Table 546. Directional control valves

Symbol Description
Used to enclose sever-
Table 543. 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 544. 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 545. 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 - 53 9813/7600-3 30 - 53
00 - General
Table 547. 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 548. 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 - 54 9813/7600-3 30 - 54
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 - 55 9813/7600-3 30 - 55
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-56 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-57 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 - 56 9813/7600-3 30 - 56
00 - General
Diagram
For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW], 550-80
[5UW] ........................................ Page 30-57
For: 550-80 [5AW], 550-80 [5UW]
................................................. Page 30-130
................................................. Page 30-136
For: 560-80 [5AY], 560-80 [5UY]
................................................. Page 30-141
For: 526-56 [T4F] .................... Page 30-148
For: 535-95 [5AB], 535-95 [5TB]
................................................. Page 30-153
For: 536-60 [5AC], 536-60 [5TC]
................................................. Page 30-159
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80
[5UW])
Figure 1573. Parallel Dual Lever Control 334/L1242-9 (531-70)........................................... Page 30-59
Figure 1574. Parallel Dual Lever Control 334/L1244-10 (535-95)......................................... Page 30-65
Figure 1575. Parallel Dual Lever Control 334/L1243-10 (541-70, 536-70)............................ Page 30-71
Figure 1576. Parallel Single Lever Control 334/L1247-10 (531-70)....................................... Page 30-77
Figure 1577. Parallel Single Lever Control 334/L1245-13 (535-95)....................................... Page 30-83
Figure 1578. Parallel Single Lever Control 334/L1246-11 (536-70, 541-70).......................... Page 30-89
Figure 1579. LSP Electro Servo (S1) 334/L7029-7 (531-70, 536-70, 541-70)....................... Page 30-95
Figure 1580. LSP Electro Servo (S2) 333/G4103-9 (531-70).............................................. Page 30-101
Figure 1581. LSP Electro Servo (S2) 333/G4105-11 (535-95).............................................Page 30-107
Figure 1582. LSP Electro Servo (S2) 333/G4102-8 (536-60).............................................. Page 30-113
Figure 1583. LSP Electro Servo (S2) 333/G1967-8 (536-70, 541-70)................................. Page 30-119
Figure 1584. LSP Electro Servo (S4) 332/H1323-14 (550-80).............................................Page 30-125
Specification Variants- Hydraulic 2. Parallel Lever Single Control (P4), Refer to
Schematics Figure 1577.
3. LSP Electro Servo Control (S2), Refer to Figure
531-70 Machines 1581.
1. Parallel Lever Dual Control (P1), Refer to Figure
1573. 536-60 Machines
2. Parallel Lever Single Control (P6), Refer to 1. LSP Electro Servo Control (S2), Refer to Figure
Figure 1576. 1582.
3. LSP Electro Servo Control (S1), Refer to Figure 536-70, 541-70 Machines
1579.
1. Parallel Lever Dual Control (P2), Refer to Figure
4. LSP Electro Servo Control (S2), Refer to Figure 1575.
1580.
2. Parallel Lever Single Control (P5), Refer to
535-95 Machines Figure 1578.
1. Parallel Lever Dual Control (P3), Refer to Figure 3. LSP Electro Servo Control (S1), Refer to Figure
1574. 1579.
1583.
30 - 57 9813/7600-3 30 - 57
00 - General
550-80 Machines
1584.
30 - 58 9813/7600-3 30 - 58
00 - General
Page 30-60 Figure 1573. Parallel Dual Lever

Control 334/L1242-9 (531-70) Page 30-61
J
J
J
A J
J
B
E
F
G
H
30 - 59 9813/7600-3 30 - 59
00 - General
Page Page
30-60 30-61
Page 30-61
D
G
H
30 - 60 9813/7600-3 30 - 60
00 - General
Page Page
30-60 30-61
J
J
J
A J
J
B
C
Page 30-60
E
F
G
H
30 - 61 9813/7600-3 30 - 61
00 - General
Note The schematic shows the sway option. On

non sway machines the pump flow goes
directly to the fan motor.
Table 549. Parallel Dual Lever Control 334/L1242-9 (531-70)

A Auxiliary spool
B Tilt spool
C Extend spool
D Lift spool
E Proportional valve
F MRV (Main Relief Valve)
G Compensator valve
H Pilot pressure valve
J Quick release couplings
1 Hydraulic pump - 2 section - dou-
ble pump
5 Hydraulic control valve
8 Poppet valve - 2 port SRS (Smooth Ride System) - rod
side drain
9 Poppet valve - 2 port, 2 position SRS
10 Lift cylinder SRS lift
11 Lift cylinder Non SRS lift
12 Tilt cylinder Tilt
13 Displacement cylinder Displacement
14 Extend cylinder Extend
16 Steering power track rod Steering
18 Hydraulic pin locking cylinder Carriage
19 Ball valve Hydraulic pin lock
20 Filter element Fan return
21 Suction strainer In tank
23 Filter head Fan return
30 Counterbalance cartridge Lift
31 Counterbalance cartridge Tilt
32 Counterbalance cartridge Extend
35 Adaptor Lift assist
36 6-Way solenoid change over valve Auxiliary
37 Pressurised hydraulic oil filler / Tank
breather
38 Pressure transducer SRS
40 Fan motor - 19cc 55kW
41 Variable fan motor - reversing 81–108kW
42 Variable fan motor - 11cc 81–93kW
50 Accumulator Pilot
51 Accumulator SRS
52 Accumulator SRS
55 Steering control valve Orbitrol
56 Steer mode valve Manual
57 Steer mode valve Auto / electrical
60 Sway valve Sway
30 - 62 9813/7600-3 30 - 62
00 - General

61 Sway cylinder Sway
62 Check valve - low leak Sway
63 Pilot piston Sway
64 Restrictor Sway
65 Check valve
30 - 63 9813/7600-3 30 - 63
Notes:
30 - 64 9813/7600-3 30 - 64
00 - General

Control 334/L1244-10 (535-95) Page 30-67
J
J J
J
A
J
B K
C
L
F
E
G
H
30 - 65 9813/7600-3 30 - 65
00 - General
Page Page
30-66 30-67
Page 30-67
D
F
E
G
H
30 - 66 9813/7600-3 30 - 66
00 - General
Page Page
30-66 30-67
J
J J
J
J
K
Page 30-66
30 - 67 9813/7600-3 30 - 67
00 - General
Note The schematic shows sway or trailer Note On non sway/trailer brakes machines the
brake options. pump flow goes direct to the fan motor
Note When sway and trailer brakes are
combined then: Port N (TBV (Trailer Brake
Valve)) to port P (sway), Port F (sway) to
fan feed, Port R (TBV) tees in to port T
(sway)
Table 550. Parallel Dual Lever Control 334/L1244-10 (535-95)

A Auxiliary spool
B Tilt spool
C Extend spool
D Lift spool
F MRV
G Compensator valve
K Make up valve detail
L Regen valve
ble pump
7 Trailer brake valve
8 Poppet valve - 2 port SRS - rod side drain
14 Inner extend cylinder Extend
15 Outer extend cylinder Extend
17 Hitch cylinder
30 Counterbalance cartridge SRS lift
31 Counterbalance cartridge Tilt and extend
33 Counterbalance cartridge Extend outer
breather
39 Cartridge Extend outer
30 - 68 9813/7600-3 30 - 68
00 - General

51 Accumulator SRS
52 Accumulator SRS
53 Accumulator Trailer brake
60 Sway valve Sway
64 Restrictor Sway
65 Vented counterbalance valve Extend outer
67 Make up valve Extend
68 Check valve
30 - 69 9813/7600-3 30 - 69
Notes:
30 - 70 9813/7600-3 30 - 70
00 - General

Control 334/L1243-10 (541-70, 536-70) Page 30-73
J
J
J
A J
J
B
F
E
G
H
30 - 71 9813/7600-3 30 - 71
00 - General
Page Page
30-72 30-73
Page 30-73
D
G
H
30 - 72 9813/7600-3 30 - 72
00 - General
Page Page
30-72 30-73
J
J
J
A J
J
B
C
Page 30-72
F
E
G
H
30 - 73 9813/7600-3 30 - 73
00 - General

non sway machines, the pump flow goes
direct to the fan motor.
Table 551. Parallel Dual Lever Control 334/L1243-10 (541-70, 536-70)

A Auxiliary spool
B Tilt spool
C Extend spool
D Lift spool
F MRV
G Compensator valve
ble pump
30 Counterbalance valve Lift
breather
51 Accumulator SRS
52 Accumulator SRS
60 Sway valve Sway
30 - 74 9813/7600-3 30 - 74
00 - General

64 Restrictor Sway
65 Check valve
Schematics- Parallel System with Single Lever Controls
30 - 75 9813/7600-3 30 - 75
Notes:
30 - 76 9813/7600-3 30 - 76
00 - General
Page 30-78 Figure 1576. Parallel Single Lever

Control 334/L1247-10 (531-70) Page 30-79
J
J
J
J
J J
J
A
F
E
G
H
30 - 77 9813/7600-3 30 - 77
00 - General
Page Page
30-78 30-79
Page 30-79
D
30 - 78 9813/7600-3 30 - 78
00 - General
Page Page
30-78 30-79
J
J
J
J
J J
J
A
C
Page 30-78
F
E
G
H
30 - 79 9813/7600-3 30 - 79
00 - General

direct to the fan motor
Table 552. Parallel Single Lever Control 334/L1247-10 (531-70)

A Auxiliary spool
B Extend spool
C Tilt spool
D Lift spool
F MRV
G Compensator valve
1 Hydraulic pump - 3 section - triple
pump
17 Hitch cylinder
breather
51 Accumulator SRS
52 Accumulator SRS
30 - 80 9813/7600-3 30 - 80
00 - General

58 Bi-directional check valve AG tyre option
59 Check valve
30 - 81 9813/7600-3 30 - 81
Notes:
30 - 82 9813/7600-3 30 - 82
00 - General

Control 334/L1245-13 (535-95) Page 30-85
J J
J
A
K
B
L
C
F
E
G
H
30 - 83 9813/7600-3 30 - 83
00 - General
Page Page
30-84 30-85
Page 30-85
D
F
E
G
H
30 - 84 9813/7600-3 30 - 84
00 - General
Page Page
30-84 30-85
J J
L
Page 30-84
30 - 85 9813/7600-3 30 - 85
00 - General

Table 553. Parallel Single Lever Control 334/L1245-13 (535-95)

A Auxiliary spool
B Extend spool
C Tilt spool
D Lift spool
F MRV
G Compensator valve
K Make up valve detail
L Regen valve
pump
14 Inner extend cylinder Extend
15 Outer extend cylinder Extend
17 Hitch cylinder
30 Counterbalance cartridge SRS Lift
31 Counterbalance cartridge Tilt and Extend
33 Counterbalance cartridge Extend outer
breather
30 - 86 9813/7600-3 30 - 86
00 - General

51 Accumulator SRS
52 Accumulator SRS
65 Vented counterbalance valve Extend outer
67 Make up valve Extend
68 Check valve
30 - 87 9813/7600-3 30 - 87
Notes:
30 - 88 9813/7600-3 30 - 88
00 - General

Control 334/L1246-11 (536-70, 541-70) Page 30-91
J
J
J
J
J
A
E F
G
H
30 - 89 9813/7600-3 30 - 89
00 - General
Page Page
30-90 30-91
Page 30-91
D
G
H
30 - 90 9813/7600-3 30 - 90
00 - General
Page Page
30-90 30-91
J
J
J
J
J
A
C
Page 30-90
E F
G
H
30 - 91 9813/7600-3 30 - 91
00 - General

Table 554. Parallel Single Lever Control 334/L1246-11 (536-70, 541-70)

A Auxiliary spool
B Extend spool
C Tilt spool
D Lift spool
F MRV
G Compensator valve
pump
5 Hydraulic control valve EN 15000
17 Hitch cylinder
breather
51 Accumulator SRS
52 Accumulator SRS
30 - 92 9813/7600-3 30 - 92
00 - General

59 Check valve
Schematics- LSP Electro Servo System (S1)
30 - 93 9813/7600-3 30 - 93
Notes:
30 - 94 9813/7600-3 30 - 94
00 - General
Page 30-96 Figure 1579. LSP Electro Servo (S1)

334/L7029-7 (531-70, 536-70, 541-70) Page 30-97
H
H
H
H
H
A
B
H
C
D
30 - 95 9813/7600-3 30 - 95
00 - General
Page Page
30-96 30-97
A
B
C
D
Page 30-97
30 - 96 9813/7600-3 30 - 96
00 - General
Page Page
30-96 30-97
H
H
H
H
H
A
B
H
C
D
G
Page 30-96
30 - 97 9813/7600-3 30 - 97
00 - General
Table 555. LSP Electro Servo (S1) 334/L7029-7 (531-70, 536-70, 541-70)
A Steer priority valve
B Flow regulator valve
C LSRV (Load Sense Relief Valve)
D Auxiliary spool
E Tilt spool
F Extend spool
G Lift spool
H Quick release couplings
1 Hydraulic pump - variable displace-
ment
2 Hydraulic control valve 531-70
3 Hydraulic control valve 536-70 and 541-70
4 Flushing valve
5 Servo system control valve
8 3 port diverter valve Hitch
10 Lift cylinder SRS lift 531-70
11 Lift cylinder SRS lift 536-70 and 541-70
17 Hitch cylinder
22 Return filter Fan return
25 Hydraulic oil cooler 97kW
27 Accumulator SRS 541-70
30 Dual counterbalance valve Lift
32 Valve block Extend
36 6-Way solenoid change over valve Twin Auxiliary
37 LS (Load Sense) directional valve Rear Auxiliary
breather
30 - 98 9813/7600-3 30 - 98
00 - General

40 Fan motor - 11cc 81–93kW
42 Variable fan motor - 19cc 55kW
43 Check valve
44 Check valve
30 - 99 9813/7600-3 30 - 99
Notes:
30 - 100 9813/7600-3 30 - 100

00 - General
Page 30-102 Figure 1580. LSP Electro Servo

(S2) 333/G4103-9 (531-70) Page 30-103
D
E E
E
E
E
30 - 101 9813/7600-3 30 - 101

00 - General
Page Page
30-102 30-103
Page 30-103
D
30 - 102 9813/7600-3 30 - 102

00 - General
Page Page
30-102 30-103
C
Page 30-102
D
E E
E
E
E
30 - 103 9813/7600-3 30 - 103

00 - General
Table 556. LSP Electro Servo (S2) 333/G4103-9 (531-70)

A Lift spool
B Tilt spool
C Extend spool
D Auxiliary spool
E Quick release connectors
10 Variable displacement pump
20 Variable displacement pump -
power control
60 Servo system control valve Pilot feed
70 Trailer brake valve Trailer brake
80 Poppet valve - 2 port SRS rod side drain
90 Counterbalance valve SRS
100 Lift cylinder SRS Lift
110 Lift cylinder Non SRS Lift
160 Steering power track rod
170 Hitch cylinder Hydraulic hitch
200 Counterbalance valve
210 Suction filter element In tank
220 Return filter In tank
230 Accumulator Pilot valve
240 Sway valve Sway
250 Hydraulic oil cooler
260 Hydraulic oil cooler - t4
270 Bi-directional check valve For 28" wheels
300 Counterbalance valve - non SRS Lift
320 Counterbalance valve Extend.
330 Steer control valve Orbitrol
340 Accumulator SRS
360 6-way solenoid change over valve Auxiliary
370 Pressurised hydraulic filler / Tank
breather
400 Fan motor 11cc 81 ± 93kW
410 Variable fan motor - reversing 81 ± 108kW
30 - 104 9813/7600-3 30 - 104

00 - General

420 Accumulator SRS
430 Check valve
30 - 105 9813/7600-3 30 - 105

Notes:
30 - 106 9813/7600-3 30 - 106

00 - General

(S2) 333/G4105-11 (535-95) Page 30-109
C
F
F
D E
F E
E
E
E
E
30 - 107 9813/7600-3 30 - 107

00 - General
Page Page
30-108 30-109
Page 30-109
D
30 - 108 9813/7600-3 30 - 108

00 - General
Page Page
30-108 30-109
C
F
Page 30-108
D E
F E
E
E
E
E
30 - 109 9813/7600-3 30 - 109

00 - General

A Lift spool
B Tilt spool
C Extend spool
D Auxiliary spool
E Quick release couplings
F Make up valve detail view
power control
30 Make-up valve Inner extend
40 Cartridge Outer extend
100 Lift cylinder SRS SRS Lift
140 Inner extend cylinder
150 Outer extend cylinder
200 Check valve
240 Vented Counterbalance Valve Outer extend
260 Hydraulic oil cooler -t4
320 Counterbalance cartridge Inner extend
330 Counterbalance cartridge Outer extend
340 Counterbalance valve - SRS
breather
390 Cartridge Outer extend
400 Variable fan motor 11cc 81–93kW
30 - 110 9813/7600-3 30 - 110

00 - General

430 Accumulator SRS
440 Sway valve Sway
460 Accumulator SRS
490 Check valve
30 - 111 9813/7600-3 30 - 111

Notes:
30 - 112 9813/7600-3 30 - 112

00 - General

(S2) 333/G4102-8 (536-60) Page 30-115
B
A
C
D
F
H
G
H H
H
H
H
H
30 - 113 9813/7600-3 30 - 113

00 - General
Page Page
30-114 30-115
C
D
Page 30-115
G
30 - 114 9813/7600-3 30 - 114

00 - General
Page Page
30-114 30-115
B
A
C
D
F
H
Page 30-114
G
H H
H
H
H
H
30 - 115 9813/7600-3 30 - 115

00 - General

A Steer priority valve
B Flow regulator valve
C LSRV
D Lift spool
E Tilt spool
F Extend spool
G Auxiliary spool
H Quick release couplings
ment
ment - power control
90 Lift valve Non SRS - 536-60
170 Hitch cylinder
200 Fan motor - 11cc 81–93kW
230 Check valve
260 Hydraulic oil cooler Combination - T4
280 Accumulator SRS
290 Accumulator SRS
300 Counterbalance valve Lift and extend
340 Lift valve SRS - 536-60
breather
30 - 116 9813/7600-3 30 - 116

00 - General

390 Check valve
30 - 117 9813/7600-3 30 - 117

Notes:
30 - 118 9813/7600-3 30 - 118

00 - General

(S2) 333/G1967-8 (536-70, 541-70) Page 30-121
C
E
E
D
E
E E
E
E
30 - 119 9813/7600-3 30 - 119

00 - General
Page Page
30-120 30-121
Page 30-121
C
30 - 120 9813/7600-3 30 - 120

00 - General
Page Page
30-120 30-121
B
Page 30-120
C
E
E
D
E
E E
E
E
30 - 121 9813/7600-3 30 - 121

00 - General
Table 559. LSP Electro Servo (S2) 333/G1967-8 (536-70, 541-70)

A Lift spool
B Tilt spool
C Extend spool
D Auxiliary spool
E Quick release connectors
power control
90 Counterbalance valve - SRS
100 Lift cylinder SRS Lift
200 Check valve
230 Accumulator SRS
240 Sway valve Sway
260 Hydraulic oil cooler t4
320 Counterbalance valve Extend
330 Steer control valve Orbitrol
breather
400 Fan motor 11cc 81–93kW
30 - 122 9813/7600-3 30 - 122

00 - General

410 Variable speed fan motor - revers- 81–108kW
ing
420 Accumulator SRS
430 Check valve
30 - 123 9813/7600-3 30 - 123

Notes:
30 - 124 9813/7600-3 30 - 124

00 - General

(S4) 332/H1323-14 (550-80) Page 30-127
340
410
415
330
280
60 60
70
370 320 70
375
380 250
90 420
385 N 40
390 M
P 80
400 60
70
Q
120 90
140
R
310 130 130
350 150
430
170
S 160
T
360
U
190
30 180
U 200
U
180 U
10
U
290 280
300 180
U
240 U 220
20
210
50
270
230
H
90 E B
L
C G
I
H A J
D F
30 - 125 9813/7600-3 30 - 125

00 - General
Page Page
30-126 30-127
410
415
280
370 320
375
380 250
385 N 40
390 M
P
400
R
350 310
430
S
Page 30-127
T
360
30
10
290 280
300
20
50
270
H
90 E B
L
C G
I
H A J
D F
30 - 126 9813/7600-3 30 - 126

00 - General
Page Page
30-126 30-127
340
330
60 60
70
70
90 420
N 40
M
P 80
60
70
120 90
140
130 130
150
170
160
Page 30-126
U
190
180
U 200
U
180 U
U
180
U
240 U 220
210
230
30 - 127 9813/7600-3 30 - 127

00 - General
Table 560. LSP Electro Servo (S4) 332/H1323-14 (550-80)

A-L Tank ports
M Steer priority valve
N Flow regulator valve
P LSRV
Q Lift spool
R Tilt spool
S Extend spool
T Auxiliary spool
U Quick release couplings
10 Hydraulic oil filler cap Tank
ment
60 Dual counterbalance valve Lift cylinder
70 Lift cylinder
80 SRS manifold
90 Pressure transducer SRS and brake
100 Accumulator SRS
110 Accumulator SRS
120 Adaptor - check Lift assist
130 Displacement cylinder
140 Counterbalance valve Tilt
150 Tilt cylinder
160 Counterbalance valve Extend
190 Ball valve Rear
200 Hitch cylinder
210 Ball valve Carriage
240 Accumulator Servo
260 Auto steer mode valve
270 Brake charge valve
280 Pressure transducer Brake charge pressure
290 Accumulator Brake
300 Power brake valve
310 Trailer brake valve If installed
320 Sway valve
330 Sway cylinder
340 Check valve - low leak
350 Variable fan motor
370 Axle - front - pad mount 213 - Standard 38°
30 - 128 9813/7600-3 30 - 128

00 - General

375 Axle - front - pad mount 213 - LSD (Limited Slip Differen-
tial)38°
380 Axle - front - pad mount 213 - Standard 32°
385 Axle - front - pad mount 213 - LSD32°
390 Axle - front - trunnion mount 213 - Standard 38°
400 Axle - front - trunnion mount 213 - LSD38°
410 Axle - rear - trunnion mount 223 - Standard 38°
415 Axle - rear - trunnion mount 223 - Standard 32°
420 Manifold Auto SRS 550 and 560
430 Check valve
30 - 129 9813/7600-3 30 - 129

00 - General
(For: 550-80 [5AW], 550-80 [5UW])

Figure 1585. Hydraulic System 550-80, 560-80 -332/H1323-12.......................................... Page 30-131
30 - 130 9813/7600-3 30 - 130

00 - General
Page 30-132 Figure 1585. Hydraulic System

550-80, 560-80 -332/H1323-12 Page 30-133
H
B
E
I
L
C G
H A
332-H1323-12
D F J
30 - 131 9813/7600-3 30 - 131

00 - General
Page Page
30-132 30-133
Page 30-133
30 - 132 9813/7600-3 30 - 132

00 - General
Page Page
30-132 30-133

Page 30-132
H
B
E
I
L
C G
H A
332-H1323-12
D F J
30 - 133 9813/7600-3 30 - 133

00 - General
Table 561. 332/H1323-12

Item Description
10 Filler Cap Hydraulic Oil
20 Suction Element
30 Variable Displacement Pump- Gear 0.019
40 V/Block 5Aw Ag Elec
50 Return Filter
60 Counterbalance Valve - Dual
70 Cylinder 140X75 Lift P420
80 SRS Manifold - 5Aw
90 SRS Pressure Transducer
100 Accumulator 21.37bar (309.7psi)
120 Adaptor. G1/4A - 7/16 SAE (Society of Automotive
Engineers)
130 Cylinder 70X40 Displacement P420
140 Counterbalance Valve - Tilt 5Aw/5Tw
150 Cylinder 130X75 Tilt P420
160 Counterbalance Valve - Ext 5Aw/5Tw
170 Cylinder 90X60 Extension P420
180 6-Way Solenoid Changeover Valve
190 Ball Valve Including Lever
200 Hitch Cylinder
210 Ball Valve
220 Cylinder - Hydraulic Pin Locking
230 Pilot Valve
240 Accumulator 0.24L5bar (72.5psi)
250 Steer Valve + Shocks
260 Steer Mode Valve
270 Charge Valve
280 Pressure Transducer 0–250bar (0.0–3,623.2psi)
300 Valve- Power Brake
310 Plug & Brake Trailer Brake Valve
320 Sway Valve
330 Cylinder Sway 532 110X50
340 Check Valve - Low Leak
350 Variable Fan Motor
360 Denso - Oil Cooler
370 Axle - 213 Pad Standard 38°
375 Axle - 213 Pad LSD38°
380 Axle - 213 Pad Standard 32°
385 Axle - 213 Pad LSD32°
390 Axle - 213 Trunnion Standard 38°
400 Axle - 213 Trunnion LSD38°
420 Auto SRS Manifold 550 & 560 80
430 Check Valve 2.5bar (36.2psi)
A Hydraulic tank port A
30 - 134 9813/7600-3 30 - 134

00 - General
Item Description
B Hydraulic tank port B
C Hydraulic tank port C
D Hydraulic tank port D
E Hydraulic tank port E
F Hydraulic tank port F
G Hydraulic tank port G
H Hydraulic tank port H
J Hydraulic tank port J
K Hydraulic tank port K
L Hydraulic tank port L
M Hydraulic tank port M
N Hydraulic tank port N
30 - 135 9813/7600-3 30 - 135

00 - General

Figure 1586. DTVT Transmission 334/D1133-11 (sheet 1 of 1)........................................... Page 30-137
30 - 136 9813/7600-3 30 - 136

00 - General
Page 30-138 Figure 1586. DTVT Transmission

334/D1133-11 (sheet 1 of 1) Page 30-139
30
160 160 80
410 420
300
90 230
400
290 110
380 100
330 280 270 20
150
310
350
130
120
260 240
140
320
370 40
210 220 170
10
200 360
50 360
55 180
340 360 190
250
70 60
30 - 137 9813/7600-3 30 - 137

00 - General
Page Page
30-138 30-139

30
160 160
410
290
330 280 270 20

150
260 240
Page 30-139
370 40
210 220
10
200
250
70
30 - 138 9813/7600-3 30 - 138

00 - General
Page Page
30-138 30-139

30
80
410 420
300
90 230
400
110
380 100
310
350
130
120
140
320
Page 30-138
170
360
50 360
55 180
340 360 190
60
30 - 139 9813/7600-3 30 - 139

00 - General
Table 562. 334/D1133-11

Item Description
10 Variable power pump-19cc gear
40 Priority accumulator charging valve
50 Valve Block 5AD/R AG Electric
55 Valve block 5AA AG Electric
60 Pilot valve
70 Hydrostatic mechanical hybrid transmission
80 Poppet valve assembly- 2 Port
90 Pilot operated counterbalance valve- lift ram- SRS
100 Lift ram SRS 140 X 75 P492
110 Lift ram SRS 130X70
120 Tilt ram 120 X 60
130 120 X 60 Displacement ram
140 Extension ram 70X50 P492
160 Power track rod
170 Hitch ram
180 Ram- hydraulic pin locking
190 Ball valve
200 Suction strainer
220 Return filter
240 Accumulator 25bar (362.3psi)
250 Cooling pack -81 P414
260 Bi-directional check valve
270 Quick release coupling 06 male- 6 SAE
280 Quick release coupling 06 female- 6 SAE
290 Steer mode valve
310 Counter balance cartridge
320 Pilot operated counterbalance valve- extension ram
330 Steer valve + shocks
340 Accumulator 0.24L5bar (72.5psi)
350 Adaptor. G1/4A - 7/16 SAE
360 6-Way solenoid change over valve
370 Hydraulic oil filler cap
380 Pressure transducer
400 Check valve & body assembly
410 Oil cooler fluid to fluid
420 Oil cooler and brackets
30 - 140 9813/7600-3 30 - 140

00 - General
(For: 560-80 [5AY], 560-80 [5UY])

Figure 1587. .........................................................................................................................Page 30-143
334/D7578-7
30 - 141 9813/7600-3 30 - 141

Notes:
30 - 142 9813/7600-3 30 - 142

00 - General
Page 30-144 Figure 1587. Page 30-145
410
415
260
70 70
60
370
375
250
380 90 420
385 40
60 80
390 100
70
400 110
A
90
120
B 150
310
350
430 130 130 140
160 170
C
D
E
360 180 190
30 200
E
E
180
10
E
290 280 E
180
TA TB TE TF TG TI TJ TL
300 E
T TC 230
20 240 E 220
TD
50 TH
210
270 TH
T TB
TE TL
90 TC TI TG
TH TA TJ
TD TF
334-d7578-7
30 - 143 9813/7600-3 30 - 143

00 - General
Page Page
30-144 30-145
410
415
260
370
375
250
380
385 40
390
400
A
B
310
350
430
C
Page 30-145
D
360
30
10
290 280
TA TB TE TF TG TI TJ TL
300
T TC 230
20
TD
50 TH
270
90
30 - 144 9813/7600-3 30 - 144

00 - General
Page Page
30-144 30-145
70 70
60
90 420
40
60 80
100
70
110
A
90
120
B 150
130 130 140

160 170
C
Page 30-144
D
E
180 190
200
E
E
180
E
180 E
E
230
240 E 220
210
TH
T TB
TE TL
TC TI TG
TH TA TJ
TD TF
334-d7578-7
30 - 145 9813/7600-3 30 - 145

00 - General
Table 563. 334/D7578-7

Item Description
A Control valve lift section
B Control valve tilt section
C Control valve extend section
D Control valve auxiliary section
E Hydraulic quick release connectors
T Hydraulic tank
TA Hydraulic tank port- TA
TB Hydraulic tank port- TB
TC Hydraulic tank port- TC
TD Hydraulic tank port- TD
TE Hydraulic tank port- TE
TF Hydraulic tank port- TF
TG Hydraulic tank port- TG
TH Hydraulic tank port- TH
TJ Hydraulic tank port- TJ
TL Hydraulic tank port- TL
10 Hydraulic oil filler
20 Suction filter element
30 Hydraulic pump
50 Return filter
60 Dual counterbalance valve- lift
70 Lift cylinder
80 SRS manifold
90 SRS pressure transducer
100 Accumulator - SRS
110 Accumulator- SRS
120 Adaptor- check- lift assist
140 Counterbalance valve - tilt
150 Tilt cylinder
160 Counterbalance valve - extend
170 Extend cylinder
180 6 way solenoid change over valve
190 Ball valve
200 Hydraulic hitch cylinder
210 Ball valve
220 Hydraulic locking pin cylinder
240 Accumulator- servo
250 Steering control valve
260 Manual steer mode valve
270 Charge valve- brakes
280 Brake pressure transducer
290 Brake charge accumulator
310 Trailer brake valve- if installed
30 - 146 9813/7600-3 30 - 146

00 - General
Item Description
370 Axle- pad mount 38°
375 Axle- pad mount- LSD - 38°
380 Axle- pad mount 32°
385 Axle- pad mount- LSD - 32°
390 Axle- trunnion mount 38°
400 Axle - trunnion mount- LSD - 38°
410 Axle - trunnion mount 32°
415 Axle- trunnion mount- LSD - 32°
420 Auto SRS manifold
430 Check valve
30 - 147 9813/7600-3 30 - 147

00 - General
(For: 526-56 [T4F])

Figure 1588. .........................................................................................................................Page 30-149
334/L7016-7 (526-56 Machines T4i/T4f)
30 - 148 9813/7600-3 30 - 148

00 - General
Page 30-150 Figure 1588. Page 30-151

7 27
8 4
16 16
30 10
5
36
23 20
30
25
11
9 31
33
3
A
26 B 13 12
40
C
15 38 32 14
34 D 39
35 G
G
28 E
22
17
29
F G
G
29 19
21
1 G
2 G 18
29 G
H G
37 29
334-l7016-7
30 - 149 9813/7600-3 30 - 149

00 - General
Page Page
30-150 30-151
7
8
16 16
25
3
A
26 B
40
C
15
34 D
35
Page 30-151
28 E
22
21
1
2
37
30 - 150 9813/7600-3 30 - 150

00 - General
Page Page
30-150 30-151

27
4
30 10
5
36
23 20
30
11
31
33
13 12
38 32 14
39
G
Page 30-150
17
29
G
G
29 19
G
G 18
29 G
H G
29
334-l7016-7
30 - 151 9813/7600-3 30 - 151

00 - General
Table 564. 334/L7016-7

Item Description
A Control valve inlet section
B Control valve bypass compensator valve
C Control valve auxiliary section
D Control valve tilt section
E Control valve extend section
F Control valve lift section
G Hydraulic quick release connectors
H Rear auxiliary circuit (if installed)
1 Hydraulic pump
4 Diverter valve
5 Diverter valve
7 Auto steer mode valve
8 Manual steer mode valve
9 Steering control valve
10 Lift cylinder - with SRS
11 Lift cylinder - without SRS
12 Tilt cylinder
14 Extension cylinder
15 Accumulator
17 Hydraulic hitch cylinder
18 Hydraulic locking pin cylinder
19 Hydraulic locking pin ball valve
20 Accumulator, 1L, 18bar (260.9psi) (If installed)
21 Suction filter element
22 Return filter
23 Accumulator, 1L, 7bar (101.4psi) (If installed)
26 Variable fan motor - 11cc - reversing
27 SRS pressure transducer
28 Pressurised hydraulic oil filler / breather
29 6 way solenoid change over valve
31 Tilt HBCV (Hose Burst Check Valve)
33 Adaptor
35 Fan return filter
37 Servo pilot filter
38 Shut off valve - auxiliary venting (if installed)
39 Shuttle valve - auxiliary venting (if installed)
40 Check valve
30 - 152 9813/7600-3 30 - 152

00 - General
(For: 535-95 [5AB], 535-95 [5TB])

Figure 1589. DTVT Transmission 400/G4301 issue 3 (sheet 1 of 1)................................... Page 30-155
30 - 153 9813/7600-3 30 - 153

Notes:
30 - 154 9813/7600-3 30 - 154

00 - General
Page 30-156 Figure 1589. DTVT Transmission

400/G4301 issue 3 (sheet 1 of 1) Page 30-157
30 - 155 9813/7600-3 30 - 155

00 - General
Page Page
30-156 30-157
Page 30-157
30 - 156 9813/7600-3 30 - 156

00 - General
Page Page
30-156 30-157

Page 30-156
30 - 157 9813/7600-3 30 - 157

00 - General
Item Description
250 Cooling pack- 81 kw
Table 565.
P414
Item Description 260 Bi-directional check
10 Variable power pump- valve
19cc gear 270 Quick release coupling
20 Power brake valve 06 male - 6 SAE
30 Variable fan motor 280 Quick release coupling
40 Priority accumulator 06 female - 6 SAE
charging valve 290 Steer mode valve
50 Valve block 5AB AG 300 Accumulator 12bar
electric (173.9psi)
60 Pilot valve 310 Counter balance car-
70 DTVT (Dual Technology tridge
Variable Transmission) 320 Counter balance car-
transmission tridge
80 Poppet valve assembly- 330 Steer valve + shocks
2 port 340 Accumulator 0.24L5bar
90 Pilot operated counter (72.5psi)
balance valve- lift ram- 350 Check adaptor G1/4A -
SRS 7/16 SAE
100 Lift arm SRS 120 x 70 360 6 way solenoid change
P492 over valve
120 Tilt ram 130 x 75 370 Hydraulic oil filler cap
130 Displacement ram 70 x 380 Pressure transducer
40
400 Check valve and body
140 Inner extension ram 80 x assembly
50 P33
410 Oil cooler fluid to fluid
420 Oil cooler and brackets
160 Power track rod
430 Outer extension ram 100
170 Hitch ram x 60
180 Ram- hydraulic pin lock- 440 Counter balance car-
ing tridge
190 Ball valve 450 Cartridge
200 Suction strainer 460 Vented counterbalance
210 Suction strainer valve
220 Return filter 470 Cartridge
230 Accumulator 30.3bar 480 Assembly make-up
(439.1psi) valve 1" UNF
240 Accumulator 25bar
(362.3psi)
30 - 158 9813/7600-3 30 - 158

00 - General
(For: 536-60 [5AC], 536-60 [5TC])

Figure 1590. HM560 Variable Transmission 400-K1102-2................................................... Page 30-161
30 - 159 9813/7600-3 30 - 159

Notes:
30 - 160 9813/7600-3 30 - 160

00 - General
Page 30-162 Figure 1590. HM560 Variable

Transmission 400-K1102-2 Page 30-163
30 - 161 9813/7600-3 30 - 161

00 - General
Page Page
30-162 30-163
Page 30-163
30 - 162 9813/7600-3 30 - 162

00 - General
Page Page
30-162 30-163

Page 30-162
30 - 163 9813/7600-3 30 - 163

00 - General
Item Description
340 Accumulator 0.24L5bar
Table 566. 400-K1102-2
(72.5psi)
Item Description 350 Check adaptor G1/4A -
10 Variable power pump- 7/16 SAE
19cc gear 360 6 way solenoid change
20 Power brake valve over valve
30 Variable fan motor 370 Filler breather cap
40 Priority accumulator 380 Pressure transducer
charging valve 400 Check valve and body
50 Valve block 5AD/R AG assembly
electric 410 Oil cooler fluid to fluid
60 Pilot valve 420 Oil cooler and brackets
70 DTVT transmission 430 Ball valve including lever
80 Poppet valve assembly-
2 port
90 SRS lift valve 536-60
100 Lift ram SRS 130 x 70
P492
120 Tilt ram 120 x 60
130 Displacement ram P69
90 x 50
140 Extension ram 70 x 50
P492
160 Power track rod
170 Hitch ram
180 Ram- hydraulic pin lock-
ing
190 Ball valve
220 Return filter
230 Accumulator 18.6bar
(269.6psi)
(362.3psi)
250 Cooling pack- 81 kw
P414
260 Bi-directional check
valve
270 Quick release coupling
06 male- 6 SAE
280 Quick release coupling
06 female- 6 SAE
290 Steer mode valve
(130.4psi)
310 Counter balance car-
tridge
320 Pilot operated counter
balance valve- extension
ram
330 Steer valve + shocks
30 - 164 9813/7600-3 30 - 164

03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ......................................................................................................................... 30-167

30 - 165 9813/7600-3 30 - 165

Notes:
30 - 166 9813/7600-3 30 - 166

03 - Tank
00 - General
Introduction .................................................. 30-167 The hydraulic tank holds excess hydraulic oil to
Drain and Fill ............................................... 30-168 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 - 167 9813/7600-3 30 - 167

03 - Tank
00 - General
Drain and Fill
3. Discharge the hydraulic pressure from the

(For: 531-70 [5AA], 531-70 [5TA], 535-95 system. Refer to (PIL 30-00).
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 4. Drain the hydraulic tank.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW], 4.1. Clean the area around cover plate and the
drain plug below the tank.
550-80 [5UW], 560-80 [5AY], 560-80
[5UY]) 4.2. Put a suitable size container below the drain
plug.
Remove 4.3. Remove drain plug and allow the hydraulic
oil to drain.
2. Open the rear cover (if installed). Refer to (PIL
06-06-14).
Figure 1591.
A Hydraulic tank drain plug
30 - 168 9813/7600-3 30 - 168

03 - Tank
00 - General
Install
1. Install the drain plug and tighten the drain plug to
2. Fill the hydraulic system to the correct oil level.
3. Install the filler cap.
4. Close the rear cover (if installed).

Item Description Nm
A Drain plug 122
30 - 169 9813/7600-3 30 - 169

03 - Tank

Remove and Install ..................................... 30-171 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 - 170 9813/7600-3 30 - 170

03 - Tank
Remove and Install
For: 536-60 [5AC], 536-60 [5TC], 536-70 4.2. Put a suitable size container below the drain
[5AE], 536-70 [5TE] ................. Page 30-171 plug.
For: 526-56 [T4F], 531-70 [5AA], 531-70 4.3. Remove drain plug and allow the hydraulic
[5TA], 535-95 [5AB], 535-95 [5TB], 541-70 oil to drain.
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY] 5. Hold the cover plate and remove the bolts.
................................................. Page 30-173
6. Carefully lower the cover plate away from the
(For: 536-60 [5AC], 536-60 [5TC], 536-70 machine.
[5AE], 536-70 [5TE]) 7. There is a spring positioned behind the cover
WARNING Personal injury can result from being plate which can move suddenly when you
struck by parts propelled by a released spring remove the cover plate.
force. Make sure to wear all necessary protective
equipment. Follow the recommended procedure 8. Discard the gasket.
and use all recommended tools to release the 9. Remove the strainer.
spring force.
9.1. Use a spanner of the specified size -
measured across the flats - to remove the
Remove strainer.
1. Make the machine safe. Refer to (PIL 01-03). Length/Dimension/Distance: 69mm
2. Open the rear cover (if installed). Refer to (PIL 9.2. Carefully remove the strainer from pipe.
06-06-14).
10. Use a suitable cleaning fluid to clean the suction
3. Discharge the hydraulic pressure. Refer to (PIL strainer at every applicable service interval.
30-00).
11. Make sure that the strainer is free from
4. Drain the hydraulic tank. contamination. If the strainer is defective replace
it with a new one.
4.1. Clean the area around cover plate and the
drain plug below the tank. 12. At the applicable service interval replace the
suction strainer with a new one.
30 - 171 9813/7600-3 30 - 171

03 - Tank
Figure 1592.
B D C
A Suction strainer B Cover plate

C Drain plug D Bolts
E Gasket
30 - 172 9813/7600-3 30 - 172

03 - Tank
Install 2. Open the rear cover (if installed). Refer to (PIL

06-06-14).
1. Install strainer.
1.1. Screw the strainer onto the pipe by hand. 30-00).
1.2. Tighten the strainer to the correct torque 4. Drain the hydraulic tank.
value.
2. Install new gasket. drain plug below the tank.
3. Install the cover plate and secure the cover plate 4.2. Put a suitable size container below the drain
with the bolts. plug.
4. Locate the spring on the cover plate boss. 4.3. Remove drain plug and allow the hydraulic
oil to drain.
5. Hold the cover plate and remove the bolts.
the correct torque value. 6. Carefully lower the cover plate away from the
machine.
Refer to (PIL 30-00). 7. Discard the gasket.
8. Install the filler cap. 8. Remove the strainer.
9. Close the rear cover (if installed). 8.1. Use a spanner of the specified size-
measured across the flats - to remove the
Table 568. Torque Values strainer.
Item Nm Length/Dimension/Distance: 69mm
A 12 8.2. Carefully remove the strainer from pipe.
C 122
9. Use a suitable cleaning fluid to clean the suction
D 9.9 strainer at every applicable service interval.
10. Make sure that the strainer is free from
(For: 526-56 [T4F], 531-70 [5AA], 531-70 contamination. If the strainer is defective replace
[5TA], 535-95 [5AB], 535-95 [5TB], 541-70 it with a new one.
[5AD], 541-70 [5TD], 550-80 [5AW], 11. At the applicable service interval replace the
550-80 [5UW], 560-80 [5AY], 560-80 suction strainer with a new one.
[5UY])
Remove
30 - 173 9813/7600-3 30 - 173

03 - Tank
Figure 1593.
B D C
A Suction strainer B Cover plate

C Drain plug D Bolts
E Gasket
30 - 174 9813/7600-3 30 - 174

03 - Tank
Install
1. Install strainer.
1.1. Screw the strainer onto the pipe by hand.
1.2. Tighten the strainer to the correct torque
value.
2. Install new gasket.
3. Install the cover plate and secure the cover plate
with the bolts.

Item Nm
A 12
C 122
D 9.9
30 - 175 9813/7600-3 30 - 175

04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ......................................................................................................................... 30-177

30-04-03 Main .............................................................................................................................. 30-178
30-04-09 Return Line ................................................................................................................... 30-180
30-04-60 Pilot Pressure Supply Main .......................................................................................... 30-187
30 - 176 9813/7600-3 30 - 176

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 - 177 9813/7600-3 30 - 177

04 - Filter
03 - Main
03 - Main Figure 1594.
Remove and Install
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
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.
A Canister filter
1. Make the machine safe with the lift arm lowered,
C Seal
4.1. Run the engine for a few minutes.
2. Discharge the hydraulic system pressure. Refer
to (PIL 30-00). 4.2. Make the machine safe.
3. Clean the area around the filter body. 4.3. Check for leaks at the filter.
4. Place a container of suitable size beneath the Oil Filter (Hydraulic Oil Tank, Top
machine to catch the oil. Mounting)
5. From under the machine, unscrew and remove
the element. The element will contain hydraulic Remove
fluid; keep your face clear of spilling fluid.
1. Make the machine safe with the lift arm raised,
Install
2. Open rear cover. Refer to (PIL 06-06).
1. Install the new element.
3. Discharge the hydraulic system pressure. Refer
1.1. Clean the mating faces on the new element
to (PIL 30-00).
and filter holder.
1.2. Smear the seal with clean new hydraulic 4. Clean the top of the tank around the filter.
fluid.
5. Either disconnect the hose or undo clip to enable
1.3. Screw the new element in place, hand-tight cover plate removal.
only.
6. Remove the element assembly:
2. Check oil level and replenish as required through
filler. Refer to (PIL 30-00). 6.1. Remove the screws. Remove the cover
plate and gasket, discard the gasket.
6.2. Remove the spring.
4. Check for leaks: 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 the
specified angle counter clockwise.
Angle: 90°
30 - 178 9813/7600-3 30 - 178

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
1.1. 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.
4. Close the rear cover.
Figure 1595.
A Screws
B Cover plate
C Gasket
D Spring
E Handle
F Canister
G Element
30 - 179 9813/7600-3 30 - 179

04 - Filter
09 - Return Line
09 - Return Line
Remove and Install
For: 526-56 [T4F] .................... Page 30-180 1.1. Install a new seal 1.
For: 535-95 [5AB], 535-95 [5TB] 1.2. Make sure that seal 2 is installed in the new
................................................. Page 30-181 element.
For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-70 [5AE], 536-70 1.3. Push the element into its canister and rotate
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 the element 90° to lock it into position.
[5AW], 550-80 [5UW], 560-80 [5AY], 560-80 Check that the element has locked into
[5UY] ....................................... Page 30-182 position by pulling on the handle.
For: 536-60 [5AC], 536-60 [5TC], 536-70 1.4. Install the element assembly in the
[5AE], 536-70 [5TE] ................. Page 30-184 hydraulic tank.
1.5. Install the spring and gasket.
(For: 526-56 [T4F])
1.6. Install the cover plate and tighten the
CAUTION When the strainer is removed, oil will screws.
gush out. Keep to one side when you remove the
strainer. 2. Check oil level and replenish as required through
filler.
Remove 3. Install and lock the filler cap.
1. Make the machine safe with the lift arm raised, 3.1. When the key is removed the cap turns and
refer to (PIL 01-03). can not be undone.
2. Open rear cover. Refer to (PIL 06-06). 4. Close the rear cover.
3. Discharge the hydraulic system pressure. Refer Figure 1596.
to (PIL 30-00).
4. Clean the top of the tank around the filter.
5. Either disconnect the hose or undo clip to enable
cover plate removal.
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.
7.3. Pull on handle, the element should separate
from its canister. Discard the old element. A Screws
B Cover plate
7.4. Remove and discard the seal. C Gasket
7.5. Clean the inside of canister. D Spring
E Handle
F Canister
Install G Element
30 - 180 9813/7600-3 30 - 180

04 - Filter
09 - Return Line
H Seal 1 4. Drain the hydraulic tank.

J Seal 2
K Hose 4.1. Clean the area around cover plate and the
4.2. Put a suitable size container below the drain
(For: 535-95 [5AB], 535-95 [5TB]) plug.
Special Tools 4.3. Remove drain plug and allow the hydraulic
Description Part No. Qty. oil to drain.
Special Spanner (117 332/G2160 1
mm) 5. Hold the cover plate and remove the bolts.
WARNING Personal injury can result from being machine.
struck by parts propelled by a released spring
force. Make sure to wear all necessary protective 7. Discard the gasket.
equipment. Follow the recommended procedure
and use all recommended tools to release the 8. Remove the filter element.
spring force.
8.1. Use a spanner to remove the filter element.
8.2. Carefully remove the filter from pipe.
Remove
8.3. Make sure you hold the filter tightly. When
1. Make the machine safe. Refer to (PIL 01-03). you remove the filter from the return pipe,
the spring 2 can cause the filter to move
2. Open the rear cover (if installed). Refer to (PIL suddenly.
06-06-14).
Figure 1597.
G
K
E
L
B D C
Table 570.
Item Description
B Cover plate
C Drain plug
D Bolts
30 - 181 9813/7600-3 30 - 181

04 - Filter
09 - Return Line
Item Description
E Gasket
F Filter element
G Pipe
H Spring 2
J Spring 1
K Spanner
L Distance between handle and ratchet.
Install (For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-70 [5AE], 536-70
1. Install a new filter element.
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
1.1. Screw the filter onto the pipe by hand. [5AW], 550-80 [5UW], 560-80 [5AY],
1.2. Make sure you install spring 2 together with 560-80 [5UY])
the filter. Special Tools
1.3. Use the correct special spanner together Description Part No. Qty.
with a torque wrench and extension. Special Spanner (66 332/F2828 1
Because the torque wrench handle is mm)
extended by the spanner care must be used
to obtain the correct torque on the filter. WARNING Personal injury can result from being
Special Tool: Special Spanner (117 mm) struck by parts propelled by a released spring
(Qty.: 1) force. Make sure to wear all necessary protective
1.4. Set the torque wrench to the specified and use all recommended tools to release the
value. spring force.
Torque: 33N·m
1.5. Operate the wrench, holding the handle at Remove
a specified distance from the ratchet.
Distance: 300mm
2. Open the rear cover (if installed). Refer to (PIL
1.6. Torque tighten the filter.
06-06-14).
2. Install new gasket.
3. Install the cover plate and secure the cover plate system. Refer to (PIL 30-00).
with the bolts.
4. Drain the hydraulic tank.
5. Install the drain plug and tighten the drain plug to drain plug below the tank.
the correct torque value. 4.2. Put a suitable size container below the drain
plug.
Refer to (PIL 30-00). 4.3. Remove drain plug and allow the hydraulic
oil to drain.
Table 571. Torque Values machine.
Item Description Nm 7. Discard the gasket.
C Drain plug 122
D Bolt 9.9 8. Remove the filter element.
8.1. Use a spanner to remove the filter element.
8.2. Carefully remove the filter from pipe.
30 - 182 9813/7600-3 30 - 182

04 - Filter
09 - Return Line
8.3. Make sure you hold the filter tightly. When the spring 2 can cause the filter to move
you remove the filter from the return pipe, suddenly.
Figure 1598.
G
K
E
L
B D C
Table 572.
Item Description
B Cover plate
C Drain plug
D Bolts
E Gasket
F Filter element
G Pipe
H Spring 2
J Spring 1
K Spanner
Install 1.4. Set the torque wrench to the specified

value.
Torque: 33N·m
1.1. Screw the filter onto the pipe by hand. 1.5. Operate the wrench, holding the handle at
1.2. Make sure you install spring 2 together with a specified distance from the ratchet.
the filter. Distance: 300mm
1.3. Use the correct special spanner together 1.6. Torque tighten the filter.
with a torque wrench and extension.
Because the torque wrench handle is 2. Install new gasket.
extended by the spanner care must be used
to obtain the correct torque on the filter. 3. Install the cover plate and secure the cover plate
with the bolts.
Special Tool: Special Spanner (66 mm)
(Qty.: 1) 4. Tighten the bolts to the correct torque value.
30 - 183 9813/7600-3 30 - 183

04 - Filter
09 - Return Line
5. Install the drain plug and tighten the drain plug to 2. Open the rear cover (if installed). Refer to (PIL
the correct torque value. 06-06-14).
6. Fill the hydraulic system to the correct oil level. 3. Discharge the hydraulic pressure from the
Refer to (PIL 30-00). system. Refer to (PIL 30-00).
7. Install the filler cap. 4. Drain the hydraulic tank.
8. Close the rear cover (if installed). 4.1. Clean the area around cover plate and the
4.2. Put a suitable size container below the drain
Item Description Nm plug.
C Drain plug 122 4.3. Remove drain plug and allow the hydraulic
D Bolt 9.9 oil to drain.
(For: 536-60 [5AC], 536-60 [5TC], 536-70 6. Carefully lower the cover plate away from the
[5AE], 536-70 [5TE]) machine.
Special Tools 7. There is a spring 1 positioned behind the
Description Part No. Qty. cover plate which can move suddenly when you
Special Spanner (66 332/F2828 1 remove the cover plate.
mm)
8. Discard the gasket.
WARNING Personal injury can result from being
struck by parts propelled by a released spring 9. Remove the filter element.
force. Make sure to wear all necessary protective 9.1. Use a spanner to remove the filter element.
and use all recommended tools to release the 9.2. Carefully remove the filter from pipe.
spring force. 9.3. Hold the filter tightly. When you remove the
filter from the return pipe, the spring 2 can
Remove cause the filter to move suddenly.
30 - 184 9813/7600-3 30 - 184

04 - Filter
09 - Return Line
Figure 1599.
G
K
E
L
B D C
Table 574.
Item Description
B Cover plate
C Drain plug
D Bolts
E Gasket
F Filter element
G Pipe
H Spring 2
J Spring 1
K Spanner
Install 1.4. The specified torque valve on the filter is

Torque: 33N·m
1.5. Operate the wrench, holding the handle at
1.1. Screw the filter onto the pipe by hand. a specified distance from the ratchet.
1.2. On 531-70, 535-95, 536-70, 541-70 Distance: 300mm
machines install spring 2 together with the
filter. 1.6. Torque tighten the filter.
1.3. Use the correct special spanner together 2. Install a new gasket.
with a torque wrench and extension.
Because the torque wrench handle is 3. Install the cover plate and secure the cover plate
extended by the spanner care must be used with the bolts.
to obtain the correct torque on the filter.
4. Make sure you locate the spring on the cover
Special Tool: Special Spanner (66 mm) plate boss.
(Qty.: 1)
30 - 185 9813/7600-3 30 - 185

04 - Filter
09 - Return Line


Item Description Nm
C Drain plug 122
D Bolt 9.9
30 - 186 9813/7600-3 30 - 186

04 - Filter
60 - Pilot Pressure Supply Main
Remove and Install
For: 526-56 [T4F] .................... Page 30-187 4. Remove the filter.

For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 4.1. Use a spanner of the specified size -
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 measured across the flats - to remove the
[5AD], 541-70 [5TD], 550-80 [5AW], filter bowl.
550-80 [5UW], 560-80 [5AY], 560-80 [5UY] Length/Dimension/Distance: 24mm
................................................. Page 30-189
4.2. Carefully remove the filter bowl.
(For: 526-56 [T4F]) 4.3. Remove the filter and seal from the valve
block.
Remove 4.4. Discard the seal.
1. Make the machine safe. Refer to (PIL 01-03). 5. Use a suitable cleaning fluid to clean the filter at
every applicable service interval.
30-00). 6. Make sure that the filter is free from
contamination. If the filter is defective replace it
3. Get access to the Pilot Pressure Supply Valve. with a new one.
3.1. Clean the area around the valve. 7. At the applicable service interval replace the filter
3.2. Put a suitable size container below the filter with a new one.
bowl.
30 - 187 9813/7600-3 30 - 187

04 - Filter
Figure 1600.
A Pilot pressure supply valve B Filter bowl

C Seal D Filter
30 - 188 9813/7600-3 30 - 188

04 - Filter
Install Figure 1602.
1. Install filter.
1.1. Use a new seal and install the filter into the
valve block. B
1.2. Install the filter bowl.
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 B Servo pilot pressure valve
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 5. Discharge the hydraulic pressure .
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 Refer to: PIL 30.
[5UY]) 6. Refer to Refer to Figure 1603. and Refer to
Figure 1604. for old and new servo pilot pressure
Remove valves.
1. This procedure applies to servo pilot pressure Figure 1603.

valves installed from machine serial number
2472234 onwards.
2. Make the machine safe. E
3. Remove the cab side panel. Refer to Figure
1601.
Figure 1601.
E Servo pilot pressure valve - Old

Figure 1604.
A F
A Cab side panel

4. Identify the servo pilot pressure valve under the
cab. Refer to Figure 1602.
F Servo pilot pressure valve - New
30 - 189 9813/7600-3 30 - 189

04 - Filter
7. Unscrew and remove the filter cartridge. Be 4. Operate the machines hydraulic system. Check
aware that there could be some residual for correct operation and leaks.
hydraulic pressure. Refer to Figure 1605.
5. Install the cab side panel.
Figure 1605.
G Filter cartridge location

8. Clean the filter cartridge. Refer to Figure 1606.
Figure 1606.
Install
1. Install the filter cartridge and tighten to the correct
torque.
Torque: 65N·m
2. Make sure that the servo pilot pressure is of the
specified value.
3. Check the hydraulic fluid level and top up as
required.
30 - 190 9813/7600-3 30 - 190

11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ......................................................................................................................... 30-193
30 - 191 9813/7600-3 30 - 191

Notes:
30 - 192 9813/7600-3 30 - 192

11 - Gear Pump
00 - General

Technical Data ............................................. 30-193 For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-70 [5AE],
Component Identification ............................. 30-196 536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
Operation ..................................................... 30-197 ................................................. Page 30-193
Diagram ....................................................... 30-198 For: 531-70 [5AA], 531-70 [5TA], 535-95
Check (Pressure) ........................................ 30-199 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
Remove and Install ..................................... 30-202 [5AD], 541-70 [5TD] ................ Page 30-194
Disassemble and Assemble ........................ 30-203 For: 526-56 [T4F] .................... Page 30-195
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] ................ Page 30-195
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
The pump installed on your machine will be one of
two types:
2 Section (Double pump)

Table 576. Double Pump
Mounting Gearbox
Direction of rotation Counter clockwise
Theoretical displace- 0.000036m³
ment per RPM (Revolu-
tions Per Minute)- Main
services pump (mount-
ing flange end)
ment per RPM-Cooling
fan pump
Flow- Main services 71.3L/min
pump
(1)
Flow- Cooling fan pump 31.7L/min

Maximum pressure- port 265 (3,840.6)
EF
Maximum pressure- port 200 (2,898.5)
P
Maximum speed 3000 RPM
Minimum speed 500 RPM
Weight 22.7kg
(1) At 2200 RPM and system pressure (90% min
displacement).
3 Section (Triple pump)

Table 577. Triple Pump
Mounting Gearbox
ment per RPM- Main
services pump (mount-
ing flange end)
30 - 193 9813/7600-3 30 - 193

11 - Gear Pump
00 - General
Theoretical displace- 0.000019m³ Table 581.

ment per RPM-Cooling Minimum pressure Value
fan pump
Port EF 265bar (3,840.6psi)
ment per RPM-Cooling Port P 200bar (2,898.5psi)
fan pump
Flow- Main services 71.3L/min Two section double pump (2)
pump
(1)
Table 582.
Flow- Steering pump 37.6L/min
Flow- Cooling fan pump 31.7L/min Type Gear pump
Maximum pressure- port 265 (3,840.6) Mounting Gearbox
EF Direction of rotation Anti-clockwise
Maximum pressure- port 200 (2,898.5) Maximum speed 2200RPM
P Minimum speed 500RPM
Maximum speed 2500 RPM Weight TBA
Minimum speed 500 RPM
Weight 34.1kg Table 583.
(1) At 2200 RPM and system pressure (90% min Theoretical displace- Value
displacement). ment
Main services pump 45 cc/rev
(mounting flange end)
(For: 531-70 [5AA], 531-70 [5TA], 535-95 Cooling fan pump 16 cc/rev
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 Table 584.
[5AD], 541-70 [5TD]) Flow at 2200RPM and Value
system pressure (90%
Depending on the specification of your machine, the min. displacement)
following pumps may be installed: Main services pump TBA
Two section double pump (1) Cooling fan pump TBA

Type Double gear pump Minimum pressure Value
Mounting Gearbox Port EF 260bar (3,768.1psi)
Direction of rotation Anti-clockwise Port P 180bar (2,608.7psi)
Minimum speed 500 RPM Three section triple pump (3)
Weight 22.7kg
Table 586.
Table 579. Type Triple gear pump
Theoretical displace- Value Mounting Gearbox
ment Direction of rotation Anti-clockwise
Main services pump 36 cc/rev Maximum speed 2500RPM
(mounting flange end) Minimum speed 500RPM
Cooling fan pump 16 cc/rev Weight 34.1kg

Flow at 2200RPM and Value Theoretical displace- Value
system pressure (90% ment
min. displacement) Main services pump 36 cc/rev
Main services pump 71.3L/min (mounting flange end)
(mounting flange end) Steering pump 19 cc/rev
Cooling fan pump 31.7L/min Cooling fan pump 16 cc/rev
30 - 194 9813/7600-3 30 - 194

11 - Gear Pump
00 - General
Table 588. Maximum speed 3000 RPM

Flow at 2200RPM and Value Minimum speed 500 RPM
system pressure (90% Weight (when assem- 42.7
min. displacement) bled to variable pump)
Main services pump 71.3L/min (1) Pump manufacturers specification
Steering pump 37.6L/min
Cooling fan pump 31.7L/min
Table 589.
Minimum pressure Value
Port EF 265bar (3,840.6psi)
Port P 200bar (2,898.5psi)
(For: 526-56 [T4F])

Table 590. Gear Pumps 526-56
Pump type Fixed displacement twin
gear with integrated pri-
ority and load sense
valve
Main pump displace- 36 CC
ment
Fan pump displacement 16 CC
Rotational direction Counter clockwise
Operating oil tempera- -15–106°C (5.0–
ture range 222.7°F)
Suction pressure Min -0.75 (-10.9) (ab-
solute) Maximum 2
(29.0), Min -0.25 (-3.6)
(gauge).
(For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY])
Your machine is installed with a double pump. One
pump is a gear type (for the cooling fan) and one is
a variable piston type (for the main services). They
are mounted together inline on the gearbox. Refer
to component identification, (PIL 30-00) and variable
displacement pump, (PIL 30-12).
Gear Pump (Fan Hydraulics)

Table 591.
Mounting Gearbox (rear of vari-
able pump)
Theoretical displace- 19 cc
ment per RPM
Flow
Maximum pressure
(1)
230 (3,333.3)
Maximum continuous 210 (3,043.5)
pressure
(1)
30 - 195 9813/7600-3 30 - 195

11 - Gear Pump
00 - General
Figure 1607. Typical Double Pump
D
C
Figure 1608. Typical Triple Pump
A
D
B
C
A Main services section
B Steering section (if fitted)
C Cooling fan section
D Steering priority valve
30 - 196 9813/7600-3 30 - 196

11 - Gear Pump
00 - General
Operation
The pump is a gear type and driven by the engine. the gears come into mesh the oil is forced through the
The separate sections of the gear pump assembly outlet port, or through an internal port into the integral
supply hydraulic oil to the main hydraulic circuits, to priority valve depending on the type of pump.
the steering circuit and to the hydraulic cooling fan
circuit. Some oil is allowed to circulate behind the bushes to
hold them in balance against the gears and minimise
The separate sections of the gear pump operate oil leakage.
individually as described below.
Lubrication is provided by the hydraulic oil,which is
The working principle of a gear pump depends on the directed around the unit via oil ways, by the motion
meshing of two spur gears. Oil is picked up on the of the meshing gears.
suction side of the pump by the gears and carried
round between the gear teeth and the pump body. As For the priority valve operation, refer to (PIL 25-03).
Figure 1609.
A Spur gear 1 B Spur gear 2

C Bushes 1 D Bushes 2
Table 592. Colour coding

Color Coding Description
Green Pump oil inlet (suction
side)
Amber Pump oil outlet (at pump
pressure)
30 - 197 9813/7600-3 30 - 197

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 1610.
LS P EF F G
C A
B
Item Description
Table 593. 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 594. Port details

Item Description
F Fan and pilot valve feed
G Test point
P Pump main output
30 - 198 9813/7600-3 30 - 198

11 - Gear Pump
00 - General
Check (Pressure) Figure 1612.
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
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 1611. 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 1613.
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)
(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 - 199 9813/7600-3 30 - 199

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: 240bar (3,478.2psi) and place the end of the slave hose inside
the filler tube.
12. Check the flow reading.
Figure 1615.
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
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 1614.
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 - 200 9813/7600-3 30 - 200

11 - Gear Pump
00 - General
Figure 1616. 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: 240bar (3,478.2psi)
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 1618.
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 1617.
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 - 201 9813/7600-3 30 - 201

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 1620. 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 1619. 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 - 202 9813/7600-3 30 - 202

11 - Gear Pump
00 - General
1.5. Tighten the mounting bolts to the correct Disassemble and Assemble
torque value.
1.6. Make sure that the mounting bolts are 10.9 Do not try to disassemble this component. If this
grade M12 Tuf-Lok. component is defective a new one must be installed.
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

Item Description Nm
A Flange bolts 46
B Socket head screws 46
D Mounting bolts 96
30 - 203 9813/7600-3 30 - 203

12 - Variable Displacement Pump
Contents Page No.
30-12-00 General ......................................................................................................................... 30-205
30 - 204 9813/7600-3 30 - 204

00 - General
Introduction .................................................. 30-205
Technical Data ............................................. 30-206
(For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
Operation ..................................................... 30-209
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY])
The most common variable displacement pump used
in vehicle technology is the axial piston pump. This
pump has several pistons in cylinders arranged
parallel to each other and rotating around a central
shaft. A swashplate at one end is connected to the
pistons. As the pistons rotate, the angle of the plate
causes them to move in and out of their cylinders.
A rotary valve at the opposite end from the

swashplate alternately connects each cylinder to
the fluid supply and delivery lines. By changing the
angle of the swashplate, the stroke of the pistons
can be varied continuously. If the swashplate is
perpendicular to the axis of rotation, no fluid will flow.
If it is at a sharp angle, a large volume of fluid will be
pumped.
Some pumps allow the swashplate to be moved in

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

by inserting springs inline with the pistons. The
displacement is not positively controlled, but
decreases as the back-pressure increases.
30 - 205 9813/7600-3 30 - 205

00 - General
Technical Data
a variable piston type (for the main services). They

(For: 531-70 [5AA], 531-70 [5TA], 535-95 are mounted together inline on the gearbox. Refer
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 to component identification, (PIL 30-00) and gear
pump, (PIL 30-11).
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY])
Your machine is installed with a double pump. One
pump is a gear type (for the cooling fan) and one is
Variable Pump (Main Services)

Table 596.
Displacement 11.1 cc to 63 cc/rev
Minimum speed 500 RPM (Revolutions Per Minute)
Maximum pressure
(1)
315 (4,565.2)
Maximum continuous pressure
(1)
250 (3,623.2)
ARV (Auxiliary Relief Valve)
(1)
290 (4,202.9)
(1) Pump manufacturers specification
30 - 206 9813/7600-3 30 - 206

00 - General
For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................. Page 30-207
................................................. Page 30-208
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80
[5UW], 560-80 [5AY], 560-80 [5UY])
Figure 1621.
G1
F1
G
F
A
J
H
B
A
E D
K L
L
C
Item Description
F Pressure cut off safety
Table 597.
valve spool
Item Description F1 Pressure cut off safety
A Drive shaft. Driven from valve adjuster cover (not
the bevel gearbox adjustable)
B Inlet (suction) port G Flow compensator valve
C Outlet port spool
D Separate gearpump G1 Flow compensator valve
(cooling fan circuit) dri- adjuster cover (not ad-
ven by drive shaft justable)
E Hydraulic control valve H Swash control piston
30 - 207 9813/7600-3 30 - 207

00 - General

J Swash plate control K Swash plate
spring L Axial pistons
Figure 1622. Hydraulic Services Pump- Dual Tech Variable Transmission

G
E D
M
D P
F
C M
C
H
B
A
B M
N C
C M
334/E2996-3 K
A Pump drive coupling B O-ring

C Pressure test point D Adapter
E Cap screw M12 x 35 12.9 grade F Set screw M12 x 35 12.9 grade
G Adapter- Tee H Temperature sensor- Hydraulic oil
J Suction adapter K Set screw M12 x 30 8.8 grade
L Fan suction pipe M Spring washer M12
N Variable displacement pump P Pump- fan
30 - 208 9813/7600-3 30 - 208

00 - General
Operation
Rotation of the input drive shaft produces linear

(For: 531-70 [5AA], 531-70 [5TA], 535-95 movement of the axial pistons. The pump output is
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 controlled via the swash control piston. The piston
varies the angle of the tilting swash plate, which
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 alters the displacement (stroke) of the pistons. This
[5AD], 541-70 [5TD], 550-80 [5AW], has the effect of changing the hydraulic oil flow in the
550-80 [5UW]) system.
The hydraulic services pump is a variable

displacement axial piston pump, which uses the
swash plate design principle.
Figure 1623.
Item Description
Table 598. F Spring3
Item Description G Pressure cut-off spool
A Swashplate X Solenoid valve
B Spring1 LS Load sense line
C Piston P Operating pressure
D Compensator spool
E Spring2
30 - 209 9813/7600-3 30 - 209

00 - General
The swash control piston is controlled by two equivalent to 25bar (362.3psi), therefore the pump
systems, as follows. operating pressure (i.e. main system pressure) will
always be maintained at 25bar (362.3psi) above the
• The flow compensator valve. The valve is load sense pressure. This is sometimes referred to
actuated by load sense hydraulic pressure. This as the 'Delta-P' pressure setting.
system controls the pump in response to the
demands of the hydraulic services. Pressure cut-off valve
• The hydraulic control valve operates to make
sure that the torque required to turn the The pressure cut-off valve is a secondary safety
pump does not exceed the maximum engine device to limit the maximum operating pressure
torque range. Two types of valve are installed thereby protect the pump from over pressurisation.
depending on the machine variant. If the pump operating pressure (i.e. main system
pressure) ever reaches the setting of the valve
Pump control spring3, the pressure cut-off spool will be pushed to
the left, this in turn, increases the control pressure
The pump output flow and operating pressure are acting on the swash control piston, which decreases
controlled by varying the angle of the tilting swash the angle of the swash plate, and reduces the pump
plate. The swashplate is moved in one direction output flow to minimum. While the pressure cut-off
by the force of the spring1, and in the opposite valve is operating the pump will remain hydraulically
direction by control pressure (orange) acting behind stalled i.e. maintaining maximum operating pressure
the swash control piston. The control pressure is at minimum flow.
derived from the pump operating pressure (red)
by the action of the flow compensator spool. The Hydraulic variable control solenoid valve
flow compensator spool regulates the angle of the
swashplate automatically in response to changes in
(HVCS)
the hydraulic load sense pressure (yellow) from the
The proportional solenoid valve is part of the HVCS
hydraulic service.
(Hydraulic Variable Control Solenoid Valve). The
system automatically adjusts the pump performance
Flow compensator valve (power curve characteristic) to limit the hydraulic
power available to the hydraulic services under
When a hydraulic service is operated, boom lift for conditions of high engine load or high hydraulic fluid
example, a pressure signal (demand) is generated temperature.
in the load sense line (LS) from the control valve
block. The increase in the load sense pressure, The solenoid valve is controlled by a current
combined with the force of the spring2 pushes the signal output from an ECU (Electronic Control
flow compensator spool to the right, this in turn, Unit). The solenoid valve works as a separate
allows some control pressure (orange) acting on the pressure regulating valve and increases the control
swash control piston to vent back to tank via the case pressure acting on the swash control piston by a
drain (green). The force of the spring1 increases the set amount, according to the valve current signal.
angle of the swashplate and the pump output flow Because the control pressure is regulated by the
increases proportionally. solenoid valve independently (down stream) of the
flow compensator spool, this means that when it
When the output flow is enough to satisfy the is operating, it will alter the way that the pump
flow demanded by the service, the pump operating swashplate normally responds to changes in the
pressure (red) increases sufficiently to start to move hydraulic load sense pressure.
the service ram. The increase in the pump operating
pressure pushes the flow compensator spool back In this way, the hydraulic power curve of the pump
to the left, against the force of the spring2 and can be adjusted electrically by the current signal from
hydraulic load sense pressure; this in turn increases the ECU.
the control pressure acting on the swash control
piston, which decreases the angle of the swash plate
against the force of spring1. As the swash plate angle
decreases, the output flow from the pump decreases.
In this way, the pump delivers only the minimum flow
needed to maintain the system pressure required to
operate the service.
The flow compensator spool is moving constantly,

thereby regulating the pump swash plate to balance
the pressures acting on each end of the spool.
The additional force of spring2 is factory set to be
30 - 210 9813/7600-3 30 - 210

00 - General
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 535-95 Remove

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 1. Make the machine safe. Refer to (PIL 01-03).
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY] 2. Discharge the hydraulic pressure. Refer to (PIL
................................................. Page 30-211 30-00).
................................................. Page 30-213 3. Drain the hydraulic fluid from the hydraulic tank
into a suitable clean container.
(For: 531-70 [5AA], 531-70 [5TA], 535-95 4. Disconnect the outlet hose from the fan pump.
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
5. Disconnect the electrical connector 1 from the
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 pump control solenoid.
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 6. Disconnect the electrical connector 2 from the
[5UY]) hydraulic fluid temperature switch.
Consumables 7. Remove the clips and disconnect the suction

Description Part No. Size hose from the pump inlet manifold.
JCB Threadlocker and 4101/0550 0.01L 8. Plug the open port and cap the hose to prevent
Sealer (High Strength) 4101/0552 0.2L loss of fluid and ingress of dirt.
Working Under the Machine 9. Remove flange bolts and remove the outlet hose
from the pump body.
Make sure that any attachments on the machine are 10. Plug the open port and cap the hose to prevent
correctly attached. Engage the park brake, remove loss of fluid and ingress of dirt.
has wheels use blocks to prevent unintentional 11. Disconnect the load sense hose from the pump.
movement. Plug the open port and cap the hose to prevent
loss of fluid and ingress of dirt.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 12. Disconnect the case drain hose from the pump.
Before connecting or removing any hydraulic hose, Plug the open port and cap the hose to prevent
residual hydraulic pressure trapped in the service loss of fluid and ingress of dirt.
service line has been vented before connecting or CAUTION! This component is heavy. It must only
removing hoses. Make sure the engine cannot be be removed or handled using a suitable lifting
started while the hoses are open. method and device.
The fan pump is bolted to the variflow pump. This 13. Make sure you use a sling around the pump
procedure describes removing the variflow pump and assembly.
fan pump as one unit.
14. With the pump correctly supported, remove the
Before you remove the pump, make sure the exterior mounting bolts and carefully remove the pump
of the pump and working area is thoroughly cleaned from the gearbox.
and free of possible sources of contamination.
Two bolts are hexagon head and other two are
caphead bolts. Record the position of the bolts for
correct installation.
30 - 211 9813/7600-3 30 - 211

00 - General
Figure 1624.
H K J
Item Description
Table 599. F Flange bolts (x4)
G Load sense hose
Item Description
H Case drain hose
A Outlet hose
J Mounting bolts (x4)
B Fan pump
K Cap
C Electrical connector 1
D Electrical connector 2
E Clips
30 - 212 9813/7600-3 30 - 212

00 - General
Install Working Under the Machine

Before you start the engine the variflow pump body Make sure that any attachments on the machine are
must be filled with hydraulic fluid. If the engine is correctly attached. Engage the park brake, remove
started with no fluid in the pump, pump can be the ignition key, disconnect the battery. If the machine
damaged. has wheels use blocks to prevent unintentional
movement.
1. Make sure the pump flanges and gearbox mating
faces are clean and free from oil and grease Hydraulic Pressure
before installation. Hydraulic fluid at system pressure can injure you.
2. Install new O-ring seals to the pump to gearbox Before connecting or removing any hydraulic hose,
case mating face and inlet and outlet hose residual hydraulic pressure trapped in the service
flanges. hose line must be vented. Make sure the hose
3. Lubricate the O-rings with clean hydraulic fluid. removing hoses. Make sure the engine cannot be
4. Apply sealant to the flange bolts and tighten the
bolts to the correct torque value. Refer to Hydraulic System, Variable Displacement
Pump, General, Component Identification, refer to
(PIL: 30-12-00).
(High Strength)
5. Remove the cap and fill the pump case with clean This procedure uses illustrations from another
hydraulic fluid. Install the cap. transmission, however the removal procedure is
similar.
6. Reconnect the hydraulic hoses and suction hose
to the pump. The fan pump is bolted to the variflow pump. This
procedure describes removing the variflow pump and
7. Connect the electrical connectors with the fan pump as one unit.
hydraulic fluid temperature switch and the pump
control solenoid. Before you remove the pump, make sure the exterior
of the pump and working area is thoroughly cleaned
8. Fill the hydraulic tank to the correct level with and free of possible sources of contamination.
clean hydraulic fluid. Refer to (PIL 30-00).
9. Loosen cap and allow any trapped air to escape Remove
from the pump body and drain hose. Tighten the 1. Make the machine safe. Refer to (PIL 01-03).
cap.
30-00).
Item Value 3. Drain the hydraulic fluid from the hydraulic tank
into a suitable clean container.
J
(1)
87N·m
J
(2)
97N·m 4. Disconnect the outlet hose from the fan pump.
K
(1)
84N·m 5. Disconnect the electrical connector 1 from the
K
(2)
84–92N·m pump control solenoid.
(1) 550-80 machines only. 6. Disconnect the electrical connector 2 from the
(2) Other machines. hydraulic fluid temperature switch.
7. Remove the clips and disconnect the suction
hose from the pump inlet manifold.
8. Plug the open port and cap the hose to prevent
Consumables loss of fluid and ingress of dirt.
9. Remove flange bolts and remove the outlet hose
from the pump body.
Moly Grease 4003/1326 12.5kg
10. Plug the open port and cap the hose to prevent
30 - 213 9813/7600-3 30 - 213

00 - General
11. Disconnect the load sense hose from the pump. 13. Make sure you use a sling around the pump
Plug the open port and cap the hose to prevent assembly.
14. With the pump correctly supported, remove the
12. Disconnect the case drain hose from the pump. mounting bolts and carefully remove the pump
Plug the open port and cap the hose to prevent from the gearbox.
Two bolts are hexagon head and other two are
CAUTION! This component is heavy. It must only caphead bolts. Record the position of the bolts for
be removed or handled using a suitable lifting correct installation.
method and device.
30 - 214 9813/7600-3 30 - 214

00 - General
Figure 1625. Typical Pump Installation.
H K J
Item Description
Table 601. F Flange bolts (x4)
G Load sense hose
Item Description
H Case drain hose
A Outlet hose
J Mounting bolts (x4)
B Fan pump
K Cap
C Electrical connector 1
D Electrical connector 2
E Clips
30 - 215 9813/7600-3 30 - 215

00 - General
Install
Before you start the engine the variflow pump body
must be filled with hydraulic fluid. If the engine is
started with no fluid in the pump, pump can be
damaged.
1. Make sure the pump flanges and gearbox mating

faces are clean and free from oil and grease
2. Install new O-ring seals to the pump to gearbox
case mating face and inlet and outlet hose
flanges.
3. Make sure the pump drive coupling is greased
and installed before assembly.
Consumable: Extreme Performance Moly
Grease
4. Lubricate the O-rings with clean hydraulic fluid.
5. Apply JCB Medium strength locking fluid
4101/0200 to the flange bolts and tighten the
bolts to the correct torque value. Refer to (PIL
75-10-00).
6. Remove the cap and fill the pump case with clean
hydraulic fluid. Install the cap.
7. Reconnect the hydraulic hoses and suction hose
to the pump.
8. Connect the electrical connectors with the
hydraulic fluid temperature switch and the pump
control solenoid.
9. Fill the hydraulic tank to the correct level with
clean hydraulic fluid. Refer to (PIL 30-00).
10. Loosen cap and allow any trapped air to escape
from the pump body and drain hose. Tighten the
cap.

Item Value
J 87N·m
30 - 216 9813/7600-3 30 - 216

00 - General
Do not try to disassemble this component. If this

component is defective a new one must be installed.
30 - 217 9813/7600-3 30 - 217

13 - Hydrostatic Pump
Contents Page No.
30-13-00 General ......................................................................................................................... 30-219
30 - 218 9813/7600-3 30 - 218

00 - General
Introduction .................................................. 30-219 The A4VG is an axial piston variable pump with
Technical Data ............................................. 30-220 swashplate design for hydrostatic drives in closed
Component Identification ............................. 30-220 circuits. Flow is proportional to drive speed and
Operation ..................................................... 30-221 displacement. The flow can be changed smoothly by
controlling the swashplate.
Fault-Finding ................................................ 30-222
Disconnect and Connect ............................. 30-224 A hydraulic system is considered to be closed if the
Drain and Fill ............................................... 30-225 hydraulic fluid which flows back from the consumer
Check (Pressure) ........................................ 30-225 is directed directly back to the pump. Here, there
is a high-pressure side and a low-pressure side
Bleed ........................................................... 30-226 depending on the load direction (output torque on the
Remove and Install ..................................... 30-226 consumer).
For axial piston units with swashplate design, the
pistons are arranged axially with respect to the drive
shaft. They are guided in the rotating cylinder and
support themselves with the slipper pads on the non-
rotating swashplate. The drive shaft and cylinder are
connected to one another by means of gearing.
30 - 219 9813/7600-3 30 - 219

00 - General
Weight 115kg Figure 1626. Assembly of the Axial Piston Unit

D
For pressure specifications and test points refer to C
(PIL 27-05-00).
B E
A F
K J H G
A Drive shaft
B Retaining plate
C Stroke piston
D Control unit
E Control plate
F Auxiliary pump
G Suction port
H Cylinder
J Piston
K Slipper pad
L Swashplate
30 - 220 9813/7600-3 30 - 220

00 - General
Operation centered. Increasing the swivel angle increases the

displacement. Reducing the swivel angle reduces
the displacement.
Pump
Torque is applied to the pump drive shaft from the
engine. The pump cylinder turns with the drive shaft,
turning with it the pump pistons. On each rotation, the
pistons perform a stroke movement which is defined
by the pitch of the swashplate. The slipper pads are
held on and guided along the glide surface of the
swashplate by the retaining plate. During a rotation,
each piston moves over the bottom and top dead
centers back to its initial position. During this action,
the fluid volume defined by the piston surface and the
stroke is fed in or removed through the two control
slits in the control plate. On the low-pressure side,
fluid flows into the enlarging piston chamber – in
a closed circuit this is supported by the return and
boost pressures. At the same time, on the pressure
side the fluid is pushed out of the cylinder chamber
into the hydraulic system by the pistons.
Pressure Cut-Off
The operating pressure is limited by the pressure cut-
off.
The pressure cut-off corresponds to a pressure

regulator which reduces the pump capacity once the
set specified pressure value is reached so that the
set pressure is maintained but not exceeded.
High-Pressure Safeguarding
The pressure spikes which occur during very rapid
swiveling operations as well as the maximum
pressure are safeguarded by the superordinate high-
pressure relief valves. These valves open if the set
value is exceeded, thereby depressurizing the low
pressure side. The fluid quantity remains constant
in the closed circuit. The leakage at the pump and
motor is replaced by the auxiliary pump.
Auxiliary Pump
The auxiliary pump continuously supplies a sufficient
volume of fluid (boost volume) from a small tank to
the low-pressure side of the closed circuit via a check
valve to replenish the internal leakage of the variable
pump and consumer.
Control
The swivel angle of the swashplate is infinitely
variable. By changing the swivel angle, the piston
stroke and, therefore, the displacement change. The
swivel angle is controlled hydraulically via the stroke
piston. The swashplate is mounted for easy motion
in swivel bearings and the neutral position spring
30 - 221 9813/7600-3 30 - 221

00 - General
Fault-Finding
Fault
Pump Is Noisy Table 603. Page 30-222
No Or Insufficient Flow Table 604. Page 30-222
No Or Insufficient Pressure Table 605. Page 30-223
Pressure / Flow Fluctuations Table 606. Page 30-223
Pump Hydraulic Fluid Temperature Too High Table 607. Page 30-223
Table 603. Pump Is Noisy

Cause Remedy
Drive speed too high. Contact machine or system manufacturer.
Wrong direction of rotation. Ensure correct direction of rotation.
Insufficient suction conditions, e.g. air in the suction Contact machine or system manufacturer (e.g.
line, insufficient diameter of the suction line, viscosity optimize inlet conditions, use suitable hydraulic fluid).
of the hydraulic fluid too high, suction height too high, Completely air bleed axial piston unit, fill suction line
suction pressure too low, contaminants in the suction with hydraulic fluid.
line. Remove contaminants from the suction line.
Improper fixing of the axial piston unit. Check fixing of the axial piston unit according
to the specifications of the machine or system
manufacturer. Observe tightening torques.
Improper installation of the attachment parts, e.g. Install attachment parts according to the information
coupling and hydraulic lines. provided by the coupling or armature manufacturer.
Pressure-relief valve of the axial piston unit (boost Air bleed axial piston unit. Check viscosity of
pressure, high pressure, pressure cut-off). the hydraulic fluid. Contact machine or system
manufacturer.
Mechanical damage to the axial piston unit. Exchange axial piston unit. Contact machine or
system manufacturer.
Table 604. No Or Insufficient Flow

Cause Remedy
Faulty mechanical drive (e.g. defective coupling). Contact machine or system manufacturer.
Drive speed too low. Contact machine or system manufacturer.
Insufficient suction conditions, e.g. air in the suction Contact machine or system manufacturer. (e.g.
of the hydraulic fluid too high suction height too high, Completely air bleed axial piston unit, fill suction line
Hydraulic fluid not in optimum viscosity range. Use suitable hydraulic fluid specified by machine or
External control of the control device defective. Check external control. Contact machine or system
manufacturer.
Insufficient pilot pressure. Check pilot pressure. Contact machine or system
manufacturer.
Malfunction of the control device or controller of the Contact machine or system manufacturer.
axial piston unit.
Wear of axial piston unit. Exchange axial piston unit. Contact machine or
30 - 222 9813/7600-3 30 - 222

00 - General
Table 605. No Or Insufficient Pressure

Cause Remedy
Faulty mechanical drive (e.g. defective coupling). Contact machine or system manufacturer.
Drive power too low. Contact machine or system manufacturer.
Hydraulic fluid not in optimum viscosity range. Use suitable hydraulic fluid Contact machine or
External control of the control device defective. Check external control Contact machine or system
manufacturer.
Insufficient pilot pressure. Check pilot pressure. Contact machine or system
manufacturer.
Malfunction of the control device or controller of the Contact machine or system manufacturer.
axial piston unit.
Output unit defective (e.g. hydraulic motor or Contact machine or system manufacturer.
cylinder).
Table 606. Pressure / Flow Fluctuations

Cause Remedy
Axial piston unit not or insufficiently air bled. Completely air bleed axial piston unit.
Table 607. Pump Hydraulic Fluid Temperature Too High

Cause Remedy
Excessive inlet temperature at the axial piston unit. Contact machine or system manufacturer. Inspect
system, e.g malfunction of the cooler, insufficient
hydraulic fluid in the tank.
Malfunction of the pressure control valves (e.g. high- Contact machine or system manufacturer.
pressure relief valve, pressure cut-off, pressure
control).
Malfunction of the flushing valve. Contact machine or system manufacturer.
30 - 223 9813/7600-3 30 - 223

00 - General
Disconnect and Connect
Bypass Function Activation WARNING This component will be very hot during
and after towing.
WARNING When performing this procedure, the
machine will have no brakes. Make sure the Notice: While towing with the bypass function
machine is hitched to the towing vehicle(s) before activated, the closed hydraulic circuit empties
proceeding. itself. This can result in unintended functions
when restarting the travel drive.
Notice: Failure to place the machine in
'freewheel' mode before towing will cause serious Start the travel drive only after completely filling
damage to the pump, motor and hydraulic and bleeding the air from the hydraulic circuit.
system.
Notice: High towing speeds and long towing Before moving or recovering a disabled machine,
distances will result in too much heat and not make sure you refer to the correct operators manual
enough lubrication. This will damage the pump. for instructions on moving a disabled machine.
Make sure you only tow the machine out of the
This bypass procedure is provided for information
immediate danger zone.
only and may not be required.
Figure 1627. A4VG Series 40 Axial Piston Pump
A
1
1A
B
2 2B
A Shuttle Valve B Stop
Make sure you understand and take the correct Bypass Function Deactivation
action for your machine to prevent it moving when
the bypass function is activated. 1. Immediately after towing, set the bypass function
to off.
Make sure you know the maximum towing speed of
the machine. 2. Use the correct tool to turn the shuttle valve
clockwise to the stop. Tighten it to the specified
In all cases the machine may only be towed out of torque.
the immediate danger zone only. Torque: 50N·m
The pump flow can be altered using a bypass 3. The bypass function is now deactivated.
function in order to tow the vehicle out of an
immediate danger zone. Turning the correct screw 4. Make sure the hydraulic circuit is bled correctly
allows the hydraulic fluid to flow freely. before attempting to restart the transmission
system. Refer to hydraulic system, general,
1. To activate the bypass function, set the engine to bleed (PIL 30-00-00).
off.
2. Use the correct tool to turn the shuttle valve
counter clockwise to the stop.
3. The bypass is now active.
30 - 224 9813/7600-3 30 - 224

00 - General
Drain and Fill Check (Pressure)

Notice: The gearbox has separate hydraulic and
mechanical systems and they use different fluids. Pressure Test Point
Make sure you use the correct fluid.
Refer to hydraulic system, hydrostatic pump,
The gearbox hydrostatic drive system is supplied general, technical data (PIL 30-13-00).
from the machines hydraulic system. To drain and fill
the hydraulic system, refer to (PIL 30-03-00). Figure 1628. AVG085 Pump
B
The gearbox mechanical drive system oil supply is
separate form the hydraulic system. To drain and
fill the gearbox mechanical system, refer to (PIL
27-05-00).
B
A Hydrostatic pump
B Pressure test point
30 - 225 9813/7600-3 30 - 225

00 - General
Bleed Remove and Install

Refer to hydraulic system, general, general, bleed, be removed or handled using a suitable lifting
(PIL 30-00-00). method and device.
Removal
1. Make the machine safe, refer to (PIL 01-03).
2. Vent the hydraulic system, refer to the machines
operator manual. Also refer to (PIL 30-00-00).
3. Isolate the machines battery, refer to (PIL
33-03-03).
4. Make sure the pump is cool enough to work on.
5. If required on your machine, seal the connection
to the tank to prevent loss of fluid.
6. Label and remove the hydraulic and electrical
connections. Use suitable containers to collect
the displaced fluid.
7. This component is heavy, make sure you
attach suitable lifting equipment and remove
the pump retaining bolts. Refer to hydraulic
system, hydrostatic pump, general, introduction,
technical data (PIL 30-13-00).
8. Empty the pump of fluid over a suitable container
and place the pump on a suitable surface.
9. Plug all openings to prevent the ingress of debris.
10. The pump may subsequently be moved by use
of a suitable eyebolt.
30 - 226 9813/7600-3 30 - 226

00 - General
Figure 1629. Lifting the Pump Disassemble and Assemble
Refer to JCB Service for advice.
A Pump lifted using a sling

B Subsequent movement of the pump using an
eye bolt.
Installation
Installation is the reverse of removal. In addition carry
out the following procedures:
1. Make sure the hydraulic fluid level is correct

when installation is complete.
2. Make sure all connections are correct according
to the labels made during removal.
3. Bleed the pump. Refer to hydraulic system,
general, bleed, (PIL 30-00-00).
30 - 227 9813/7600-3 30 - 227

15 - Cylinder / Ram
15 - Cylinder / Ram
Contents Page No.
30-15-00 General ......................................................................................................................... 30-229

30-15-06 Lift Arm ......................................................................................................................... 30-241
30-15-07 Lift Extension ................................................................................................................ 30-247
30-15-08 Lift Compensating ........................................................................................................ 30-258
30-15-11 Lift Arm Crowd ............................................................................................................. 30-263
30-15-34 Steering ........................................................................................................................ 30-274
30-15-63 Sway ............................................................................................................................. 30-277
30-15-99 Seal Kit ......................................................................................................................... 30-280
30 - 228 9813/7600-3 30 - 228

15 - Cylinder / Ram
00 - General
Introduction .................................................. 30-229 A hydraulic cylinder ram is a mechanical actuator
Health and Safety ........................................ 30-230 that is used to give a single directional force
Technical Data ............................................. 30-232 through a single action stroke. It is used in many
Operation ..................................................... 30-233 applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
Check (Condition) ........................................ 30-236 consists of a cylinder barrel, in which a piston
Disassemble and Assemble ........................ 30-237 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 - 229 9813/7600-3 30 - 229

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.
prevent the machine being started while you are
2.2. There is a large amount of air in a new
beneath it.
ram or one which has been left for a long
time, so the ram will not operate smoothly.
Precautions for Installation Also, if pressure is applied suddenly without
bleeding the air, high temperatures will be
1. Precautions when installing the ram on the
generated due to adiabatic compression
machine.
and the seals may burn.
1.1. When installing and removing from the 2.3. Before beginning work, always move the
machine, suspend the ram safely. ram at full stroke with no load and expel air
1.2. Suspending the ram by the piping is not only from the cylinder.
dangerous, but can also cause damage to
3. When stopping or storing, do it at a safe and fixed
the cylinder.
position.
1.3. Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. 3.1. The installed ram cannot maintain the same
Also, the rod can be damaged and become position for a long period of time, because
unusable. the oil inside the ram may leak and the
hydraulic oil volume decreases as it cools.
2. Welding after installing the ram may result in Stop or store the machine in a safe and
damage. fixed position.
2.1. If electric welding is done even at a point Maintenance, Inspection Points

away from the ram, there may be sparking
inside the ram and it will become necessary 1. Carry out daily maintenance and inspection.
to replace the ram with a new one.
1.1. The key point for correct long-term
3. When painting the machine, mask the ram. If ram function is daily maintenance and
paint adheres to the rod surface or to the wiper inspection. Carry out maintenance and
ring and the ram is operated, the wiper ring will inspection so that the ram functions fully at
not function properly and foreign matter and paint all times. Always remove any mud, water,
can easily enter the ram. This will cause damage dust or oil film adhering to the rod and
to the seals, drastically shortening the life of the keep it in normal condition. However, when
ram. cleaning the wiper ring and seals, do not get
them wet with water but wipe clean with a
4. Install the ram only when it is clean.
rag. To prevent rust forming during storage,
the amount of exposed ram piston rod
30 - 230 9813/7600-3 30 - 230

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 - 231 9813/7600-3 30 - 231

15 - Cylinder / Ram
00 - General
Technical Data
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 536-70LP [5A1], 536-70LP [5T1], 541-70 [5AD],
541-70 [5TD], 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY])
Table 608. Cycle Times (Seconds)
Opera- 526-56 531-70 535-95 536-60 536-70 536-70 541-70 550-80 560-80
tion Agri, Agri, Agri, Agri, Agri, LP Agri, Agri, Agri Agri
Agri Agri Agri Agri Agri Agri Agri Plus, Plus,
Plus Plus, Plus, Plus, Plus, Plus, Plus, Agri Su- Agri Su-
Agri Su- Agri Su- Agri Su- Agri Su- Agri Su- Agri Su- per per
per, Agri per per per, Agri per per, Agri
Pro Pro Pro
Lift 5.2 4.5 5.6 5.7 5.0 5.0 5 7.4 7.4
Lower 3.8 5.7 6.3 5.7 5.2 5.2 5.2 5.9 8.3
Extend 4.5 6.7 9.4 5.9 6.7 6.7 6.7 8.3 8.3
Retract 2.4 5 10 4.8 5.0 5.0 5 5.9 5.9
Shovel 2.6 2.9 1.9 2.7 2.9 2.9 3.5 2.8 2.8
dump
Shovel 3.1 2.3 2.5 2.1 2.3 2.3 2.9 3.0 3.0
crowd
All measurements taken with the machine at normal

operating temperature.
30 - 232 9813/7600-3 30 - 232

15 - Cylinder / Ram
00 - General
Operation
Ram- Cylinder end

(For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 A restrictor probe installed to the end of the cylinder,
aligns with a groove in the piston rod.
[5TE], 541-70 [5AD], 541-70 [5TD])
As the ram closes to full retract, the probe engages
Ram end damping with the groove in the piston rod, the damping effect
is caused as the orifice plate seats on the face of
When you operate the lift and extension rams, it can the piston rod counterbore. The holes in the probe
cause a shake when the ram is at full travel. This control the speed of the ram by restricting the flow of
could cause load instability and operator discomfort. oil at a gradual rate until the ram is fully closed.
Figure 1630. Ram retracting (Cylinder end of ram)

A
C D E F G H
A Feed port C Cylinder end

D Orifice plate E Piston rod counterbore
F Piston rod G Restrictor probe
H Piston rod hole
To extend the ram, oil goes into the feed port and the oil pushes on the ram decreasing the pressure
through the centre of the probe to the hole in the necessary to extend the ram (pressure spike).
piston rod. This flow pushes the orifice plate away
from the counterbore increasing the area on which The flow rate, pressure, load and viscosity of the oil
have an effect on the damping rate.
30 - 233 9813/7600-3 30 - 233

15 - Cylinder / Ram
00 - General
Figure 1631. Ram extending (Cylinder end of ram)

A
C D E F G H
A Feed port C Cylinder end

D Orifice plate E Piston rod counterbore
F Piston rod G Restrictor probe
H Piston rod hole
30 - 234 9813/7600-3 30 - 234

15 - Cylinder / Ram
00 - General
Ram- Rod end flows through the four holes in the end cap through
the cylinder port. The O- ring compresses on the anti
The damping effect is caused by a tapered collar on extrusion ring which closes the four oil galleries on
the piston rod which engages with the end cap to the front of the end cap. The damping effect is caused
decrease the flow of oil. by the tapered collar gradually decreasing the area
between the piston rod and the end cap restricting
As the ram opens to full extend the tapered collar the flow of oil.
on the piston rod engages with the end cap, the oil
Figure 1632.
N J
J
Q K M
L
J End cap K Piston rod

L Oil feed port M Tapered collar
N Flats of the tapered collar P End cap front
Q Oil hole in the end cap
To retract the ram, oil flows through the feed port, this
pushes the anti extrusion ring and compresses the
O-ring and allow oil to flow through the four galleries
which pushes on the piston head. Also the oil flows
through the four holes in the end cap through the flats
of the tapered collar. The function of the flats and
oil pathways is to decrease the pressure necessary
to retract the ram from full open centres (pressure
spike).
Figure 1633.
R S
R O-ring
S Extrusion ring
30 - 235 9813/7600-3 30 - 235

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 - 236 9813/7600-3 30 - 236

15 - Cylinder / Ram
00 - General
procedure will remain unchanged and can be carried

(For: 526-56 [T4F], 531-70 [5AA], 531-70 out without the removal of the check valve.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 1. Place the ram assembly on a locally
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 manufactured strip or on a rebuild bench.
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY], Figure 1634.
560-80 [5UY])
Consumables
- General purpose
solvent based parts
cleaner
JCB Activator 4104/0251 0.2L 2. Use the correct size spanner to remove the end
cap and then remove the piston rod assembly
4104/0253 1L from the cylinder.
and Sealer (Medium 4101/0251 0.05L 3. Place the piston rod assembly on the bench in
Strength) place of the ram cylinder.
Lifting Equipment 4. Remove and discard the seal 1,seal 2 and the
wear ring 1, wear ring 2 from the piston head.
equipment. You must identify the weight of the item to 5. Put appropriate sized screw threaded into the
be lifted then choose lifting equipment that is strong extractor hole to remove dowel from the piston
enough and suitable for the job. Make sure that lifting head.
local regulations. 6. Use the correct size spanner to remove the
piston head from the rod and then discard the O-
ring 1.
Single piston rams
7. For extension ram, after removal of then piston,
Disassembly slide and remove the spacer from the piston rod.
CAUTION If air or hydraulic pressure is used to 8. Remove the gland bearing and the end cap from
force out the piston assembly, ensure that the end the piston rod.
cap is securely installed. Severe injury can be
caused by a suddenly released piston rod. 9. Remove the O-ring 2, wiper seal and the rod seal.
10. Check the end cap bearing for damage, scores or
The disassembly and assembly procedures for many nicks. If damaged, the bearing must be replaced
jcb hydraulic rams are same. as part of the end cap assembly.
The ram must be removed from the machine before 11. Make sure that the metal components are free
you disassemble it. from scoring, nicks and burrs. A damaged piston
rod will reduce the life of gland seals.
The ram shown in the illustration is not installed with
HBCV (Hose Burst Check Valve). If HBCV is installed 12. Check the bore of the ram cylinder for damage.
also with the ram, the disassembly and assembly
30 - 237 9813/7600-3 30 - 237

15 - Cylinder / Ram
00 - General
Figure 1635.
T S
R
U
F
A
G
J
H
E
K
L
C B
D
Q
P
N
Table 609.
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 - 238 9813/7600-3 30 - 238

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: 15min 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 610.. 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 610.. 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: 15min
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 1h, applies at
20°C (68.0°F) and is the minimum period between
assembly and filling the ram with oil.
30 - 239 9813/7600-3 30 - 239

15 - Cylinder / Ram
00 - General
Figure 1636.
AH
AJ
AH Diameter
AJ Depth
Table 610. Drilling dimensions

Ram size Diameter (AH) Depth (AJ)
50 x 25 6.02–6.1mm 23mm
90 x 50 8.02–8.1mm 28mm
100 x 60 12.02–12.1mm 33mm
110 x 60 12.02–12.1mm 33mm
120 x 60 12.02–12.1mm 38mm
130 x 70 12.02–12.1mm 38mm
130 x 75 12.02–12.1mm 38mm
140 x 75 12.02–12.1mm 48mm
160 x 80 12.02–12.1mm 48mm

Item Description Nm
F Piston head 405
H Gland bearing and end cap 678
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15 - Cylinder / Ram
06 - Lift Arm
06 - Lift Arm Bleed

Bleed ........................................................... 30-241
(For: 535-95 [5AB], 535-95 [5TB])
Bleed Procedure
Whenever a hydraulic component is removed or
disconnected from the lift arm extension circuit, the
circuit must be bled to make sure that any residual
air is removed.
During the following procedure, it is important that

the inner ram is not allowed to extend more than the
outer ram, to prevent damage to the inner ram and
auxiliary feed and return hoses.

01-03).
2. Engage the park brake and set the transmission
to neutral.
3. Raise the lift arm to the horizontal position.
5. Assemble a suitable bleed hose, fitted with a
male quick release coupling (QRC) and female
quick release coupling.
6. Make sure that the male quick release coupling is
connected to the straight swivel end of the hose.
For bleed hose specification, refer to Refer to
Table 612.
Figure 1637.
B A
C
A Bleed hose
B Male quick release coupling
C Female quick release coupling
7. Attach the bleed hose assembly to the male quick
release coupling on the top extension hose.
30 - 241 9813/7600-3 30 - 241

15 - Cylinder / Ram
06 - Lift Arm
B D
D Outer ram
12. If the inner ram extends during this sequence,
B Male quick release coupling deselect the auxiliary service. Operate the retract
service to fully retract the inner ram before
8. Connect the other end of the bleed hose
continuing to extend the outer ram with the
assembly to the female quick release coupling on
correct tank line auxiliary service.
the lift arm nose.
13. With the outer ram fully extended, and the inner
9. Put the hose beneath the lift arm so that it does
ram fully retracted, fully retract the outer ram
not entangle when the lift arm is extended or
using the lift arm retract and auxiliary service
retracted.
together. Use the auxiliary service in the opposite
Figure 1639. direction to provide an additional pressure feed
during the retract function.
14. Make sure that the hoses are located correctly in
the roller assembly at the base of the lift arm.
CAUTION! Allow the hydraulic fluid temperature

to cool before removing the hydraulic tank filler
cap. Open the cap slowly to prevent oil being
forced out of the filler neck.
C
15. Release the hydraulic pressure. Refer to
hydraulic system- general, refer to (PIL 30-00).
16. Check the hydraulic fluid level. Refer to hydraulic
system- general, refer to (PIL 30-00.
A
17. Install the hydraulic tank filler cap again.
A Bleed hose
C Female quick release coupling
10. Start the engine. Operate the lift arm service to
fully retract the inner and outer lift arm sections.
11. Slowly operate the lift arm extend and auxiliary
service together until the outer ram is fully
extended. Make sure that the auxiliary service
selected provides a return to tank for the outer
ram so that the inner ram does not extend.
30 - 242 9813/7600-3 30 - 242

15 - Cylinder / Ram
06 - Lift Arm
Figure 1641.
E
F
E Roller assembly
F Hydraulic tank filler cap
18. Detach the bleed hose assembly from the quick
release couplings on the machine.
19. On completion, extend and retract the lift arm
fully five times while checking that the lift arm
sections open and close fully together. Inspect
the hydraulic connections and check for leaks.
20. If the lift arm sections do not open and close fully
together, repeat the bleeding procedure.
21. If the lift arm sections do not open and close fully
together after repeating the bleeding procedure,
refer to hydraulic system fault finding, refer to
(PIL 30-00).
Table 612. Bleed Hose Specification

Length (Approx.) 6,300mm
Bore 9.5mm
Pressure rating High (Suitable for
240bar (3,478.2psi) op-
erating pressure)
30 - 243 9813/7600-3 30 - 243

15 - Cylinder / Ram
06 - Lift Arm
Remove and Install

(For: 526-56 [T4F], 531-70 [5AA], 531-70 Refer to (PIL 01-03).
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 5. Discharge the hydraulic pressure from the
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 system. Refer to (PIL 30-00).
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
6. If installed, disconnect the remote greasing pipe.
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY]) Figure 1643.
Special Tools

method and device.
Remove K
1. Make the machine safe. Refer to (PIL 01-03). K Remote greasing pipe
2. Remove any attachments from the carriage. 7. Disconnect the lift ram hydraulic hoses. Put
adaptors on all the open ports.
3. Lower the lift arm onto a suitable support.
Figure 1642.
9. Support the lift ram. Remove the nut, bolt and
washers (if installed).
10. Remove the pivot pin 1 from the rod end.
11. At this point it is advisable to remove the lift arm
in order to provide access for lifting out the ram.
12. Attach suitable lifting equipment to the ram rod
eye end. Support the ram.
13. Remove both the bolt 1 and bolt 2.
14. Remove the spacer and the lock plate.
15. Remove the pivot pin 2 from the cylinder end.
16. Remove ram from the machine.
30 - 244 9813/7600-3 30 - 244

15 - Cylinder / Ram
06 - Lift Arm
Figure 1644. Typical Lift Ram

J H
E
G
B
A
A Lift ram B Nut and bolt

C Pivot pin 1 D Hydraulic hoses
E Bolt 1 F Bolt 2
G Spacer H Lock plate
J Pivot pin 2
30 - 245 9813/7600-3 30 - 245

15 - Cylinder / Ram
06 - Lift Arm
Install
steps.
1.1. Grease the ram pivot pins.
1.2. Check the hydraulic fluid level.
1.3. Tighten all fastenings to the correct torque
value. Refer to (PIL 72).
30 - 246 9813/7600-3 30 - 246

15 - Cylinder / Ram
07 - Lift Extension
07 - Lift Extension
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 536-60 6. Remove the capscrew, lock plate and then
[5AC], 536-60 [5TC], 536-70 [5AE], remove the extension ram rod end pivot pin.
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................. Page 30-247 7. Put a label on the hoses to help installation.
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] ................ Page 30-249 8. Disconnect the extension ram hydraulic hoses.
For: 531-70 [5AA], 531-70 [5TA], 535-95 9. Plug all the open ports and hoses to prevent
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 contamination.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 560-80 [5AY], 560-80 10. For 531-70 and 541-70 machines, to gain access
[5UY] ....................................... Page 30-250 to the extension ram, remove the displacement
For: 526-56 [T4F] .................... Page 30-254 ram.
11. Remove the nut and bolt, then remove the
(For: 531-70 [5AA], 531-70 [5TA], 536-60 extension ram pivot pin far enough so that you
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 can remove the displacement ram easily.
[5TE], 541-70 [5AD], 541-70 [5TD])
11.1. Remember that the extension ram pivot
pin is also the main pivot for the lift arm.
Remove
11.2. Make sure you use a dummy pivot pin to
1. Remove any attachments installed on the drive out the extension ram pivot pin so the
carriage. other side of the lift arm is supported.
2. Extend the lift arm sufficiently to gain access to CAUTION! This component is heavy. It must only
the extension ram rod end pivot pin 1. be removed or handled using a suitable lifting
3. Lower the lift arm to the ground. method and device.
4. Discharge the hydraulic pressure from the 12. Use suitable lifting equipment to remove the
system. Refer to (PIL 30-00). extension ram from the lift arm.
Figure 1645. Typical 2 Stage (2 Section) Lift Arm
30 - 247 9813/7600-3 30 - 247

15 - Cylinder / Ram
07 - Lift Extension
A Extension ram rod end pivot pin B Capscrew

C Lock plate D Hydraulic hose
E Bolt F Main pivot pin
30 - 248 9813/7600-3 30 - 248

15 - Cylinder / Ram
07 - Lift Extension
Install 3. Extend the lift arm sufficiently to gain access to

the extension ram rod end pivot pin.
removal procedure. Additionally do the following 4. Lower the lift arm to the ground.
steps.
1.1. Apply the correct grease to the pivot pins. Refer to (PIL 01-03).
1.2. Install the bolts and tighten to the correct system. Refer to (PIL (30-00).
torque value. Refer to (PIL 72-00).
7. Remove the capscrew, lock plate and then
remove the extension ram rod end pivot pin.
(For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY]) 8. Put a label on the hoses to help installation.
CAUTION This component is heavy. It must only 9. Disconnect the extension ram hydraulic hoses.
method and device. 10. Plug all the open ports and hoses to prevent
contamination.
Remove 11. Remove the nut and bolt, then remove the
extension ram pivot pin enough so that you can
1. Remove any attachments from the carriage. remove the displacement ram easily.
2. Make the machine safe. Refer to (PIL 01-03). 12. Use suitable lifting equipment and remove the
extension ram from the lift arm.
Figure 1646.
A
C D
E F
A Extension ram rod end pivot pin B Capscrew

C Lock plate D Bolt
E Extension ram F Main pivot pin
30 - 249 9813/7600-3 30 - 249

15 - Cylinder / Ram
07 - Lift Extension
Install 2. Make the machine safe. Refer to (PIL 01-03).
step.
1.1. Apply the correct grease to the pivot pins. system. Refer to (PIL 30-00).
5. Operate the controls back and forth several times
to discharge the residual hydraulic pressure from
(For: 531-70 [5AA], 531-70 [5TA], 535-95 the system.
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 6. Put label on the hoses to help installation.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 560-80 [5AY], 560-80 7. Disconnect and plug feed hose 1, feed hose 2,
[5UY]) carry over hose 1 and carry over hose 2.
Consumables 8. Plug all the open ports and hoses to prevent

Description Part No. Size contamination.
JCB Threadlocker and 4101/0550 0.01L 9. Remove the restraining strap.
10. Support the extension ram.
11. Remove the nut and bolt, then remove the pivot
1 from the cylinder end.
method and device.
12. Remove the snap ring and then remove the pivot
Outer ram 2 from the rod end.
13. Remove the ram from the machine.
Remove
1. Fully retract and lower the lift arm to the ground.
30 - 250 9813/7600-3 30 - 250

15 - Cylinder / Ram
07 - Lift Extension
Figure 1647. Machines with 3 Stage Lift Arm - Outer Ram
H
E
A
B J
F
A Feed hose 1 B Feed hose 2

C Carry over hose 1 D Carry over hose 2
E Restraining strap F Pivot 1
G Nut and bolt H Pivot 2
J Snap ring
30 - 251 9813/7600-3 30 - 251

15 - Cylinder / Ram
07 - Lift Extension
Install section must be kept equal to avoid damage

to the internal hoses.
removal procedure. Additionally do the following 6. Lower the lift arm to align the inner ram rear pivot
steps. pin with the access holes in the chassis.
1.1. Grease the pivot pins. Refer to (PIL 06-30). 7. Stop the engine and remove the ignition key.
1.2. Bleed the lift arm extension hydraulic circuit. 8. Remove the hydraulic tank filler cap and operate
the lift arm extend and retract controls to
Inner ram discharge residual pressure.
Remove 9. Open the cover at the rear of the lift arm to gain
access to the hose guides and roller assembly.
1. Make sure you follow the procedure. Failure to
10. Release the hydraulic breather tube from the
do so may damage the internal ram and auxiliary
chassis and tie it clear of the rear of the lift arm.
feed hoses.
11. Remove bolts 2 and remove the lift arm roller
2. Park the machine on firm level ground. Apply the
assembly.
park brake and remove the carriage.
12. Remove bolts 3 and remove the hose guide.
3. Raise the lift arm to just above the horizontal.
Extend the lift arm to gain access to the front pivot 13. Disconnect the hoses from the rear of the
pin. extension cylinder. Plug the open ports and mark
the connections.
4. Remove the bolt 1. Use a suitable drift to knock
the pin through the lift arm. 14. Remove the bolts 4 (x2) that secure the guide on
the hose tray.
5. Raise the lift arm and operate the retract control
to slowly retract the extension ram. The inner 15. Support the ram.
lift arm section should retract with the hydraulic
cylinder under its own weight. 16. Use a suitable drift to remove the bolt 5 and
knock the pivot pin through the lift arm. Note the
5.1. If the inner lift arm section will not retract location of the spacers.
under its own weight, lower the lift arm and
carefully push the lift arm against an outside 17. Use suitable lifting equipment to remove the ram
force (for example, another machine). from the lift arm.
5.2. The length of the inner and intermediate 18. Make sure that the hoses inside the lift arm are
lift arm sections protruding from the outer not damaged.
30 - 252 9813/7600-3 30 - 252

15 - Cylinder / Ram
07 - Lift Extension
Figure 1648.
D
A
A Pivot pin B Bolt 1

C Access hole D Hydraulic breather tube
30 - 253 9813/7600-3 30 - 253

15 - Cylinder / Ram
07 - Lift Extension
Figure 1649. If a new cylinder is to be installed, transfer the

hose tray to the new cylinder.
2. Position the cylinder inside the inner lift arm.
3. Grease the rear pivot pin. Refer to (PIL 06-30).
E
4. Install the pin and secure it with bolt 5.
5. Operate the extend control to slowly extend the
cylinder and push out the inner lift arm section.
6. Release the control when the front pivot pin is
visible.
7. Make sure the length of the inner and
C intermediate lift arm sections protruding from the
outer section are kept equal to avoid damaging
the internal hoses.
G
F 8. Grease the front pivot pin. Refer to (PIL 06-30).
E Bolts 2 9. Align the bush on the rod end of the cylinder with
F Bolts 3 the lift arm. Install the pin and secure it with bolt 1.
G Hose guide
10. Connect hoses at the rear of the extension
Figure 1650. cylinder. Install the guide to the hose tray, roller
assembly and hose guide.
J 11. Tension the hoses equally by pivoting the roller

assembly. Make sure that the lift arm hoses are
installed over the rollers without being stretched.
12. Apply sealant and tighten the bolt 2 to the correct
torque value.
(High Strength)
13. Secure the breather tube and fill the hydraulic
tank. Refer to (PIL 30-00).
14. Bleed the lift arm extension hydraulic circuit.
L
(For: 526-56 [T4F])

Consumables
H
K Special HP Grease 4003/2020 0.5kg
4003/2017 0.4kg
4003/2006 12.5kg
M 4003/2005 50kg

H Hoses
J Bolts 4
method and device.
K Bolt 5
L Pin
M Spacers Remove
Install 1. Remove any attachments (if installed) on the
carriage.
1. Make sure that the head side and rod side
bushes are aligned before installing the cylinder.
30 - 254 9813/7600-3 30 - 254

15 - Cylinder / Ram
07 - Lift Extension
2. Extend the lift arm sufficiently to gain access to 11. Use suitable lifting equipment to support the rear
the extension ram rod end pivot pin. of the lift arm.
3. Lower the lift arm to the ground. 12. Remove the nut 1 and bolt 1, then remove the
extension ram pivot pin completely whilst making
4. Make the machine safe. Refer to (PIL 01-03). sure the rear of the lift arm is correctly supported
using the correct lifting equipment.
system. Refer to (PIL 30-00). 12.1. Remember that the extension ram pivot
pin is also the main pivot for the lift arm.
6. Remove the cap screw, the lock plate and then
remove the extension ram rod end pivot pin. 12.2. The lift and compensation rams remain
connected, do not lift the rear of the lift arm
7. Get access to the rear of the lift arm. any more than is required to remove the
extend ram over the hydraulic tank.
13. Use additional suitable lifting equipment to
9. Disconnect the extension ram hydraulic hoses 1 remove the extension ram from the rear of the
and 2. boom. Reposition the lifting equipment during
10. Plug all the open ports and hoses to prevent this operation as required to keep the ram level.
contamination.
30 - 255 9813/7600-3 30 - 255

15 - Cylinder / Ram
07 - Lift Extension
Figure 1651. Typical 2 Stage (2 Section) Lift Arm

D
A B C E
A End cap B Main lift arm and extension ram pivot pin
C Nut 1 / bolt 1 D Extension ram rod end pivot pin
E Nut 2 / bolt 2 F Hydraulic hose 1
G Hydraulic hose 2
30 - 256 9813/7600-3 30 - 256

15 - Cylinder / Ram
07 - Lift Extension
Install
steps.
1.1. Apply the correct grease to the pivot pins.
1.2. Tighten all fastenings to the correct torque
value. Refer to (PIL 72-00).
1.3. Bleed the extension ram hydraulic circuit.
1.4. Check the hydraulic oil level and top up if
required. Refer or (PIL 30-00).
30 - 257 9813/7600-3 30 - 257

15 - Cylinder / Ram
08 - Lift Compensating
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 536-70 2. Make the machine safe. Refer to (PIL 01-03).
[5AE], 536-70 [5TE], 541-70 [5AD], 541-70
[5TD] ....................................... Page 30-258 3. Follow the general health and safety procedures.
For: 526-56 [T4F] .................... Page 30-260 Refer to (PIL 01-03).
For: 536-60 [5AC], 536-60 [5TC], 550-80 4. Lower the lift arm and the carriage to the ground.
[5AW], 550-80 [5UW], 560-80 [5AY], 560-80
[5UY] ....................................... Page 30-261 5. Discharge the hydraulic pressure. Refer to (PIL
30-00).
(For: 531-70 [5AA], 531-70 [5TA], 536-70 6. Put a label on the hoses to help installation.
[5AE], 536-70 [5TE], 541-70 [5AD], 541-70
[5TD]) 7. Disconnect the hydraulic hoses.
Special Tools 8. Plug all the open hoses and ports to prevent
Description Part No. Qty. contamination.
9. Support the displacement ram.
Consumables 10. Remove the lock bolt/nut and washers (if
Description Part No. Size installed).
Special MPL-EP 4003/1501 0.4kg
Grease 11. Remove the pivot pin 1 from the rod end with a
4003/1506 12.5kg
slide hammer kit.
4003/1510 50kg
CAUTION This component is heavy. It must only 12. Remove the lock bolt.
method and device. 13. Remove the pivot pin 2 from the cylinder end with
the slide hammer kit.
Remove 14. Remove the ram from the machine.
1. Raise the lift arm to get access to the lower pivot
of the displacement ram. Retract the lift arm fully.
Support the front end of the lift arm.
30 - 258 9813/7600-3 30 - 258

15 - Cylinder / Ram
Figure 1652.
C
B
E
F
D
A Hydraulic hoses B Lock bolt/nut

C Pivot pin 1 D Lock bolt
E Pivot pin 2 F Displacement ram
30 - 259 9813/7600-3 30 - 259

15 - Cylinder / Ram
Install 3. Discharge the hydraulic pressure from the

removal procedure. Additionally do the following 4. Remove the lift ram.
steps.
5. Support the lift arm.
1.1. Put grease on the ram pivot pins.
6. Use the correct lifting equipment to lift the boom
Consumable: Special MPL-EP Grease and get access to the displacement ram top pivot.
1.2. Check the hydraulic fluid level and top up as 7. Put label on the hoses to help installation.
8. Disconnect the displacement ram hydraulic
hoses.
(For: 526-56 [T4F])
Special Tools 9. Plug all the open ports and hoses to prevent
contamination.
Slide Hammer Kit 993/68100 1 10. Support the displacement ram.
CAUTION This component is heavy. It must only 11. Remove the lock bolt 1 and washers (if installed).
12. Use a slide hammer kit to remove the pivot pin1
method and device.
from the cylinder end. Refer to (PIL 06-30).
Remove
13. Remove the lock bolt 2 and washers (if installed).
14. Use a slide hammer kit to remove the pivot pin 2
2. Follow the general health and safety procedures. from the rod end. Refer to (PIL 06-30).
30 - 260 9813/7600-3 30 - 260

15 - Cylinder / Ram
Figure 1653.
E
A
D
F
A
A Displacement ram hydraulic hoses B Lock bolt 1

C Pivot pin 1 D Lock bolt 2
E Pivot pin 2 F Displacement ram
Install (For: 536-60 [5AC], 536-60 [5TC], 550-80

[5AW], 550-80 [5UW], 560-80 [5AY],
removal procedure. Additionally do the following 560-80 [5UY])
steps. Special Tools
1.1. Grease the ram pivot pins.
1.2. Check the hydraulic fluid level and top up as
30 - 261 9813/7600-3 30 - 261

15 - Cylinder / Ram
Remove Figure 1655.
1. Make the machine safe. Refer to (PIL 01-03). B

2. Remove any attachments from the carriage.
3. Lower the lift arm onto a suitable support as
shown. Refer to Figure 1654. C
Figure 1654.
A Displacement rams
B Nut and bolt 1
C Pivot pin 1
Figure 1656.
4. Follow the hydraulic system, health and safety

30-00).
6. Put labels on the hoses to help installation. D
7. Disconnect the hydraulic hoses to the rams.
E
contamination.
9. Support the displacement rams. D Pivot pin 2
E Nut and bolt 2
10. Remove nut and bolt 1 and washers (if installed).
11. Remove the pivot pin 1 from the displacement Install
rams with the slide hammer kit.
Special Tool: Slide Hammer Kit (Qty.: 1) removal procedure. Additionally do the following
steps.
12. Attach suitable lifting equipment to the cylinder
end of the displacement rams. Support the rams. 1.1. Grease on the ram pivot pins.
13. Remove nut and bolt 2 and washers (if installed). 1.2. Check the hydraulic fluid level and top up as
14. Remove the pivot pin 2 from the rod end of the
displacement rams. Remove the rams from the
machine.
30 - 262 9813/7600-3 30 - 262

15 - Cylinder / Ram
11 - Lift Arm Crowd
11 - Lift Arm Crowd Bleed

Bleed ........................................................... 30-263
(For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW])
2. Engage the park brake and set the transmission
to neutral.
3. Raise the lift arm to a convenient height to access
the tilt ram.
30-00).
to discharge the residual hydraulic pressure.
7. Release the locknut and remove the screw.
8. Start the engine and operate the tilt lever several
times.
9. Tighten the screw and the locknut.
10. Operate the tilt lever several times again. Stop
the engine.
11. Repeat step 7 to step 10 if required.
12. Tighten the screw and the locknut to the specified
torque value.
30 - 263 9813/7600-3 30 - 263

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1657.
A Locknut
B Screw

Item Description Nm
A Locknut 12
B Screw 15
30 - 264 9813/7600-3 30 - 264

15 - Cylinder / Ram
11 - Lift Arm Crowd
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 536-60 3. Extend the lift arm to get access to the capscrew.
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD] 4. Lower the lift arm and carriage to the ground.
................................................. Page 30-265
For: 526-56 [T4F] .................... Page 30-267 5. Make the machine safe. Refer to (PIL 01-03).
For: 550-80 [5AW], 550-80 [5UW] 6. Follow the general health and safety procedures.
................................................. Page 30-269 Refer to (PIL 01-03).
For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 7. Discharge the hydraulic pressure from the
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 system. Refer to (PIL 30-00).
[5AD], 541-70 [5TD], 550-80 [5AW], 550-80
[5UW] ...................................... Page 30-270 8. Remove the lift arm nose cover (if installed).
9. Put a label on each hose to help installation.
(For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 10. Disconnect the tilt ram hydraulic hoses.
[5TE], 541-70 [5AD], 541-70 [5TD]) 11. Plug all the open ports hoses to prevent
Special Tools contamination.
Description Part No. Qty. 12. Support the tilt ram.
13. Remove the bolt.
be removed or handled using a suitable lifting 14. Use the slide hammer kit to remove the pivot pin
method and device. 1 from the rod end. Refer to (PIL 06-30).
Remove 15. Remove the capscrew and the lock plate.
1. Remove the attachments from the carriage. 16. Use the slide hammer kit to remove the pivot pin
2 from the cylinder end. Refer to (PIL 06-30).
2. Extend the tilt ram fully.
30 - 265 9813/7600-3 30 - 265

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1658.
C D
A F
Install
Table 614. 1. The installation procedure is the opposite of the
Item Description removal procedure. Additionally do the following
steps.
A Capscrew
B Hydraulic hoses 1.1. Grease the ram pivot pins.
C Bolt 1.2. Check the hydraulic fluid level and top up as
D Pivot pin 1 required. Refer to (PIL 30-00).
E Lock plate 1.3. Bleed the tilt ram. Refer to (PIL 30-15-11).
F Pivot pin 2
30 - 266 9813/7600-3 30 - 266

15 - Cylinder / Ram
11 - Lift Arm Crowd
(For: 526-56 [T4F]) 3. Follow all the general health and safety
Special Tools
Description Part No. Qty. 4. Discharge the hydraulic system. Refer to (PIL
Slide Hammer Kit 993/68100 1 30-00).
5. Put labels on the hoses to help installation.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 6. Disconnect the hydraulic hoses to the ram.
7. Plug all the open ports and hoes to prevent
contamination.
service line has been vented before connecting or 8. Remove the nut and bolt 1 and washers (if
removing hoses. Make sure the engine cannot be installed).
CAUTION! This component is heavy. It must only be 9. Use a slide hammer kit to remove the pivot pin 1
removed or handled using a suitable lifting method from the rod end. Refer to (PIL 06-30).
and device. Special Tool: Slide Hammer Kit (Qty.: 1)
Remove 10. Support the ram, remove nut and bolt 2and
washers (if installed).
1. Remove all attachments installed on the tool
carrier, tilt back and lower the lift arm to the 11. Use a slide hammer kit to remove the pivot pin 2
ground. from the cylinder end. Refer to (PIL 06-30).
30 - 267 9813/7600-3 30 - 267

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1659.
A
B
A A
A Nut and bolt 1 B Pivot pin 1

C Nut and bolt 2 D Pivot pin 2
30 - 268 9813/7600-3 30 - 268

15 - Cylinder / Ram
11 - Lift Arm Crowd
Install 5. Extend the lift arm to get access to the retaining

screw.
removal procedure. Additionally do the following 6. Lower the lift arm and carriage to the ground.
steps.
1.2. Check the hydraulic fluid level and top up as Refer to (PIL 01-03).
1.3. Bleed the tilt ram. Refer to (PIL 30-15). system. Refer to (PIL 30-00).
(For: 550-80 [5AW], 550-80 [5UW])
11. Get access to the tilt ram hydraulic hoses through
Special Tools
the cut-out in the inner lift arm and disconnect
Description Part No. Qty. them.
12. Support the tilt ram.
be removed or handled using a suitable lifting 13. Remove the nut/bolt and washers (if installed).
method and device.
1 from the rod end. Refer to (PIL 06-30).
Remove Special Tool: Slide Hammer Kit (Qty.: 1)
1. Remove attachments from the carriage. 15. Remove the retaining screw and the lock plate.
2. Extend the tilt ram fully. 16. Use the slide hammer kit to remove the pivot pin
2 from the cylinder end. Refer to (PIL 06-30).
3. Remove the lift arm nose cover (if installed).
4. Disconnect remote greasing pipe (if installed).
30 - 269 9813/7600-3 30 - 269

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1660.
D E
B C
A Retaining screw B Lock plate

C Pivot pin 2 D Pivot pin 1
E Tilt ram F Bolt
G Cut-out in the inner lift arm.
Install (For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
removal procedure. Additionally do the following [5TC], 536-70 [5AE], 536-70 [5TE], 541-70
steps. [5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW])
1.1. Grease the ram pivot pins. Refer to (PIL
06-30). Special Tools
required. Refer to (PIL 30-00). Slide Hammer Kit 993/68100 1
1.3. Bleed the tilt ram. Refer to (PIL 30-15-11).

Remove
1. Remove any attachments from the carriage.
2. Extend the lift arm approximately to the specified
limit.
Length: 600mm
3. Lower the lift arm onto a suitable support so that
the carriage is clear of the ground.
30 - 270 9813/7600-3 30 - 270

15 - Cylinder / Ram
11 - Lift Arm Crowd
4. Make the machine safe. Refer to (PIL 01-03). 11. Support the tilt ram.
5. Follow the general health and safety procedure. 12. Remove the recessed capscrew.
6. Discharge the hydraulic pressure from the 1 from the rod end.
7. Remove the lift arm nose cover (if installed).
14. Remove the nut and bolt and washers (if
8. Put a label on the hoses to help installation. installed).
9. Disconnect the tilt ram hydraulic hoses. 15. Use the slide hammer kit to remove the pivot pin
2 from the cylinder end.
10. Plug all the open ports and hoses to prevent Special Tool: Slide Hammer Kit (Qty.: 1)
contamination.
30 - 271 9813/7600-3 30 - 271

15 - Cylinder / Ram
11 - Lift Arm Crowd
Figure 1661.
A Capscrew B Pivot pin 1

C Tilt ram hydraulic hoses D Bolt
E Pivot pin 2
30 - 272 9813/7600-3 30 - 272

15 - Cylinder / Ram
11 - Lift Arm Crowd
Install
steps.
1.1. Grease the ram pivot pins. Refer to (PIL
06-30).
1.3. Bleed the tilt ram. Refer to (PIL 30-15-11).
30 - 273 9813/7600-3 30 - 273

15 - Cylinder / Ram
34 - Steering
34 - Steering Remove and Install

Remove and Install ..................................... 30-274 Working Under the Machine
Disassemble and Assemble ........................ 30-276 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 1662.
B
C
A
A Hoses B Screws
C Pins
30 - 274 9813/7600-3 30 - 274

15 - Cylinder / Ram
34 - Steering
Install
steps.
1.1. Tighten the screws to the correct torque
value.
1.2. Before you drive the machine, bleed the

Item Description Nm
B Screws 56
30 - 275 9813/7600-3 30 - 275

15 - Cylinder / Ram
34 - Steering
Refer to Hydraulic system, cylinder ram, general (PIL

30-15-00).
30 - 276 9813/7600-3 30 - 276

15 - Cylinder / Ram
63 - Sway
63 - Sway Bleed
Bleed ........................................................... 30-277
(For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY])
Communications
Bad communications can cause accidents. If two
or more people are working on the machine, make
sure each is aware of what the others are doing.
Before starting the engine make sure the others are
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured
if these precautions are not taken.
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: 1.2mm
30 - 277 9813/7600-3 30 - 277

15 - Cylinder / Ram
63 - Sway
5. Start the engine. Remove and Install

6. Operate the sway lever to sway the machine fully
to the operator's left side (sway ram extended).
(For: 531-70 [5AA], 531-70 [5TA], 535-95
7. Stop the engine and discharge the hydraulic [5AB], 535-95 [5TB], 536-70 [5AE], 536-70
pressure. Refer to (PIL 30-00). [5TE], 541-70 [5AD], 541-70 [5TD])
8. Tell the assistant to carefully loosen the bleed Consumables
valve and expect hydraulic fluid to escape. Make Description Part No. Size
sure the bleed valve is not unscrewed more than Special HP Grease 4003/2020 0.5kg
Length: 6.5mm 4003/2017 0.4kg
4003/2006 12.5kg
4003/2005 50kg
10. Operate the sway lever to sway the machine fully
to the operator's left side. CAUTION This component is heavy. It must only
11. Hold the lever in this position. method and device.
12. Make sure that the air is removed completely
through the bleed valve. Remove
13. Return the control lever to the neutral position. 1. Make the machine safe. Refer to (PIL 01-03).
14. Tighten the bleed valve immediately to prevent 2. Lower the lift arm and the carriage to the ground.
air entering the circuit.
Figure 1663. Refer to (PIL 01-03).
30-00).
to release the residual hydraulic pressure. There
will still be residual pressure in the ram. Make
sure you take care if you disassemble the ram.
6. Support the chassis on both sides of the
machine.
A 7. Put a label on each hose to help installation.
8. Disconnect the sway hydraulic hoses.
contamination.
A Bleed valve 10. Support the sway ram.
15. Operate the sway ram fully in both directions 10 11. Remove the nut and bolt 1.
times.
12. Remove the pivot pin 1 from the cylinder end.
16. Repeat steps 7 to 17.
13. Attach suitable lifting equipment to the cylinder
17. Stop the engine and remove the ignition key. end of the ram. Support the ram.
18. Check the hydraulic fluid level and top up as 14. Remove nut and bolt 2.
15. Remove the pivot pin 2 from rod end.
30 - 278 9813/7600-3 30 - 278

15 - Cylinder / Ram
63 - Sway
Figure 1664.
C
D
E F
A Hydraulic hoses
B Sway ram
C Nut and bolt 1
D Pivot pin 1
E Nut and bolt 2
F Pivot pin 2
Install
steps.
1.3. Bleed the sway hydraulic circuit. Refer to
(PIL 30-15).
30 - 279 9813/7600-3 30 - 279

15 - Cylinder / Ram
99 - Seal Kit
99 - Seal Kit Figure 1665.
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 1666.
(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 1667.
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 - 280 9813/7600-3 30 - 280

15 - Cylinder / Ram
99 - Seal Kit
Figure 1668. 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 1670.
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 1669.
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 1671.
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 - 281 9813/7600-3 30 - 281

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 1672.
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 - 282 9813/7600-3 30 - 282

18 - Accumulator
18 - Accumulator
Contents Page No.
30-18-00 General ......................................................................................................................... 30-285

30-18-06 Smooth Ride System (SRS) ........................................................................................ 30-291
30 - 283 9813/7600-3 30 - 283

Notes:
30 - 284 9813/7600-3 30 - 284

18 - Accumulator
00 - General
Introduction .................................................. 30-285 A hydraulic accumulator is a pressure storage
Health and Safety ........................................ 30-286 reservoir used to store hydraulic fluid, the non-
Component Identification ............................. 30-286 compressible hydraulic fluid is held under pressure
Discharge and Pressurise ........................... 30-287 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 - 285 9813/7600-3 30 - 285

18 - Accumulator
00 - General

DANGER Use only nitrogen gas to charge
accumulators. The use of any other gas can Figure 1673.
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.
pressure from the accumulators before A
disconnecting them from the hydraulic system.
Replacement accumulators will only be supplied in B

an uncharged, non pressurised condition to meet
Health and Safety, and Air freight hazardous goods
requirements.
A Diaphragm (sealed for life)-Non Rechargeable

B Diaphragm (with gas valve)-Rechargeable
C Piston Bladder-Rechargeable
30 - 286 9813/7600-3 30 - 286

18 - Accumulator
00 - General
Discharge and Pressurise Figure 1674.
Special Tools
Accumulator Charging 892/01042 1 B
Kit (Diaphragm)
Accumulator Charging 892/01043 1 A
J
Adaptor

pressure from the accumulators before
C
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 - 287 9813/7600-3 30 - 287

18 - Accumulator
00 - General
6. Connect the charging hose to the pressure Figure 1675.

regulator on the nitrogen gas bottle with the
correct adaptor.
7. Set the pressure regulator on the gas bottle to
the minimum pressure.
8. Turn the charging tool knob to open the filler plug
by three turns.
9. Open the discharge valve on the charging unit.
10. Carefully open the nitrogen gas bottle valve and
A
make sure that the nitrogen gas flows freely
through the discharge valve.
C
11. Close the gas bottle valve and the discharge
valve. B
12. Carefully open the gas bottle valve.

13. Slowly increase the pressure using the gas bottle
pressure regulator and watching the gauge on
the charging unit, allow nitrogen to flow until
the pressure reading reaches the specified value A Label position
above the operating charge pressure. B Discharged state label
Pressure: 4bar (58.0psi) C Pressurised warning label
14. Important: Do not exceed the maximum working 25. Install the accumulator and make sure the
pressure of the accumulator. The maximum pressurised warning label is clearly visible.
working pressure is marked on the accumulator
body.
15. Close the gas bottle valve.
16. Wait for the specified duration to dissipate the
heat generated during charging.
Duration: 10min
17. Carefully open and close the discharge valve to
reduce the pressure in the accumulator to the
specified operating charge pressure.
18. Turn the charging tool knob to close the filler plug
and tighten to the correct torque value.
Torque: 20N·m
19. Open the discharge valve to release the pressure
from the charging hose.
20. Disconnect the charging unit and adaptor from
the accumulator.
21. Pour oil around the filler plug to make sure that
it is gas tight.
22. Replace the plastic cap.
23. Remove the discharged state label.
24. Attach the pressurised warning label on the
accumulator at the position shown.
30 - 288 9813/7600-3 30 - 288

18 - Accumulator
00 - General
Remove and Install
2. Follow the hydraulic safety procedures. Refer to

(For: 526-56 [T4F]) (PIL 30-00).
The accumulator is not serviceable. Replace the 3. Remove the battery cover.
complete accumulator if it is defective. 4. Remove the accumulator from the valve block
outlet section.
Remove
Figure 1676.
A B
A Accumulator B Valve block outlet section
30 - 289 9813/7600-3 30 - 289

18 - Accumulator
00 - General
Install
steps.
1.1. If a new accumulator is to be installed it is
necessary to charge it. Refer to (PIL 30-18).
1.2. Tighten the accumulator to the correct
torque value.

Item Description Nm
A Accumulator 48
30 - 290 9813/7600-3 30 - 290

18 - Accumulator
06 - Smooth Ride System (SRS) Technical Data

Technical Data ............................................. 30-291 For: 531-70 [5AA], 531-70 [5TA], 536-70
[5AE], 536-70 [5TE], 541-70 [5AD], 541-70
Preparation .................................................. 30-293 [5TD] ....................................... Page 30-291
Discharge and Pressurise ........................... 30-294 For: 536-60 [5AC], 536-60 [5TC]
Remove and Install ..................................... 30-296 ................................................. Page 30-291
For: 526-56 [T4F] .................... Page 30-291
For: 550-80 [5AW], 550-80 [5UW]
................................................. Page 30-292
For: 535-95 [5AB], 535-95 [5TB]
................................................. Page 30-292
(For: 531-70 [5AA], 531-70 [5TA], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70
[5TD])
Table 617.
Charging gas Air free dry nitrogen
Accumulator capacity 1L
Accumulator weight 4.4kg
Table 618. Accumulator charge pressure

Accumulator Value
Accumulator1 10.3bar (149.3psi)
Accumulator2 20bar (289.9psi)
(For: 536-60 [5AC], 536-60 [5TC])

Table 619.

Accumulator Value
Accumulator1 9bar (130.4psi)
(For: 526-56 [T4F])

Table 621.

Accumulator Value
30 - 291 9813/7600-3 30 - 291

18 - Accumulator
(For: 550-80 [5AW], 550-80 [5UW])

Table 623.

Accumulator Value
(For: 535-95 [5AB], 535-95 [5TB])

Table 625.

Accumulator Value
30 - 292 9813/7600-3 30 - 292

18 - Accumulator
Preparation Figure 1677. Large plate
A
(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
Accumulators will only be supplied in an uncharged,
non pressurised condition to meet health and safety,
and air freight hazardous goods requirements.
Upon installation of new accumulator, the correct

decal stating charge pressure must be attached.
Remove original decal which states a zero charge
pressure. Decals may be in the form of a large plate
or small plate.
When you replace the lift ram or the HBCV (Hose

Burst Check Valve) on machines installed with SRS
(Smooth Ride System), it is important that all the
hydraulic pressure in the accumulators must be
discharged. Failure to do this may result in the valve
being forced out of the cavity as it is unscrewed.
Figure 1678. Small plate
30 - 293 9813/7600-3 30 - 293

18 - Accumulator
Figure 1679.
(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
Special Tools
Accumulator Charging 892/00948 1
Kit (Piston Type)
A B
Charge A Gas valve guard
B Gas valve cap
1. Remove the accumulator(s) from the machine.
3. Screw the valve1 all the way out (counter
2. Remove gas valve guard and the gas valve cap. clockwise) before you attach the charging tool to
the accumulator gas valve.
Special Tool: Accumulator Charging Kit (Piston
Type) (Qty.: 1)
4. Close the bleed valve.
Figure 1680.
D
F
E
C Valve1 D Bleed valve

E Hand valve F Hose
5. Do not twist the hose, connect the charging tool 9. Check the charge pressure which should be set
to the gas valve. to suit the boom and the attachment installed to
the machine.
6. Tighten the tool to the specified torque value.
10. If charge pressure is low, release the hand
Torque: 1.36N·m
valve on the nitrogen bottle and slowly fill the
7. Connect the charging tool to a bottle of accumulators.
compressed nitrogen gas.
11. Close the hand valve when the charge pressure
8. Screw the valve1 all the way in (clockwise), this is reached on the gauge.
will push the core in the gas valve.
30 - 294 9813/7600-3 30 - 294

18 - Accumulator
CAUTION! To reduce pressure use the

recommended charging tool or the charge valve
could be damaged which may result in rapid
discharge of the accumulator.
12. Wait for the specified time to let the gas

temperature become stable.
Duration: 10–15min
12.1. If the pressure is exceeded, make sure
the gas bottle is closed, then open the
bleed valve and reduce the pressure as
necessary. Close the bleed valve when the
correct pressure is set.
13. When the accumulator charging is complete,
screw the valve1 all the way out (counter
clockwise) and open the bleed valve to vent the
hose.
14. Hold the gas valve to keep from turning, loosen
the nut and remove charging tool.
15. Install the gas valve cap and valve guard.
16. Install the accumulator(s) to the machine.
Discharge
1. Remove the accumulator(s) from the machine.
2. Remove the gas valve guard and the gas valve
cap.
3. Screw the valve1 all the way out (counter
clockwise) before you attach the charging tool to
the accumulator gas valve.
Special Tool: Accumulator Charging Kit (Piston
Type) (Qty.: 1)
4. Close the bleed valve.
5. Either connect the charging tool to a bottle of
compressed nitrogen gas which is turned off
or remove hose and install a suitable blank on
charging tool.
6. Screw the valve1 all the way in (clockwise), this
will push the core in the gas valve.
7. Open the bleed valve until all the gas charge
is vented from the accumulators. Remove the
charging tool.
8. Install the accumulator(s) to the machine.
30 - 295 9813/7600-3 30 - 295

18 - Accumulator
Remove and Install
For: 526-56 [T4F], 531-70 [5AA], 531-70 indicating that manual mode is selected. Lift the
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 boom.
[5AC], 536-60 [5TC], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD] 3. Use the control lever to lower the boom and
................................................. Page 30-296 keep the lever in down position for 3 minutes
For: 550-80 [5AW], 550-80 [5UW], 560-80 while the engine is run at 1000 RPM (Revolutions
[5AY], 560-80 [5UY] ................ Page 30-297 Per Minute). The the accumulators will discharge
during this period.
(For: 526-56 [T4F], 531-70 [5AA], 531-70 4. With the engine still running and manual SRS
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 mode is active, use the lifting equipment to lift the
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 boom. Do not use the hydraulic lift service.
[5TE], 541-70 [5AD], 541-70 [5TD]) 5. Install the safety strut. Refer to (PIL 06-69).
pressure from the accumulators before 6. Loosen the nuts (x4).
disconnecting them from the hydraulic system. 7. Disconnect the hydraulic connections and plug
the ends.
Remove 8. Remove the nuts and washers (x4) and remove
1. Make the machine safe. Refer to (PIL 01-03). the 'U' clamps (x2).
2. Switch SRS (Smooth Ride System) to manual 9. Remove the accumulators from their mounting
mode, make sure the right hand console is brackets.
Figure 1681.
C
C
B A
A Hydraulic connections B Nuts (x4)

C 'U' clamps D Accumulators
E Washers (x4)
30 - 296 9813/7600-3 30 - 296

18 - Accumulator
Install 2. Switch SRS to manual mode- make sure the right

hand console is indicating that manual mode is
1. The installation procedure is the opposite of the selected. Raise the lift arm.
steps. 3. Use the control lever to lower the lift arm and
keep the lever in down position for the specified
1.1. Check the accumulator nitrogen pre-charge time while the engine is run at 1000 RPM. The the
pressure. Refer to (PIL 30-18). accumulators will discharge during this period.
1.2. Operate the machines hydraulic system. Duration: 3min
Check for correct operation and leaks.
4. With the engine still running and manual SRS
1.3. Fill the hydraulic system with the mode is active, use the lifting equipment to lift the
recommended hydraulic fluid. Refer to (PIL boom. Do not use the hydraulic lift service.
30-00).
5. Install the lift arm safety strut. Refer to (PIL
It is not possible to disassemble the accumulators. 06-69).
You can only check the nitrogen gas pre-charge
pressure. If an accumulator is suspected as being 6. Support the accumulators.
faulty it must be renewed as a complete assembly.
Although identical in appearance, the accumulators solenoids and the pressure transducer.
are charged to different pressures. When you install
8. Disconnect the pipe.
an accumulator make sure that it is charged to the
correct pressure. 9. Put label on the hoses to help installation.
10. Disconnect the hoses.
(For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY]) contamination.
Remove 12. Disconnect the hose from the port.

WARNING You must vent all the hydraulic 13. Plug all the open ports and hoses to prevent
pressure from the accumulators before contamination.
14. Loosen the retaining clips.
1. Make the machine safe. Refer to (PIL 01-03). 15. Remove the accumulators and block from the
retaining clips and the lift ram.
30 - 297 9813/7600-3 30 - 297

18 - Accumulator
Figure 1682.
F
G
F
E
D
C
G
H
A
A Pipe B Solenoids
C SRS valve block D Port
E Pressure transducer F Retaining clips
G Accumulators
30 - 298 9813/7600-3 30 - 298

18 - Accumulator
Install
steps.
1.1. Check the accumulator nitrogen pre-charge
pressure. Refer to technical data (PIL
30-18).
1.2. Operate the machines hydraulic system.
1.3. Fill the hydraulic system with the
recommended hydraulic fluid. Refer to (PIL
30-00).
It is not possible to disassemble the accumulators.

The only permissible work you can do is check the
nitrogen gas pre-charge pressure. If an accumulator
is suspected as being faulty it must be renewed as a
complete assembly.
Although identical in appearance, the accumulators

are charged to different pressures. When you install
an accumulator make sure that it is charged to the
correct pressure.
30 - 299 9813/7600-3 30 - 299

21 - Oil Cooler
21 - Oil Cooler
Contents Page No.
30-21-00 General ......................................................................................................................... 30-301
30 - 300 9813/7600-3 30 - 300

21 - Oil Cooler
00 - General
00 - General Component Identification

Operation ..................................................... 30-302
(For: 526-56 [T4F], 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY], 560-80 [5UY])
Figure 1683.
A B
A Hydraulic oil cooler matrix B Transmission oil cooler matrix
30 - 301 9813/7600-3 30 - 301

21 - Oil Cooler
00 - General
Operation
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80
[5UW], 560-80 [5AY], 560-80 [5UY], Agri, Agri-Plus, Agri-Super, Agri-Xtra)
Hydraulic Oil Cooler Bypass System

Component location
Figure 1684.
A Hydraulic oil cooler bypass valve
30 - 302 9813/7600-3 30 - 302

21 - Oil Cooler
00 - General
Operation overview Figure 1686. By-Pass Active
The schematic diagrams show an overview of the

system. For machine specific schematics, refer to
F
When the hydraulic oil is not at full operating
temperature, the viscosity of the oil increases
causing higher hydraulic pressures.
To prevent damage to the fan circuit, a bypass valve

activates when the hydraulic pressure is greater than
3.4bar (49.3psi) and allows the oil to bypass the oil
cooler. The oil then returns straight to the tank. This
reduces the pressure in the fan circuit.
E
When the oil is at operating temperature, the
pressure reduces and the bypass valve is not active
and the fan return flows through the oil cooler.
D
Figure 1685. By-Pass Not Active
B
C
G H J
E
A Hydraulic tank
B Bypass valve
C Oil cooler
D D Main pump
E Fan direction valve (if installed)
B F Fan motor
C
G H J
A Hydraulic tank
B Bypass valve
C Oil cooler
D Main pump
E Fan direction valve (if installed)
F Fan motor
30 - 303 9813/7600-3 30 - 303

21 - Oil Cooler
00 - General
Table 627. Colour Key to Oil Flow and Pressure

G Full Pressure
H Neutral
J Exhaust
30 - 304 9813/7600-3 30 - 304

21 - Oil Cooler
00 - General
Remove and Install
For: 526-56 [T4F], 531-70 [5AA], 531-70 Remove

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 1. Make the machine safe. Refer to (PIL 01-03).
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY], 560-80 2. If the engine is hot let it cool for the specified time.
[5UY] ....................................... Page 30-305
Duration: 1h
For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 3. Discharge the hydraulic pressure from the
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 system. Refer to health and safety (PIL 30-00)
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 4. Open the engine cover. Refer to (PIL 06-06).
[5UY], Agri, Agri-Plus, Agri-Super, Agri-Xtra
................................................. Page 30-307 5. If installed, remove the fuel cooler.
(For: 526-56 [T4F], 531-70 [5AA], 531-70 6. If installed, remove the air conditioning
condenser. Refer to (PIL 12-15).
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 7. Disconnect the hydraulic and transmission hoses
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 from the matrix, at the 4 couplings.
[5AW], 550-80 [5UW], 560-80 [5AY], 8. Support the matrix.
560-80 [5UY])
9. Remove the bolts.
The hydraulic oil cooler is a combination cooler. The
right hand side is used for transmission oil cooling 10. Remove the matrix from the machine.
and the left hand side is used for hydraulic oil cooling.
If the transmission or hydraulic oil cooler has failed
the complete unit must be replaced.
Figure 1687.
A A C
A Bolts B Matrix
30 - 305 9813/7600-3 30 - 305

21 - Oil Cooler
00 - General
C Couplings (x4)
30 - 306 9813/7600-3 30 - 306

21 - Oil Cooler
00 - General
Install 2. Install the safety strut. Refer to (PIL 06-69).
removal procedure. Additionally do the following Refer to (PIL 01-03)
steps.
1.1. Check the hydraulic fluid level. Refer to (PIL 30-00).
30-00).
5. Open the engine cover. Refer to (PIL 06-06).
1.2. Check the transmission oil level.
6. Remove the cooling pack from the machine.
1.3. When the installation procedure is complete Refer to (PIL 21-06).
start the engine and check for fuel leaks.
(For: 531-70 [5AA], 531-70 [5TA], 535-95 8. Disconnect the hydraulic hoses.
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
9. Plug the open ports and hoses to prevent
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 contamination.
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 10. Support the valve.
[5UY], Agri, Agri-Plus, Agri-Super, Agri- 11. Remove the bypass valve from the cooling pack.
Xtra)
Hydraulic Oil Cooler Bypass Valve

Remove
30 - 307 9813/7600-3 30 - 307

21 - Oil Cooler
00 - General
Figure 1688.
A
C
A Hydraulic hoses B Bolts

C Bypass valve
30 - 308 9813/7600-3 30 - 308

21 - Oil Cooler
00 - General
Install
steps.
1.1. Make sure all hoses are attached to the
correct ports.
30-00).
1.3. Check the coolant level. Refer to (PIL
21-06).
30 - 309 9813/7600-3 30 - 309

30 - Manifold
30 - Manifold
Contents Page No.
30-30-00 General ......................................................................................................................... 30-311
30 - 310 9813/7600-3 30 - 310

30 - Manifold
00 - General
00 - General
Remove and Install
Remove
1. Make the machine safe. Refer to PIL (01-03).
3. Raise the lift arm.
30-00).
7. Access the manifold. Refer to (PIL 06-06).
8. Make sure the area around the manifold is clean
and free of debris.
9. Put a container below the manifold to collect any
hydraulic fluid.
10. Remove the hydraulic filter. Refer to (PIL 30-04).
11. Hold the manifold block and remove the
hexagonal screws.
12. Lift the manifold block from the machine.
13. Remove and discard the O-rings.
Install
steps.
1.1. Install new O-rings. Make sure they stay in
the correct position during assembly.
1.2. Tighten the hexagonal capscrews (x4) to
the specified torque value.
Torque: 56N·m
1.3. If the filter has been removed, make sure
that it is installed correctly.
1.4. Check the hydraulic oil level and top up to
the correct level. Refer to (PIL 30-00).
1.5. Start the machine and check for leaks.
1.6. Check the operation of all the hydraulic
services.
30 - 311 9813/7600-3 30 - 311

51 - Lift Arm Control Valve Block
Contents Page No.

30-51-21 Load Sense Relief Valve .............................................................................................. 30-317
30-51-24 Flow Regulator ............................................................................................................. 30-320
30 - 312 9813/7600-3 30 - 312

03 - Main Relief Valve (MRV)
03 - Main Relief Valve (MRV) Figure 1690.

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 1689.
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 - 313 9813/7600-3 30 - 313

06 - Auxiliary Relief Valve (ARV)
06 - Auxiliary Relief Valve (ARV) Introduction

Introduction .................................................. 30-314 The auxiliary relief valves are not serviceable. The
Operation ..................................................... 30-315 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 - 314 9813/7600-3 30 - 314

Operation Figure 1692. 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 1691. 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 1693. 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 - 315 9813/7600-3 30 - 315

Consumables
A
JCB Hydraulic Fluid OP 4002/2001 5L
46 4002/2005 20L
4002/2003 200L
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.
1.4. If necessary, adjust the ARV pressure
setting. Refer to (PIL 30-00).

Item Description Nm
E Valve assembly 70
30 - 316 9813/7600-3 30 - 316

21 - Load Sense Relief Valve
21 - Load Sense Relief Valve Remove and Install

Remove and Install ..................................... 30-317 For: 526-56 [T4F] .................... Page 30-317
Disassemble and Assemble ........................ 30-319 Otherwise ................................ Page 30-318
(For: 526-56 [T4F])

Consumables
46 4002/0805 20L
4002/0803 200L
The LSRV (Load Sense Relief Valve) is not

serviceable. Replace the complete valve if it is
defective.
Remove
30-00).
block.
Figure 1695.
A
A LSRV Valve
Install
steps.
30 - 317 9813/7600-3 30 - 317

1.1. Tighten the valve to the specified torque 1.1. Make sure the tamperproof cap supplied
value. with the valve is installed.
1.2. Replace all the O-rings and the back-up 1.2. Replace all O-rings and back-up rings.
rings.
1.3. Lubricate the parts with the correct clean
1.3. Lubricate the parts with JCB hydraulic fluid hydraulic fluid before installation.
before assembling.
1.4. Adjust the LSRV pressure setting as
Consumable: JCB Hydraulic Fluid HP 46 required.
1.4. Adjust the pressure setting as required. Table 629. Torque Data
(Otherwise) Item Torque
4 45N·m
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).
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 1696.
1 O-ring
2 Thrust ring
3 O-ring
4 Valve assembly
5 Tamperproof cap
Install
steps.
30 - 318 9813/7600-3 30 - 318

The load sense relief valve is not serviceable.

Replace the complete valve with the correct valve if
it is defective.
30 - 319 9813/7600-3 30 - 319

24 - Flow Regulator
24 - Flow Regulator Check (Condition)

Check (Condition) ........................................ 30-320
Inspection
Disassemble and Assemble ........................ 30-322 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 1697.
A Filler gauze
30 - 320 9813/7600-3 30 - 320

24 - Flow Regulator
Remove and Install 1.1. Clean the valve components in an

applicable solvent.
(For: 531-70 [5AA], 531-70 [5TA], 536-60
1.2. Replace all the O-rings and the back-up
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 rings.
[5TE], 541-70 [5AD], 541-70 [5TD], Agri-
Xtra) 1.3. Lubricate the parts with JCB hydraulic fluid
Consumables
Description Part No. Size Table 630. Torque Values
Surface Cleaning Fluid 4103/1204 1L Item Description Nm
E Valve assembly 20
The flow regulator valve is not serviceable and
adjustable. replace the complete valve if found
defective.
Remove
block.
2. Remove and discard the regulator filter.
3. Remove the oil ring 1, oil ring 2 and the thrust
ring.
When you remove the O-rings and seals, use a

rounded tool that will not cause any damage to the
grooves. Discard all the O-rings and the back-up
rings. Do not use worn or damaged items.
Figure 1698.
A
B
A O-ring 1
B Thrust ring
C O-ring 2
D Regulator filter
E Valve assembly
Install
steps.
30 - 321 9813/7600-3 30 - 321

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 631. 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 1699.
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 - 322 9813/7600-3 30 - 322

53 - Servo System Control Valve Block
Contents Page No.
30-53-00 General ......................................................................................................................... 30-325

30-53-27 Pressure Compensator Valve ...................................................................................... 30-356
30-53-80 Spool ............................................................................................................................ 30-360
30 - 323 9813/7600-3 30 - 323

Notes:
30 - 324 9813/7600-3 30 - 324

00 - General

Technical Data ............................................. 30-325 For: 531-70 [5AA], 531-70 [5TA]
................................................. Page 30-325
For: 535-95 [5AB], 535-95 [5TB]
Fault-Finding ................................................ 30-333 ................................................. Page 30-327
Remove and Install ..................................... 30-336 For: 536-60 [5AC], 536-60 [5TC]
Disassemble and Assemble ........................ 30-344 ................................................. Page 30-327
For: 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD] ................ Page 30-328
For: 536-70 [5AE], 536-70 [5TE], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY], 560-80
[5UY] ....................................... Page 30-329
(For: 531-70 [5AA], 531-70 [5TA])
Load Sense Pressure System (Agri, Agi-

Plus, Agri-Super Machines)
Depending on the specification of your machine,
alternative valves may be installed. Refer to (PIL
30-54-00).
Figure 1700. 4 Spool control valve block

F
B
C
B4 A4
B3 A3
B2 A2
B1 A1
LS
D P E
T
G A
A LSRV (Load Sense Relief Valve)
B Auxiliary ram rod side
C Auxiliary ram head side
D Carriage tilt ram rod side
E Carriage tilt ram head side
F Flushing valve
G Steer priority valve
Table 632.
Type Spool, load sense- pressure
compensated, double acting
spools
Spool 1 Boom lift & low- Integral propor-
er service tional electro
servo pilot oper-
ated
30 - 325 9813/7600-3 30 - 325

00 - General
Spool 2 Carriage tilt ser- Integral propor- Load Sense Pressure System (Agri-Extra
vice tional electro Machines)
servo pilot oper-
ated Figure 1701. 4 Spool control valve block
Spool 3 Boom extend & Integral propor- A B E
retract Service tional electro
servo pilot oper-
ated
Spool 4 Auxiliary ser- Integral propor-
vice tional electro
servo pilot oper-
ated
The maximum auxiliary service flow available is up

to 95L/min with 'manual' thumb wheel operation, and
up to 65L/min with 'constant' operation selected. C
Table 633. Relief valve pressures

Item Value
LSRV
(1)
260bar (3,768.1psi)
ARV (Auxiliary Relief - D
Valve)
A LSRV
Auxiliary ram rod side 220bar (3,188.4psi) B Auxiliary ram rod side
Auxiliary ram head side 220bar (3,188.4psi) C Auxiliary ram head side
Carriage tilt ram rod side 275bar (3,985.5psi) D Carriage tilt ram rod side
Carriage tilt ram head 140bar (2,029.0psi) E Carriage tilt ram head side
side
Table 634.
(1) Before you check the Load Sense relief valve
pressure, allow the hydraulic system to warm up to Type Spool, load sense- pressure
50°C (121.9°F) to make sure an accurate reading. compensated, double acting
Be sure to identify the machine variant correctly. spools
vice tional electro
servo pilot oper-
ated
Spool 2 Carriage tilt ser- Integral propor-
vice tional electro
servo pilot oper-
ated
Spool 3 Boom extend & Integral propor-
retract Service tional electro
servo pilot oper-
ated
servo pilot oper-
ated

up to 65L/min with 'constant' operation selected.

Item Value
LSRV
(1)
240bar (3,478.2psi)
ARV -
Auxiliary ram rod side 220bar (3,188.4psi)
30 - 326 9813/7600-3 30 - 326

00 - General
Item Value Spool 3 Lift arm extend Integral propor-

Auxiliary ram head side 220bar (3,188.4psi) & retract ser- tional electro
vice servo pilot oper-
Carriage tilt ram rod side 275bar (3,985.5psi)
ated
Carriage tilt ram head 200bar (2,898.5psi)
side
vice tional electro
(1) Before you check the Load Sense relief valve servo pilot oper-
pressure, allow the hydraulic system to warm up to ated
50°C (121.9°F) to make sure the reading is accurate.
Make sure you identify the machine variant correctly. The maximum auxiliary service flow available is up
(For: 535-95 [5AB], 535-95 [5TB]) Table 637. Relief valve pressures
Item Value
Load Sense Pressure System (Agri, Agri- 240bar (3,478.2psi)
LSRV
(1)

ARV -
Figure 1702. 4 Spool control valve block Auxiliary ram rod side 220bar (3,188.4psi)
F Auxiliary ram head side 220bar (3,188.4psi)
B
C Carriage tilt ram rod side 250bar (3,623.2psi)
side
B4 A4
pressure, allow the hydraulic system to warm up to
B3 A3
50°C (121.9°F) to make sure an accurate reading.
Be sure to identify the machine variant correctly.
B2 A2
B1 A1
(For: 536-60 [5AC], 536-60 [5TC])
LS
D P E Load Sense Pressure System (Agri, Agri-

T
G A Figure 1703. 4 Spool control valve block

A LSRV F
B Auxiliary ram rod side B
C
C Auxiliary ram head side
D Carriage tilt ram head side
E Carriage tilt ram rod side B4 A4
F Flushing valve
G Steer priority valve B3 A3
Table 636. B2 A2
Type 4 Spool, load sense- pressure B1 A1

spools
LS
D E
Spool 1 Lift arm raise & Integral propor- P
T
lower service tional electro

servo pilot oper- A
G
ated
Spool 2 Carriage tilt ser- Integral propor- A LSRV
vice tional electro B Auxiliary ram rod side
servo pilot oper- C Auxiliary ram head side
ated D Carriage tilt ram rod side
F Flushing valve
G Steer priority valve
30 - 327 9813/7600-3 30 - 327

00 - General
Table 638. Figure 1704. 4 Spool control valve block

Type 4 Spool, load sense- pressure F
B
compensated, double acting C
spools
Spool 1 Lift arm raise & Integral propor-
lower service tional electro B4 A4
servo pilot oper-
ated B3 A3
vice tional electro B2 A2
servo pilot oper-
ated B1 A1
Spool 3 Lift arm extend Integral propor- LS
& retract Ser- tional electro D E

P
T
ated
Spool 4 Auxiliary ser- Integral propor- G A
vice tional electro A LSRV
servo pilot oper- B Auxiliary ram rod side
ated C Auxiliary ram head side
The maximum auxiliary service flow available is up E Carriage tilt ram head side
to 95L/min with 'manual' thumb wheel operation, and F Flushing valve
up to 65L/min with 'constant' operation selected. G Steer priority valve
Item Value Table 640.
LSRV
(1)
260bar (3,768.1psi) Type Spool, load sense- pressure
ARV - compensated, double acting
spools
Auxiliary ram head side 220bar (3,188.4psi) lower service tional electro
Carriage tilt ram rod side 275bar (3,985.5psi) servo pilot oper-
Carriage tilt ram head 140bar (2,029.0psi) ated
side Spool 2 Carriage tilt ser- Integral propor-
(1) Before you check the Load Sense relief valve vice tional electro
pressure, allow the hydraulic system to warm up to servo pilot oper-
50°C (121.9°F) to make sure the reading is accurate. ated
Make sure you identify the machine variant correctly. Spool 3 Lift arm extend Integral propor-
& retract Ser- tional electro
ated
(For: 536-70 [5AE], 536-70 [5TE], 541-70 Spool 4 Auxiliary ser- Integral propor-
[5AD], 541-70 [5TD]) vice tional electro
servo pilot oper-
Load Sense Pressure System (Agri, Agri- ated
Depending on the specification of your machine, to 95L/min with 'manual' thumb wheel operation, and
alternative valves may be installed. Refer to (PIL up to 65L/min with 'constant' operation selected.
30-54-00).
Item Value
LSRV
(1)
260bar (3,768.1psi)
ARV -
Auxiliary ram head side 220bar (3,188.4psi)
30 - 328 9813/7600-3 30 - 328

00 - General
Item Value The maximum auxiliary service flow available is up

Carriage tilt ram rod side 275bar (3,985.5psi) to 95L/min with 'manual' thumb wheel operation, and
side Table 643. Relief valve pressures
(1) Before you check the Load Sense relief valve Item Value
50°C (121.9°F) to make sure an accurate reading. LSRV
(1)
260bar (3,768.1psi)
Be sure to identify the machine variant correctly. ARV -
Load Sense Pressure System (Agri-Extra Auxiliary ram head side 220bar (3,188.4psi)
Machines) Carriage tilt ram rod side 275bar (3,985.5psi)
Figure 1705. 4 Spool control valve block Carriage tilt ram head 200bar (2,898.5psi)
side
A B E
50°C (121.9°F) to make sure an accurate reading.
Be sure to identify the machine variant correctly.
(For: 536-70 [5AE], 536-70 [5TE], 550-80

[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
C
Load Sense Pressure System (Agri, Agri-
Figure 1706. 4 Spool control valve block
F
D B
A LSRV C
B Auxiliary ram rod side
C Auxiliary ram head side B4 A4
B3 A3
Table 642. B2 A2
Type 4 Spool, load sense- pressure B1 A1

spools LS
D E
Spool 1 Auxiliary ser- Integral propor- P
T
vice tional electro

servo pilot oper-
G A
ated
Spool 2 Carriage tilt ser- Integral propor- A LSRV
vice tional electro B Auxiliary ram rod side
servo pilot oper- C Auxiliary ram head side
ated D Carriage tilt ram rod side
Spool 3 Boom extend & Integral propor- E Carriage tilt ram head side
retract Service tional electro F Flushing valve
servo pilot oper- G Steer priority valve
ated
servo pilot oper-
ated
30 - 329 9813/7600-3 30 - 329

00 - General
Table 644.
Type 4 Spool, load sense- pressure
spools
lower service tional electro
servo pilot oper-
ated
vice tional electro
servo pilot oper-
ated
Spool 3 Lift arm extend Integral propor-
& retract Ser- tional electro
ated
vice tional electro
servo pilot oper-
ated

Item Value
LSRV
(1)
260bar (3,768.1psi)
ARV -
side
50°C (121.9°F) to make sure the reading is accurate.
Make sure you identify the machine variant correctly.
30 - 330 9813/7600-3 30 - 330

00 - General
Figure 1707. Dual Tech Variable Transmission Machines

B
C
D
E G
H
F
K J
L
M
Q
T P
R
S N
3 4
2
Z Y 5
U X
W 333/G3855-6
V 7
6
1
8
A Valve block B Port P1

C Port LS D Port DLS
E Port P F Port D
30 - 331 9813/7600-3 30 - 331

00 - General
G Port G H To steer orbitrol P port

J To steer orbitrol LS port K Main return
L Suction pipe M Variable displacement pump
N To pilot CCT (P port) P From pilot CCT (T port)
Q Case drain R Fan return
S Trailer brake valve T (Red)
U From steer CCY (Green/Yellow) V From fan drain (Orange)
W From brake return (Yellow) X From pilot CCT- T2 port
Y (White) 1 To brake accumulator
2 Trailer brake valve port R 3 Trailer brake valve port P
4 Trailer brake valve port N 5 Trailer brake valve port B
6 To trailer brake port A 7 To trailer brake port LS
8 To fan return 9 To fan feed
30 - 332 9813/7600-3 30 - 332

00 - General
Fault-Finding
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
Fault
All services lack power Table 646. Page 30-333
All services slow to operate Table 647. Page 30-334
The system pressure is too high Table 648. Page 30-334
A service stays selected Table 649. Page 30-334
System isolation not working Table 650. Page 30-335
All services inoperative Table 651. Page 30-335
Low flow from auxiliary service Table 652. Page 30-335
Lift arm operation is "Fierce" Table 653. Page 30-335
Servo operated spool services slow to operate or low auxiliary flow (The Table 654. Page 30-335
maximum auxiliary service flow available should be up to 95 L/min minimum
for 'manual' thumbwheel operation and up to 65 L/min with 'constant'
operation selected).
Table 646. All services lack power

Cause Remedy
Insufficient hydraulic fluid Check for leaks and top up as required.
LSRV (Load Sense Relief Valve) out of adjustment or Check and adjust as required.
defective
Internal leakage fault in the load sense circuit. Measure the load sense pressure.
Flushing valve piston within the control valve block Dismantle and inspect the flushing valve piston.
end section sticking open due to contamination.
Contamination in proportional solenoid valves or Dismantle and inspect valve block components.
mesh filters.
Service spool, check valve or compensator valve Dismantle and inspect valve block components.
sticking due to contamination.
Machines with Variflow Pump: Insufficient output Check and adjust, or renew the LSRV as required.
flow from variflow pump because the pump is not Measure the load sense pressure.
receiving the correct load sense pressure: Due to
LSRV being out of adjustment, defective and/or due
to internal leakage fault in the load sense circuit.
Machines with Variflow Pump: Insufficient output flow Check the function of the variable pump solenoid
from variflow pump: Due to the pump horsepower (HVCS) electrical circuit. Check the throttle position
solenoid (HVCS (Hydraulic Variable Control Solenoid sensor. Check condition of the associated electrical
Valve)) (if fitted) being permanently energised wiring for damage and short circuits.
and/or due to failure of the pump or internal tilting Install new pump and flush the hydraulic system to
swashplate mechanism because of contamination. remove all contamination.
Machines with Gear Pump: Low pump flow Check pump flow
Check for extra leaks, install new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install a new pump.
Electronic fault Use service master to determine the problem. Refer
to electrical system- electronic diagnostic, refer to
(PIL 33-57).
30 - 333 9813/7600-3 30 - 333

00 - General
Table 647. All services slow to operate

Cause Remedy
Insufficient hydraulic fluid. Check for leaks and top up as required.
Flushing valve piston within the control valve block Dismantle and inspect the flushing valve piston.
sticking open due to contamination.
Servo pilot pressure too low: Due to blocked Measure the servo pilot pressure and install new
servo pilot filter element and/or due to faulty servo servo pilot filter element.
regulating valve. Measure the servo pilot pressure and install new pilot
pressure supply valve.
Machines with Variflow Pump: Insufficient output Check and adjust, or install new LSRV as required.
flow from variflow pump because the pump is not Measure the load sense pressure.
receiving the correct load sense pressure: Due to
LSRV being out of adjustment, defective and/or due
to internal leakage fault in the load sense circuit.
Machines with Variflow Pump: Insufficient output flow Check the function of the variable pump solenoid
from variflow pump: Due to the pump horsepower (HVCS) electrical circuit. Check the throttle position
solenoid (HVCS) (if fitted) being permanently sensor. Check condition of the associated electrical
energised and/or due to failure of the pump or wiring for damage and short circuits.
internal tilting swashplate mechanism because of Install new pump and flush the hydraulic system to
contamination. remove all the contamination.
Machines with GearPump: Low pump flow Check the pump flow.
Check for external leaks and install new seals.
Priority valve sticking. Refer to steering system-
priority valve, refer to (PIL 25-03).
Install a new pump.
Service spool, check valve or compensator valve Dismantle and inspect valve block components.
sticking due to contamination.
Fault in electrical circuit wiring or joystick powerbase Check the condition of the associated electrical
ECU (Electronic Control Unit): Due to thumbwheel wiring for damage and that the fuses are intact.
switch defective/ solenoid at pilot pressure valve Then:
not energising/ solenoid coil faulty and/or faulty Check the function of the applicable thumbwheel
powerbase ECU. switch.
Check the applicable solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Install
new solenoid coil.
Install new joystick powerbase ECU.
Table 648. The system pressure is too high

Cause Remedy
LSRV out of adjustment or defective. Check and adjust as required. Replace if necessary.
Contamination in proportional solenoid valves, check Dismantle and inspect valve block components.
valve or mesh filters.
Table 649. A service stays selected

Cause Remedy
LSRV out of adjustment or defective. Check and adjust as required. Replace if necessary.
Service spool or associated load hold check valves Dismantle and inspect the associated service spool
damaged or sticking due to contamination. or load hold check valves.
30 - 334 9813/7600-3 30 - 334

00 - General
Table 650. System isolation not working

Cause Remedy
Poor electrical connection. Check dump solenoid wiring connections.
Contaminated or faulty dump solenoid. Replace.
Blockage in unloader drain port. Clean port, replace inlet section if necessary.
Electronic fault Use service master to determine the problem. Refer
(PIL 33-57).
Table 651. All services inoperative

Cause Remedy
Poor electrical connection. Check dump solenoid wiring connections.
Contaminated or faulty dump solenoid. Replace.
Electronic fault. Use service master to determine the problem. Refer
(PIL 33-57).
Table 652. Low flow from auxiliary service

Cause Remedy
Machines with Variflow Pump: Variflow pump Delta-P Test the system pressures and adjust as required.
pressure setting too low.
Table 653. Lift arm operation is "Fierce"

Cause Remedy
Machines with Variflow Pump: Variflow pump Delta-P Test the system pressures and adjust as required.
pressure setting too low.
Table 654. Servo operated spool services slow to operate or low auxiliary flow (The maximum auxiliary
service flow available should be up to 95 L/min minimum for 'manual' thumbwheel operation and up
to 65 L/min with 'constant' operation selected).
Cause Remedy
Fault in the electrical circuit wiring, joystick controller Check the condition of the associated electrical
hydraulic control ECU. Due to defective thumbwheel wiring for damage and that the fuses are intact.
switch/ solenoid at the pilot pressure supply valve Then:
not energising/ faulty solenoid coil/ faulty joystick Check the function of the applicable thumbwheel
controller and/or faulty hydraulic control ECU. switch.
Check the applicable solenoid coil for open or short
circuits. Measure the solenoid coil resistance. Install
new solenoid coil.
Install new joystick controller.
Install new hydraulic control ECU.
Servo pilot pressure too low: Due to blocked servo Measure the servo pilot pressure and install new
pilot filter element/ faulty pilot pressure supply valve servo pilot filter element.
and/or due to proportional solenoid valve cartridge Measure the servo pilot pressure and install new pilot
damaged or sticking due to contamination. pressure supply valve.
Counterbalance valve not working correctly. Check operation of applicable counterbalance valve.
Counterbalance pressure sensor (lift ram) not Check operation of lift ram pressure sensor.
working correctly.
30 - 335 9813/7600-3 30 - 335

00 - General
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 535-95 Incorrect handling will result in permanent damage to
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 the valve assembly. The valve block should be lifted
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 by holding the ends of the valve body, not the electric
[5AD], 541-70 [5TD], 550-80 [5AW], solenoids.
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................. Page 30-336
Remove
For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 1. Make the machine safe with the lift arm raised.
536-70 [5TE], 541-70 [5AD], 541-70 [5TD] Refer to (PIL 01-03).
................................................. Page 30-338
For: 526-56 [T4F] .................... Page 30-340 2. Install the safety strut. Refer to (PIL 06-69).
For: 536-70 [5AE], 536-70 [5TE]
................................................. Page 30-341 3. Discharge the hydraulic pressure. Refer to (PIL
30-00).
(For: 531-70 [5AA], 531-70 [5TA], 535-95 4. Remove the hydraulic filler cap.
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
5. Mark and disconnect the hoses and pipes from
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 the valve assembly.
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 6. Mark and disconnect the electrical connectors
[5UY]) from the valve block solenoids.
CAUTION This component is heavy. It must only 7. With the valve block correctly supported, remove
be removed or handled using a suitable lifting the mounting bolts. Carefully lift the valve block
method and device. away from the bracket and clear of the machine.
Figure 1708.
A
30 - 336 9813/7600-3 30 - 336

00 - General
A Mounting bolts B Valve block

C Valve block solenoids D Bracket
30 - 337 9813/7600-3 30 - 337

00 - General
Install Remove
1. The installation procedure is the opposite of the 1. Make the machine safe with the lift arm raised.
steps.
Check for correct operation and leaks. 3. Discharge the hydraulic pressure. Refer to (PIL
30-00).
recommended hydraulic fluid as necessary. 4. Remove the hydraulic filler cap.
5. Remove the valve cover panels.
1.3. After installation check the MRV (Main
Relief Valve) and the ARV (Auxiliary Relief 6. Put labels on the hoses to help installation.
Valve) pressures. Refer to (PIL 30-00).
7. Disconnect the hoses and pipes from the valve
assembly.
(For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 8. Plug all the open ports and hoses to prevent
contamination.
[5TE], 541-70 [5AD], 541-70 [5TD])
CAUTION This component is heavy. It must only 9. Mark and disconnect the electrical connectors
be removed or handled using a suitable lifting from the valve block solenoids.
method and device. 10. With the valve block suitably supported, remove
the mounting bolts. Carefully lift the valve block
The valve assembly should be handled correctly as and move away from the machine.
it can be permanently damaged. The valve block
should be lifted by holding the ends of the valve body,
not the electric solenoids.
30 - 338 9813/7600-3 30 - 338

00 - General
Figure 1709.
A
H
G
J
C H F H B

recommended hydraulic fluid as necessary.
Table 655. Refer to (PIL 30-00).
Item Description 1.3. After installation, check the MRV and ARV
A Mounting bolts pressures. Refer to (PIL 30-00).
B Valve block solenoids
C Adaptor 1 Table 656. Torque table
D Adaptor 2 Item Description Adaptor to Hose to
E Adaptor 3 valve adaptor or
F Adaptor 4 adaptor to
G Adaptor 5 adaptor
H Adaptor 6 C Adaptor 1 27N·m 33–40N·m
J Adaptor 7 D Adaptor 2 48N·m 33–40N·m
K Adaptor 8 E Adaptor 3 122N·m 58–65N·m
F Adaptor 4 122N·m 84–92N·m
Install G Adaptor 5 48N·m 44–50N·m
H Adaptor 6 27N·m 24–27N·m
1. The installation procedure is the opposite of the J Adaptor 7 200N·m 115–126N·m
removal procedure. Additionally do the following and 44–
steps. 50N·m
1.1. Operate the machines hydraulic system. K Adaptor 8 - 24–27N·m
30 - 339 9813/7600-3 30 - 339

00 - General
(For: 526-56 [T4F]) 5. Put a label on each hose before you disconnect
them.
be removed or handled using a suitable lifting 6. Disconnect the hydraulic hoses.
method and device.
contamination.
Remove
8. Put a label on the electrical connectors before
1. Make the machine safe. Refer to (PIL 01-03). you disconnect them.
2. Discharge the hydraulic pressure. Refer to (PIL 9. Disconnect all electrical connectors to the valve
30-00). block solenoids.
3. Remove the battery. Refer to (PIL 33-03). 10. With the valve block supported, remove the
mounting screws and nuts.
4. Remove the hose cover and battery
compartment. 11. Carefully lift the valve block and mounting
bracket out of the machine.
Figure 1710.
D
C
A
B
A Mounting bracket B Mounting screw

C Nuts D Valve block
30 - 340 9813/7600-3 30 - 340

00 - General
Install Remove
1. The installation procedure is the opposite of the 1. Make the machine safe with the lift arm raised.
steps.
Check for correct operation and leaks. 3. Follow the general health and safety procedures.
recommended hydraulic fluid as necessary. 4. Discharge the hydraulic pressure. Refer to (PIL
Refer to (PIL 30-00). 30-00).
1.3. After installation, check ARV and MRV 5. Remove the hydraulic filler cap.
pressures. Refer to Check Pressure (PIL
30-00). 6. Remove the valve cover panels. Refer to (PIL
06-06).
(For: 536-70 [5AE], 536-70 [5TE]) 7. Put a label on the hoses to help installation.
CAUTION This component is heavy. It must only 8. Disconnect the hoses and pipes at the valve
be removed or handled using a suitable lifting assembly.
method and device.
contamination.
Handling
10. Put a label on and disconnect the electrical
Incorrect handling will result in permanent damage connectors from the valve block solenoids.
to the valve assembly. Lift the valve block by holding
either end of the valve body. Do not use the electric 11. With the valve block suitably supported, remove
solenoids to the lift the valve. the mounting bolts. Carefully lift the valve block
clear of the machine.
Extreme care should be taken to avoid damaging
the electric solenoids when you handle the valve
assembly.
30 - 341 9813/7600-3 30 - 341

00 - General
Figure 1711.
A
L
A
J
M
E
L L
H B
A Mounting bolts B Solenoids

E Adaptor 1 F Adaptor 2
G Adaptor 3 H Adaptor 4
J Adaptor 5 L Adaptor 6
M Union 1 N Union 2
30 - 342 9813/7600-3 30 - 342

00 - General
Install 1.2. Check the hydraulic fluid level and top up as

1.3. After installation, check the ARV and MRV
pressures. Refer to (PIL 30-00).
steps.
Table 657. Torque settings

Item Adaptor to Valve Hose to Adaptor or Adaptor to
Adaptor
E 27N·m 33–40N·m
F 48N·m 33–40N·m
G 122N·m 58–65N·m
H 122N·m 84–92N·m
J 48N·m 44–50N·m
L 27N·m 24–27N·m
M 200N·m 115–126N·m and 44–50N·m
N 24–27N·m
30 - 343 9813/7600-3 30 - 343

00 - General
For: 531-70 [5AA], 531-70 [5TA], 536-60 The valve block is a 'sectional' type, which is
[5AC], 536-60 [5TC], 536-70 [5AE], made up of a number of separate sections. Make
536-70 [5TE], 541-70 [5AD], 541-70 [5TD] sure you note the location of all components when
................................................. Page 30-344 you disassemble. Although some components may
For: 531-70 [5AA], 531-70 [5TA], 535-95 appear to be identical, they are not interchangeable,
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 for example service spools are two different types.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 Make sure that components are assembled in their
[5AD], 541-70 [5TD], 550-80 [5AW], 550-80 original positions.
[5UW], 560-80 [5AY], 560-80 [5UY], Agri,
Agri-Plus, Agri-Super ............... Page 30-346 Take care when you disassemble and assemble the
For: 526-56 [T4F] .................... Page 30-348 valve. Make sure you do not damage to seals and
For: 536-70 [5AE], 536-70 [5TE] seal grooves. Damage or contamination can cause
................................................. Page 30-350 problems with valve operation.
(For: 531-70 [5AA], 531-70 [5TA], 536-60 Disassemble

[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 1. Remove the valve block from the machine. Refer
[5TE], 541-70 [5AD], 541-70 [5TD]) to (PIL 30-53-00).
Consumables 2. Remove the tie rod nuts (x4).
JCB Hydraulic Fluid OP 4002/2001 5L 3. Carefully disconnect and remove the outlet
46 4002/2005 20L section.
4002/2003 200L 4. If the outlet section is to be replaced, remove and
JCB Threadlocker and 4101/0550 0.01L keep the tie rods.
5. Disconnect and remove the remaining service
sections and the inlet section.
30 - 344 9813/7600-3 30 - 344

00 - General
Figure 1712.
B L
C
N N
M
H R
Q H N N
P
H
J
D
K
H
Q
K
A E
A Tie rod nuts B Inlet section

C Auxiliary section D Tilt section
E Lift / lower section F Outlet section
G Tie rods H Load hold check valves
J Pressure compensator valves K Service spool (Electrically operated)
L LSRV (Load Sense Relief Valve) M Flow regulator valve
N ARV (Auxiliary Relief Valve) P Steer priority valve
Q Spool activation solenoids R Shuttle valve
30 - 345 9813/7600-3 30 - 345

00 - General
Assembly (For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
the disassembly procedure. Additionally do the [5TC], 536-70 [5AE], 536-70 [5TE], 541-70
following steps. [5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
1.1. Clean the valve components in an [5UY], Agri, Agri-Plus, Agri-Super)
applicable solvent. Make sure that the
mating faces of the valve sections are fully Consumables
clean before assembly. Description Part No. Size
1.2. Replace the O-rings located between the JCB Hydraulic Fluid OP 4002/2001 5L
valve sections. Install the O-rings correctly. 46 4002/2005 20L
1.3. Apply lubricant on all the parts before 4002/2003 200L
assembly. Make sure that all the parts move JCB Threadlocker 4101/0250 0.01L
freely. and Sealer (Medium 4101/0251 0.05L
Strength)
1.4. Apply sealant to the tie rods before you The valve block is a 'sectional' type, which is
assemble them. made up of a number of separate sections. Make
Consumable: JCB Threadlocker and Sealer sure you note the location of all components when
(High Strength) you disassemble. Although some components may
1.5. Screw the tie rods into the inlet section until Make sure that components are assembled in their
they are tight. original positions.
1.6. Unscrew the tie rods for one turn.
During disassembly and assembly, take care to avoid
1.7. Once the valve block is fully assembled the following:
these rods may be adjusted to allow
sufficient thread for the tie rod nuts to • Contamination
tighten. • Damage to spools
1.8. Tighten the tie rod nuts to the correct torque
value.
Disassemble
1. Remove the valve block from the machine.
Item Description Nm
A Tie rod nuts 35 2. Remove the tie rod nuts (x3).
3. Carefully separate and remove the final element
followed by the remaining service sections.
4. If the inlet element is to be replaced, remove the
tie rod so that it can be installed in to the new
element.
30 - 346 9813/7600-3 30 - 346

00 - General
Figure 1713.
B
A A
A
D
C
E
F
H
LS
P
J
K
T
A Valve section seals B Valve section

C Tie rod D Tie rod nut
E Final element F Auxiliary section
G Extend section H Tilt section
J Lift section K Inlet element
30 - 347 9813/7600-3 30 - 347

00 - General
Assemble
(For: 526-56 [T4F])
the disassembly procedure. Additionally do the The valve block is made up of a number of sections.
following steps.
Make sure that new valve section O-rings are
1.1. Make sure that the mating faces of the available before you disassemble the valve block.
valve sections are thoroughly clean before
assembly. Make sure you record the location of all components
1.2. Replace the O-rings located between the when you disassemble the valve block. Although
valve sections. Make sure the O-ring seals some components look the same they are not
are not trapped or damaged. interchangeable. The service spools for example
are of two different types. Make sure that the
1.3. Apply lubricant to all the parts before you components are installed in the correct position.
assemble them. Make sure that all the parts
move freely. Take care when you disassemble and assemble a
Consumable: JCB Hydraulic Fluid OP 46 valve to prevent damage to seals and seal grooves.
Damage or contamination can cause problems with
1.4. If the tie rods were removed from the inlet valve operation.
section, apply threadlock to the threads
before installing the tie rod. Disassemble
(Medium Strength) 1. Remove the valve block from the machine.
1.5. Apply threadlocker to the threads of the nut. 2. Remove the tie rod nuts.
Consumable: JCB Threadlocker and Sealer 3. Move each valve section off the tie rods.
(Medium Strength)
4. If the outlet section is to be replaced, remove and
Table 659. Torque Values retain the tie rods.
Item Description Nm
D Tie rod nut 42
Figure 1714.
A
A
A
A Tie rod nuts B Inlet section

30 - 348 9813/7600-3 30 - 348

00 - General
E Extend / retract section F Lift / lower section

G Outlet section
30 - 349 9813/7600-3 30 - 349

00 - General
Assemble Description Part No. Size

1. The assembly procedure is the opposite of and Sealer (Medium
the disassembly procedure. Additionally do the 4101/0251 0.05L
Strength)
following steps.
1.1. Clean the valve components in an Some valve sections and components are omitted
applicable solvent. Make sure that the from the figure for illustration purposes. Refer to
mating faces of the valve sections are fully Figure 1715.
clean before assembly.
The valve block is a sectional type, which is made up
1.2. Replace the O-rings located between the of a number of separate sections. The illustration is
valve sections. Install the O-rings correctly. intended as a guide to identifying the components.
1.3. Lubricate the parts with JCB hydraulic oil
before you assemble them. Make sure that Make sure to note the location of all the components
all the parts move freely. when dismantling. Although some components may
1.4. If the tie rods were removed, apply sealant appear to be identical, they are not interchangeable.
to the threads before you install. Make sure that components are assembled in their
original positions.
1.5. Screw the tie rods into the valve block until
they are tight. Great care should be taken when dismantling and
1.6. Loosen the tie rods by one turn. assembling a valve to avoid the following:
1.7. Once the valve block is fully assembled • Contamination
these rods may be adjusted to allow • Damage to the spools
sufficient thread for the tie rod nuts to • Damage to the seal grooves
tighten.
1.8. Tighten the tie rods to the correct torque Any of the above may result in possible problems
value. with the operation of the valve.
Table 660. Torque Values Disassemble

Item Description Nm 1. Make the machine safe. Refer to (PIL 01-03).
A Tie rod nuts 54
30-00).
(For: 536-70 [5AE], 536-70 [5TE]) 3. Remove the valve block from the machine.
Consumables
4. Remove the tie rod nuts (x3).
JCB Hydraulic Fluid HP 4002/0801 5L 5. Carefully separate and remove the final element
46 4002/0805 20L followed by the auxiliary section, extend section,
tilt section and the lift section.
4002/0803 200L
6. If the inlet section needs to be replaced, remove
and retain the tie rods.
30 - 350 9813/7600-3 30 - 350

00 - General
Figure 1715. Valve Components
B
A
A
D
C
LS
J
P
T
A Valve section seals B Valve section

C Tie rod D Tie rod nut
E Final element F Auxiliary section
G Extend section H Tilt section
J Lift section K Inlet section
30 - 351 9813/7600-3 30 - 351

00 - General
Assemble
following steps.
1.1. Make sure that the mating faces of the
assembly.
1.2. Renew the O-rings located between the
valve sections. Make sure that the O-ring
seals are not trapped or damaged.
1.3. Lubricate parts with JCB hydraulic fluid
before assembling. Make sure that all the
parts move freely.
1.4. If the tie rods were unscrewed from the inlet
section, apply JCB sealant to the threads
(Medium Strength)
1.5. Apply JCB sealant to the threads of the
nuts.

Item Description Nm
D Tie rod nut 42
30 - 352 9813/7600-3 30 - 352

Introduction
30 - 353 9813/7600-3 30 - 353


Introduction .................................................. 30-354 Refer to (PIL 30-51-06).
30 - 354 9813/7600-3 30 - 354


Item Nm
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] ................ Page 30-355 A 44.7
For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Agri-Xtra (For: 531-70 [5AA], 531-70 [5TA], 536-60
................................................. Page 30-355 [5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Agri-
(For: 550-80 [5AW], 550-80 [5UW], 560-80 Xtra)
[5AY], 560-80 [5UY])
The ARV (Auxiliary Relief Valve)'s are not adjustable.
If the pressure is incorrect, replace the valve. Each
ARV has its pressure setting stamped on the top
face, make sure you replace the ARV with one of the
same pressure setting.
The ARV shown is for illustration purposes. Refer to

Figure 1716. Make sure you select the correct ARV.
Refer to technical data, (PIL 30-53-00).
Remove
1. Raise the lift arm and make the machine safe.
2. Install the safety strut. Refer (PIL 06-69).
30-00).
4. Unscrew and remove the ARV from the valve
block.
Figure 1716.
A ARV
Install
1. Install a new ARV into the valve block and tighten
30 - 355 9813/7600-3 30 - 355

27 - Pressure Compensator Valve
27 - Pressure Compensator Valve Operation

Operation ..................................................... 30-356
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 - 356 9813/7600-3 30 - 356

Figure 1717.
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 - 357 9813/7600-3 30 - 357

A
(For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-70 [5AE], 536-70 B
[5TE], 541-70 [5AD], 541-70 [5TD], Agri-
C
Xtra)
Consumables
D
- General purpose
solvent based parts
cleaner
This procedure can be carried out with the valve

block removed or in position.
Remove
A Compensator plug
2. Install the safety strut. Refer to (PIL 06-69). B O-ring
C Compensator piston
3. Follow the general health and safety procedures. D Valve block section
Inspection
30-00). Examine the valve components for scratches, pitting,
5. Remove the hydraulic filler cap. corrosion or damage. Replace if necessary.
6. Put a label on the hoses connected to the valve Install

slice to help installation.
Although the pressure compensator valves look
7. Disconnect the hoses. identical, they are not interchangeable.
8. Plug all the open ports and hoses to prevent 1. The installation procedure is the opposite of the
contamination. removal procedure. Additionally do the following
9. Remove the compensator plug from the valve steps.
block section. 1.1. Clean the valve components in an
10. Remove the compensator piston from the bore applicable solvent.
with a magnet. Consumable: Cleaner/Degreaser - General
1.2. Replace all the O-rings and back-up rings.
1.3. Lubricate the parts with JCB Hydraulic Fluid
before assembling.

Item Description Nm
A Compensator plug 60
30 - 358 9813/7600-3 30 - 358

36 - Load Hold Check Valve
36 - Load Hold Check Valve Figure 1719.
B
Consumables
and Sealer (Medium 4101/0251 0.05L 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.
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 - 359 9813/7600-3 30 - 359

80 - Spool
80 - Spool Adjust
Adjust .......................................................... 30-360
(For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
The extend / retract and lift / lower valve slices have
a spool stroke limitation stop screw. During normal
operation this must not be adjusted.

2. Get access to the valve block.
3. Loosen the locknut.
4. Adjust the stop screw with an Allen key to adjust
the flow rate.
5. When the setting is correct, tighten the locknut.
Figure 1720.
A Stop screw
B Locknut
30 - 360 9813/7600-3 30 - 360

80 - Spool
3. Remove the cover plate screws.

(For: 531-70 [5AA], 531-70 [5TA], 536-60 4. Remove the housing and the O-ring from the
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 valve block.
[5TE], 541-70 [5AD], 541-70 [5TD])
5. Hold the spool assembly in a vice using the spool
Consumables clamp.
Cleaner/Degreaser 4104/1557 0.4L 6. Remove the spool end screw, the centering
- General purpose spring, the spring retainers and the spring cup.
solvent based parts If necessary pre-heat the spool to the specified
cleaner temperature in an oven or with a heat gun to
remove the spool end.
46 4002/0805 20L Temperature: 200°C (391.7°F)
4002/0803 200L 7. Carefully remove the spool from the valve body.
Disassemble When you remove the O-rings and seals, use a

rounded tool that will not cause damage to the seal
1. Remove the solenoid assembly. grooves. Discard all the O-rings and back-up rings.
Refer to: PIL 33-86-00. Do not use worn or damaged items.
2. Remove the mounting screws and the mounting

plate.
Figure 1721.
A B C E F
G
H J K L M
N
A Solenoid assembly B Mounting screws

C Mounting plate D O-ring 1
E O-ring 2 F Valve block
G Spool H Spring retainers
J Centering spring K Spring cup
L Spool end screw M O-ring 3
N Housing P Cover plate screws
30 - 361 9813/7600-3 30 - 361

80 - Spool
Figure 1722. Holding the Spool Assembly
X
Y
X Spool assembly
Y Spool clamp
Assemble
Before you assemble, check the valve components
for scratches, pitting, corrosion or other type of
damage. Replace if required.

following steps.
1.1. Clean the valve components in an
applicable solvent.
1.2. Lubricate the parts with hydraulic fluid
before assembling. Make sure that all the
parts move freely.
1.3. Replace all O-rings.
1.4. Make sure that the spools are in the correct
position before installing into the valve block
body.

Item Description Nm
B Mounting screws 4.5
L Spool end screw 10
P Cover plate screws 4.5
30 - 362 9813/7600-3 30 - 362

54 - Parallel Circuit Control Valve Block
Contents Page No.
30-54-00 General ......................................................................................................................... 30-365

30 - 363 9813/7600-3 30 - 363

Notes:
30 - 364 9813/7600-3 30 - 364

00 - General

Technical Data ............................................. 30-365 For: 531-70 [5AA], 531-70 [5TA]
................................................. Page 30-365
For: 535-95 [5AB], 535-95 [5TB]
Operation ..................................................... 30-371 ................................................. Page 30-366
Fault-Finding ................................................ 30-374 For: 536-60 [5AC], 536-60 [5TC]
Adjust .......................................................... 30-375 ................................................. Page 30-367
Remove and Install ..................................... 30-376 For: 536-70 [5AE], 536-70 [5TE], 541-70
Disassemble and Assemble ........................ 30-381 [5AD], 541-70 [5TD] ................ Page 30-367
For: 526-56 [T4F] .................... Page 30-368
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] ................ Page 30-368
(For: 531-70 [5AA], 531-70 [5TA])
Single lever control

alternative valves may be installed. Refer to (PIL
30-53-00).
Table 666. 4 Spool, parallel

service, double acting spools
Spool 1 Lift arm raise & Manually oper-
lower service ated
Spool 2 Carriage tilt ser- Manually oper-
vice ated
Spool 3 Lift arm extend Solenoid, servo
& retract ser- pilot operated
vice
Spool 4 Auxiliary ser- Solenoid, servo
vice pilot operated

Relief valve Pressure value
MRV (Main Relief Valve) 240bar (3,478.2psi)
ARV (Auxiliary Relief -
Valve)
side
30 - 365 9813/7600-3 30 - 365

00 - General

A D D
A
4 B A
4 B A
3 B A
3 B A
B
2 B A C
2 B A
1 B A
1 B A
B C
T P
T P
A Auxiliary ram rod side
A Auxiliary ram rod side B Carriage tilt ram rod side
B Carriage tilt ram rod side C Carriage tilt ram head side
C Carriage tilt ram head side D Auxiliary ram head side
D Auxiliary ram head side T Test port
T Test port P Pressure port
P Pressure port
Table 668. (For: 535-95 [5AB], 535-95 [5TB])

Pilot pressure range: Value
(machines with single Single lever control
lever controls)
All machines 10–30bar (144.9– alternative valves may be installed. Refer to (PIL
434.8psi) 30-53-00).
Dual lever control Table 671. 4 Spool, parallel

Table 669. 4 Spool, parallel Spool 1 Lift arm raise & Manually oper-
service, double acting spools lower service ated
Spool 1 Lift arm raise & Manually oper- Spool 2 Carriage tilt ser- Manually oper-
lower service ated vice ated
Spool 2 Lift arm extend Manually oper- Spool 3 Lift arm extend Solenoid, servo
& retract ser- ated & retract ser- pilot operated
vice vice
Spool 3 Carriage tilt ser- Manually oper- Spool 4 Auxiliary ser- Solenoid, servo
vice ated vice pilot operated
Spool 4 Auxiliary ser- Manually oper-
vice ated
Table 670. Relief valve pressures Relief valve Pressure value

MRV 240bar (3,478.2psi)
Relief valve Pressure value
ARV -
MRV 240bar (3,478.2psi)
ARV -
Carriage tilt ram rod side 276bar (4,000.0psi) side
side
30 - 366 9813/7600-3 30 - 366

00 - General

A D A D
4 B A 4 B A
3 B A 3 B A
2 B A 2 B A
1 B A 1 B A
B C B C
T P T P
A Auxiliary ram rod side A Auxiliary ram rod side
B Carriage tilt ram rod side B Carriage tilt ram rod side
C Carriage tilt ram head side C Carriage tilt ram head side
D Auxiliary ram head side D Auxiliary ram head side
T Test port T Test port
P Pressure port P Pressure port
Table 673.
(For: 536-60 [5AC], 536-60 [5TC])
(machines with single Depending on the specification of your machine,
lever controls) alternative types of valve(s) are installed. Refer to
All machines 10–30bar (144.9– (PIL 30-53-00).
434.8psi)
Dual lever control (For: 536-70 [5AE], 536-70 [5TE], 541-70

[5AD], 541-70 [5TD])
service, double acting spools Single lever control
Spool 1 Lift arm raise & Manually oper- Depending on the specification of your machine,
lower service ated alternative valves may be installed. Refer to (PIL
Spool 2 Lift arm extend Manually oper- 30-53-00).
& retract ser- ated
vice Table 676. 4 Spool, parallel
Spool 3 Carriage tilt ser- Manually oper- service, double acting spools
vice ated Spool 1 Lift arm raise & Manually oper-
Spool 4 Auxiliary ser- Manually oper- lower service ated
vice ated Spool 2 Carriage tilt ser- Manually oper-
vice ated
Table 675. Relief valve pressures Spool 3 Lift arm extend Solenoid, servo
Relief valve Pressure value & retract ser- pilot operated
vice
MRV 240bar (3,478.2psi)
Spool 4 Auxiliary ser- Solenoid, servo
ARV -
vice pilot operated
side
30 - 367 9813/7600-3 30 - 367

00 - General
Table 677. Relief valve pressures Table 680. Relief valve pressures
Relief valve Pressure value Relief valve Pressure value
MRV 260bar (3,768.1psi) MRV 260bar (3,768.1psi)
ARV - ARV -
Auxiliary ram rod side 220bar (3,188.4psi) Auxiliary ram rod side 220bar (3,188.4psi)
Auxiliary ram head side 220bar (3,188.4psi) Auxiliary ram head side 220bar (3,188.4psi)
Carriage tilt ram rod side 276bar (4,000.0psi) Carriage tilt ram rod side 276bar (4,000.0psi)
Carriage tilt ram head 138bar (2,000.0psi) Carriage tilt ram head 138bar (2,000.0psi)
side side
A D D
A
4 B A 4 B A
3 B A 3 B A
B 2 B C
2 B A A
1 B A 1 B A
B C
T P T P
A Auxiliary ram rod side A Auxiliary ram rod side

B Carriage tilt ram rod side B Carriage tilt ram rod side
C Carriage tilt ram head side C Carriage tilt ram head side
D Auxiliary ram head side D Auxiliary ram head side
T Test port T Test port
P Pressure port P Pressure port
Table 678.
(For: 526-56 [T4F])
(machines with single Depending on the specification of your machine,
lever controls) alternative types of valve(s) are installed. Refer to
All machines 10–30bar (144.9– (PIL 30-53-00).
434.8psi)
Dual lever control (For: 550-80 [5AW], 550-80 [5UW], 560-80

[5AY], 560-80 [5UY])
alternative types of valve(s) are installed. Refer to
Spool 1 Lift arm raise & Manually oper- (PIL 30-53-00).
lower service ated
Spool 2 Lift arm extend Manually oper-
& retract ser- ated
vice
Spool 3 Carriage tilt ser- Manually oper-
vice ated
Spool 4 Auxiliary ser- Manually oper-
vice ated
30 - 368 9813/7600-3 30 - 368

00 - General
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-70 [5AE], 536-70
[5TE])
Machines with dual lever controls
Figure 1729.
B
A
C D
H G
Item Description
F Hydraulic cooling fan
Table 681.
motor pipework
Item Description G Trailer brake valve
A Hydraulic tank H Sway Valve
B Control Valve J Hydraulic cooling fan
C Fan supply pump motor case drain line
D Main hydraulic supply K Trailer brake coupling
pump L Steer return line
E Sway ram
30 - 369 9813/7600-3 30 - 369

00 - General
Machines with single lever controls
Figure 1730.
B
A
C D E
J
H
K
M
Table 682.
Item Description
A Hydraulic tank
B Control valve
C Steer pump
D Fan supply pump
E Main hydraulic supply
pump
F Sway ram
G Hydraulic cooling fan
motor pipework
H Trailer brake valve
J Sway valve
K Hydraulic cooling fan
motor case drain line
L Steer return line
M Trailer brake coupling
30 - 370 9813/7600-3 30 - 370

00 - General
Operation Figure 1732. 4 Spool Control Valve

(Dual Lever Control) Schematic
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD]) A
B J
4 Spool Control Valve (Dual Lever
Control)
E E
When the spools are actuated, oil from the pump
passes into the service port 1 or service port A
2 and operates the relevant hydraulic ram. See B H
the applicable hydraulic schematic for service port
connections.
E E
Depending on your machine, some sections are pilot
operated and controlled by an electrical switch. A
G
Figure 1731. 4 Spool Con- B
trol Valve (Dual Lever Control)
E E
A
J B F
B A
H
B A
E G D
B A
E
F
B A
T C
A Service port 1
B Service port 2 T C
C Inlet port A Service port 1
E ARV (Auxiliary Relief Valve) B Service port 2
F Spool 1 C Inlet port
G Spool 2 D MRV
H Spool 3 E ARV
J Spool 4 F Spool 1
T Tank port G Spool 2
H Spool 3
The oil from the pump enters the control valve at J Spool 4
the inlet port, passing the adjustable MRV (Main T Tank port
Relief Valve). As the spool 1, spool 2, spool 3 and
spool 4, are in neutral, the oil passes round their
central waists, the spool lands preventing the oil
from entering the service ports. On reaching the end
housing, the oil enters the exhaust gallery and is
discharged back to the tank. The control valve also
incorporates adjustable ARV's.
30 - 371 9813/7600-3 30 - 371

00 - General
4 Spool Control Valve (Single Lever Figure 1734. 4 Spool Control Valve
Control) (Single Lever Control) Schematic
When the spools are actuated, oil from the pump

passes into the service port 1 or the service port 2,
operating the relevant hydraulic ram.
See the applicable hydraulic schematic for service A

port connections. Refer to hydraulic system- general, J
refer to (PIL 30-00). B
Figure 1733. E E
E E
A
H
B
J A B
A B
H
A B A
G G
E E B
A B
F
E E
A
F
B
T C
A Service port 1
B Service port 2
C Inlet port
E ARV D
F Spool 1
G Spool 2
H Spool 3
J Spool 4
T Tank port
Oil from the pump enters the control valve through

the inlet port, passing the adjustable MRV.
The pressure reduction valve provides oil at pilot K

pressure for control of spool 3 and spool 4. L
As the spool 1, spool 2, spool 3 and spool 4, are
in neutral, the oil passes round their central waists, T
the spool lands preventing the oil from entering the C
service ports. On reaching the end housing, the oil
enters the exhaust gallery and is discharged back A Service port 1
to the tank. The control valve also incorporates B Service port 2
adjustable ARV's. C Inlet port
D MRV
An accumulator is attached to the accumulator E ARV
attachment port. The accumulator traps and stores F Spool 1
oil at pilot pressure and enables operation of the G Spool 2
service spools a limited number of times with the H Spool 3
engine stopped. J Spool 4
30 - 372 9813/7600-3 30 - 372

00 - General
K Pressure reduction valve

L Accumulator attachment port
T Tank port
30 - 373 9813/7600-3 30 - 373

00 - General
Fault-Finding
Fault
Lack of power at all hydraulic functions Table 683. Page 30-374
All mechanically operated hydraulic services slow to operate Table 684. Page 30-374
All solenoid/servo operated hydraulic services slow to operate Table 685. Page 30-374
Is the machine experiencing boom extend or retract problems? Table 686. Page 30-374
Bleed air from the hydraulic cylinders - is it OK now? Table 687. Page 30-374
Table 683. 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.
Low pump flow. Check pump flow.
Check for external leaks, replace seals.
Priority valve sticking. Refer to (PIL 25-03).
Replace pump.
Table 684. All mechanically operated hydraulic services slow to operate

Cause Remedy
Neutral circuit or low pressure lines leaking, Check pipe lines and if necessary replace.
damaged, trapped or kinked.
MRV setting not correct. Check and adjust as necessary.
Low pump flow. Check pump flow.
Check for external leaks, replace seals.
Priority valve sticking. Refer to (PIL 25-03).
Replace pump.
Table 685. 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 686. Is the machine experiencing boom extend or retract problems?

Cause Remedy
YES = Go to Table 5, NO = done
Table 687. Bleed air from the hydraulic cylinders - is it OK now?

Cause Remedy
YES = Done, NO = Go to Table 6
30 - 374 9813/7600-3 30 - 374

00 - General
Adjust 5.2. Measure the spool displacement 1.

6. Check spool displacement 2.
(For: 531-70 [5AA], 531-70 [5TA], 535-95 6.1. Use the control lever to move and hold the
[5AB], 535-95 [5TB], 536-70 [5AE], 536-70 spool in the position.
[5TE], 541-70 [5AD], 541-70 [5TD]) 6.2. Measure spool displacement 2.
Communications
7. Repeat the procedure for each manual spool as
Bad communications can cause accidents. Keep necessary.
people around you informed of what you will be
doing. If you will be working with other people, Table 688. Manual Spool Displacement
make sure any hand signals that may be used are
Displacement Measurement
understood by everybody. Worksites can be noisy, do
not rely on spoken commands. A 7–9mm
B 7–9mm
Two people are required to complete the procedure.
One person should sit in the operator cab, while the Adjustment
other person requires access to the control valve
assembly. Spool displacement is influenced by the control lever
linkage. Check, adjust and replace if necessary. If
1. Make the machine safe with the lift arm raised. sufficient adjustment can not be achieved it may be
Refer to (PIL 01-03). necessary to replace the spool assembly
3. Follow the general health and safety procedure.
30-00).
5. Check the spool displacement 1.
Figure 1735.
A Spool displacement 1
B Spool displacement 2
5.1. Use the control lever to move and hold the
spool in the position.
30 - 375 9813/7600-3 30 - 375

00 - General
Remove and Install
6. Remove the cab side cover (if installed) to get

(For: 531-70 [5AA], 531-70 [5TA], 535-95 access to the valve block. Refer to (PIL 06-06).
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 7. Put a label on each hose to help installation.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD]) 8. Disconnect the hydraulic hoses.
Remove and Install (P1) contamination.
CAUTION This component is heavy. It must only 10. Remove the securing clip and pin.
method and device. 11. Disconnect the control lever rod from the spool
end.
Remove 12. Repeat step 7 and step 8 for other control
1. Make the machine safe. Refer to (PIL 01-03). linkages.
2. Follow the general health and safety procedures. 13. Put a label on the electrical connectors to help
Refer to (PIL 01-03). installation.
3. Install the safety strut. Refer to (PIL 06-69). 14. Disconnect all electrical connectors to the valve
block sensors.
(PIL 30-00). 15. After you support the valve block properly,
remove the mounting screws. Carefully lift the
5. Discharge the hydraulic pressure. Refer to (PIL valve block away from the bracket and clear of
30-00). the machine.
30 - 376 9813/7600-3 30 - 376

00 - General
Figure 1736.
B
B
C D
B
G
H
B
F
A Electrical connector B Mounting screws

C Control linkage D Locknut
E Control rod F Spool end
G Clip H Pin
30 - 377 9813/7600-3 30 - 377

00 - General
Install 2. Follow the general health and safety procedures.

removal procedure. Additionally do the following 3. Install the safety strut. Refer to (PIL 06-69).
steps.
1.1. After you install, check the operation of the (PIL 30-00).
mechanical control linkages. Operate the
control levers. Make sure that the lever 5. Discharge the hydraulic pressure. Refer to (PIL
travel is same in both the directions. To 30-00).
adjust the levers, remove the locknuts at 6. Remove the cab side cover (if installed) to get
each end of the control rod. Turn the access to the valve block. Refer to (PIL 06-06).
rod to increase or decrease the length as
necessary. Tighten locknuts. 7. Put a label on each hose to help installation.
1.3. Check and fill the hydraulic system with the 9. Plug all the open ports and hoses to prevent
recommended hydraulic fluid as necessary. contamination.
10. Remove the securing clip and pin.
1.4. After installation, check the ARV (Auxiliary
Relief Valve) and MRV (Main Relief 11. Disconnect the control lever rod from the spool
Valve) pressure. Refer to hydraulic system- end.
12. Repeat step 7 and step 8 for other control
linkages.
Remove and Install (P2)
13. Put a label on the electrical connectors to help
installation.
method and device. 14. Disconnect all electrical connectors to the valve
block sensors.
Remove 15. After you support the valve block properly,
1. Make the machine safe. Refer to (PIL 01-03). remove the mounting screws. Carefully lift the
valve block away from the bracket and clear of
the machine.
30 - 378 9813/7600-3 30 - 378

00 - General
Figure 1737.
A B
B
C D
B
G
H
B
F
A Electrical connector B Mounting screws

C Control linkage D Locknut
E Control rod F Spool end
G Clip H Pin
30 - 379 9813/7600-3 30 - 379

00 - General
Install
steps.
1.1. After you install, check the operation of the
mechanical control linkages. Operate the
control levers. Make sure that the lever
travel is the same in both directions. To
adjust the levers, remove the locknuts at
each end of the control rod. Turn the
necessary. Tighten locknuts.
1.3. Check and fill the hydraulic system with the
recommended hydraulic fluid as necessary.
1.4. After installation, check the ARV and MRV
pressure. Refer to (PIL 30-00).
30 - 380 9813/7600-3 30 - 380

00 - General

(For: 531-70 [5AA], 531-70 [5TA], 535-95 Make sure that components are assembled in their
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 original positions.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 Great care should be taken when you disassemble
[5AD], 541-70 [5TD]) and assemble a valve to avoid the following:
Consumables • Contamination.
Description Part No. Size • Damage to spools.
JCB Hydraulic Fluid HP 4002/0801 5L • Damage to seal grooves.
46 4002/0805 20L
4002/0803 200L
Sealer (High Strength) 4101/0552 0.2L Disassemble
Valve Block Sections 1. Remove the valve block from the machine.
Some valve sections and components are omitted
from the figure for illustration purposes. 2. Remove the tie rod nuts.
The valve block is a sectional type, which is made up 3. Carefully separate and remove the outlet section
of a number of separate sections. The illustration is followed by the remaining service sections. If the
intended as a guide to identify the components. inlet section is to be replaced, remove and retain
the tie rods.
Be sure to note the location of all components when
you disassemble. Although some components may
30 - 381 9813/7600-3 30 - 381

00 - General
Figure 1738.
A B
C
D
E
F
M
L
M
L
J
K H
K
J
P
R K
K
L B
1
3 2
A ARV (Auxiliary Relief Valve) B Outlet section

E Extend section F Lift section
30 - 382 9813/7600-3 30 - 382

00 - General
G MRV (Main Relief Valve) H Inlet section

J Nut 1 K Nut 2
L Seals M Service sections
N Tie rods P Top tie rod identification
R Top tie rod
30 - 383 9813/7600-3 30 - 383

00 - General
Assemble
following steps.
1.1. Make sure that the mating faces of the
assembly.
1.2. Renew the seals located between the valve
sections. Make sure that the seals are not
trapped or damaged.
1.3. Lubricate parts with hydraulic fluid before
assembling. Make sure that all the parts
move freely.
1.4. If the tie rods were removed from the inlet
section, make sure that the tie rod with the
identification marker is used in the top hole
and that the marker is in the inlet section.
1.5. Apply sealant to the threads of nut 1 and
nut 2. Tighten the nuts to the correct torque
value in the sequence 1, 2, 3 and then 1
again to the specified torque value.
(High Strength)

Item Description Nm
J Nut 1 40
K Nut 2 27
30 - 384 9813/7600-3 30 - 384

03 - Main Relief Valve (MRV) Introduction

30 - 385 9813/7600-3 30 - 385

(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 A
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD])
The MRV (Main Relief Valve) is not serviceable.
Replace the complete valve if it is defective.
Remove
30-00).
block.
4. Remove the O-rings.
4.1. When you remove the O-rings and seals, A
use a rounded tool that will not cause any
damage to the seal grooves.
4.2. Discard all the O-rings.
4.3. Do not use worn or damages items.
A Valve assembly
Install
steps.
1.1. Replace all the O-rings.
1.2. Lubricate the parts with JCB hydraulic fluid
before assembling.
1.3. Tighten the valve to the specified torque
value.
1.4. Adjust the pressure setting as required.

Item Description Nm
A Valve assembly 20
30 - 386 9813/7600-3 30 - 386


30 - 387 9813/7600-3 30 - 387

(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD])
The ARV (Auxiliary Relief Valve) is not serviceable.
Replace the valve if it is defective.
A
Remove
30-00).
block.
4. Remove the O-rings.
4.1. When you remove the O-rings and seals,
use a rounded tool that will not cause any
damage to the seal grooves. A
4.2. Discard all the O-rings.
4.3. Do not use worn or damaged items.
A Valve assembly
Install
steps.
1.1. Replace all the O-rings.
1.2. Lubricate the parts with JCB hydraulic fluid
before assembling.
1.3. Tighten the valve assembly to the specified
torque value.
1.4. Adjust the pressure setting as required.

Item Description Nm
A Valve assembly 20
30 - 388 9813/7600-3 30 - 388

39 - Load Hold Check Valve
39 - Load Hold Check Valve Figure 1741.
B
Remove and Install
Consumables
and Sealer (Medium 4101/0251 0.05L 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.
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 - 389 9813/7600-3 30 - 389

60 - Directional Control Valve
Contents Page No.
30-60-00 General ......................................................................................................................... 30-391

30-60-12 Electro Proportional Control ......................................................................................... 30-393
30-60-15 Joystick ......................................................................................................................... 30-406
30-60-18 Shuttle .......................................................................................................................... 30-415
30-60-27 Auxiliary Circuit ............................................................................................................ 30-416
30-60-82 Sway ............................................................................................................................. 30-417
30-60-90 Flow Regulator ............................................................................................................. 30-421
30 - 390 9813/7600-3 30 - 390

00 - General
00 - General
Introduction
Flow Control Valves Figure 1745.
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 1742.
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 1743. 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 1747.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 391 9813/7600-3 30 - 391

00 - General
Figure 1748. 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 - 392 9813/7600-3 30 - 392

12 - Electro Proportional Control
12 - Electro Proportional Control Operation

Operation ..................................................... 30-393
Diagram ....................................................... 30-405
(For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
Electronic Servo Proportional Control

A summary of the proportional control functions are
as follows:
• System enable and isolation

• Constant auxiliary selection
• Constant auxiliary flow setting
• Constant auxiliary changeover
• System isolation switches i.e. tilt lock
• Operation of the lift arm services- raise, lower,
extend, retract, crowd and dump.
The control lever and attached thumbwheels operate

the hydraulic services using electrical signals.
This type of lever has two functions, proportional

thumbwheel control and electro servo lever control.
The control lever moves in two axies and also

includes two thumbwheel switches. The control
lever and thumbwheel switches control eight electro
proportional solenoid valves which operate the four
service spools in the valve block.
In the control lever assembly is the joystick

controller ECU (Electronic Control Unit). The ECU
receives analogue electrical inputs in relation to the
movement of the lever or thumbwheel switches. The
ECU changes the analogue signals and broadcasts
messages on the machine CAN (Controller Area
Network)bus.
The hydraulic control ECU recognises the CAN

messages and generates the correct PWM (Pulse
Width Modulation) signal for operation of the control
valve proportional solenoids.
The proportional solenoid valves operate as

pressure reducing valves. These supply servo pilot
oil to move the auxiliary, or extend retract service
spool. The supply is at a pressure in relation to
the amount the operator moves the joystick or
thumbwheel switch.
30 - 393 9813/7600-3 30 - 393

Figure 1749.
B4 A4
A
B3 A3
B2 A2
B1 A1
LS
D T
CANBus
A Control lever B Joystick controller ECU

C Hydraulic control ECU D Control valve proportional solenoid
Joystick and controller When you move the control lever, an electrical
signal is produced proportional to the control lever
All of the machine hydraulic services are actuated movement. The controller ECU monitors these
electrically. CAN enabled electronic control units signals (inputs) and converts the voltage into a
and proportional solenoid valves are central to the corresponding CAN message (output) which is
system. broadcast on the machine CANbus.
30 - 394 9813/7600-3 30 - 394

Figure 1750.
G F
A H J
K L
E
4 1
3 2
1 2 3 4 5 6
12 11 10 9 8 7
A Main control lever handle B CAN joystick control ECU

C Electrical connector- Thumbwheels D Electrical connector- Joystick buttons
E Electrical connector- CAN joystick control ECU F Constant flow button
G Auxiliary II button H Axis 3- Thumbwheel
J Axis 4- Thumbwheel K Axis 1- Raise lower
L Axis 2- Carriage tilt M Electrical connector- CAN joystick control ECU
30 - 395 9813/7600-3 30 - 395

Proportional signal generation System enable and isolation

When the control lever is operated, the plunger The system will not enable unless the switch is
pushes against the return spring. A variable resistor latched. When the switch is not latched, its input
position sensor is allocated to each axis. The slider is sensed by the hydraulic control ECU. The ECU
moves up or down when the lever is moved, energises the pump shut off valve solenoid coil.
changing the electrical voltage depending on lever
position. The tilt isolation switch state is sensed by inputs
at the hydraulic control ECU. The ECU isolates the
The position sensors are integral with the joystick joystick control by switching off the PWM signals to
controller ECU. If a sensor is defective, replace the the control valve tilt spool proportional solenoids.
controller ECU.
The joystick isolation switch state is sensed by inputs
Figure 1751. at the hydraulic control ECU. The ECU isolates the
joystick controls by switching off the PWM signals to
the control valve proportional solenoids.
A Control lever
B Plunger
C Return spring
D Slider
30 - 396 9813/7600-3 30 - 396

Figure 1752.
A
E1
ECU
D
E2
IGN +VE
A Pump shut off valve solenoid B Tilt isolation switch

C Hydraulic stop watch D Joystick controls isolation switch
E1 Hydraulic control ECU- connector1 E2 Hydraulic control ECU- connector2
30 - 397 9813/7600-3 30 - 397

Second auxiliary changeover A CAN message causes the LMS (Loadall

Monitoring System) display AUX II indicator LED
When you press the momentary switch, a signal is (Light Emitting Diode) to come ON.
sent to the joystick controller ECU. It responds by
broadcasting a message on the machine CAN bus When you press the momentary switch again, the
through the joystick controller. The CAN message hydraulic control ECU responds by de-energising
is read by the hydraulic control ECUCAN bus the relay. Auxiliary changeover solenoid coil is de-
interface. The ECU responds by energising the energised and the oil is diverted to the Auxiliary I
second auxiliary relay. The auxiliary changeover circuit.
solenoid coil is energised and the oil is diverted to
the AUX II circuit. A CAN message causes the LMS display AUX II
indicator LED to go OFF.
Figure 1753.
E1
A CAN H
CAN L
CAN L
CAN H
ECU
ECU ECU
ECU
B
D
G
C
E2
IGN +VE
A CAN joystick control ECU B Joystick auxiliary changeover switch

C Joystick connector D CAN joystick control ECU
30 - 398 9813/7600-3 30 - 398

E1 Hydraulic control ECU- connector1 E2 Hydraulic control ECU- connecotr2

F Second auxiliary changeover switch G LMS display ECU- connector
H Secondary fuse J Second auxiliary relay
30 - 399 9813/7600-3 30 - 399

Front/rear auxiliary changeover When the operator switch is moved into the rear
auxiliary position, the solenoid diverter valve is de-
When the operator switch is moved into the front energised and it supplies oil to the rear auxiliary
auxiliary position, the solenoid diverter valve is circuits.
energised and it supplies oil to the lift arm auxiliary
quick release couplings.
Figure 1754.
IGN +VE
A Secondary fuse B Front/rear auxiliary changeover switch

C Front/rear auxiliary changeover solenoid
30 - 400 9813/7600-3 30 - 400

Constant auxiliary When the momentary switch is pressed, a signal is

sent to the joystick controller ECU. It responds by
The constant auxiliary switch state is sensed by broadcasting a message on the machine CANbus.
inputs at the hydraulic control ECU. When constant The CAN message is read by the hydraulic control
auxiliary is enabled by the operator, the hydraulic ECU. The ECU responds by holding the auxiliary
control ECU holds the auxiliary spool on a constant spool in the position set by the operator (thumbwheel
position by means of the PWM signals to the spool switch position). The selected spool position is also
proportional solenoids. stored by the ECU and is automatically selected
again when the operator selects the constant
A CAN message causes the LMS display constant auxiliary function again.
auxiliary indicator LED to come ON.
Figure 1755.
G1
B CAN H
CAN L
CAN L
CAN H
ECU
ECU
C
E
D
A
F
ECU
G2
IGN +VE
A Secondary fuse B CAN joystick control ECU

C Joystick constant auxiliary switch D Joystick controller
E CAN joystick control ECU F Constant auxiliary enable switch
G1 Hydraulic control ECU- connecotr1 G2 Hydraulic control ECU- connector2
30 - 401 9813/7600-3 30 - 401

Extend/retract and auxiliary services the position of the thumbwheel switch. The ECU
(Thumbwheel switches) responds by broadcasting thumbwheel position as a
message on the machine CANbus.
The ECU provides the thumbwheel switch- auxiliary
service and the thumbwheel switch- extend/retract The CAN message is read by the hydraulic
service with a 5V power supply. control ECUCANbus interface. The ECU responds
by producing a PWM signal in proportion to the
The thumbwheels send a voltage between 0.7V and thumbwheel position to the proportional solenoid
4.3V to the ECU. The voltage is determined by coils for operation of the service spools.
Figure 1756.
F1
A CAN H
CAN L
CAN L
CAN H
ECU
ECU
G H
D
F2 J K
E
IGN +VE
A CAN joystick control ECU B Thumbwheel switch- auxiliary service

C Thumbwheel- extend/retract service D Joystick controller
E Secondary fuse F1 Hydraulic control ECU- connector1
F2 Hydraulic control ECU- connector2 G Proportional control valve solenoid- retract
service
H Proportional control valve solenoid- extend J Proportional control valve solenoid- auxiliary B
service service
30 - 402 9813/7600-3 30 - 402

K Proportional control valve solenoid- auxiliary A

service
30 - 403 9813/7600-3 30 - 403

Lift/lower and tilt services The CAN message is read by the hydraulic control
ECU CANbus interface. The ECU responds by
The ECU responds to operation of the joystick by producing a PWM signal in proportion to the
broadcasting the joystick position as a message on joystick position to the proportional solenoid coils for
the machine CANbus. operation of the service spools.
Figure 1757.
C1
CAN H
ECU
CAN L
CAN L
CAN H
A
ECU
D E
C2 F G
IGN +ve
A CAN joystick control ECU B Secondary fuse

C1 Hydraulic control ECU- connector1 C2 Hydraulic control ECU- connecotr2
D Proportional control valve solenoid- dump E Proportional control valve solenoid- crowd
service service
F Proportional control valve solenoid- lift service G Proportional control valve solenoid- lower
service
30 - 404 9813/7600-3 30 - 404

Diagram
pressure flows to the proportional solenoid valves at

(For: 526-56 [T4F], 531-70 [5AA], 531-70 each service spool.
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW])
Oil from the hydraulic pump flows to the pilot
pressure control valve via internal filters. Oil at pilot
Figure 1758.
C C
D
TP1 TP2
B
ACC
P P1
T T1
P2
T2
A
B Pilot pressure control valve C Proportional solenoid valves

D Service spool
Table 693. Hydraulic Connection Colour Key

A Oil at servo pressure
30 - 405 9813/7600-3 30 - 405

15 - Joystick
15 - Joystick Operation
Operation ..................................................... 30-406 For: 526-56 [T4F], 531-70 [5AA], 531-70
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
Fault-Finding ................................................ 30-408 [5AC], 536-60 [5TC], 536-70 [5AE], 536-70
Remove and Install ..................................... 30-409 [5TE], 536-70LP [5A1], 536-70LP [5T1],
Disassemble and Assemble ........................ 30-414 541-70 [5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................. Page 30-406
For: Manual Controls ............... Page 30-407
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
For details of operation for Electro Proportional
Controls refer to (PIL 30-60-12).
30 - 406 9813/7600-3 30 - 406

15 - Joystick
(For: Manual Controls)
Figure 1759.
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 - 407 9813/7600-3 30 - 407

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 - 408 9813/7600-3 30 - 408

15 - Joystick
Remove and Install
For: 526-56 [T4F], 531-70 [5AA], 531-70 Figure 1760.

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 A
[5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 [5UY] B
................................................. Page 30-409
For: Manual Controls ............... Page 30-411
(For: 526-56 [T4F], 531-70 [5AA], 531-70

[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 C
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 J
[5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY]) H

Remove D
The control lever and the attached powerbase is a
non serviceable part. If it is faulty, it must be renewed.

2. Release the hydraulic pressure. Refer to (PIL E
30-00).
G
3. Prise the screw cover from the armrest.
4. Remove the screws 3 and washers. F
5. Lift away the arm rest and the trim assembly.
A Arm rest
6. Remove the screws 1. B Screw cover
C Trim assembly
7. Remove the gaiter collar. D Control lever
8. Remove the screws 2 and lift the control E Screws 1
lever and power base assembly to access the F Housing
electrical connectors. G Screws 2
H Gaiter collar
9. Put label on the electrical connectors for correct J Screws 3
installation.
Install
10. Disconnect the electrical connectors.
11. Remove the control lever from the housing. removal procedure.

Remove
The control lever and the attached powerbase is a
non serviceable part. If it is faulty, it must be renewed.
30 - 409 9813/7600-3 30 - 409

15 - Joystick
2. Release the hydraulic pressure. Refer to (PIL Figure 1761.

30-00).
3. Prise the screw cover from the armrest.
4. Remove the screws and washers 1.
B
5. Lift away the arm rest. C
6. Remove the rear screws and washers 2. C

A
7. Remove front screws and washers 3.
8. Remove the gaiter collar. E
9. Remove the pod top cover until you can access
the switch electrical connectors.
10. Put label on the electrical connectors for correct G
installation. M
11. Disconnect the switch connectors.

M H H
12. Disconnect the electrical connector 1, electrical
connector 2 and the electrical connector 3.
13. Remove the control lever from the pod.
14. Remove the screws 4.
15. Remove the control lever and the power base F
assembly.
D D J K L
A Arm rest
B Screws and washers 1
C Screws and washers 2
D Screws and washers 3
E Gaiter collar
F Power base
G Top cover
H Switch electrical connectors
J Electrical connector 1
K Electrical connector 2
L Electrical connector 3
M Screws 4
Install
removal procedure.
30 - 410 9813/7600-3 30 - 410

15 - Joystick
(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).
Figure 1762.
A B
H
D
E
F
G
A
L
M
N
K
N
A
N J
30 - 411 9813/7600-3 30 - 411

15 - Joystick
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 - 412 9813/7600-3 30 - 412

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
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 - 413 9813/7600-3 30 - 413

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 - 414 9813/7600-3 30 - 414

18 - Shuttle
18 - Shuttle 1.1. Clean the valve components in an

applicable solvent.
Remove and Install 1.2. Lubricate the parts with JCB hydraulic fluid
before assembling.
(For: 531-70 [5AA], 531-70 [5TA], 536-60
1.3. Apply JCB sealant to the inner seat and
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 tighten it to the specified torque value into
[5TE], 541-70 [5AD], 541-70 [5TD], Agri- the housing.
Xtra) Consumable: JCB Threadlocker and Sealer
Consumables (Medium Strength)
Description Part No. Size 1.4. Put the shuttle ball into the housing.
46 1.5. Apply JCB sealant to the outer seat and
4002/0805 20L tighten it to the housing.
4002/0803 200L
JCB Threadlocker 4101/0250 0.01L (Medium Strength)
Strength) Table 694. Torque Values
Item Description Nm
Remove
B Inner seat 20
30-00).
3. Use an Allen key to remove the outer seat from
the valve block.
4. Remove the shuttle ball and the inner seat.
Figure 1763.
A
B C
A Valve block
B Inner seat
C Outer seat
D Shuttle ball
Install
steps.
30 - 415 9813/7600-3 30 - 415

27 - Auxiliary Circuit
27 - Auxiliary Circuit
Refer to discharge and pressurise, (PIL 30-00).
30 - 416 9813/7600-3 30 - 416

82 - Sway
82 - Sway Operation (Hydraulic)

Operation (Hydraulic) .................................. 30-417
(For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-70 [5AE], 536-70
[5TE], 536-70LP [5A1], 536-70LP [5T1],
541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY])
The schematic diagrams show an overview of the
system. For machine specific schematics, refer to
The engine cooling fan hydraulic oil supply is also

used to operate the sway system when installed.
When the sway system is operated, the supply to the
engine cooling fan is diverted to the sway system.
The hydraulic fan does not operate while the sway
system is in use. The sway ram will stay in position
until the switch is operated.
Later machines have a pressure relief valve installed.

For details of the valve pressures, refer to the
Operation of the switch energises the sway/fan

selection solenoid and the sway direction control
solenoid in the sway/fan changeover valve. The
sway/fan selection solenoid diverts the fan hydraulic
supply to feed the sway system. The sway direction
control solenoid is a double acting solenoid which
controls the direction of the supply to the correct side
of the sway ram.
A proximity switch located on the lift arm operates

when the lift arm is at an angle of 10° or higher.
The proximity switch prevents the sway relay from
energising and operating the sway system solenoid
until the lift arm is lowered.
30 - 417 9813/7600-3 30 - 417

82 - Sway
Figure 1764. Sway Switch Not Operated Figure 1766. Left Sway Switch Operated
C
C
B
A A
T F P T F P D
D
Figure 1765. Right Sway Switch Operated
T F P
D
Table 695.
A Sway/Fan selection solenoid
B Sway direction control solenoid
C Sway ram
D Pressure relief valve
F Fan hydraulic supply
P Pump hydraulic supply
T Tank return
30 - 418 9813/7600-3 30 - 418

82 - Sway
(For: 531-70 [5AA], 531-70 [5TA], 535-95 A

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 B
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80 C
[5UY])
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 D
being started while you are beneath it.
Remove
Refer to (PIL 01-03). E E
4. Put labels on the hydraulic hoses to help A Bracket
installation. B Sway/fan selector solenoid
C Sway direction control solenoids
5. Disconnect the hydraulic hoses. D Sway/fan valve
E Bolts
contamination. Figure 1768. Typical Sway Valve Harness
stabiliser sway/fan selector solenoid.
F
sway direction control solenoids.
9. Make a note of the route of the harness.
10. Remove the harness retaining clips.
11. Support the sway/fan valve.
12. Release the bolts and remove the sway/fan valve
from the bracket. G
F Harness retaining clips

G Harness
30 - 419 9813/7600-3 30 - 419

82 - Sway
Install
steps.
1.1. Discard the old seals and install new seals
and O-rings. When you install adaptors, do
not overtighten as this distorts the body and
the valve may fail to operate correctly.
1.2. Reconnect the hoses in the correct
positions as labelled during removal.
1.3. Make sure to route the harness correctly
and replace the retaining clips.
1.4. Reconnect the electrical harness.
1.5. After installation, check that the valve
operates correctly and there are no
hydraulic leaks.
30 - 420 9813/7600-3 30 - 420

90 - Flow Regulator
90 - Flow Regulator
Introduction
30 - 421 9813/7600-3 30 - 421

61 - Counterbalance Valve
Contents Page No.
30-61-00 General ......................................................................................................................... 30-423

30-61-06 Lift Arm ......................................................................................................................... 30-431
30 - 422 9813/7600-3 30 - 422

00 - General
Introduction .................................................. 30-423
Operation ..................................................... 30-424
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 - 423 9813/7600-3 30 - 423

00 - General
Operation
For: 531-70 [5AA], 531-70 [5TA], 535-95 When there is a load on the carriage, the weight of
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 the load could cause the lift arm to lower or dump.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 This would be dangerous as the load may lower
[5AD], 541-70 [5TD], 550-80 [5AW], suddenly or fall off the carriage.
550-80 [5UW], 560-80 [5AY], 560-80 [5UY]
................................................. Page 30-424 To prevent this, counterbalance valves are installed
For: 526-56 [T4F] .................... Page 30-427 to make sure that, only the pressure of flow from the
control valve spool will move the lift arm or carriage
(For: 531-70 [5AA], 531-70 [5TA], 535-95 and the weight will not affect it. Therefore when the
lift/lower or crowd/dump services are not operated,
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 the valve is closed effectively locking the ram in
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70 position regardless of load.
[5AD], 541-70 [5TD], 550-80 [5AW],
550-80 [5UW], 560-80 [5AY], 560-80
[5UY])
The extend and tilt ram circuits have a
counterbalance valve.
Component Location
Figure 1769.
A Extend ram counterbalance valve B Tilt ram counterbalance valve
30 - 424 9813/7600-3 30 - 424

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 1770. Typical Valve Schematics
A B
A Extend counterbalance valve B Tilt counterbalance valve
30 - 425 9813/7600-3 30 - 425

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 1771. 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 1771.
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 1772. 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 1772.
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 1773. remains closed.
Pressure is supplied to extend the ram. The check
30 - 426 9813/7600-3 30 - 426

00 - General
Figure 1773.
D
A
B
+
C
Electrical Operation This would be dangerous as the load may lower

suddenly or fall off the carriage.
There are no electrical devices used in this system.
To prevent this, counterbalance valves are installed
to make sure that, only the pressure of flow from the
(For: 526-56 [T4F]) control valve spool will move the lift arm or carriage
and the weight will not affect it. Therefore when the
The extend and tilt ram circuits have a lift/lower or crowd/dump services are not operated,
counterbalance valve. the valve is closed effectively locking the ram in
position regardless of load.
When there is a load on the carriage, the weight of
the load could cause the lift arm to lower or dump.
30 - 427 9813/7600-3 30 - 427

00 - General
Component Location
Figure 1774.
A Extend ram counterbalance valve B Tilt ram counterbalance valve
30 - 428 9813/7600-3 30 - 428

00 - General
Hydraulic Operation and Schematics and the weight of this load is tries to compress the
ram. The counterbalance valve housing contains two
System schematic valves to prevent the compression of the ram due to
the pressure in the ram returning to tank. The check
The schematic diagrams below show a typical valve only allows flow when the piston end service
system. For information about machine specific is operated. The pressure valve will only open and
schematics, refer to hydraulic system- general, allow a return to tank when there is pressure in the
schematic circuit, refer to (PIL 30-00-50). + line feeding the piston side of the ram. If there is
no pressure in this line the pressure valve will remain
The figure shows no hydraulic service operated. closed and the ram is locked in position.
Refer to Figure 1775. There is a load on the carriage
Figure 1775.
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 1776. 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 1776.
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 1777. remains closed.
Pressure is supplied to extend the ram. The check
30 - 429 9813/7600-3 30 - 429

00 - General
Figure 1777.
D
A
B
+
C
Electrical Operation
There are no electrical devices used in this system.
30 - 430 9813/7600-3 30 - 430

06 - Lift Arm
06 - Lift Arm
Operation
operation of the lift arm service. A pressure

(For: 526-56 [T4F], 531-70 [5AA], 531-70 transducer is installed in the full bore (rod end) side
[5TA], 535-95 [5AB], 535-95 [5TB], 536-60 of the lift arm circuit.
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 If the pressure in the circuit is less than 10bar
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 (144.9psi) and the crowd and lift service operate at
[5AW], 550-80 [5UW], 560-80 [5AY], the same time, the hydraulic ECU (Electronic Control
560-80 [5UY]) Unit) deselects the crowd service. This allows the
pressure to increase in the lift ram circuit.
The counter balance valve is used to hold the lift
arm in position and for it not to lower under its own When the pressure in the circuit raises to more than
weight. Refer to hydraulic system- counterbalance 20bar (289.9psi) the hydraulic ECU responds by
valve, refer to (PIL 30-61). restoring normal operation of the crowd service.
When you operate the crowd and lift arm raise On machines with SRS (Smooth Ride System), the
hydraulic services, there are rare occasions when SRS pressure transducer is used. For information
the flow may divert through the displacement ram about the SRS system, refer to hydraulic system-
circuit and cause the lift arm to raise under the power general, refer to (PIL 30-00).
of the displacement ram.
On machines without the SRS, a pressure transducer
Pressure monitoring of the lift ram full bore (rod is installed.
end) maintains a minimum pressure ensuring correct
30 - 431 9813/7600-3 30 - 431

06 - Lift Arm
Component Location
Figure 1778.
A Pressure transducer B Lift ram
30 - 432 9813/7600-3 30 - 432

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 1779.
1 4 4 1
2 3 3 2
30 - 433 9813/7600-3 30 - 433

63 - Hose Burst Check Valve
Contents Page No.
30-63-00 General ......................................................................................................................... 30-435
30 - 434 9813/7600-3 30 - 434

00 - General
Introduction .................................................. 30-435 The HBCV (Hose Burst Check Valve) prevents the
Check (Operation) ....................................... 30-436 uncontrolled movement of the cylinder ram pistons.
The HBCV will lock if the hydraulic pressure is
unsatisfactory or if a hose bursts.
30 - 435 9813/7600-3 30 - 435

00 - General
Check (Operation) 5.1. The lift arm movement must slow as the
engine slows. The lift arm movement must
stop when the engine stops.
(For: 526-56 [T4F]) 5.2. If the lift arm moves after the engine stops,
DANGER Before lowering the attachments to the then the lift arm HBCV is faulty. Do not use
ground, make sure that the machine and the area the machine until you correct the fault.
around it are clear of other people. Anyone on or
close to the machine could fall and be crushed by Carriage tilt cylinder
the attachments, or get caught in the linkages.
1. Pick up a load on the forks.
WARNING Maintenance must be done only by
suitably qualified and competent persons. 2. Tilt the carriage fully back.
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.
To prevent anyone starting the engine, remove 4. Raise the lift arm and put it in a position that, the
the ignition key. Disconnect the battery (by means carriage can be tilted forward fully.
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.
Check each movement in turn. 5.1. The carriage movement must slow as the
engine slows. The carriage movement must
Lift arm lift cylinders stop when the engine stops.
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.
Sway cylinder (if installed)
3. Raise the lift arm to the specified angle.
Angle: 45°
4. Run the engine at mid speed and operate the transmission to neutral.
control lever to lower the lift arm. While the lift
arm is moving, switch off the engine. 3. Sway the machine body approximately halfway
to the left and release the sway control.
4.1. The lift arm movement must slow as the
engine slows. The lift arm movement must 4. Stop the engine.
stop when the engine stops.
5. Operate the sway control to the left. Check that
4.2. If the lift arm moves after the engine stops, the machine does not sway.
then both the lift arm HBCV (Hose Burst
Check Valve) are faulty. Do not use the 6. Do steps 1 to 5 again for right sway.
machine until you correct the fault.
7. If the body moves when the sway control is
Lift arm extension cylinder moved with the engine stopped, the hose burst
protection valves are faulty.
8. Do not use the machine until you correct the fault.
transmission to neutral.
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.
30 - 436 9813/7600-3 30 - 436

70 - Pilot Pressure Supply Valve
Contents Page No.
30-70-00 General ......................................................................................................................... 30-439
30 - 437 9813/7600-3 30 - 437

Notes:
30 - 438 9813/7600-3 30 - 438

00 - General
Operation ..................................................... 30-439 For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
Check (Pressure) ........................................ 30-443 [5TE], 541-70 [5AD], 541-70 [5TD], Agri-Xtra
Remove and Install ..................................... 30-445 ................................................. Page 30-439
For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], Agri, Agri-Plus, Agri-
Super ...................................... Page 30-440
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] ................ Page 30-441
(For: 531-70 [5AA], 531-70 [5TA], 536-60

[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Agri-
Xtra)
The servo pilot pressure supply valve is supplied
from the fan section of the hydraulic pump.
The pressure regulating valve maintains servo pilot

pressure by regulating the incoming supply pressure.
Oil at servo pilot pressure is supplied to the main
control valve inlet section.
The pressure regulating valve incorporates an

accumulator. The accumulator traps and stores
servo 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 even after the engine stops.
The supply of pilot oil can be isolated from the main

control valve by de-energising the solenoid. The
solenoid is controlled by a switch in the cab. When
the valve is de-energised , the trapped pilot oil in the
main control valve is diverted to the 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 servo pilot system when the solenoid is de-
energised.
30 - 439 9813/7600-3 30 - 439

00 - General
Figure 1780.
C
TP1 TP2
A ACC
P P1
T T1
P2
B
T2
A Servo pilot pressure supply valve B Solenoid

C Accumulator
servo pilot pressure to enable the service spools

(For: 531-70 [5AA], 531-70 [5TA], 535-95 to be operated for a limited period with a stopped
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60 engine. This allows for attachments to be lowered
safely to the ground when the engine stops.
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD], Agri, Agri-Plus, Agri- Supply of pilot oil can be isolated from the main
Super) control valve by the de-energising solenoid. The
solenoid is controlled by the switch in the cab. When
The servo pilot pressure supply valve is supplied the valve is de-energised, the trapped pilot oil in the
from the fan section of the hydraulic pump. main control valve is diverted to the tank. The service
spools are locked and services cannot be operated
The pressure regulating valve maintains servo pilot with or without the engine running.
pressure by regulating the incoming supply pressure.
Oil at the servo pilot pressure is supplied to the main The oil stored in the accumulator is isolated from
control valve inlet section. the servo pilot system when the solenoid is de-
energised.
The pressure regulating valve incorporates the
accumulator. The accumulator traps and stores the
30 - 440 9813/7600-3 30 - 440

00 - General
Figure 1781.
A
B
A Solenoid B Accumulator
C Servo pilot pressure supply valve
to be operated for a limited period with a stopped

(For: 550-80 [5AW], 550-80 [5UW], 560-80 engine. This allows for attachments to be lowered
[5AY], 560-80 [5UY]) safely to the ground when the engine stops.
Supply of pilot oil can be isolated from the main

The servo pilot pressure supply valve is supplied
control valve by de-energising the solenoid. The
from the fan section of the hydraulic pump.
solenoid is controlled by switch in the cab. When
The pressure regulating valve maintains the servo the valve is de-energised, the trapped pilot oil in the
pilot pressure by regulating the incoming supply main control valve is diverted to the tank. The service
pressure. The oil at servo pilot pressure is supplied spools are locked and services cannot be operated
to the main control valve inlet section. with or without the engine running.
The pressure regulating valve incorporates the The oil stored in the accumulator is isolated from
accumulator. The accumulator traps and stores the the servo pilot system when the solenoid is de-
servo pilot pressure to enable the service spools energised.
30 - 441 9813/7600-3 30 - 441

00 - General
Figure 1782.
A
B
A Solenoid B Pilot pressure supply valve

C Accumulator
30 - 442 9813/7600-3 30 - 442

00 - General
Check (Pressure)
1. Turn the ignition key switch to on, but do not start

(For: 531-70 [5AA], 531-70 [5TA], 535-95 the engine.
[5AB], 535-95 [5TB], 536-70 [5AE], 536-70 2. Discharge the hydraulic pressure from the
[5TE], 541-70 [5AD], 541-70 [5TD]) system. Refer to (PIL 30-00).
Hydraulic Pressure 3. Separate the hose from the filter and install tee-
Hydraulic fluid at system pressure can injure you. piece between the them.
removing hoses. Make sure the engine cannot be
Figure 1783.
A Hose B Filter
30 - 443 9813/7600-3 30 - 443

00 - General
C Tee-piece D Pressure gauge
4. Connect a pressure gauge of the specified value

to the tee-piece.
5. Start the engine and bring the hydraulic system
up to the specified working temperature.
6. Gradually increase the engine speed to 2200
RPM (Revolutions Per Minute). while you check
the maximum gauge reading, it should be as
stated on specification.
7. Make sure that the pressure does not fall below
the lower limit at engine idle speed.
Clean the valve

The servo pilot pressure reducing valve is not
adjustable. The valve cartridge is not serviceable
beyond cleaning. A cartridge should be renewed
complete if wear or damage is visible.
30 - 444 9813/7600-3 30 - 444

00 - General
Remove and Install
For: 531-70 [5AA], 531-70 [5TA], 536-60 Figure 1784.

[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Agri-Xtra
................................................. Page 30-445
For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
Super ...................................... Page 30-446
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] ................ Page 30-447
A
(For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70 B
[5TE], 541-70 [5AD], 541-70 [5TD], Agri-
Xtra) A
Remove
E
C
30-00).
4. Disconnect the electrical harness at the solenoid
6. Disconnect the hydraulic hoses. G
7. Plug all the open ports and hoses to prevent D F
contamination.
8. Support the valve. A Hoses
B Solenoid electrical connector
9. Remove the bolts, washers and remove the valve C Valve
and bracket from the machine. D Accumulator
E Bracket
F Bolts
G Washers
Install
1. If a new accumulator is to be installed, it may
require charging. Refer to (PIL 30-00).
steps.
2.1. Make sure that the hoses are reconnected
to the correct ports.
2.2. After installation, check the servo pressure.
30 - 445 9813/7600-3 30 - 445

00 - General
The extent of permissible servicing is the renewal Figure 1785.

of the solenoid coil and the accumulator. Further
dismantling of the valve is not recommended. If the
A B C
valve is suspected as being faulty it must be renewed
(For: 531-70 [5AA], 531-70 [5TA], 535-95

[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
Super)
A
Remove A

D
3. Discharge the hydraulic pressure. Refer to
(PIL30-00).
4. Disconnect the electrical harness from the
solenoid electrical connector. E

contamination.
8. Support the valve.
F
9. Remove the bolts and washers, remove the valve
from the bracket. A Hoses
B Solenoid coil
C Accumulator
D Valve
E Washers
F Bracket
Install
steps.
The extent of permissible servicing is the renewal

30 - 446 9813/7600-3 30 - 446

00 - General
(For: 550-80 [5AW], 550-80 [5UW], 560-80 4. Disconnect the electrical harness at the solenoid
[5AY], 560-80 [5UY]) electrical connector.
Remove
Refer to (PIL 01-03). 7. Plug all the open ports and hoses to prevent
contamination..
8. Support the valve.
30-00). 9. Remove the bolts, washers and remove the valve
from the machine.
Figure 1786.
A Bolts and washers B Solenoid coil

C Valve D Accumulator
30 - 447 9813/7600-3 30 - 447

00 - General
Install
steps.
The extent of permissible servicing is the renewal

30 - 448 9813/7600-3 30 - 448

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-451

30-93-03 Lift Arm ......................................................................................................................... 30-464
30 - 449 9813/7600-3 30 - 449

Notes:
30 - 450 9813/7600-3 30 - 450

93 - Hose
00 - General
Introduction .................................................. 30-451 Hydraulic hoses are used to connect different
Component Identification ............................. 30-452 components in the hydraulic circuit. The hoses
Disconnect and Connect ............................. 30-461 are graded by pressure, temperature, and fluid
Check (Condition) ........................................ 30-463 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 - 451 9813/7600-3 30 - 451

93 - Hose
00 - General
For: 536-60 [5AC], 536-60 [5TC]

................................................. Page 30-452
For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-70 [5AE],
536-70 [5TE], 541-70 [5AD], 541-70 [5TD]
................................................. Page 30-454
For: 531-70 [5AA], 531-70 [5TA], 536-70
[5AE], 536-70 [5TE], 541-70 [5AD], 541-70
[5TD] ....................................... Page 30-456
For: 536-60 [5AC], 536-60 [5TC]
................................................. Page 30-458
(For: 536-60 [5AC], 536-60 [5TC])
Figure 1787.
30 - 452 9813/7600-3 30 - 452

93 - Hose
00 - General
Figure 1788.
Item Description
Table 696. 70 Hose 3/8 BSP (British
Item Description Standard Pipe)1,210mm
10 Bolt M8 x 60 G8.8 80 Hose
20 Plain washer M8 90 Hose 3/8 BSP
30 Accumulator 9/16" 18 110 Tee adaptor M/F/M
UNF 120 Hose 5/8 BSP550mm
40 Adaptor 130 Hose 5/8 BSP2,590mm
3/8BSPX3/8BSPX3/8 140 Hose- 06 BSP HP
50 Trailer brake valve 950mm A
60 Trailer brake coupling
30 - 453 9813/7600-3 30 - 453

93 - Hose
00 - General
Item Description
150 Plain washer M16
170 Adaptor- bulkhead
180 Label- hydraulic trailer
brake speed
(For: 531-70 [5AA], 531-70 [5TA], 535-95 [5AB], 535-95 [5TB], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD])
Figure 1789. Neutral Circuit Layout
30 - 454 9813/7600-3 30 - 454

93 - Hose
00 - General
Figure 1790.
Item Description
90 Hose 3/8 BSP
Table 697.
110 Tee adaptor M/F/M
Item Description
120 Hose 5/8 BSP480mm
10 Bolt M8 x 60 Grade 8.8
130 Hose 5/8 BSP2,590mm
20 Plain washer M8
140 Hose 1/4 BSP1,110mm
30 Accumulator 9/16" 18
160 BSP adaptor 5/8 x 5/8 x
UNF
1/4
40 Adaptor 3/8 BSP X
170 Grommet
3/8BSP X 3/8
180 Label- hydraulic trailer
brake speed
60 Trailer brake coupling
70 Hose 3/8 BSP2,100mm
30 - 455 9813/7600-3 30 - 455

93 - Hose
00 - General
(For: 531-70 [5AA], 531-70 [5TA], 536-70 [5AE], 536-70 [5TE], 541-70 [5AD], 541-70
[5TD])
Figure 1791.
30 - 456 9813/7600-3 30 - 456

93 - Hose
00 - General
Figure 1792.
Item Description
Table 698. 200 Hose 1,645mm White
Item Description 210 Hose- 04 BSP HP
10 Plain washer M10 740mm
20 Spring washer M10 220 Hose 3/4 " BSP- 1"
SAE570mm
30 HMH tank return tem-
plate 230 Hose 1,350mm Green/
Yellow
40 Adaptor G1/2A x 3/4
SAE (Society of Auto- 240 Hose 1,550mm Red
motive Engineers) 250 Hose 3/8" 285LG
50 5/8 BSP cap 260 Hose 5/8 LP
60 CPV 270 Hose-06 BSP HP
70 Trailer brake 1,300mm A
90 BSP adaptor 5/8 x 5/8 x 280 Cap screw M10 x 65
1/4 G12.9
100 Hose 1,150mm Yellow 290 Low pressure hose
150mm
110 HOSE 5/8" BSP 1585
300 Clip worm drive 60/80
120 Hose 5/8 BSP980mm mm
130 Hose 3,560mm Orange 310 Tube suction HMH
150 Hose- 10 BSP HP 320 Plug 9/16 ring boss
680mm C
330 Port adaptor flange
170 Hose 1" BSP1,420mm
340 Pressure test point
350 O-ring
190 Hose 1/4 BSP1,155mm
30 - 457 9813/7600-3 30 - 457

93 - Hose
00 - General

360 Split flange 410 M8 locknut
370 Plain washer M8 420 Cable tie 300mm
380 Set screw M10 x 25 430 Plain washer M10
G8.8
390 Bolt M8 x 50 G8.8
400 WA fan pipes
(For: 536-60 [5AC], 536-60 [5TC])
Figure 1793.
30 - 458 9813/7600-3 30 - 458

93 - Hose
00 - General
Figure 1794.
Item Description
Table 699.
130 Hose 3,360mm Orange
Item Description 140 5/8 BSP cap
10 Plain washer M10 150 Hose- 10 BSP680mm C
20 Spring washer M10 160 Set screw M10 x 25
30 HMH P69 tank return G8.8
template 170 Hose
40 Adaptor G1/2A x 3/4 180 Hose 1/2 BSP950mm
SAE
190 Hose 1/4 BSP1,155mm
50 Fan pipes
200 Hose 1,645mm White
60 CPV
210 Hose- 04 BSP HP
70 SLTB right side pod 740mm C
80 Cable tie 300mm 220 Hose 3/4" BSP- 1"
90 BSP adaptor 5/8 x 5/8 x SAE570mm
1/4 230 Hose 1,150mm Green/
100 Hose 1,150mm Yellow Yellow
110 Hose 5/8" BSP 1585 240 Hose 1,150mm Red
30 - 459 9813/7600-3 30 - 459

93 - Hose
00 - General
Item Description
260 Hose 5/8 LP
270 Hose- 06 BSP HP
1,300mm A
280 Cap screw M10 x 65
G12.9
290 Low pressure hose
150mm
300 Clip wormdrive 60/80
mm
310 Tube section P69 HMH
320 Plug 9/16 O-ring boss
330 Port adaptor flange
340 Pressure test point
350 O-ring
360 Split flange
370 Plain washer M8
380 Bolt M8 x 50 G8.8
390 M8 locknut
400 Hose 760mm Pink
410 Hose- 06 BSP HP
420mm B
420 TB pipes
430 Hose- 08 BSP HP
780mm B
440 Hose 1,880mm Brown
450 Plain washer M10
460 Set screw M10 x 30
G8.8
470 Spacer 10.5 x 20 x 5
mm
30 - 460 9813/7600-3 30 - 460

93 - Hose
00 - General
Disconnect and Connect 3. Push the coupling into the port as far as possible.
For: JCB Tier 4F Engine 4 Cyl 3.1. The coupling will click when it is fully
................................................. Page 30-461 engaged.
Otherwise ................................ Page 30-461 4. Pull the hose to verify that the coupling is fully
engaged.
(For: JCB Tier 4F Engine 4 Cyl) 4.1. If the connection is not good the coupling
Special Tools will release very easily.
Quick Connect Hose 825/10053 1 (Otherwise)
Release Tool
Some attachments are hydraulically powered. The
WARNING Hydraulic fluid at system pressure following procedures show how to connect and
can injure you. Before connecting or removing disconnect the hydraulic hoses safely.
any hydraulic hose, residual hydraulic pressure
trapped in the service hose line must be vented. Connecting the Hydraulic Hoses
Make sure the hose service line has been vented
before connecting or removing hoses. Do not start 1. Make the machine safe.
the engine with loose or open hose connections. Refer to: PIL 01-03.
2. Discharge the hydraulic system pressure.
Disconnect
3. Check the hoses and adaptors for damage.
4. Connect the hoses:
2. Push the hose. Refer to Figure 1795.
4.1. Make sure that the hose is not twisted.
3. Insert the specified tool. Pressure applied to a twisted hose can
Special Tool: Quick Connect Hose Release Tool cause the hose to fail or the connections to
(Qty.: 1) loosen.
4. Push on the hose, and at the same time use the Figure 1796.
tool as a lever to release the coupling.
Figure 1795.
A
4.2. Make sure that the hose does not touch

hot parts. High ambient temperatures can
B cause the hose to fail.
A Hose 4.3. Make sure that the hose does not touch
B Quick connect hose release tool parts which can rub or cause abrasion.
4.4. Use the hose clamps (where possible) to
Connect support long hose runs and keep the hoses
1. Make sure that the hose coupling is clean and away from moving parts, etc.
the O-rings are not damaged.
1.1. Apply some clean hydraulic fluid to the O-
rings.
2. Align the coupling to the hydraulic port.
30 - 461 9813/7600-3 30 - 461

93 - Hose
00 - General
Figure 1797. 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.
Figure 1798.
5. Check for leaks:

5.1. Start the machine.
5.2. Operate the related controls to increase the
pressure in the hydraulic system.
5.3. Stop the machine then remove the key.
5.4. Check for indications of leakage at the hose
connections. Correct, as necessary.
Disconnecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Disconnect the hoses.
4. Check the hoses and adaptors for damage.
5. If necessary, install the blanking caps.
6. Check for leaks:
6.1. Start the machine.
6.2. Operate the related controls to increase the
pressure in the hydraulic system.
6.3. Stop the machine then remove the key.
30 - 462 9813/7600-3 30 - 462

93 - Hose
00 - General
Check (Condition)
Hydraulic Hoses
WARNING Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not
use the machine if a hose or hose fixture is
damaged.
WARNING Fine jets of fluid at high pressure can
penetrate the skin. Keep face and hands well
clear of fluid under pressure and wear personal
protective equipment. Hold a piece of cardboard
close to suspected leaks and then examine the
cardboard for signs of fluid. If fluid penetrates your
skin, get medical help immediately.
Examine the hoses for:
• Damaged hose ends

• Worn outer covers
• Ballooned outer covers
• Kinked or crushed hoses
• Exposed armouring in the outer covers
• Displaced hose end fittings.
• Worn cover sheathing or hose burst protection
covering
Replace a damaged hose before you use the

machine again.
The replacement hoses must be of the same size,

standard and pressure rating. If necessary, for more
information contact your JCB dealer.
30 - 463 9813/7600-3 30 - 463

93 - Hose
03 - Lift Arm
03 - Lift Arm
Technical Data
Refer to hydraulic system, hose, lift arm, component

identification (PIL 30-93-03).
30 - 464 9813/7600-3 30 - 464

96 - Pipe
96 - Pipe
Contents Page No.
30-96-03 Lift Arm ......................................................................................................................... 30-467
30 - 465 9813/7600-3 30 - 465

Notes:
30 - 466 9813/7600-3 30 - 466

96 - Pipe
03 - Lift Arm
03 - Lift Arm
Refer to component identification, (PIL 30-93-03).
30 - 467 9813/7600-3 30 - 467

97 - Connectors
97 - Connectors
Contents Page No.
30-97-03 Quick Release Coupling .............................................................................................. 30-469

30-97-09 Adaptor ......................................................................................................................... 30-471
30-97-24 Push Lock Fitting ......................................................................................................... 30-473
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-474
30 - 468 9813/7600-3 30 - 468

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-469 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-470 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 1799.
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 - 469 9813/7600-3 30 - 469

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 1800.
C D E
C Ball
D Slot
E Sleeve
30 - 470 9813/7600-3 30 - 470

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-471 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-472 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 1801.
A O-ring seal
B Locknut
C Washer
30 - 471 9813/7600-3 30 - 471

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 1802.
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 - 472 9813/7600-3 30 - 472

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 1804.
D A
C B
A Tube
B Collet
C O-ring
D Steel support tube
30 - 473 9813/7600-3 30 - 473

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 1805.
A B C
E D
A Snap ring
B O-ring and back-up ring
C Tube
D Fitting body
E Hose
30 - 474 9813/7600-3 30 - 474

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 ................................................................................................................. 33-1130
33-03 Battery
33-03-00 General ....................................................................................................................... 33-1135
33-03-03 Isolator Switch ............................................................................................................ 33-1146
33-06 Battery Cable
33-06-00 General ....................................................................................................................... 33-1149
33-06-12 Earth Strap ................................................................................................................. 33-1151
33-09 Power Distribution
33-09-00 General ....................................................................................................................... 33-1155
33-09-03 Fuse ........................................................................................................................... 33-1157
33-09-06 Relay .......................................................................................................................... 33-1171
33-12 Harness
33-12-00 General ....................................................................................................................... 33-1179
33-12-04 Chassis ....................................................................................................................... 33-1192
33-12-06 Lift Arm ....................................................................................................................... 33-1262
33-12-09 Engine ........................................................................................................................ 33-1327
33-12-12 Operator Station ......................................................................................................... 33-1350
33-12-14 Sway ........................................................................................................................... 33-1402
33-12-15 Front Console ............................................................................................................. 33-1413
33-12-22 Armrest ....................................................................................................................... 33-1460
33-12-30 Gearbox ...................................................................................................................... 33-1472
33-12-34 Trailer ......................................................................................................................... 33-1496
33-12-36 Work Lights ................................................................................................................ 33-1499
33-12-39 Road Lights ................................................................................................................ 33-1523
33-12-44 Battery ........................................................................................................................ 33-1549
33-12-45 Power Distribution ...................................................................................................... 33-1583
33-12-46 Immobiliser ................................................................................................................. 33-1593
33-12-93 Selective Catalytic Reduction (SCR) ......................................................................... 33-1599
33-15 Alarm
33-15-03 Reverse Warning ........................................................................................................ 33-1619
33-21 Immobiliser
33-21-00 General ....................................................................................................................... 33-1621
33-24 Instruments
33-24-03 Instrument Panel ........................................................................................................ 33-1627
33-24-10 Hourmeter .................................................................................................................. 33-1631
33-27 Interior Switch
33-27-03 Multi-Purpose ............................................................................................................. 33-1633
33-27-51 Hydraulic Flow ............................................................................................................ 33-1635
33-33 Console Switch
9813/7600-3
2018-02-14
33-33-04 Direction Indicators .................................................................................................... 33-1643
33-33-15 Transmission Disconnect ........................................................................................... 33-1654
33-40 Bulb
33-40-00 General ....................................................................................................................... 33-1657
33-45 Control Module
33-45-00 General ....................................................................................................................... 33-1661
33-45-01 Instrument Panel ........................................................................................................ 33-1664
33-45-06 Engine ........................................................................................................................ 33-1689
33-45-09 Gearbox ...................................................................................................................... 33-1692
33-45-24 Servo .......................................................................................................................... 33-1707
33-45-36 Hydraulic .................................................................................................................... 33-1714
33-45-42 Selective Catalytic Reduction (SCR) ......................................................................... 33-1727
33-45-44 Nitrogen Oxide (NOx) Sensor .................................................................................... 33-1730
33-48 Entertainment
33-48-03 Radio .......................................................................................................................... 33-1733
33-51 Beacon
33-51-00 General ....................................................................................................................... 33-1737
33-51-03 Socket ........................................................................................................................ 33-1738
33-54 Window Washer/Wipe
33-54-00 General ....................................................................................................................... 33-1741
33-57 Electronic Diagnostic
33-57-00 General ....................................................................................................................... 33-1743
33-57-03 Servicemaster ............................................................................................................ 33-1747
33-57-90 Fault Codes ................................................................................................................ 33-1814
33-66 Load Motion Control System
33-66-00 General ....................................................................................................................... 33-1895
33-84 Sensor
33-84-09 Speed Sensor ............................................................................................................ 33-1911
33-84-15 Transmission Oil Temperature ................................................................................... 33-1912
33-84-41 Lift Arm ....................................................................................................................... 33-1913
33-84-51 Rear Axle ................................................................................................................... 33-1918
33-84-72 Chassis ....................................................................................................................... 33-1924
33-86 Solenoid
33-86-00 General ....................................................................................................................... 33-1935
9813/7600-3
2018-02-14
Acronyms Glossary
2WD Two Wheel Drive

2WS Two Wheel Steer
4WS Four Wheel Steer
AWS All Wheel Steer
DLA Data Link Adaptor
DTC Diagnostic Trouble Code
Transmission
LCD Liquid Crystal Display
LED Light Emitting Diode
MAF Mass Air Flow
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
NOx Nitrogen Oxide
OEM Original Equipment Manufacturer
RAS Rear Axle Stabilization
TMAF Temperature and Mass Air Flow
USB Universal Serial Bus
VIN Vehicle Identification Number
9813/7600-3
2018-02-14
Notes:
9813/7600-3
2018-02-14
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ................................................................................................................. 33-1130
33 - 1 9813/7600-3 33 - 1
Notes:
33 - 2 9813/7600-3 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.
Fault-Finding .................................................... 33-5
Check (Condition) ............................................ 33-7 Make sure that all the health and safety warnings
in this section are followed. The machine must be
safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.
33 - 3 9813/7600-3 33 - 3
00 - General
Health and Safety

Arc Welding
To prevent the possibility of damage to electronic
components, disconnect the battery and the
alternator before arc-welding on the machine or
attached implements.
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
units (ECUs), monitor displays, etc., then disconnect
them before welding. Failure to disconnect the
sensitive electrical equipment could result in
irreparable damage to these components.
Parts of the machine are made from cast iron, welds
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to
the same component that is being welded to avoid
damage to pivot pins, bearings and bushes. Attach
the welder earth (ground) cable a distance from the
part being welded no more than 0.6m.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION! Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
33 - 4 9813/7600-3 33 - 4
00 - General
Fault-Finding
Fault
Battery Fault Table 700. Page 33-5
General Relay Fault Table 701. Page 33-5
Electrical Network - CAN (Controller Area Network) Bus system Table 702. Page 33-6
ECM Faults Table 703. Page 33-6
Table 700. 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.
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 701. 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,
necessary.
If no fault is found, proceed to ECM connection fault.
33 - 5 9813/7600-3 33 - 5
00 - General
Cause Remedy
ECM Connection Fault Disconnect the harness from engine ECM and
necessary.
Check the continuity and electrical insulation, repair
or replace as necessary.
If a relay fault is found, raise Techweb Helpdesk Call.
Table 702. 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 703. 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.
33 - 6 9813/7600-3 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 9813/7600-3 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 9813/7600-3 33 - 8
Figure 1806.
/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 9813/7600-3 33 - 9
Figure 1807. 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 9813/7600-3 33 - 10
Diagram
For: 531-70 [5AA], 531-70 [5TA], 536-60

[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80
[5AW], 550-80 [5UW], 560-80 [5AY],
560-80 [5UY], HM560 Variable Transmission
................................................... Page 33-11
For: 535-95 [5AB], 535-95 [5TB]
................................................. Page 33-168
For: 526-56 [T4F], 535-95 [5AB], 535-95
[5TB], JCB Tier 4i /T4F <55kW Engine 4 Cyl
................................................. Page 33-297
For: 536-60 [5AC], 536-60 [5TC]
................................................. Page 33-446
For: 531-70 [5AA], 531-70 [5TA], 535-95
[5AB], 535-95 [5TB], 536-60 [5AC], 536-60
[5TC], 536-70 [5AE], 536-70 [5TE], 541-70
[5AD], 541-70 [5TD] ................ Page 33-692
For: 550-80 [5AW], 550-80 [5UW], 560-80
[5AY], 560-80 [5UY] ................ Page 33-772
For: 531-70 [5AA], 531-70 [5TA], 536-60
[5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], Agri-Pro
................................................. Page 33-994
(For: 531-70 [5AA], 531-70 [5TA], 536-60 [5AC], 536-60 [5TC], 536-70 [5AE], 536-70
[5TE], 541-70 [5AD], 541-70 [5TD], 550-80 [5AW], 550-80 [5UW], 560-80 [5AY], 560-80
[5UY], HM560 Variable Transmission)
Figure 1808. Battery and Primary Fuses (160/F8690-1)........................................................Page 33-13
Figure 1809. Ignition and Secondary Fuses (160/F8690-1)...................................................Page 33-17
Figure 1810. Engine Fuse and Starter Motor (160/F8690-1)................................................. Page 33-21
Figure 1811. Engine- ECU and Sensors (160/F8690-1)........................................................ Page 33-25
Figure 1812. Engine- After Treatment (160/F8690-1)............................................................ Page 33-29
Figure 1813. Transmission- PS750-07/11 (160/F8690-1)...................................................... Page 33-33
Figure 1814. Transmission- PS766-IFM (160/F8690-1)......................................................... Page 33-37
Figure 1815. Transmission- Dual Tech Variable Transmission (160/F8690-1)....................... Page 33-41
Figure 1816. Live Link and Immobiliser (160/F8690-1)..........................................................Page 33-45
Figure 1817. Instruments (160/F8690-1)................................................................................ Page 33-49
Figure 1818. Roadlights (160/F8690-1)..................................................................................Page 33-53
Figure 1819. Directional Indicators (160/F8690-1)................................................................. Page 33-57
Figure 1820. Wiper Motors (160/F8690-1)............................................................................. Page 33-61
Figure 1821. Worklights and Beacon (160/F8690-1)..............................................................Page 33-65
Figure 1822. In Cab Entertainment (160/F8690-1)................................................................ Page 33-69
Figure 1823. Reverse Fan (160/F8690-1).............................................................................. Page 33-73
Figure 1824. Can Bus (160/F8690-1).....................................................................................Page 33-77
Figure 1825. Can Bus Engine (160/F8690-1)........................................................................ Page 33-81
Figure 1826. HVAC (160/F8690-1)......................................................................................... Page 33-85
Figure 1827. Switch Illumination Splice (160/F8690-1).......................................................... Page 33-89
Figure 1828. Ground Panel Splices (160/F8690-1)................................................................Page 33-93
Figure 1829. Ground Chassis Splices (160/F8690-1)............................................................ Page 33-97
Figure 1830. 07/11 Controller (160/F8690-1)....................................................................... Page 33-101
Figure 1831. IFM Transmission Controller (160/F8690-1)....................................................Page 33-105
33 - 11 9813/7600-3 33 - 11
Figure 1832. Hydraulics ECU (160/F8690-1)....................................................................... Page 33-109

Figure 1833. Bosch Transmission ECU- Dual Tech Variable Transmission (160/
F8690-1)................................................................................................................................ Page 33-113
Figure 1834. Pin Lock (160/F8690-1)...................................................................................Page 33-117
Figure 1835. Hitch Harness (160/F8690-1).......................................................................... Page 33-121
Figure 1836. Steer Mode (160/F8690-1).............................................................................. Page 33-125
Figure 1837. Park Brake and Auto Manual (160/F8690-1).................................................. Page 33-129
Figure 1838. SRS (160/F8690-1)......................................................................................... Page 33-133
Figure 1839. LLMI (160/F8690-1).........................................................................................Page 33-137
Figure 1840. Footbrake Dump (160/F8690-1)......................................................................Page 33-141
Figure 1841. Valve Block (160/F8690-1).............................................................................. Page 33-145
Figure 1842. Joystick (160/F8690-1)....................................................................................Page 33-149
Figure 1843. Joystick- Dual Tech Variable Transmission (160/F8690-1)..............................Page 33-153
Figure 1844. Pump Control (160/F8690-1)...........................................................................Page 33-157
Figure 1845. Hydraulic Isolation (160/F8690-1)................................................................... Page 33-161
Figure 1846. Unloader Circuit (160/F8690-1).......................................................................Page 33-165
33 - 12 9813/7600-3 33 - 12
Page 33-14 Figure 1808. Battery and

Primary Fuses (160/F8690-1) Page 33-15
95.00 mm² RED BATT +VE

TO
/4.F5 C033
C/D A/B
PRIMARY FUSE
-P046 50A 50A -P045
BATT +VE 4.00 mm² 200D B/2 B/2 4.00 mm² 200A BATT +VE
P002:11 /3.C4 TO TO
/3.F1 P043:1
5 3
50A 50A
BATT +VE 4.00 mm² 200C A/2 A/2 4.00 mm² 202B BATT +VE
SP26 /3.C1 TO TO
/3.D1 SP35
4 2
1
FUSE LINK BOX BLUE FUSE LINK BOX GREY
-B001
M6
16.00 mm² RED
ISOLATOR -C001
-C002 -C002 BATTERY
95.00 mm² BLACK
M10 1 2 M10 95.00 mm² BLACK -VE +VE -B001 95.00 mm² RED
-B003
LUG LUG
M8
M8 25.00 mm² RED -S1
M8
M8 -CS1
16.00 mm² RED

20.00 mm² RED
M10
M10
M8
-C001
-C002
-C002
-B002
M10
G/H E/F
M6
CHASSIS GROUND -P047 50A 50A -P048
10.00 mm² BLACK PURGE -VE BATT +VE 2 4 BATT +VE
1
C001 P003:11 /3.B4 4.00 mm² 200F A/2 A/2 4.00 mm² 200G
TO
/6.F3 TO TO
/3.A1 SP30
50A 50A
BATT +VE 4.00 mm² 200E B/2 3 5 B/2 4.00 mm² 319 BATT +VE
SP15 /3.B1 TO TO
/4.B1 P093:1
10.00 mm² BLACK PURGE -VE C003 FUSE LINK BOX GREY 2 FUSE LINK BOX BLUE 2
TO
/6.F3
PRIMARY FUSE

TO
/4.D4 CS1:1
160- F8690_SHEET 2
33 - 13 9813/7600-3 33 - 13
Page Page
33-14 33-15
95.00 mm² RED
ISOLATOR -C001
-C002 -C002 BATTERY
95.00 mm² BLACK
M10 1 2 M10 95.00 mm² BLACK -VE +VE -B001 95.00 mm² RED
Page 33-15
-B003
LUG LUG
M8
M8
M8
M8 -CS1 20.00 mm² RED
M10
M10
M8
-C001
-C002
-C002
M10
CHASSIS GROUND
10.00 mm² BLACK PURGE -VE C001
TO
/6.F3
10.00 mm² BLACK PURGE -VE C003

TO
/6.F3
20.00 mm² RED
33 - 14 9813/7600-3 33 - 14
Page Page
33-14 33-15

TO
/4.F5 C033
C/D A/B
PRIMARY FUSE
-P046 50A 50A -P045
BATT +VE 4.00 mm² 200D B/2 B/2 4.00 mm² 200A BATT +VE
P002:11 /3.C4 TO TO
/3.F1 P043:1
5 3
50A 50A
BATT +VE 4.00 mm² 200C A/2 A/2 4.00 mm² 202B BATT +VE
SP26 /3.C1 TO TO
/3.D1 SP35
4 2
1
FUSE LINK BOX BLUE FUSE LINK BOX GREY

-B001
M6
16.00 mm² RED
Page 33-14
25.00 mm² RED -S1

16.00 mm² RED
-B002
G/H E/F
M6
-P047 50A 50A -P048

BATT +VE 2 4 BATT +VE
1
P003:11 /3.B4 4.00 mm² 200F A/2 A/2 4.00 mm² 200G
TO TO
/3.A1 SP30
50A 50A
BATT +VE 4.00 mm² 200E B/2 3 5 B/2 4.00 mm² 319 BATT +VE
SP15 /3.B1 TO TO
/4.B1 P093:1
FUSE LINK BOX GREY 2 FUSE LINK BOX BLUE 2

PRIMARY FUSE

TO
/4.D4 CS1:1
160- F8690_SHEET 2
33 - 15 9813/7600-3 33 - 15
33 - 16 9813/7600-3 33 - 16
Page 33-18 Figure 1809. Ignition and

Secondary Fuses (160/F8690-1) Page 33-19
-P043 -P044
IGNITION SWITCH -P001 -P004
III START
HEAT
FUSE BOX A FUSE BOX D

PRE
0 OFF
I ON
II
BATT+VE 4.00 mm² 200A 1 5 4.00 mm² 001A 4.00 mm² 001A 1 5A 2 1.00 mm² 100 4.00 mm² 201G 1 20A 2 2.00 mm² 203 BATT+VE
P045:B /2.D6 FROM TO
/26.D1 C045 / P039:C8
2 6 4.00 mm² 014 1 31
3 4.00 mm² 005A 4.00 mm² 005A 3 30A 4 4.00 mm² 004 STARTER 3 3A 4 1.50 mm² 300TR BATT+VE
TO
/4.E2 P010:1 TO
/24.D5 SP38
4 2 32
8 4.00 mm² 015B 5 5A 6 2.00 mm² 150 IGNITION +VE 1.50 mm² 114 IGNITION +VE 5 10A 6 1.50 mm² 300NX BATT+VE
TO
/16.E4 P054:1 TO
/29.C2 P017:2 TO
/6.B1 P101:1
9 3 33
7 7 10A 8 1.50 mm² 114J IGNITION +VE 7 3A 8 1.00 mm² 300 BATT+VE
TO
/29.E1 P067:3 TO
/13.C3 P020
4 34
9 5A 10 1.00 mm² 1100A IGNITION +VE 9 15A 10 1.00 mm² 301E BATT+VE
TO
/6.B1 P101:3 TO
/11.C3 SP40 / P071
5 35
11 3A 12 1.00 mm² 107B IGNITION +VE 1.00 mm² 1100 IGNITION +VE 4.00 mm² 011G 11 3A 12 1.00 mm² 100TR IGNITION +VE
TO
/5.B1 C032:5 / P039:E7 TO
/6.B1 C010E:22 / P199:9 TO
/24.E5 P070:1
1.00 mm² 100 6 36
4.00 mm² 010B 13 30A 14 2.00 mm² 102 IGNITION +VE 13 5A 14 1.00 mm² 110LL IGNITION +VE
TO
/16.C1 P033:3 TO
/10.C1 P013:1
7 37
-P006 15 10A 16 1.00 mm² 108 IGNITION +VE 15 3A 16 1.00 mm² 101A IGNITION +VE
TO
/12.F5 P011:1 TO
/33.E2 P042-A
IGNITION RELAY1 8 38
4 17 3A 18 1.00 mm² 107PB IGNITION +VE 17 3A 18 1.00 mm² 106 IGNITION +VE
TO
/31.C1 RC012:3 / P049:10 TO
/11.E3 P071:2
4.00 mm² 200B 1 2 4.00 mm² 015B 9 39
19 3A 20 1.00 mm² 104 IGNITION +VE 1.00 mm² 107SP IGNITION +VE 19 5A 20 1.00 mm² Y IGNITION +VE
TO
/13.B1 P038:14 TO
/17.C3 RC012:1 / P049:14 TO
/10.D4 P101:6
0.75 mm² 100J 3 5 0.75 mm² 601HB GROUND 10 40
TO
/22.F4 SP3
-SP20 1.50 mm² 155 IGNITION +VE
TO
/26.B2 SC12 / P039:F9
-P006
IGNITION RELAY2
9 -P002 -P005
BATT+VE 4.00 mm² 202B 4.00 mm² 203B 6 7 4.00 mm² 010B FUSE BOX B FUSE BOX E
P045:A /2.D6 FROM
-SP35
0.75 mm² 100B 8 10 0.75 mm² 601EK GROUND 4.00 mm² 013C 1 25A 2 2.00 mm² 116 IGNITION +VE DIPPED BEAM 2.00 mm² 833 1 15A 2 1.50 mm² 834 DIPPED BEAM
TO
/22.F4 SP3 TO
/16.D4 P015:6 P038:9 /12.B3 FROM TO
/12.B4 SFC3
11 41
3 20A 4 2.00 mm² 133 IGNITION +VE MAIN BEAM 2.00 mm² 836 3 20A 4 2.00 mm² 838 MAIN BEAM
TO
/14.D3 SP16 P038:13 /12.B3 FROM TO
/12.B4 SP19
-P007 12 42
IGNITION RELAY3 5 15A 6 1.50 mm² 110 IGNITION +VE SWITCH ILLUMINATION 2.00 mm² 942D 5 7.5A 6 1.50 mm² 829E SWITCH ILLUMINATION
TO
/14.A2 SP33 SP22 /12.C3 FROM TO
/21.C4 SP7
4 13 43
4.00 mm² 201C 1 2 4.00 mm² 013C 4.00 mm² 012CA 7 20A 8 2.00 mm² 997 IGNITION +VE SWITCH ILLUMINATION 2.00 mm² 942E 7 5A 8 0.75 mm² 830 SWITCH ILLUMINATION
TO
/16.C2 P015:1 SP22 /12.C3 FROM TO
/12.C4 P039:E2
14 44
0.75 mm² 100H 3 5 0.75 mm² 601HL GROUND 9 15A 10 1.50 mm² 119 IGNITION +VE FOG 1.00 mm² 832B 9 3A 10 1.00 mm² 905 FOG
TO
/22.F4 SP3 TO
/17.B3 P056:1 SP21 /12.C3 FROM TO
/12.F2 P023:2
15 45
BATT+VE 4.00 mm² 200D 11 5A 12 2.00 mm² 3100A BATT+VE 1.00 mm² 601LL 11 5A 12 1.00 mm² 601L LIVELINK GND
P046:B /2.D4 FROM TO
/6.D1 C199:1 TO
/10.C4 P068:9
ADDITIONALFUSES 16 46 2.00 mm² 151 IGNITION +VE
TO
/16.F3 RC002:1 / P049:7
13 25A 14 2.00 mm² 308 BATT+VE 4.00 mm² 014 13 20A 14
TO
/15.D3 P012:1
-P132

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Foreword

The Operator's Manual

You and others can be killed or seriously injured

SERVICE MANUAL Do not operate the machine without an Operator's

Treat the Operator's Manual as part of the machine.

LOADALL (ROUGH TERRAIN

Copyright 2018 © JCB SERVICE

SERVICE MANUAL SERVICE MANUAL

526-56, 531-70, 535-95, 526-56, 531-70, 535-95,

SERVICE MANUAL SERVICE MANUAL

526-56, 531-70, 535-95, 526-56, 531-70, 535-95,

Acronyms Glossary .................................................................................................................................... 01-2

FOPS Falling Object Protective Structure

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual there are safety notices. Each notice

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system symbol (shown) also helps

Figure 1. The safety alert system symbol

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety Worksites

Electrical Power Cables Hands and Feet

21 - Worksite Safety An applicable worksite organisation is required in

24 - Risk Assessment Loading/Unloading Area

27 - Maintenance Positions Introduction

Lift Arm Lowered

A Lift arm lowered

Lift Arm Raised

Health and Safety

06 - About this Manual

Contents Page No.

01-06-03 Model and Serial Number .............................................................................................. 01-15

03 - Model and Serial Number

06 - Using the Manual

Machine Variants • Use the applicable Servicemaster diagnostics

Contents Page No.

01-09-00 General ........................................................................................................................... 01-19

A main structural support is designed to carry an

When used normally the machine lifts and places

The machine is intended to be used in normal

03 - Log Moving/Object Handling

Do not use the machine to move or handle logs

06 - Optional Equipment and

A wide range of optional attachments are available

12 - Main Component Locations

A Lift arm B Carriage

15 - Service Point Locations

A Air filter B Transmission oil dipstick

Hydraulic Oil Level Indicator

A Hydraulic oil level indicator

A Label - hydraulic oil filling point B Hydraulic oil level indicator

Machines without External Sight Gauge

A Hydraulic oil level indicator