Service Manual: Foreword

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

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

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

Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
BACKHOE LOADER
2DX Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
EN - 9813/8500 - ISSUE 2 - 09/2017 27 - Driveline
30 - Hydraulic System
33 - Electrical System
This manual contains original instructions, verified by

72 - Fasteners and Fixings
the manufacturer (or their authorized representative). 75 - Consumable Products
78 - After Sales
Copyright 2017 © JCB SERVICE

All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Notes:
9813/8500-2
Spine Cards
SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2
2DX 2DX
EN 9813/8500 EN 9813/8500
SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4
2DX 2DX
EN 9813/8500 EN 9813/8500
9813/8500-2
Notes:
9813/8500-2
01 - Machine
Contents Page No.
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 .............................................................................................. 01-17
01-09 Description
01-09-12 Main Component Locations ........................................................................................... 01-19
01-09-15 Service Point Locations ................................................................................................. 01-20
01-33 Cleaning
01-33-00 General ........................................................................................................................... 01-23
9813/8500-2
2017-02-07
Notes:
9813/8500-2
2017-02-07
01 - Machine
03 - Safety
03 - Safety
Contents Page No.
01-03-03 Safety - Yours and Others ............................................................................................... 01-3

01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 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 9813/8500-2 01 - 1
Notes:
01 - 2 9813/8500-2 01 - 2
01 - Machine
03 - Safety
03 - Safety - Yours and Others
03 - Safety - Yours and Others
Introduction
All machinery can be hazardous. When a machine

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

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

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

the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
01 - 3 9813/8500-2 01 - 3
01 - Machine
03 - Safety
06 - Safety Warnings
06 - Safety Warnings
Introduction
In this manual and on the machine, there are safety

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

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

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

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

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

important safety messages in this manual and on the
machine. When you see this symbol, be alert, your
safety is involved, carefully read the message that
follows, and inform other operators.
Figure 1. The safety alert system
01 - 4 9813/8500-2 01 - 4
01 - Machine
03 - Safety
09 - General Safety
09 - General Safety Lifting Equipment

You can be injured if you use incorrect or faulty lifting
Introduction equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
Training equipment is in good condition and complies with all
To operate the machine safely you must know the local regulations.
machine and have the skill to use it. You must abide Raised Equipment
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The Never walk or work under raised equipment unless
operator's manual instructs you on the machine, its it is supported by a mechanical device. Equipment
controls and its safe operation; it is not a training which is supported only by a hydraulic device can
manual. If you are a new operator, get yourself drop and injure you if the hydraulic system fails
trained in the skills of using a machine before trying or if the control is operated (even with the engine
to work with it. If you don't, you will not do your job stopped).
well, and you will be a danger to yourself and others. Make sure that no-one goes near the machine while
In some markets and for work on certain jobsites you you install or remove the mechanical device.
may be required to have been trained and assessed
in accordance with an operator competence scheme. Raised Machine
Make sure that you and your machine comply with Never position yourself or any part of your body
relevant local laws and jobsite requirements - it is under a raised machine which is not correctly
your responsibility. supported. If the machine moves unexpectedly you
Care and Alertness could become trapped and suffer serious injury or be
killed.
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always Lightning
be alert for hazards. Lightning can kill you. Do not use the machine if there
Clothing is lightning in your area.
You can be injured if you do not wear the correct Machine Modifications
clothing. Loose clothing can get caught in the This machine is manufactured in compliance with
machinery. Keep cuffs fastened. Do not wear a prevailing legislative requirements. It must not be
necktie or scarf. Keep long hair restrained. Remove altered in any way which could affect or invalidate its
rings, watches and personal jewellery. compliance. For advice consult your JCB dealer.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
01 - 5 9813/8500-2 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 9813/8500-2 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 9813/8500-2 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 9813/8500-2 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 and mirrors clean. machine.
Do not operate the machine if you cannot see clearly. If the machine is struck by lightning do not use the
Modification of the machine's configuration by the machine until it has been checked for damage and
user (e.g. the fitting of large and non-approved malfunction by trained personnel.
attachments) may result in a restriction of the
machine visibility.
01 - 9 9813/8500-2 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 9813/8500-2 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 9813/8500-2 01 - 11
01 - Machine
03 - Safety
27 - Maintenance Positions
27 - Maintenance Positions Introduction

Introduction .................................................... 01-12 Make the machine safe before you start a
Health and Safety .......................................... 01-14 maintenance procedure. You can complete most
of the maintenance procedures with the lift arm
lowered. Unless a maintenance procedure instructs
you differently, you must lower the lift arm.
Lift Arm Lowered
Figure 2.
1. Park the machine on level, solid ground. 6. If necessary, put chocks against the two sides of
the wheels before you get below the machine.
2. Lower the lift arm.
3. Put the attachment flat on the ground. Lift Arm Raised
4. Stop the engine and remove the ignition key. If you raise the lift arm to get access for maintenance,
you must install the maintenance strut on the lift arm.
5. Disconnect the battery to prevent accidental
operation of the engine.
Figure 3.
Installing the Lift Arm Safety Strut 3. Release the strut.
Install the lift arm safety strut before you work 3.1. Release the fastener.
underneath the raised lift arms. 3.2. Remove the strut from the stowage bracket.
1. Empty the shovel and raise the lift arms fully. 4. Install the strut.
2. Stop the engine and remove the ignition key. 4.1. Push the strut over the ram piston rod.
01 - 12 9813/8500-2 01 - 12
01 - Machine
03 - Safety
4.2. Secure the strut in position with strap. 2. Stop the engine and remove the ignition key.
5. Lower the lift arm onto the strut. 3. Remove the strut.
5.1. Start the engine and slowly lower the 3.1. Loosen the strap.
lift arms onto the safety strut, stop the
3.2. Remove the strut from the ram piston rod.
movement immediately when the weight of
the lift arms are supported by the safety 4. Stow the strut.
strut.
4.1. Secure the strut in the stowage position with
Removing the Lift Arm Safety Strut the fastener. Refer to Figure 4.
1. Fully raise the lift arms to take the weight off the
safety strut.
Figure 4.
A Fastener- unlock position B Fastener- lock position

C Strap D Safety strut
01 - 13 9813/8500-2 01 - 13
01 - Machine
03 - Safety
Health and Safety

WARNING Maintenance must be done only by
suitably qualified and competent persons.
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
the ignition key. Disconnect the battery when you
are not using electrical power. If you do not take
these precautions you could be killed or injured.
WARNING Make the machine safe before getting
beneath it. Make sure that any attachments on
the machine are correctly attached. Engage the
park brake, remove the ignition key, disconnect
the battery.
01 - 14 9813/8500-2 01 - 14
01 - Machine
06 - About this Manual
Contents Page No.
01-06-03 Model and Serial Number .............................................................................................. 01-17
01 - 15 9813/8500-2 01 - 15
Notes:
01 - 16 9813/8500-2 01 - 16
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:
2DX 1915700 1917405
2299800 2304689
01 - 17 9813/8500-2 01 - 17
01 - Machine
09 - Description
09 - Description
Contents Page No.
01-09-12 Main Component Locations ........................................................................................... 01-19

01-09-15 Service Point Locations ................................................................................................. 01-20
01 - 18 9813/8500-2 01 - 18
01 - Machine
09 - Description
12 - Main Component Locations
12 - Main Component Locations
Component Identification
Figure 5.
J
B
E
D
G
A
F
H
A Loader arm B Canopy

C Hydraulic oil tank D Battery Compartment
E Boom F Fuel tank
G Stabilisers H Kingpost
J Dipper
Your machine might have a cab instead of canopy

which is optional.
01 - 19 9813/8500-2 01 - 19
01 - Machine
09 - Description
15 - Service Point Locations
Introduction
Engine Compartment
Figure 6.
A
A Air filter assembly B Engine fuel filter

C Fuel filter/water separator D Engine oil dipstick
E Engine oil filler point
01 - 20 9813/8500-2 01 - 20
01 - Machine
09 - Description
Right Side
Figure 7.
A Fuel filler point
Left Side
Figure 8.
A Hydraulic level indicator

B Hydraulic oil filler cap
01 - 21 9813/8500-2 01 - 21
01 - Machine
33 - Cleaning
33 - Cleaning
Contents Page No.
01-33-00 General ........................................................................................................................... 01-23
01 - 22 9813/8500-2 01 - 22
01 - Machine
33 - Cleaning
00 - General
00 - General Introduction
WARNING When using cleaning agents, solvents
Introduction .................................................... 01-23 or other chemicals, you must adhere to
Preparation .................................................... 01-24 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 - 23 9813/8500-2 01 - 23
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 - 24 9813/8500-2 01 - 24
03 - Attachments, Couplings and Load Handling
Contents Page No.
03-00 Attachments
03-00-00 General ............................................................................................................................. 03-3
03-09 Lift Arm Quickhitch
03-09-00 General ............................................................................................................................. 03-7
03-27 Bucket
03-27-00 General ............................................................................................................................. 03-9
03-27-90 Teeth ............................................................................................................................... 03-12
03-30 Shovel
03-30-00 General ........................................................................................................................... 03-15
03-30-12 6-in-1 .............................................................................................................................. 03-19
03-30-90 Teeth ............................................................................................................................... 03-22
03-54 Earth Drill
03-54-00 General ........................................................................................................................... 03-25
9813/8500-2
2017-09-12
Notes:
9813/8500-2
2017-09-12
00 - Attachments
00 - Attachments
Contents Page No.
03-00-00 General ............................................................................................................................. 03-3
03 - 1 9813/8500-2 03 - 1
Notes:
03 - 2 9813/8500-2 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
Lubricate .......................................................... 03-4 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 9813/8500-2 03 - 3
00 - Attachments
00 - General
Health and Safety Lubricate

Attachments Where applicable, refer to the specific manufacturers
Use only the JCB approved attachments that are manual for instructions on the lubrication of optional
specified for your machine. Operating with non- attachments.
specified attachments can overload the machine,
causing possible damage and machine instability Apply grease to all the points and linkages.
which could result in injury to yourself or others.
The use of non-approved attachments could 6-in-1 Clamshovel
invalidate your warranty.
Figure 9.
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 A,B
pertinent information. Install attachments only on the
machines for which they were designed.
WARNING! Load and unload on firm, level ground. C.D
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.
E,F
Excavator Arm Quickhitch (Mechanical)

(If installed)
Figure 10.
03 - 4 9813/8500-2 03 - 4
09 - Lift Arm Quickhitch
Contents Page No.
03-09-00 General ............................................................................................................................. 03-7
03 - 5 9813/8500-2 03 - 5
Notes:
03 - 6 9813/8500-2 03 - 6
00 - General
00 - General
Introduction
Quickhitches are used on machines to allow the rapid

change of buckets, shovels and other attachments
on the machine.
Quickhitches do not normally have a specific function

themselves in that they do not carry out handling or
digging operations, but when installed on a machine
they become a part of the overall machine system.
They are usually mounted on the machine by means
of pins that would otherwise be the mountings for the
shovel or attachment.
03 - 7 9813/8500-2 03 - 7
27 - Bucket
27 - Bucket
Contents Page No.
03-27-00 General ............................................................................................................................. 03-9

03-27-90 Teeth ............................................................................................................................... 03-12
03 - 8 9813/8500-2 03 - 8
27 - Bucket
00 - General
Introduction ...................................................... 03-9 A bucket can be installed on many different types
Health and Safety .......................................... 03-10 of excavating machines. The bucket can be directly
Remove and Install ....................................... 03-10 mounted on to an excavator arm assembly or
mounted to the excavator arm via a quickhitch
assembly. There are a vast amount and size of
buckets used for numerous applications.
Excavator buckets are made of solid steel and

generally have teeth protruding from the cutting
edge.
03 - 9 9813/8500-2 03 - 9
27 - Bucket
00 - General
Health and Safety Remove and Install

CAUTION Stand clear and to one side of the CAUTION Stand clear and to one side of the
bucket while you remove the pivot pins. With the bucket while you remove the pivot pins. With the
pins removed, the bucket could roll over. pins removed, the bucket could roll over.
WARNING The bucket selected must be the CAUTION This component is heavy. It must only
correct width to suit the hole/trench to be be removed or handled using a suitable lifting
excavated. However, if the hole width demands method and device.
a larger bucket, consideration must be given to
the density/weight of the material to be moved
affecting the stability of the machine especially Remove
if working on a slope. If there is danger of
1. Make the machine safe.
the machine's stability being compromised, then
select a smaller bucket or reposition the machine. Refer to: PIL 01-03-27.
2. Position the excavator arm straight behind the
machine. Rest the bucket on level ground, with
the bucket flat. Block the bucket to prevent any
movement.
3. Unclip and remove the tipping lever lynch pin and
spacer. Use the slide hammer kit to remove the
pivot pin.
Refer to: PIL 06-30-00.
4. Remove the dipper pivot lynch pin, spacer and
pivot pin.
5. Use the excavator controls to carefully lift the
dipper clear of the bucket.
03 - 10 9813/8500-2 03 - 10
27 - Bucket
00 - General
Figure 11. Install

1. Use a suitable lifting device to position the bucket
flat on level ground.
2. Reverse the machine while aligning the dipper
end with the bucket tipping lever.
3. Carefully operate the excavator controls to line
H up the holes in the dipper and tipping link with the
holes in the bucket.
4. Install the pivot pin. Install the spacer and the
lynch pin.
5. After the dipper pivot pin has been locked in,
install the tipping link pivot pin, spacer and lynch
pin.
A Tipping lever lynch pin

B Spacer
C Pivot pin
D Dipper pivot lynch pin
E Spacer
F Pivot pin
G Bucket
H Dipper
03 - 11 9813/8500-2 03 - 11
27 - Bucket
90 - Teeth
90 - Teeth Introduction
Introduction .................................................... 03-12 Excavator buckets generally have teeth protruding
Remove and Install ....................................... 03-13 from the cutting edge, to disrupt hard material and
avoid wear and tear of the bucket. Bucket teeth are
available in a wide range of sizes and profiles.
03 - 12 9813/8500-2 03 - 12
27 - Bucket
90 - Teeth
Remove and Install
Standard Teeth
Remove
2. Put the bucket flat on level ground.
3. Stop the engine.
4. Remove the ignition key.
5. Discharge the hydraulic pressure.
6. Remove the nut and bolt.
7. Remove the relevant tooth.
Figure 12.
B
A
A Tooth
B Nut and bolt
Installation
1. Put the tooth in position.
2. Install the nuts and bolts to secure the tooth in
position.
03 - 13 9813/8500-2 03 - 13
30 - Shovel
30 - Shovel
Contents Page No.
03-30-00 General ........................................................................................................................... 03-15

03-30-12 6-in-1 .............................................................................................................................. 03-19
03-30-90 Teeth ............................................................................................................................... 03-22
03 - 14 9813/8500-2 03 - 14
30 - Shovel
00 - General
Introduction .................................................... 03-15 A shovel can be installed on many different types of
Health and Safety .......................................... 03-16 earthmoving machines. The shovel can be directly
Remove and Install ....................................... 03-17 mounted on to a lift arm assembly or mounted to the
lift arm via a quickhitch assembly.
There are a vast amount and size of shovels used for

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

from the ground, such as dirt, sand or gravel, and
move it from one place to another without pushing
the material across the ground. It is commonly used
to move stockpiled material from ground level and
deposited into a dump truck or into an open trench
excavation.
03 - 15 9813/8500-2 03 - 15
30 - Shovel
00 - General
Health and Safety

CAUTION This component is heavy. It must only
be removed or handled using a suitable lifting
method and device.
03 - 16 9813/8500-2 03 - 16
30 - Shovel
00 - General
Remove and Install
Lifting Equipment 3. Remove the bolt (x2), washer (x2) from the pivot
pin that attaches the shovel and lift arm.
equipment. You must identify the weight of the item to 4. Remove the pivot pins (x4) from the shovel.
enough and suitable for the job. Make sure that lifting Refer to: PIL 06-30-00.
equipment is in good condition and complies with all
local regulations. 5. Disconnect the shovel from the shovel lever and
lift arm with suitable lifting equipment.
Remove 6. Inspect the condition of the bushes and seals at
the pivot pin joints.
1. Make the machine safe with the lift arm lowered.
Refer to: PIL 01-03-27. 7. Replace worn or damaged bushes and/or seals.
Use a press to remove and install the bushes and
2. Remove the bolt (x2), washer (x2) from the pivot seals.
pin that attaches the shovel and the shovel link.
Figure 13.
A E
F
C
D
A Shovel B Shovel link

C Lift arm D Bolt
E Nut F Pivot pin
03 - 17 9813/8500-2 03 - 17
30 - Shovel
00 - General
Install
1. The installation procedure is the opposite of the
removal procedure.
03 - 18 9813/8500-2 03 - 18
30 - Shovel
12 - 6-in-1
12 - 6-in-1 Introduction
Introduction .................................................... 03-19
Operation ....................................................... 03-20
6-in-1 Shovel
Remove and Install ....................................... 03-21 The 6-in-1 shovel allows you to load, dig, grab, grade,
Store and Recommission .............................. 03-21 doze and spread without changing attachments.
It is similar to a normal shovel except that it has an

opening clam which is operated by hydraulic rams
mounted on the bucket frame.
03 - 19 9813/8500-2 03 - 19
30 - Shovel
12 - 6-in-1
Operation Grading
To grade, open the clam and drag the shovel
Always operate the controls slowly and carefully. backwards. When the shovel is full, roll it back and
Drive slowly and carefully when the bucket is loaded. close the clam.
Keep the shovel low to the ground when moving,
this increases your visibility and makes the machine Figure 16.
more stable.
Control
The lift, lower, open and close movements of the
6-in-1 shovel are controlled by the loader control
lever(s).
The shovel clam is operated either by a foot pedal or

by the right hand control lever.
Loading and digging Dozing

With the clam closed, the shovel can be used as a To doze, open the clam and drive the machine
conventional shovel. For higher dumping, open the forward.
clam instead of rolling the shovel.
Figure 17.
Figure 14.
Grabbing
Open the clam and set the shovel directly above the
object to be grabbed. To grab the object, lower the
shovel and close the clam.
Spreading
Load the shovel with the material to be spread. Set
Figure 15.
the clam opening to suit the size of material and rate
of flow. Drag the shovel backwards, allowing it to
discharge an even layer of material as it goes.
Figure 18.
03 - 20 9813/8500-2 03 - 20
30 - Shovel
12 - 6-in-1
Remove and Install Store and Recommission

1. Clean the unit thoroughly.
Remove
2. Remove all the mud, dirt, and grease.
Refer to: PIL 01-03-27. 3. Inspect for visible signs of wear, breakage, or
damage.
2. Turn off the engine.
4. Order any parts required and make the
3. Release the hydraulic pressure. necessary repairs to avoid delays when starting
next season.
4. Disconnect the couplers.
5. Tighten loose nuts, capscrews, and hydraulic
5. Connect the couplers together or install caps to connections.
prevent contaminants from entering the hydraulic
system. 6. Put caps on the hydraulic couplers to prevent
contamination.
6. Lower the bucket to the ground.
7. Apply paint on all un-painted surfaces, to prevent
7. Detach the bucket. rust.
8. Frequent lubrication of grease fittings at the end 8. Apply grease on the exposed portions of the
of the cylinders and pivot points with a multi- cylinder rods.
purpose grease will greatly increase the life of the
product. 9. Store the unit in a dry and protected place.
Install 10. Leaving the unit outside will shorten its life.
1. To avoid serious personal injury, make sure that

the bucket is securely latched to the attachment
mechanism of your unit. Failure to do so could
result in separation of the bucket from the unit.
2. Connect the hydraulic quick couplers to the
auxiliary hydraulics and route the hoses in such
a fashion as to prevent chafing and pinching.
3. Start the engine and slowly cycle the bucket
cylinders several times to purge the system of air.
4. Check for proper hydraulic connection, hose
routing, and hose length.
03 - 21 9813/8500-2 03 - 21
30 - Shovel
90 - Teeth
90 - Teeth
Remove and Install
Standard Teeth
Remove
2. Put the bucket flat on level ground.
3. Stop the engine.
4. Remove the ignition key.
6. Remove the nut and bolt.
7. Remove the relevant tooth.
Figure 19.
B
A
A Tooth
B Nut and bolt
Installation
1. Put the tooth in position.
2. Install the nuts and bolts to secure the tooth in
position.
03 - 22 9813/8500-2 03 - 22
54 - Earth Drill
54 - Earth Drill
Contents Page No.
03-54-00 General ........................................................................................................................... 03-25
03 - 23 9813/8500-2 03 - 23
Notes:
03 - 24 9813/8500-2 03 - 24
54 - Earth Drill
00 - General
00 - General
Figure 20.
A Auger B Drill motor
03 - 25 9813/8500-2 03 - 25
Notes:
03 - 26 9813/8500-2 03 - 26
Contents Page No.
Acronyms Glossary .................................................................................................................................... 06-2
06-00 Body and Framework

06-00-00 General ............................................................................................................................. 06-3
06-03 Chassis
06-03-00 General ............................................................................................................................. 06-9
06-06 Moveable Panel and Cover
06-06-00 General ........................................................................................................................... 06-13
06-06-06 Engine Compartment ..................................................................................................... 06-14
06-06-21 Front Grille ..................................................................................................................... 06-16
06-06-22 Side Grille ...................................................................................................................... 06-18
06-12 Lift Arm
06-12-00 General ........................................................................................................................... 06-21
06-15 Excavator Arm
06-15-00 General ........................................................................................................................... 06-31
06-15-03 Boom .............................................................................................................................. 06-34
06-15-06 Dipper ............................................................................................................................. 06-37
06-30 Pivot Pins
06-30-00 General ........................................................................................................................... 06-41
06-36 Kingpost
06-36-00 General ........................................................................................................................... 06-45
06-39 Carriage
06-39-00 General ........................................................................................................................... 06-51
06-42 Stabiliser
06-42-00 General ........................................................................................................................... 06-57
06-42-03 Leg ................................................................................................................................. 06-61
06-42-09 Wear Pads ..................................................................................................................... 06-63
06-63 Identification Label
06-63-00 General ........................................................................................................................... 06-67
06-63-03 Machine .......................................................................................................................... 06-68
06-63-06 Engine ............................................................................................................................ 06-69
06-63-09 Axle ................................................................................................................................ 06-70
06-63-12 Gearbox .......................................................................................................................... 06-71
06-63-21 Hydraulic Pump .............................................................................................................. 06-73
06-66 Tools
06-66-00 General ........................................................................................................................... 06-75
06-66-03 Toolbox ........................................................................................................................... 06-76
06-69 Maintenance Strut
06-69-00 General ........................................................................................................................... 06-79
06-69-09 Boom Vertical ................................................................................................................. 06-80
06-69-12 Boom Horizontal Swing .................................................................................................. 06-81
06-75 Fire Extinguisher
06-75-00 General ........................................................................................................................... 06-83
9813/8500-2
2017-09-12
Acronyms Glossary
PIN Product Identification Number

RPM Revolutions Per Minute
9813/8500-2
2017-09-12
Contents Page No.
06-00-00 General ............................................................................................................................. 06-3
06 - 1 9813/8500-2 06 - 1
Notes:
06 - 2 9813/8500-2 06 - 2
00 - General
Introduction ...................................................... 06-3 The body and framework is the main structure of the
Repair .............................................................. 06-4 machine to which the operator station, excavator arm
Clean ............................................................... 06-5 and lift arm are mounted.
Check (Condition) ............................................ 06-7
06 - 3 9813/8500-2 06 - 3
00 - General
Repair
In the event of a weld failure, it is recommended (American Welding Society) classification 5.18.79
that the affected area may be inspected as per the with tensile strength of 700bar (10,144.9psi).
sample defect sheet, before any attempt to rectify/
repair the weld joint on the site. Make sure that the For field repair of factory welding, the recommended
paint is removed before you inspect the weld joint. equivalent is low hydrogen basic coated "Supercito
X Plus 7018 " electrode for root-run and 3.15mm
The services of a professional/weld repair shop of a diameter overcord electrode conforming to AWS
prominent electrode manufacturer are to be used for 6013 for filling the final run/ overlays.
corrective repair.
The effects of current, arc length, and travel speed
The welding production are currently using Advani on covered electrode beads are illustrated. Refer to
Oerlikon CITOFIL ER70S-6 1.2mm diameter MS Figure 21.
(Mild Steel) copper- coated wire conforming to AWS
Figure 21.
J K
B C D E F G
H
A B C D E F G
A Correct current, arc length and travel speed B Amperage too low
C Amperage too high D Too short an arc length
E Arc length too long F Travel speed too slow
G Travel speed too fast H Base metal
J Spatter K Undercut
06 - 4 9813/8500-2 06 - 4
00 - General
Clean
Pay particular attention to: 2. Around twin slew rams. Refer to Figure 22.
1. Excavator hoses passing through mainframe. 3. Twin ram slew recess in chassis (centremount).
Refer to Figure 22. Refer to Figure 23.
Figure 22.
C B
A Excavator hoses B Twin slew rams

C Twin slew rams recess
4. Kingpost slide rails (sideshift). Refer to Figure 23. 6. Recess between slew ram and kingpost casting.
Refer to Figure 23.
5. Kingpost hose tray and bottom shelf (sideshift).
Refer to Figure 23.
06 - 5 9813/8500-2 06 - 5
00 - General
Figure 23.
B
A
A Kingpost slide rails B Kingpost hose tray and bottom shelf

C Recess between slew ram and chassis kingpost
06 - 6 9813/8500-2 06 - 6
00 - General
Check (Condition)
1. Make sure that all of the guards and protective 6. Check that all of the attachment teeth are
devices are in position, secured by their locking undamaged and correctly attached.
devices and free from damage.
7. Check that all of the safety and instructional
2. Inspect all of the steelwork for damage. Include labels are undamaged and in position. Install new
the following: labels where necessary.
2.1. Examine all of the lifting point welds. 8. Note any damaged paintwork for future repair.
2.2. Examine all of the pivot point welds. 9. Inspect the machine for broken or loose
2.3. Examine the condition of all the pivot pins. fasteners.
2.4. Check that the pivot pins are correctly
in position and secured by their locking
Boom Lock Engagement Functional Test
devices. 1. Position the excavator in central protruding
position.
3. Check the steps and handrails are undamaged
and correctly attached. 2. Raise the boom fully.
4. Check for broken, cracked or crazed window 3. Deactivate the excavator controls.
glass and mirrors. Replace the damaged items.
4. Visually check the boom lock is engaged.
5. Check that the lamp lenses are undamaged.
Figure 24.
A Boom raise
06 - 7 9813/8500-2 06 - 7
03 - Chassis
03 - Chassis
Contents Page No.
06-03-00 General ............................................................................................................................. 06-9
06 - 8 9813/8500-2 06 - 8
03 - Chassis
00 - General
Introduction ...................................................... 06-9 The chassis is the underpart of the vehicle or
Health and Safety .......................................... 06-10 machine, consisting of the frame on which the body
Component Identification ............................... 06-11 or cab is mounted.
06 - 9 9813/8500-2 06 - 9
03 - Chassis
00 - General
Health and Safety

method and device.
06 - 10 9813/8500-2 06 - 10
03 - Chassis
00 - General
Make a note that the illustration shows a typical

chassis assembly. The actual chassis of the machine
may look different.
Figure 25.
A
E
A Chassis B Front cab mount

C Rear cab mount D Stabiliser
E Radiator mount plate F Engine mount
G Lift arm tower
06 - 11 9813/8500-2 06 - 11
06 - Moveable Panel and Cover
Contents Page No.
06-06-00 General ........................................................................................................................... 06-13

06-06-06 Engine Compartment ..................................................................................................... 06-14
06-06-21 Front Grille ..................................................................................................................... 06-16
06-06-22 Side Grille ...................................................................................................................... 06-18
06 - 12 9813/8500-2 06 - 12
00 - General
00 - General
Introduction
Access panels provide easy access to the machine

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

of the access panels are in their operation position
and secure.
06 - 13 9813/8500-2 06 - 13
06 - Engine Compartment
06 - Engine Compartment Open and Close

Open and Close ............................................ 06-14
Remove and Install ....................................... 06-15
Open
1. Make the machine safe with the lift arm raised.
Refer to (PIL 01-03).
2. Unlock and remove the front grille.
3. To release the engine cover, press the lever.
4. When the engine cover is fully raised, engage the
engine cover stay to support the engine cover.
Figure 26.
A Engine cover
B Engine cover stay
C Lever
Close
1. Remove the engine cover stay to close the
engine cover.
2. Push the engine cover down.
3. Make sure that the engine cover is locked in the
closed position.
4. Install and lock the front grille.
06 - 14 9813/8500-2 06 - 14
06 - Engine Compartment
Remove and Install

WARNING The engine has exposed rotating
parts. Switch off the engine before working in the
engine compartment. Do not use the machine
with the engine cover open.
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.
Remove
2. Open the engine compartment cover.
3. Support the engine compartment cover.
4. Remove the setscrews and washers from the
hinges at both sides of the engine cover.
5. Remove the engine compartment cover from the
machine.
Figure 27.
A
D
C
B
A Engine compartment cover

B Setscrews
C Washers
D Hinges
Install
removal procedure.
06 - 15 9813/8500-2 06 - 15
21 - Front Grille
21 - Front Grille Open and Close

Open and Close ............................................ 06-16 1. Make the machine safe with the lift arm raised.
Remove and Install ....................................... 06-17 Refer to: PIL 01-03-27.
2. Use the ignition key to unlock the front grille.
3. Press the top part of the grille if the key is difficult
to turn.
4. Remove the front grille, lift the grille upwards and
outwards.
5. Install the front grille, carefully slot the grille into
position.
6. Use the ignition key to lock and secure the front
grille.
Figure 28.
A Front grille
06 - 16 9813/8500-2 06 - 16
21 - Front Grille
Remove and Install Install

Remove removal procedure. Additionally do the following
step.
2. Tighten the bolts to the correct torque value.
2. Stop the engine and remove the ignition key.
3. Remove the front grille.
5. Remove the side grilles from both sides of the
machine.
6. Remove the bolts, washers and nut from each
side of the grille housing.
7. Remove the grommet from each side of the grille
housing.
8. Remove the buffers from the front grille.
9. Carefully remove the front grille housing from the
machine.
Figure 29.
E
C
F
D
A Front grill housing

B Bolts
C Washers
D Nuts
E Buffer
F Grommet
06 - 17 9813/8500-2 06 - 17
22 - Side Grille
22 - Side Grille Install

Remove and Install removal procedure. Additionally do the following
step.
Remove 2. Tighten the screws and bolts to the correct torque

value.
4. Remove the screws 1 and washers 1 that attach
the side grille to the front grille.
5. Remove the bolts 1, washers 2 and nuts 1 that
attach the side grille to the mounting bracket.
6. Remove the screws 2 and washers 3 that attach
the side grille to the chassis.
7. Remove the side grilles from both sides of the
machine.
Figure 30.
C
H
E
F
D
G
J
A
K
B
A Side grille (Left side)
B Side grille (Right side)
C Screws 1
D Washers 1
E Bolts 1
F Washers 2
G Nuts 1
H Brackets
J Screws 2
K Washers 3
06 - 18 9813/8500-2 06 - 18
12 - Lift Arm
12 - Lift Arm
Contents Page No.
06-12-00 General ........................................................................................................................... 06-21
06 - 19 9813/8500-2 06 - 19
Notes:
06 - 20 9813/8500-2 06 - 20
12 - Lift Arm
00 - General
Introduction .................................................... 06-21 The lift arm or loader assembly is a fabricated steel
Health and Safety .......................................... 06-22 construction. It usually has a front mounted shovel
Component Identification ............................... 06-23 connected to the end of two lift arms.
Check (Condition) .......................................... 06-24
The lift arm assembly is permanently mounted to
Lubricate ........................................................ 06-25 the machine. The shovel can be replaced with other
Remove and Install ....................................... 06-26 devices or tools for example, forks to lift heavy pallets
or shipping containers, and a hydraulically opening
clam shovel allows the lift arm to act as a light dozer
or scraper.
06 - 21 9813/8500-2 06 - 21
12 - Lift Arm
00 - General
Health and Safety

Lifting Equipment
equipment. You must identify the weight of the item to
local regulations.
WARNING! Do not work under raised lift arms unless
they are adequately supported by stands and/or
slings.
CAUTION! The lift arm pivot levers are potentially
dangerous, when pivoting about their centre they
form a scissor point with the lift arm. Make sure the
pivot levers are securely blocked when working in the
lift arm area.
CAUTION! This component is heavy. It must only be
removed or handled using a suitable lifting method
and device.
06 - 22 9813/8500-2 06 - 22
12 - Lift Arm
00 - General
Figure 31.
K
S
L
D H
B
F
R
P
U
T E
A
M
C
N
A Lift arm B Shovel links

C Lift rams D Shovel rams
E Level links - Strut F Level links - Plain
G Arm/frame pivot pins H Link/frame pivot pins
J Lift ram pivot pins K Shovel ram pivot pins
L Interlever / arm pivot pins M Interlever / link pivot pins
N Lift ram pivot pins P Shovel ram pivot pins
Q Lever / arm pivot pins R Safety strut
S Interlevers T Shovel levers
U Shovel stops
06 - 23 9813/8500-2 06 - 23
12 - Lift Arm
00 - General
Check (Condition)
1. Make sure that the bushes and the pivot pins
are within the permitted tolerances. Replace the
pivot pin or bushes as necessary.
2. Examine the lift arm structure for wear, damage
or corrosion. Replace as necessary.
3. Examine the pivot levers for wear, damage or
corrosion. Replace as necessary.
06 - 24 9813/8500-2 06 - 24
12 - Lift Arm
00 - General
Lubricate
Consumables 1. Make the machine safe.

Description Part No. Size Refer to: PIL 01-03-27.
Special HP Grease 4003/2017 0.4kg
4003/2006 12.5kg 2. Apply grease to all the points and linkages. Total
22 grease points.
4003/2005 50kg
Consumable: Special HP Grease
Figure 32.
A,B C,D
E,F
W,X
G,H
J,K
U,V L,M
N,P
Q,R
S,T
06 - 25 9813/8500-2 06 - 25
12 - Lift Arm
00 - General
Remove and Install
Special Tools 12.1. Make sure that the lift rams do not foul
Description Part No. Qty. when retracted.
Slide Hammer Kit 993/68100 1 13. Make sure that the residual hydraulic pressure
has been discharged.
Consumables
Description Part No. Size 14. Disconnect the shovel ram and the auxiliary
Special HP Grease 4003/2017 0.4kg hoses, if installed.
4003/2006 12.5kg 14.1. Put caps on all the open hoses to prevent
4003/2005 50kg contamination.
Remove 15. Remove all the pivot pin retaining bolts. Refer to
Figure 33.
15.1. Remove the silencer and the air cleaner to
Refer to: PIL 01-03-27. get access to the retaining bolts and nuts.
2. Turn the ignition switch to the OFF position. 16. Put the lift arms into position with the sling.
3. Discharge the hydraulic pressure from the 16.1. Make sure that the sling is wrapped
system. around the lift arms only and not the pivot
Refer to: PIL 30-00-00. lever links.
4. Remove any lift arm attachments, if installed. 17. Remove the nut and bolt that attach the lever link
pivot pin. Refer to Figure 33.
4.1. If the attachment is hydraulically operated,
disconnect the hydraulic hoses from the 17.1. Remove the retaining ring and shim from
attachment. the lever link pivot pin.
4.2. Put caps on all the open hoses and ports to 18. Use a cable to attach the inter lever linkage to
prevent contamination. avoid damage when you remove the lever link
pivot pin.
5. Turn the ignition switch to the ON position.
19. Use a slide hammer to remove the level link pivot
6. Raise the lift arms to get access to the lift ram pin.
pivot pins.
Special Tool: Slide Hammer Kit (Qty.: 1)
7. Use suitable lifting equipment to raise the lift Refer to: PIL 06-30-00.
arms.
20. Do steps 17 thru 19 to remove the other lever link
7.1. Make sure that the cables are in tension and pivot pin.
they can hold the weight of the lift arms.
21. Remove the nut and bolt that attach the lift arm
8. Turn the ignition switch to the OFF position. pivot pin. Refer to Figure 33.
9. Operate the lift arm control levers several times 21.1. Remove the retaining ring and shim from
to remove the hydraulic pressure from the the lever link pivot pin.
system.
22. Use a slide hammer to remove the lift arm pivot
10. Remove the lift ram pivot pins that attach the pin.
rams. Special Tool: Slide Hammer Kit (Qty.: 1)
11. Be careful when you remove the lift ram pivot pin,
once the pin is removed the ram will drop. 23. Do steps 21 thru 22 to remove the other lift arms
pivot pins.
11.1. Use a sling to hold the ram or get help from
a second person before you remove the lift 24. When you have removed all the pivot pins,
ram pivot pin. carefully move the machine in the reverse
direction to remove the lift arms.
12. Use the slings to lower the lift arms to the ground,
it may be necessary to retract the lift rams to rest
them fully on the ground.
06 - 26 9813/8500-2 06 - 26
12 - Lift Arm
00 - General
Figure 33.
K H
C
D
F
E
A Lift ram pivot pins B Hydraulic hoses

C Lift arm pivot pin bolt (Right side) D Lift arm pivot pin bolt (Left side)
E Lever link pivot pin bolt (Left side) F Lever link pivot pin bolt (Right side)
G Cable H Lever link pivot pin
J Lift arm pivot pin K Sling
06 - 27 9813/8500-2 06 - 27
12 - Lift Arm
00 - General
Install
removal procedure. Additionally do the following
steps.
1.1. Install all the pivot pins with the extraction
hole on the outside of the machine.
1.2. Apply grease to all mainframe bores.
1.3. Apply rust inhibiting oil to all pivot pins
before you install the pivot pins.
1.4. All the clip ring installations have a
maximum specified end float.
Length/Dimension/Distance: 2mm
1.5. Use a shouldered mandrel to install the new
liner bearings in the lift arms and/or the lever
link.
06 - 28 9813/8500-2 06 - 28
15 - Excavator Arm
15 - Excavator Arm
Contents Page No.
06-15-00 General ........................................................................................................................... 06-31

06-15-03 Boom .............................................................................................................................. 06-34
06-15-06 Dipper ............................................................................................................................. 06-37
06 - 29 9813/8500-2 06 - 29
Notes:
06 - 30 9813/8500-2 06 - 30
15 - Excavator Arm
00 - General
Introduction .................................................... 06-31 The excavator arm is a fabricated steel construction.
Component Identification ............................... 06-32 The excavator arm comprises a bucket, dipper and
Lubricate ........................................................ 06-33 boom assembly attached to a kingpost.
The excavator arm is pivoted on the kingpost to

enable right and left movement. The bucket, dipper
and boom are connected through pivots to enable a
full range of bucket and other attachment options.
06 - 31 9813/8500-2 06 - 31
15 - Excavator Arm
00 - General
Figure 34.
A Boom B Dipper
C Tipping linkage D Bucket
Note: Figure shows a typical boom and dipper

arrangement.
06 - 32 9813/8500-2 06 - 32
15 - Excavator Arm
00 - General
Lubricate
Consumables
Description Part No. Size
4003/2006 12.5kg
4003/2005 50kg
1. Make the machine safe. Refer to (PIL 01-03).

2. Apply grease to all the points and linkages. Total
22 grease points.
Figure 35.
J K
H Q
X
R
G L
S
P
M
T
V
E B
C A N
W U
06 - 33 9813/8500-2 06 - 33
15 - Excavator Arm
03 - Boom
03 - Boom
Remove and Install
Special Tools Refer to: PIL 06-15-06.

Description Part No. Qty.
9. Put a sling around the boom. Refer to Figure 36.
Slide Hammer Kit 993/68100 1
9.1. Make sure that the sling is in tension and
Remove holds the weight of the boom, before you
remove the pivot pins.
10. Put a suitable support below the boom ram. Refer
Refer to: PIL 01-03-27. to Figure 36.
2. Remove the excavator bucket and put the 11. Remove the thin nuts and bolt that attach the
excavator arm in the extended position. Refer to boom ram pivot pin. Refer to Figure 36.
Figure 36.
11.1. Use a slide hammer to remove the boom
3. Lower the stabilisers. ram pivot pin.
4. Turn the ignition switch to the OFF position. Special Tool: Slide Hammer Kit (Qty.: 1)
5. Disconnect the battery from the machine.
Refer to: PIL 33-03-00. 12. Remove the locknuts, bolts and spacers that
attach the boom pivot pin.
6. Operate the excavator control levers several
times to remove the hydraulic pressure. 12.1. Make a mark on the spacers (left side
and right side) to help installation. Refer to
7. Disconnect the hydraulic hoses from the Figure 36.
bulkhead plate. Refer to Figure 36. 12.2. Use a slide hammer to remove the boom
pivot pin.
7.1. Put labels on the hoses to help identification
for installation. Special Tool: Slide Hammer Kit (Qty.: 1)
7.2. Put caps on the open hoses and ports to
prevent contamination. 13. Lift the boom to remove from the kingpost
assembly.
8. Remove the dipper from the machine.
06 - 34 9813/8500-2 06 - 34
15 - Excavator Arm
03 - Boom
Figure 36.
F G
E
B
J
C A
H
A Dipper B Bulkhead plate

C Boom ram D Boom
E Nuts F Bolt
G Boom ram pivot pin H Spacers
J Boom pivot pin
06 - 35 9813/8500-2 06 - 35
15 - Excavator Arm
03 - Boom
Install
steps.
2. Use the thin nuts to retain the top boom pivot pin
by tightening with your hand.
2.1. Tighten the thin nuts to the specified correct
torque value.
Torque: 98N·m
3. When you install the boom to the kingpost
assembly, make sure that the spacers are
installed in the correct positions.
4. Replace all the pivot pin seals, if required.
06 - 36 9813/8500-2 06 - 36
15 - Excavator Arm
06 - Dipper
06 - Dipper
Remove and Install
Special Tools 7.1. Put labels on the hoses to help identification

Description Part No. Qty. for installation.
Slide Hammer Kit 993/68100 1 7.2. Put caps on the open hoses and ports to
prevent contamination.
be removed or handled using a suitable lifting 8. Put a suitable support below the dipper ram.
method and device. Refer to Figure 37.
9. Put a sling around the dipper. Refer to Figure 37.
Remove
9.1. Make sure that the sling is in tension and
1. Make the machine safe. Refer to (PIL 01-03). holds the weight of the dipper, before you
remove the pivot pins.
2. Remove the excavator bucket and put the
excavator arm in the extended position. Refer to 10. Remove the nut and bolt that attach the dipper
Figure 37. ram pivot pin. Refer to Figure 37.
3. Lower the stabilisers. 10.1. Use a slide hammer to remove the dipper
ram pivot pin. Refer to (PIL 06-30).
4. Turn the ignition switch to the OFF position.
5. Disconnect the battery from the machine. Refer
to (PIL 33-03). 11. Remove the thin nuts and bolt that attach the
dipper pivot pin. Refer to Figure 37.
6. Operate the excavator control levers several
times to remove the hydraulic pressure. 11.1. Use a slide hammer to remove the dipper
pivot pin. Refer to (PIL 06-30).
7. Disconnect the hydraulic hoses that are attached Special Tool: Slide Hammer Kit (Qty.: 1)
between the boom and the dipper. Refer to
Figure 37. 12. Lift the dipper to remove from the boom.
06 - 37 9813/8500-2 06 - 37
15 - Excavator Arm
06 - Dipper
Figure 37.
F G B
E
K
H
C A
A Dipper B Hydraulic hoses

C Dipper ram D Dipper
E Nut F Bolt
G Dipper ram pivot pin H Nuts
J Bolt K Dipper pivot pin
L Shim
06 - 38 9813/8500-2 06 - 38
15 - Excavator Arm
06 - Dipper
Install
1. Installation is the opposite of the removal
procedure.
2. Use the thin M12 nuts to retain the dipper pivot
pin by tightening with your hand.
2.1. Tighten the thin nuts to the specified torque
value.
Torque: 98N·m
3. When you install the dipper to the boom, make
sure that a shim is installed.
4. Replace all the pivot pin seals, if required.
06 - 39 9813/8500-2 06 - 39
30 - Pivot Pins
30 - Pivot Pins
Contents Page No.
06-30-00 General ........................................................................................................................... 06-41
06 - 40 9813/8500-2 06 - 40
30 - Pivot Pins
00 - General
Introduction .................................................... 06-41 Pivot pins are a short shaft or pin that supports
Remove and Install ....................................... 06-42 something that turns. Pivot pins are installed in
numerous positions on the machine. There is usually
a greasing point associated with the pivot pin.
Make sure that the pivot points are greased at
regular intervals. Refer to the Machine Maintenance
Schedules. Refer to: PIL 78-24.
Slide Hammer Kit

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

thread at each end. One of the threads will always
be M20 size, this is to accommodate the end stops.
The other end of the adaptor will have varying thread
sizes to suit the different size of threads in the pivot
pins.
06 - 41 9813/8500-2 06 - 41
30 - Pivot Pins
00 - General
Remove and Install Figure 38. Typical Machine
Special Tools
C
Make a note that the illustration shows a typical pivot
pin. The actual pivot pin installed on the machine may
look different.
1. Prepare the pivot pin for removal, remove the

locking device e.g. pivot pin retaining bolt.
2. Prepare the slide hammer kit.
2.1. Install the slide hammer onto the slide bar.
2.2. Determine the thread size of the pivot pin A Adaptor
and then install the appropriate adaptor. B End stop
Use the spanner flats to securely install the C End stop
adaptor. D Spanner flats
2.3. Install an end stop onto the other end of the E Slide bar
adaptor (M20 thread size), make sure that F Slide hammer
the adaptor threads are fully engaged.
2.4. Install the slide bar into the end stop. Make
sure that the threads are fully engaged.
2.5. Finally install the other end stop at the end
of the slide bar. The slide hammer kit is now
ready to use.
3. To extract the pivot pin, slide the hammer along
the bar until it contacts the end stop. Repeat this
step until the pivot pin is released.
4. To remove the slide hammer kit, reverse steps 2
to 3.
06 - 42 9813/8500-2 06 - 42
36 - Kingpost
36 - Kingpost
Contents Page No.
06-36-00 General ........................................................................................................................... 06-45
06 - 43 9813/8500-2 06 - 43
Notes:
06 - 44 9813/8500-2 06 - 44
36 - Kingpost
00 - General
Introduction .................................................... 06-45 The kingpost is the large kingpin that connects the
Check (Condition) .......................................... 06-46 boom to the chassis in an excavating machine.
Lubricate ........................................................ 06-46
06 - 45 9813/8500-2 06 - 45
36 - Kingpost
00 - General
Check (Condition) Lubricate

Consumables
1. Examine the kingpost, pivot bushes, and the Description Part No. Size
pivot pins for wear or damage. Replace the pivot
pins and/or pivot bushes as necessary. Special HP Grease 4003/2017 0.4kg
4003/2006 12.5kg
2. Examine the kingpost structure for wear, damage 4003/2005 50kg
or corrosion. Replace as necessary.
2. Apply grease to all the points and linkages.
Figure 39.
9
8
3 2 1
The Figure shows a centremount kingpost, greasing

is the same for the sideshift kingpost.
It is recommended that grease points 6 and 7 are

lubricated using a hand grease gun. The use of a
power grease gun may result in the mounting plate
being distorted.
06 - 46 9813/8500-2 06 - 46
36 - Kingpost
00 - General
Remove and Install
Special Tools 7.1. Use a slide hammer kit to remove the slew
Description Part No. Qty. ram rod end pivot pin. Refer to (PIL 06-30).
Slide Hammer Kit 993/68100 1 Special Tool: Slide Hammer Kit (Qty.: 1)
Consumables 7.2. Make sure that you remove both the slew
ram rod end pivot pins.
Special HP Grease 4003/2017 0.4kg 7.3. Turn the slew ram rod ends outwards, so
4003/2006 12.5kg they are clear of the kingpost.
4003/2005 50kg 8. Attach suitable lifting equipment to the kingpost
casting.
Remove 8.1. Make sure that the slings are in tension
1. Make the machine safe. Refer to (PIL 01-03). and hold the weight of the kingpost casting,
before you remove the kingpost pivot pins.
2. Make sure that the slew lock pin is in its stowage
position. 9. Remove the think locknuts and retaining screws
that attach the top and bottom kingpost pivot
3. Move the kingpost to the central position. pins.
4. Remove the boom from the machine. Refer to 9.1. Use a slide hammer kit to remove the top
(PIL 06-15-03). and bottom kingpost pivot pin. Refer to (PIL
06-30).
5. Remove the dipper from the machine. Refer to
(PIL 06-15-06). 10. Carefully remove the kingpost from the rear
machine frame.
6. Disconnect the excavator hydraulic hoses from
the kingpost bulkhead plate. 10.1. Remove the thrust washers from the rear
machine frame.
6.1. Put labels on the hoses to help identification
for installation. 10.2. Put labels on the thrust washers to help
installation.
6.2. Put caps on the open hydraulic hoses and
the ports to prevent contamination. 11. If the bearings are damaged, remove the
bearings and replace as required.
6.3. Place a suitable receptacle below the
kingpost to collect any hydraulic fluid 12. Make sure that all of the bearings grease holes
spillage. are aligned with the appropriate holes in the
casting.
7. Remove the pivot pin retaining bolt.
06 - 47 9813/8500-2 06 - 47
36 - Kingpost
00 - General
Figure 40.
F
D
C B
A
A Kingpost B Bolt
C Pivot pin D Locknut
E Pivot pin F Pivot pin
G Washer H Slew ram
Install 4. Tighten the thin locknuts so that the pivot

pin retaining screws have approximately the
1. The installation procedure is the opposite of the specified value of free movement.
Dimension: 1mm
steps.
5. Make sure that the kingpost moves freely and
2. Clean and lightly oil the pivot bores and pivot
does not foul.
pins.
6. Check the operation of the boom lock.
3. Make sure that the pivot pin retaining holes align
with their corresponding holes in the kingpost.
06 - 48 9813/8500-2 06 - 48
36 - Kingpost
00 - General
7. After the complete installation, apply grease at

each grease nipple of the pivot pins, before you
operate the machine.
06 - 49 9813/8500-2 06 - 49
39 - Carriage
39 - Carriage
Contents Page No.
06-39-00 General ........................................................................................................................... 06-51
06 - 50 9813/8500-2 06 - 50
39 - Carriage
00 - General
00 - General Operation
Operation ....................................................... 06-51
Check (Condition) .......................................... 06-52
Kingpost Clamps
Remove and Install ....................................... 06-53 On Sideshift machines, the kingpost assembly must
be clamped to the cross rails before you start any
excavation work.
Release Clamps
Press the switch to release the clamps, the switch
light should be illuminated. Refer to Figure 41.
Tighten Clamps
Press the switch off to enable the clamps to tighten.
Manual Sideshift
Make sure that the kingpost rails are clear of debris
before sideshifting the excavator.
1. Use the stabilisers to set the machine level and

stable, with the kingpost vertical.
2. Set the bucket on the ground, straight behind the
machine.
3. Release the clamps, press the kingpost clamp
switch to the on position, the switch light should
be illuminated.
Figure 41.
A B
A Kingpost B Kingpost clamp switch
4. Loosen the kingpost on its rails, operate the or lower the boom slightly to keep the kingpost
boom up and down for few times. vertical to the rails.
5. Raise and slew the excavator directly to one side 8. Once the kingpost is in the required position,
of the machine. Slew to the left if you want to tighten the clamps by pressing the kingpost
sideshift to the right. Slew to the right if you want clamp switch to the off position.
to sideshift to the left.
Pressure generated in the excavator services will
6. Set the bucket on the ground, with the dipper as make sure the clamps fully engage. Before you
illustrated Refer to Figure 41. operate the excavator, move the bucket control lever
to fully crowd the bucket, hold the lever in this position
7. Open the bucket. As the bucket opens, the for a minimum of specified time 5s (engine at 1500
kingpost will be pushed across the back of the RPM (Revolutions Per Minute)).
machine. If the kingpost sticks in mid-travel, raise
06 - 51 9813/8500-2 06 - 51
39 - Carriage
00 - General
Check (Condition)
1. Inspect the nickel bronze liner bearings for signs
of damage, wear, scores or nicks etc.
2. Make sure that grease holes in the bearings align
with the appropriate holes in the casting.
3. Check the condition of the bearings, if necessary
then replace them.
4. For powered side-shift machines:
4.1. Make sure that the wear pads are in good
condition.
4.2. If necessary, replace the wear pads.
06 - 52 9813/8500-2 06 - 52
39 - Carriage
00 - General
Remove and Install
Consumables 2. Disconnect all the feed hoses to the hydraulic

Description Part No. Size clamp units.
Special HP Grease 4003/2017 0.4kg 3. Plug all the open ports to prevent loss of fluid and
4003/2006 12.5kg ingress of dirt.
4003/2005 50kg
4. Put a label on the hoses to help installation.
Remove 5. Support the carriage casting with suitable lifting
equipment.
1. The following procedure assumes that the
kingpost has already been removed. It is possible 6. Make sure that the weight of the carriage is
to remove the side-shift carriage with the supported by the sling.
kingpost installed providing that all the necessary
hoses are first disconnected at the kingpost 7. Remove the bolt 1 (x4) and the clamp bar.
bulkhead plate.
Figure 42.
A
B
A Carriage B Hydraclamp unit

C Bolt 1 D Clamp bar
E Bolt 2
8. Remove the bolt 2 (x4).
06 - 53 9813/8500-2 06 - 53
39 - Carriage
00 - General
9. Carefully lift the carriage away from the rear

frame rails.
10. If the pivot bearing bushes are damaged, remove
it and replace as required.
11. Make sure that all of the pivot bearing bushes
grease holes are aligned with the appropriate
holes in the casting.
Install
steps.
2. Make sure that the rear frame rails and the
carriage mating face are clean.
3. Tighten the bolt 1 to the correct torque value.
Torque: 660N·m
4. Tighten the bolt 2 to the correct torque value.
Torque: 660N·m
5. After the installation is complete, operate the
excavator and make sure that the kingpost/
carriage moves freely and does not foul.
6. Apply grease at each grease nipple of the pivot
pins, before you operate the machine.
06 - 54 9813/8500-2 06 - 54
42 - Stabiliser
42 - Stabiliser
Contents Page No.
06-42-00 General ........................................................................................................................... 06-57

06-42-03 Leg ................................................................................................................................. 06-61
06-42-09 Wear Pads ..................................................................................................................... 06-63
06 - 55 9813/8500-2 06 - 55
Notes:
06 - 56 9813/8500-2 06 - 56
42 - Stabiliser
00 - General
Introduction .................................................... 06-57 The stabilisers are a safety device to stop the
Health and Safety .......................................... 06-58 machine tipping over when the excavator arm is
Operation ....................................................... 06-59 used.
Clean ............................................................. 06-60
There are two stabiliser legs located behind the
rear wheels. The stabiliser legs can be deployed
by controls in the cab, to give the machine added
stability when the machine is stationary.
06 - 57 9813/8500-2 06 - 57
42 - Stabiliser
00 - General
Health and Safety

WARNING The stability of the machine can be
reduced when you use the excavator without
stabilisers. Before using the excavator make sure
the stabilisers and the loader shovel are set on
stable ground.
WARNING You must be sitting in the driving seat
when operating the stabiliser controls.
Do not operate any machine controls from outside
the machine. You or others could be injured or
killed by movement of the machine or its working
tools or attachments.
The stabilisers must be down when you use the
excavator, or the machine will rock violently. Each
stabiliser has its own control lever and can be
operated independently.
Lower each stabiliser to level the machine and
take the weight off of the rear tyres. The loader
shovel should be used along with the stabilisers
to level and steady the machine.
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 - 58 9813/8500-2 06 - 58
42 - Stabiliser
00 - General
Operation
WARNING You must be sitting in the driving seat shovel should be used along with the stabilisers
when operating the stabiliser controls. to level and steady the machine.
Do not operate any machine controls from outside
the machine. You or others could be injured or Raise Stabilisers
killed by movement of the machine or its working
tools or attachments. To raise the stabilisers, push the levers towards the
The stabilisers must be down when you use the rear of the machine.
excavator, or the machine will rock violently. Each
stabiliser has its own control lever and can be Lower Stabilisers
operated independently.
To lower the stabilisers, pull the levers towards the
Lower each stabiliser to level the machine and
front of the machine.
take the weight off of the rear tyres. The loader
Figure 43.
A C
A C
B D
B D
A Raise left stabiliser B Lower left stabiliser

C Raise right stabiliser D Lower right stabiliser
06 - 59 9813/8500-2 06 - 59
42 - Stabiliser
00 - General
Clean
Make sure that Stabiliser cavities are kept clean,

they can become clogged when operating in soft/
wet ground conditions. Remove and clean away all
debris that may have built up.
06 - 60 9813/8500-2 06 - 60
42 - Stabiliser
03 - Leg
03 - Leg
Remove and Install
Remove 7. Put a suitable jack below the inner leg. Refer to

Figure 44.
8. Use the jack to lift the inner leg until the top
Refer to: PIL 01-03-27. wear pads protrude from the top of the outer leg
1.1. Make sure that the excavator arm assembly section.
is set central to the mainframe. 9. Remove the upper wear pads.
2. Discharge the hydraulic pressure. 10. Attach a suitable lifting device to the inner leg at
Refer to: PIL 30-00-00. the wear pad holes.
3. Remove the stabiliser leg alarm switch (if 11. Remove the inner leg.
installed).
Install
4. Remove the cap from the stabiliser.
5. Remove the stabiliser foot and ram from the removal procedure. Additionally do the following
machine. steps.
2. Install the wear pad.
6. Remove the lower wear pad.
3. Adjust and check the operation of the stabiliser
leg alarm.
06 - 61 9813/8500-2 06 - 61
42 - Stabiliser
03 - Leg
Figure 44.
G K
A
M
L
B F
E
D
A Stabiliser cap B Stabiliser foot

C Bolt D Nut
E Pivot pin 1 F Lower wear pads
G Stabiliser ram H Circlip
J Spacer K Pivot pin
L Inner leg M Upper wear pad
N Stabiliser
06 - 62 9813/8500-2 06 - 62
42 - Stabiliser
09 - Wear Pads
09 - Wear Pads Check (Condition)

Check (Condition) .......................................... 06-63 The wear pads support and guide the inner leg
Adjust ............................................................ 06-64 section. They ensure that during extension and
Remove and Install ....................................... 06-65 retraction the inner leg is kept central and has a
minimum amount of float.
The float between the stabiliser inner and outer leg

should be set to approximately 1mm.
The upper wear pads (x4) are installed to the top

of the inner leg. The upper pads are available in 3
sizes and are colour coded; 5mm (green); 6mm (red)
and 7mm (blue). The lower wear pads comprise of
adjustable pads (x2) and fixed pads (x2).
When the upper pads and lower fixed pads have

worn to a minimum thickness of 0.5mm they must
be replaced with new ones. To replace the pads, the
stabiliser inner leg must be removed. Refer to: PIL
06-42-03.
It is important to note that the lower fixed pads are

designed to take most of the load during stabiliser
leg operation, as a consequence these pads must be
checked regularly for wear.
When replacing pads, it is recommended that the

complete lower set of pads are replaced. The top
pads should be inspected and replaced as required.
Figure 45.
A Lower fixed pads

B Lower adjustable pads
C Upper fixed pads
06 - 63 9813/8500-2 06 - 63
42 - Stabiliser
09 - Wear Pads
Adjust
It is very important that the wear pads are adjusted 4. Tighten the screw pad fully until it just touches
at the recommended service intervals, as the inner the inner leg.
leg may contact the outer leg, this can cause scoring.
Scoring will dramatically reduce the life of the wear 4.1. Loosen the screw pad in increments of the
pads. specified angle.
Angle: 90°
Do the steps below to adjust the stabiliser leg wear
pads. 5. If you tighten the screw pad too much during the
adjustment, it will not be possible to loosen or
1. Remove all the debris that may have built up in remove the pad.
the stabiliser cavities.
5.1. If the screw pad is tightened too much,
2. Make sure that the float between the stabiliser operate the stabiliser leg for normal
inner and outer legs is not more than the operation.
specified.
5.2. Be aware that the screw and permanent
Dimension: 3mm pads will wear more rapidly, because of the
stabiliser leg operation with the screw pad
3. Make sure that the stabiliser leg is extended up
tightened too much.
to above the ground but not fully retracted, before
you adjust the clearance.
Figure 46.
A
A Upper wear pads B Screw wear pads

C Permanent pads
06 - 64 9813/8500-2 06 - 64
42 - Stabiliser
09 - Wear Pads
Remove and Install Figure 47.
Consumables
4003/2006 12.5kg C
4003/2005 50kg
Remove
2. Remove the cap from the stabiliser.
3. Remove the stabiliser foot and ram from the D
machine.
4. Support the inner leg.
5. Remove the lower wear pad (x4).
6. Remove the adjuster assembly (x2).
7. Put a suitable jack below the inner leg. B
8. Use the jack to lift the inner leg until the top
wear pads protrude from the top of the outer leg
section.
9. Remove the upper wear pad (x4).
A
A Lower wear pads
B Adjuster assembly
C Upper wear pads
D Inner leg
Install
steps.
2. Select the suitable size of upper wear pads to get
the specified maximum permissible float.
Dimension: 3mm
3. Apply grease to the threads of the pad.
06 - 65 9813/8500-2 06 - 65
63 - Identification Label
Contents Page No.
06-63-00 General ........................................................................................................................... 06-67

06-63-03 Machine .......................................................................................................................... 06-68
06-63-06 Engine ............................................................................................................................ 06-69
06-63-09 Axle ................................................................................................................................ 06-70
06-63-12 Gearbox .......................................................................................................................... 06-71
06-63-21 Hydraulic Pump .............................................................................................................. 06-73
06 - 66 9813/8500-2 06 - 66
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 - 67 9813/8500-2 06 - 67
03 - Machine
03 - Machine
Introduction
Your machine has an identification plate. The serial new one, the serial number on the identification plate
numbers of the machine and its major components will be wrong. Either get a replacement identification
are marked on the plate. plate from your JCB dealer or simply remove the
old number. This will prevent the wrong unit number
The serial number of each major unit is also shown being quoted when replacement parts are ordered.
on the unit itself. If a major unit is replaced by a
Figure 48.
The machine model and build specification are

indicated by the PIN (Product Identification Number).
The PIN has 17 digits and must be read from left to
right.
Figure 49.
HA R 2 D X PC C 1 2 3 4 5 6 7 8
1 World manufacturer identification (3 Digits)

2 Machine model (5 Digits)
3 Check letter (1 Digit) - The check letter is used
to verify the authenticity of a machine's PIN.
4 Machine serial number (8 Digits) - Each
machine has a unique serial number.
06 - 68 9813/8500-2 06 - 68
06 - Engine
06 - Engine
Introduction
Typical engine identification number

Each engine has a unique identification number
shown on to the main engine block. When ordering
replacement parts, always quote the complete
engine serial number.
Figure 50.
ENGI N
E TYPE
RATI NG kW/ hp rpm
RATI NG STD.
GOVERNIG
NCLASS
ENGI N
E No.
KI R
LOSKAR OIL ENGI NE
S LTD
I NDI A
06 - 69 9813/8500-2 06 - 69
09 - Axle
09 - Axle
Introduction
For: 2DX [T3], 2WD .................. Page 06-70

For: 2DX [T3], 4WD .................. Page 06-70
(For: 2DX [T3], 2WD)

The axles have a serial number stamped on a data
plate as shown.
Figure 51.
A B
A Data plate - front axle B Data plate - rear axle

The axles have a serial number stamped on a data
plate as shown.
Figure 52.
A B
A Data plate - front axle B Data plate - rear axle
06 - 70 9813/8500-2 06 - 70
12 - Gearbox
12 - Gearbox
Introduction
For: 2DX [T3], 2WD .................. Page 06-71

For: 2DX [T3], 4WD .................. Page 06-71

The gearbox has a serial number stamped on a data
plate as shown.
Figure 53.

The gearbox has a serial number stamped on a data
plate as shown.
06 - 71 9813/8500-2 06 - 71
12 - Gearbox
Figure 54.
06 - 72 9813/8500-2 06 - 72
21 - Hydraulic Pump
21 - Hydraulic Pump
Introduction
Figure 55.
A
xxxxx
A Data plate - hydraulic pump
06 - 73 9813/8500-2 06 - 73
66 - Tools
66 - Tools
Contents Page No.
06-66-00 General ........................................................................................................................... 06-75

06-66-03 Toolbox ........................................................................................................................... 06-76
06 - 74 9813/8500-2 06 - 74
66 - Tools
00 - General
00 - General
Introduction
When you carry tools onto the machine, you must

keep three points of contact with the machine at all
times. If necessary, lift the tools on to the machine in
intervals. Put the tools down before you adjust your
grips on the machine. Do not try to adjust your grips
on the machine while holding tools.
06 - 75 9813/8500-2 06 - 75
66 - Tools
03 - Toolbox
03 - Toolbox
Introduction
Toolbox
All tools must be kept in the toolbox (If installed) when
not in use.
Figure 56.
A A
A Toolbox
06 - 76 9813/8500-2 06 - 76
69 - Maintenance Strut
Contents Page No.
06-69-00 General ........................................................................................................................... 06-79

06-69-09 Boom Vertical ................................................................................................................. 06-80
06-69-12 Boom Horizontal Swing .................................................................................................. 06-81
06 - 77 9813/8500-2 06 - 77
Notes:
06 - 78 9813/8500-2 06 - 78
00 - General
00 - General
Introduction
Before you start any service procedures on the

machine, make sure that the relevant maintenance
strut is installed in its correct position and secure.
06 - 79 9813/8500-2 06 - 79
09 - Boom Vertical
09 - Boom Vertical
Disconnect and Connect
We recommend that the boom lock and the slew lock 2. Make sure that the boom lock is fully raised.
be engaged before travelling on the road.
3. Close the boom ram (raise the boom).
Check on a daily basis that the boom lock fully
engages and secures the boom. 4. Make sure that the lock is fully engaged in the
boom lugs.
It is recommended that the slew lock is engaged
5. Lower the boom a little to tighten the lock.
before fitting the boom lock.
The illustration shows boom and slew lock Disengage the Boom Lock
arrangement. The slew lock is placed in toolbox.
1. Raise the boom a little to release the lock.
Engage the Boom Lock 2. Raise the boom lock.
1. Set the excavator straight behind the machine,
rest the boom on the ground.
Figure 57.
A B
A Boom lock B Slew lock

C Boom lugs
06 - 80 9813/8500-2 06 - 80
12 - Boom Horizontal Swing
12 - Boom Horizontal Swing Figure 58.

A
Disconnect and Connect D B
WARNING If two people are doing this job make

sure that the person working the controls is a
competent operator. If the wrong control lever is
moved, or if the controls are moved violently, the E
other person could be killed or injured.
WARNING Do not attempt to install or remove
the slew lock pin when sat in the cab, you will be
leaning over the control levers. You or others can
be killed or seriously injured if the control levers
are accidentally operated.
We recommend that the boom lock and the slew lock

be engaged before travelling on the road.
It is recommended that the slew lock is engaged

before fitting the boom lock.
The illustration shows slew lock arrangement. Slew A Boom lock

lock pin is placed in toolbox. B Slew lock
D Hole in the kingpost
E Hole in the mainframe
Engage the Slew Lock
1. Slew the excavator into the required position.
Make sure that hole in the kingpost aligns with
hole in the mainframe. Stop the engine.
2. Take the slew lock pin from toolbox.
Disengage the Slew Lock

1. Stop the engine.
2. Remove the lock pin and and keep it in the
toolbox. Refer to Figure 58.
06 - 81 9813/8500-2 06 - 81
75 - Fire Extinguisher
Contents Page No.
06-75-00 General ........................................................................................................................... 06-83
06 - 82 9813/8500-2 06 - 82
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 59.
A Gauge
B Safety Pin
06 - 83 9813/8500-2 06 - 83
Notes:
06 - 84 9813/8500-2 06 - 84
Contents Page No.
09-00 Operator Station

09-00-00 General ............................................................................................................................. 09-3
09-06 Exterior Roof
09-06-03 Cab Roof ........................................................................................................................ 09-13
09-09 Window
09-09-00 General ........................................................................................................................... 09-17
09-12 Operator Seat
09-12-00 General ........................................................................................................................... 09-25
09-15 Seat Belt
09-15-00 General ........................................................................................................................... 09-29
09-18 Door
09-18-00 General ........................................................................................................................... 09-31
09-27 Controls
09-27-00 General ........................................................................................................................... 09-33
09-27-03 Lift Arm ........................................................................................................................... 09-34
09-27-09 Excavator Arm ................................................................................................................ 09-37
09-27-57 Park Brake ..................................................................................................................... 09-40
09-30 Trim Panel
09-30-09 Dashboard ...................................................................................................................... 09-43
09-30-12 Side Console Trim ......................................................................................................... 09-45
09-33 Safety Label/Chart
09-33-00 General ........................................................................................................................... 09-49
09-36 Steering Wheel
09-36-00 General ........................................................................................................................... 09-53
09-81 Mount
09-81-00 General ........................................................................................................................... 09-57
9813/8500-2
2017-09-13
Acronyms Glossary
4WD Four Wheel Drive
9813/8500-2
2017-09-13
Contents Page No.
09-00-00 General ............................................................................................................................. 09-3
09 - 1 9813/8500-2 09 - 1
Notes:
09 - 2 9813/8500-2 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
Clean ............................................................... 09-7 it is supported by a mechanical device. Equipment
Remove and Install ......................................... 09-8 which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails
or if the control is operated (even with the engine
stopped).
Make sure that no-one goes near the machine while
you install or remove the mechanical device.
Lifting Equipment
equipment. You must identify the weight of the item to
local regulations.
09 - 3 9813/8500-2 09 - 3
00 - General
For: 2DX [T3], 2WD .................... Page 09-4

For: 2DX [T3], 4WD .................... Page 09-5
Figure 60.
R
S K
T
U
L V
N
M
J
E
G
C
D
H Q
A Instruments B Instrument panel

C Ignition switch D Auxiliary power socket
E Switches F Excavator controls
09 - 4 9813/8500-2 09 - 4
00 - General
G Park brake lever H Stabiliser controls

J Service brake pedal K Transmission lever (4-speed syncro shuttle
transmission)
L Lift arm Control levers M Accelerator pedal
N Steering wheel P Toolbox
Q Hand throttle lever R Hazard light switch
S Head light switch T Multipurpose steering column switch
U Drive lever / horn V Auxiliary control lever
Figure 61.
R
S K
T
U
L V
N
M
J
E
W
G
C
D
H Q
09 - 5 9813/8500-2 09 - 5
00 - General
A Instruments B Instrument panel

C Ignition switch D Auxiliary power socket
E Switches F Excavator controls
G Park brake lever H Stabiliser controls
J Service brake pedal K Transmission lever (4-speed syncro shuttle
transmission)
L Lift arm control lever M Accelerator pedal
N Steering wheel P Toolbox
Q Hand throttle lever R Hazard light switch
S Head light switch T Multipurpose steering column switch
U Drive lever/horn V Auxiliary control lever
W 4WD (Four Wheel Drive) selector switch
09 - 6 9813/8500-2 09 - 6
00 - General
Clean
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.
Remove debris and loose articles from inside the

cab.
09 - 7 9813/8500-2 09 - 7
00 - General
Remove and Install
CAUTION This component is heavy. It must only 6. Put a label on the electrical harness to help
be removed or handled using a suitable lifting installation
method and device.
7. Disconnect the chassis harness connectors at
WARNING Do not work below a raised cab the rear of the cab.
unless the cab is secured in position and safely
supported. 8. Remove the securing bolt and disconnect the cab
earth cable from the chassis.
Remove 9. Drain the cooling system.
1. Make the machine safe. Refer to: PIL 21-00-00.
Refer to: PIL 01-03-12. 10. Put a label on the hoses to help installation.
2. Discharge the hydraulic pressure. 11. Disconnect the hoses from the steer unit.
Refer to: PIL 30-00-00. Refer to: PIL 25-06-00.
3. Open the engine compartment cover. 12. Plug all the open ports and hoses to prevent
Refer to: PIL 06-06-06. contamination.
4. Disconnect the battery cables. 13. Attach suitable lifting equipment to the cab.
Refer to: PIL 33-03-00. 14. To remove the cab mounts, do the steps from
14.1 to 14.5.
5. Remove the trim panel and side skirt from both
sides of the machine.
09 - 8 9813/8500-2 09 - 8
00 - General
Figure 62.
H F
E
G
F
D
E
C
D
C
A Front mount B Rear mount

C Locknut D Compression plate
E Cab mount F Rebound plate
G Washer H Bolt
14.1. Remove the locknuts and compression 14.4. Remove the locknuts and compression
plate from the front mounts. plate from the rear mounts.
14.2. Remove the bolts, washers and rebound 14.5. Remove the bolts, washers and rebound
plate from inside the cab. plate from inside the cab.
14.3. Remove the rear wheels to get access to 15. Raise the cab sufficiently to access the
the rear mounts. components below the cab.
09 - 9 9813/8500-2 09 - 9
00 - General
16. Remove the cab mounts from the chassis.

17. Remove the end of the park brake lever out and
turn until there is no tension on the park brake
cable.
18. Put a label on the electrical connections and the
hoses to help installation.
19. Disconnect the hoses from the brake cylinder.
20. Disconnect the park brake cable. Make sure that
the park brake cable is free from the chassis.
21. Disconnect the electrical connector from the
accelerator pedal.
22. Plug all the open ports and hoses to prevent
contamination.
23. Carefully lift the cab assembly away from the
chassis.
Install
steps.
2. Inspect the cab mounts for wear or damage,
replace as necessary.
3. Tighten the cab mounting bolts and nuts to the
correct torque value.
4. Adjust the park brake cable.
5. Check the hydraulic oil level and top up to the
correct level.
6. Top up the cooling system and check for leaks.
09 - 10 9813/8500-2 09 - 10
06 - Exterior Roof
06 - Exterior Roof
Contents Page No.
09-06-03 Cab Roof ........................................................................................................................ 09-13
09 - 11 9813/8500-2 09 - 11
Notes:
09 - 12 9813/8500-2 09 - 12
06 - Exterior Roof
03 - Cab Roof
03 - Cab Roof
Remove and Install
Remove 4. Carefully lift the roof moulding to get access to

the electrical harness connector.
5. Disconnect the electrical harness connector from
Refer to: PIL 01-03-27. the number plate lights.
2. Get access to the roof moulding from outside the 6. Lift the complete roof moulding with the number
cab. plate lights and remove it from the machine.
3. Remove the screws (x8) and washers that attach
the roof moulding to the cab.
Figure 63.
B
C
A
E
F
A Roof moulding B Screws

C Washer D Harness connector
E Number plate light F Grommet
09 - 13 9813/8500-2 09 - 13
06 - Exterior Roof
03 - Cab Roof
Install
steps.
2. Tighten the screws to the correct torque value.
3. After the roof moulding is installed, check the
number plate lights for correct operation.
09 - 14 9813/8500-2 09 - 14
09 - Window
09 - Window
Contents Page No.
09-09-00 General ........................................................................................................................... 09-17
09 - 15 9813/8500-2 09 - 15
Notes:
09 - 16 9813/8500-2 09 - 16
09 - Window
00 - General
Introduction .................................................... 09-17 The service procedures, explain how to correctly
Health and Safety .......................................... 09-18 remove and install panes of glass that are directly
Preparation .................................................... 09-18 bonded to the cab frame apertures. When you carry
Remove and Install ....................................... 09-20 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 - 17 9813/8500-2 09 - 17
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 - 18 9813/8500-2 09 - 18
09 - Window
00 - General
Figure 64. Figure 66.
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 67.
polyurethane sealant.
Special Tool: Rubber Spacer Blocks (Qty.: 4)
Special Tool: Folding Stand (Qty.: 1)
Figure 65.
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 - 19 9813/8500-2 09 - 19
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 68.
Consumables
Black Polyurethane 4102/2310 0.31L
Sealant
A Black Primer/Activator 4104/2304 0.1L
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
B JCB Glass Cleaner 4006/3175 0.75L
A 12.5mm
B 9mm
Removal
6. Apply the pre-heated adhesive to the glass (do
not start in a corner). Keep the nozzle guide 1. Position the machine on level ground and apply
against the edge of the glass and make sure the park brake. Stop the engine. Put protective
that the adhesive forms a continuous pyramid' covers over the cab seat and control pedestals.
shape. Note: Once the pre-heated adhesive has
2. If a laminated pane breaks it will stay in one piece
been applied to the glass, install the glass in the
even though the glass is cracked. A toughened
aperture as soon as possible. If you wait too long
pane will shatter and fall apart. The method of
then the sealant will form a skin, this will prevent
removal of the glass depends upon which type
the glass from bonding.
it is.
Duration: 10min
2.1. Laminated glass - leave installed until the
Figure 69. 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 - 20 9813/8500-2 09 - 20
09 - Window
00 - General
Do not allow the knife blade to overheat or Figure 71.

the sealant will melt.
Figure 70.
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 72.
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 - 21 9813/8500-2 09 - 21
09 - Window
00 - General
Figure 73. 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 75. 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 76.
face of the cab frame aperture.
Figure 74.
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 - 22 9813/8500-2 09 - 22
09 - Window
00 - General
3.2. Use your finger to make the inside seal

smooth.
4. All exposed edges must be sealed using Black
Polyurethane Sealant. Important: Use extreme
caution when wiping the inside of the new glass
- pushing too hard on the inside of the glass will
affect the integrity of the bonded seal.
Special Tool: Nylon Spatula (Qty.: 1)
Consumable: Black Polyurethane Sealant
5. Clean the glass after installation:
5.1. Small amounts of sealant can be cleaned
from the glass using the surface cleaner.
Consumable: Surface Cleaning Fluid
5.2. Large amounts of excess sealant should be
left to cure and then cut off with a sharp
knife. Note: On completion of the glass
replacement procedures, the sealant curing
time is 30 minutes. This means that the
machine can be driven and used after 30
minutes, but it must not be used during the
curing period of 30 minutes.
5.3. Clean the glass using a purpose made
glass cleaner.
Consumable: Hand Cleaner
Consumable: JCB Glass Cleaner
6. On completion of the glass installation
procedures tidy the work area:
6.1. Remove all broken glass from the cab area.
6.2. Remove the protective covers from the cab
seat and control pedestals.
6.3. Renew all safety and instructional labels so
that the new installation conforms with the
original cab installation.
09 - 23 9813/8500-2 09 - 23
12 - Operator Seat
12 - Operator Seat
Contents Page No.
09-12-00 General ........................................................................................................................... 09-25
09 - 24 9813/8500-2 09 - 24
12 - Operator Seat
00 - General
00 - General Check (Condition)

Check (Condition) .......................................... 09-25 1. Check that the seat adjustments operate
Remove and Install ....................................... 09-26 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 - 25 9813/8500-2 09 - 25
12 - Operator Seat
00 - General
Remove and Install
CAUTION This component is heavy. It must only Refer to: PIL 01-03-27.
method and device. 2. Remove the base cover of the operator seat.
3. Remove the mount bolts that attach the operator
Remove seat to the body.
1. Make the machine safe. 4. Carefully lift the operator seat and remove from
the machine.
Figure 77.
A Operator seat B Base cover

C Bolts
09 - 26 9813/8500-2 09 - 26
12 - Operator Seat
00 - General
Install
removal procedure.
2. Tighten the mount bolts to the specified torque
value.
Table 1. Torque Values

Item Description Nm
C Bolts 47
09 - 27 9813/8500-2 09 - 27
15 - Seat Belt
15 - Seat Belt
Contents Page No.
09-15-00 General ........................................................................................................................... 09-29
09 - 28 9813/8500-2 09 - 28
15 - Seat Belt
00 - General
00 - General
Check (Condition)
WARNING When a seat belt is installed on your
machine replace it with a new one if it is damaged,
if the fabric is worn, or if the machine has been in
an accident.
WARNING If the seat belt does not 'lock' when
you check if the seat belt is operating correctly, do
not drive the machine. Get the seat belt repaired
or replaced immediately.
1. Make sure the seat belt can be adjusted.

2. Examine the seat belt for signs of fraying and
stretching.
3. Check that the stitching is not loose or damaged.
4. Check that the belt mounting bolts are
undamaged, correctly installed and tight.
5. Check that the buckle assembly is undamaged
and operates correctly.
09 - 29 9813/8500-2 09 - 29
18 - Door
18 - Door
Contents Page No.
09-18-00 General ........................................................................................................................... 09-31
09 - 30 9813/8500-2 09 - 30
18 - Door
00 - General
00 - General
Check (Condition)
Check the condition of the cab doors and locks as

follows:
• Check the operation of the latches and locks.

Replace worn or defective components if the
latches fail to latch, release, lock or unlock
correctly.
• Lubricate the locks and latches with light
lubricating oil.
• Check that the machine doors and access
covers open and close correctly. Make sure
that the hinges and retaining devices operate
correctly. Replace missing, worn or defective
components.
• Lubricate the door and access cover pivots with
light lubricating oil.
09 - 31 9813/8500-2 09 - 31
27 - Controls
27 - Controls
Contents Page No.
09-27-00 General ........................................................................................................................... 09-33

09-27-03 Lift Arm ........................................................................................................................... 09-34
09-27-09 Excavator Arm ................................................................................................................ 09-37
09-27-57 Park Brake ..................................................................................................................... 09-40
09 - 32 9813/8500-2 09 - 32
27 - Controls
00 - General
00 - General Figure 79.
Lubricate
The following points should be lightly oiled with

engine oil after specified duration.100h B
Control levers
Oil the clevis at the bottom of every attachment
control lever.
Figure 78.
09 - 33 9813/8500-2 09 - 33
27 - Controls
03 - Lift Arm
03 - Lift Arm
Disassemble and Assemble
Disassemble 7. Remove the control lever knobs and gaiters.
1. Make the machine safe. Refer to (PIL 01-03). 8. Disconnect the control rods from the lift arm
control valve spools.
2. Remove the hydraulic pressure from the system.
Refer to (PIL 30-00). 9. Remove the bolts that attach the complete
control lever assembly to the chassis.
3. Disconnect the battery. Refer to (PIL 33-03).
10. Remove the control lever assembly and
4. Get access to the lift arm control levers inside the mounting bracket from the cab floor.
cab.
11. Disassemble the control lever assembly as
5. Remove the console panels that are attached required.
around the lift arm control levers.
6. Disconnect the transmission dump switch
electrical connector and remove the wires from
the connector.
09 - 34 9813/8500-2 09 - 34
27 - Controls
03 - Lift Arm
Figure 80.
B
J
C B
D
J M
K
G
J
E
L
H F
A Consoles B Knobs
C Control lever tube D Rod end joint 1
E Rod end joint 2 F Rubber cover
G Universal joint H Bolts
J Control rods K Lock flat
L Mounting bracket M Lever lock
Assemble 3. Assemble the lift arm lever and auxiliary lever

together with the washer and the retaining clip.
1. The assembly procedure is the opposite of
the disassembly procedure. Additionally do the 4. Install the control rod to the lever assembly.
following steps.
5. Adjust the rod end joints.
2. Install the mount bracket to the chassis.
09 - 35 9813/8500-2 09 - 35
27 - Controls
03 - Lift Arm
5.1. Make sure that the rod end joints are

adjusted at an equal distance from their rod
ends.
6. Install the lever assembly to the mounting plate.
7. Adjust the control rods as required.
8. Install the gaiters over the control levers.
9. Thread the transmission dump switch cable
through the lift arm control lever.
10. Install the wires/pins into the electrical connector
to the chassis harness.
11. Install the control lever knobs.
12. Connect the battery. Refer to (PIL 33-03).
13. Check the controls and transmission dump
switch operate correctly.
14. Install the console panels around the lift arm
levers.
15. Make sure there is an equal amount of thread at
each end of the control rod.
15.1. Adjust the auxiliary controls rod until the
auxiliary lever aligns with lift arm lever,
then tighten the control rod lock nuts.
09 - 36 9813/8500-2 09 - 36
27 - Controls
09 - Excavator Arm
09 - Excavator Arm
The illustration shows the control rods and linkages knobs which will also need to be removed
for the excavator arm control valve and is intended as above.
as a guide for disassembly and assembly.
3. Loosen the bolt to remove the excavator arm
control lever knobs and gaiters.
Disassemble
4. Remove the excavator arm control lever knobs.
5. Disconnect the control rods from the excavator
2. Disconnect the rear horn switch electrical
valve spools.
connector and remove the wires from the
connector. 6. Remove the bolts that attach the complete lever
assembly to the excavator valve mounting plate.
2.1. Use a screwdriver to release the wires and
pins from the connector. You can also cut 7. Remove the control levers and mounting bracket.
the wires and solder them on assembly.
2.2. Some machine variants may have Assemble
additional switches in the control lever
1. Install the mounting bracket to the excavator arm
control valve mounting plate. Refer to Figure 81.
09 - 37 9813/8500-2 09 - 37
27 - Controls
09 - Excavator Arm
Figure 81.
C E
A Cover B Mounting bracket

C Stabiliser lever D Rubber seal
E Excavator lever F Universal joints
2. Install the stabiliser control levers to the mounting 3. Measure the stabiliser lever control rods (x2).
bracket. The length between the hole centres should be
of the specified values. Adjust as required.
Length: 370mm
09 - 38 9813/8500-2 09 - 38
27 - Controls
09 - Excavator Arm
4. Connect the control rods to the stabiliser control

levers.
4.1. If necessary, loosen the locknuts and rotate
the end fittings to give equal amounts of
adjustment (thread) at each end of the
control rod.
5. Assemble the excavator arm control levers to
the mounting bracket together with the universal
joint.
6. Measure the excavator arm lever control rods
(x4). The length between the hole centres should
be of the specified values. Adjust as required.
7. Connect the control rods to the excavator arm
control levers.
8. Connect the control rods to the excavator arm
valve spools with the clevis pins.
9. Adjust the control rods if necessary.
10. Install the cover and the gaiters over the control
levers.
11. Thread the rear horn switch cable through the
control lever.
12. Install the wires and pins into the electrical
connector.
13. Couple the connector to the chassis harness.
14. Install the control lever knobs.
15. Connect the battery and make sure that the
controls and rear horn switch operate correctly.
16. Minor adjustment of the control rods may be
necessary to align the levers, or to position the
levers closer or further from the operator.
16.1. After adjustment operate the levers and
check that there is sufficient travel to
give full movement of the excavator valve
spools.
09 - 39 9813/8500-2 09 - 39
27 - Controls
57 - Park Brake
57 - Park Brake Component Identification

Component Identification ............................... 09-40 Figure 82.
D B
A Park brake lever

B Park brake mounting bracket
C Park brake cable
D Park brake switch
09 - 40 9813/8500-2 09 - 40
27 - Controls
57 - Park Brake
Remove
G
D F
3. Remove the screws 1 (x6).
C
4. Remove the gaiter from the park brake lever.
E
Figure 83. J
C Park brake switch

D Electrical connector
E Screw 2
B F Bolts 1
G Park brake lever
H Bolts 2
J Bracket
Install
A
step.
2. Check the park brake. Refer to (PIL 24-18).
A Screws 1 (x6)
B Gaiter
5. Disconnect the electrical connector from the park
brake switch.
6. Pull the end of the park brake lever out and turn
until there is no tension on the park brake cable.
7. Remove the screw 2, washer and nut from the
cable end.
8. Remove the bolts 1 (x2), washers 1 (x2) and nuts
1 (x2).
9. Remove the park brake lever.
10. Remove the bolts 2 (x2), washers 2 (x2) and nuts
2 (x2).
11. Remove the bracket.
09 - 41 9813/8500-2 09 - 41
30 - Trim Panel
30 - Trim Panel
Contents Page No.
09-30-09 Dashboard ...................................................................................................................... 09-43

09-30-12 Side Console Trim ......................................................................................................... 09-45
09 - 42 9813/8500-2 09 - 42
30 - Trim Panel
09 - Dashboard
09 - Dashboard
Remove and Install
Remove 5.1. Remove the front steering column cover

and rear steering column cover.
6. Remove the multi-purpose switches.
2. Disconnect the battery.
7. Disconnect the electrical connections from the
Refer to: PIL 33-03-00. instrument panel.
3. Get access to the steering wheel in the cab. 8. Remove the screws that attach the dashboard to
4. Remove the steering wheel. the steering column assembly
Refer to: PIL 09-36-00. 8.1. Carefully lift the dashboard and remove it
from the steering column assembly.
5. Remove the screws that attach the front steering
column cover to the rear steering column cover.
Figure 85.
A Steering wheel B Steering column cover

C Steering column D Screws
E Dashboard
09 - 43 9813/8500-2 09 - 43
30 - Trim Panel
09 - Dashboard
Install
steps.
2. Be careful when you replace the dashboard.
2.1. Make sure that the electrical connectors are
connected to the correct connectors.
2.2. Make sure that the electrical harness is not
caught in the dashboard.
2.3. Make sure that the electrical harness
connections are not moved or changed
when the console is installed.
3. After the dashboard is installed, check the
operation of the controls.
09 - 44 9813/8500-2 09 - 44
30 - Trim Panel
12 - Side Console Trim
Remove and Install
Remove 5.1. Remove the handle from the slot of the

panel.
6. Remove the auxiliary circuit control lever and lift
Refer to: PIL 01-03-27. arm control lever.
2. Disconnect the battery. Refer to: PIL 09-27-03.
Refer to: PIL 33-03-00. 7. Remove the screws (x15) that attach the side
3. Remove the instrument panel from the side console panel to the cab.
console trim panel. 8. Carefully remove the side console panel from the
4. Remove the hand throttle lever knob. cab.
5. Remove the screws that attach the hand throttle

lever to the mounting bracket assembly from
inside the side console.
09 - 45 9813/8500-2 09 - 45
30 - Trim Panel
Figure 86.
C D
E F
A Instrument panel (right side) B Knob - hand throttle lever

C Lift arm control lever D Auxiliary circuit control lever
E Screws F Side console trim panel
09 - 46 9813/8500-2 09 - 46
30 - Trim Panel
Install
steps.
2. Be careful when you replace the console panel.
2.1. make sure that the electrical connections
are connected to the correct connector.
2.2. Make sure that the electrical harness is not
caught in the console fittings.
2.3. Make sure that the electrical harness
connections are not moved or changed
when the console is installed.
3. After the console is installed, check the operation
of the controls.
09 - 47 9813/8500-2 09 - 47
33 - Safety Label/Chart
Contents Page No.
09-33-00 General ........................................................................................................................... 09-49
09 - 48 9813/8500-2 09 - 48
00 - General
Introduction .................................................... 09-49 The safety labels are strategically placed around the
Health and Safety .......................................... 09-50 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 - 49 9813/8500-2 09 - 49
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 - 50 9813/8500-2 09 - 50
36 - Steering Wheel
36 - Steering Wheel
Contents Page No.
09-36-00 General ........................................................................................................................... 09-53
09 - 51 9813/8500-2 09 - 51
Notes:
09 - 52 9813/8500-2 09 - 52
36 - Steering Wheel
00 - General
Introduction .................................................... 09-53 The steering wheel is used to direct the machine. The
Remove and Install ....................................... 09-54 operator can turn the steering wheel in the direction
he wants to go.
The steering wheel incorporates an assister knob for

single handed operation.
Figure 87.
A Steering wheel
B Assister knob
09 - 53 9813/8500-2 09 - 53
36 - Steering Wheel
00 - General
Remove and Install Table 2. Torque Values

Item Nm
C 50
Remove
2. Install the articulation strut.
3. Carefully pry out and remove the centre disc from
the steering wheel, take care not to damage.
4. Mark the position of the steering wheel with
respect to the steering column.
5. Remove the nut and washer that secures the
steering wheel to the steering column.
6. Remove the steering wheel.
Figure 88.
E
B
B Centre disc
C Nut
D Washer
E Steering wheel
Install
1. Put the steering wheel in position against the
steering column. Make sure the marks made
during removal are aligned.
2. Install the washer and the nut.
3. Tighten the nut to the correct torque value.
4. Install the centre disc on the steering wheel, take
care not to damage.
09 - 54 9813/8500-2 09 - 54
81 - Mount
81 - Mount
Contents Page No.
09-81-00 General ........................................................................................................................... 09-57
09 - 55 9813/8500-2 09 - 55
Notes:
09 - 56 9813/8500-2 09 - 56
81 - Mount
00 - General
00 - General Install
Remove and Install removal procedure. Additionally do the following
steps.
Do not remove the front and rear mounts at the same 2. If the mounts are to be replaced, make sure that
time. Remove any two mounts either front or rear at the new components are identified correctly and
any one time, as required. installed in the correct positions.
Remove 3. Tighten the bolt to the correct torque value.

Torque: 205N·m
2. Remove the floor mat. Refer to (PIL 09-48).
3. Remove the trim panel. Refer to (PIL 09-30).
4. Put a suitable jack between the cab frame and
the machine chassis.
5. Raise the cab sufficiently to remove the mount
spacers.
6. Record the positions of the cab mounts to make
sure of correct replacement.
7. Use suitable supports to hold the cab.
8. Do not work below the cab which is only
supported by a jack or lifting equipment.
Figure 89.
D D
C
B
A Bolt
B Nut
C Mount
D Spacer
09 - 57 9813/8500-2 09 - 57
Notes:
09 - 58 9813/8500-2 09 - 58
15 - Engine
Contents Page No.
15-00 Engine
15-00-00 General ............................................................................................................................. 15-3
15-18 Engine Belt
15-18-00 General ........................................................................................................................... 15-19
15-18-03 Drive Belt ....................................................................................................................... 15-21
15-21 Oil Filter
15-21-00 General ........................................................................................................................... 15-25
15-24 Air Filter
15-24-00 General ........................................................................................................................... 15-29
15-24-03 Outer Element ................................................................................................................ 15-32
15-24-09 Dust Valve ...................................................................................................................... 15-33
15-24-60 Pre-Cleaner .................................................................................................................... 15-34
15-57 Oil Filler
15-57-00 General ........................................................................................................................... 15-37
15-72 Alternator
15-72-00 General ........................................................................................................................... 15-39
15-75 Starter Motor
15-75-00 General ........................................................................................................................... 15-45
15-87 Switch
15-87-18 Air Filter Vacuum ............................................................................................................ 15-51
15-90 Air Intake
15-90-00 General ........................................................................................................................... 15-53
9813/8500-2
2017-09-21
Acronyms Glossary
DC Direct Current
ESOS Engine Shut-Off Solenoid
FEAD Front End Accessory Drive
ISO International Organization for
Standardization
TDC Top Dead Centre
9813/8500-2
2017-09-21
15 - Engine
00 - Engine
00 - Engine
Contents Page No.
15-00-00 General ............................................................................................................................. 15-3
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Notes:
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15 - Engine
00 - Engine
00 - General

Health and Safety ........................................... 15-3 Hot Components
Technical Data ................................................. 15-4 Touching hot surfaces can burn skin. The engine and
Operation ......................................................... 15-5 machine components will be hot after the unit has
Drain and Fill ................................................... 15-9 been running. Allow the engine and components to
Clean ............................................................. 15-10
Check (Level) ................................................ 15-11 Turning the Engine
Remove and Install ....................................... 15-12 Do not try to turn the engine by pulling the fan or fan
Store and Recommission .............................. 15-16 belt. This could cause injury or premature component
failure.
Notice: The engine and other components could
be damaged by high pressure washing systems.
Special precautions must be taken if the machine is
to be washed using a high pressure system.Make
sure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system. Do
not aim the water jet directly at bearings, oil seals or
the engine air induction system.
WARNING! To bleed the injectors you must turn the
engine. When the engine is turning, there are parts
rotating in the engine compartment.Before starting
this job make sure that you have no loose clothing
(cuffs, ties etc) which could get caught in rotating
parts.When the engine is turning, keep clear of
rotating parts.
Notice: Clean the engine before you start
engine maintenance. Obey the correct procedures.
Contamination of the fuel system will cause damage
and possible failure of the engine.
Notice: Do not exceed the correct level of engine
oil in the sump. If there is too much engine oil,
the excess must be drained to the correct level. An
excess of engine oil could cause the engine speed
to increase rapidly without control.
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
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00 - General
accordance with local regulations. Use authorised Technical Data

waste disposal sites.
Table 3.
Model 4R810NA BS-III
Type Koel engine T4.1041
Net power 49.5 HP@2200 RPM
(Revolutions Per Minute)
Peak torque at RPM 203 @1300 RPM
Rating standard ISO (International Orga-
nization for Standardiza-
tion) 3046
Low idle RPM 800-900 RPM
High idle RPM M2 class governing
Alternator 12 V MICO, 65Amps
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Operation
The Four Cylinder Cycle Firing Order

This section describes the cycle sequence for the 4 A cylinder is said to be firing, when the fuel/air mixture
cylinder engine. ignites and the piston is about to start its power
stroke.
With the crankshaft positioned as shown, the pistons
in numbers 1 and 4 cylinders are at top dead centre From the stages described, it can be seen that
and pistons in numbers 2 and 3 cylinders are at number 1 cylinder will be next to fire. Number 3
bottom dead centre. cylinder is starting its compression stroke and is next
in the cycle, followed by cylinders 4 and 2. The firing
It is important to note that number 1 cylinder is firing order is therefore; 1, 3, 4, 2.
and about to start its Power stroke. Rotating the
crankshaft a further full rotation would position the The stages in the four stroke cycle for each cylinder
pistons as described but the engine would be at a are as follows:
different stage in its four stroke cycle, with number 1
cylinder about to start its Induction stroke.
Table 4. The Four Stroke Cycle

Cylinder number Piston operation Valve operation
1 The piston is at the top of its Compression stroke Inlet and exhaust valves closed
and is about to start its Power stroke.
2 The piston is at the bottom of its Power stroke and Inlet valves closed, exhaust
is about to start its Exhaust stroke. valves about to open
3 The piston is at the bottom of its Induction stroke Exhaust valves closed, inlet
and is about to start its Compression stroke. valves about to close.
4 The piston is at the top of its Exhaust stroke and Valve Operation Exhaust valves
is about to start its Induction stroke. about to close, inlet valves about
to open
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Figure 90. Typical Four Cylinder Engine

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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00 - General
Four Stroke Cycle The temperature rises to a point at which the fuel/air
mixture ignites. A cylinder is said to be firing when
Induction the fuel/air mixture ignites.
As the piston travels down the cylinder, it draws This combustion causes a very rapid rise in
filtered air at atmospheric pressure and ambient both temperature and pressure. The high pressure
temperature through an air filter and inlet valves into generated propels the piston downwards turning the
the cylinder. crankshaft and producing energy.
Compression Exhaust
When the piston reaches the bottom of its stroke, the Once the piston has reached the bottom of its travel,
inlet valves close. The piston then starts to rise up the the exhaust valves open and momentum stored
cylinder compressing the air trapped in the cylinder. in the flywheel forces the piston up the cylinder
This causes the temperature and pressure of the air expelling the exhaust gases.
to rise. Fuel is injected into the cylinder when the
piston is near to TDC (Top Dead Centre). In a running engine, these four phases are
continuously repeated. Each stroke is half a
revolution of the crankshaft, thus, in one cycle of a
Power
four stroke engine, the crankshaft revolves twice.
The piston continues to rise after the start of fuel
injection, causing a further increase in pressure and
temperature.
Figure 91.
3
2
C
B
1 4
746030
1 Induction stroke 2 Compression stroke

3 Power stroke 4 Exhaust stroke
C Camshaft lobe - Exhaust valve operation BDC Bottom dead centre
TDC TDC
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Figure 92.
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
C Camshaft lobe - Exhaust valve operation
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Drain and Fill 13. Through the top filler point, fill the engine with
the recommended oil to the MAX mark on the
dipstick.
Drain the oil when the engine is warm as
contaminants held in suspension will then be drained 14. Clean the spilt oil.
with the oil.
15. Install the filler cap and make sure that it is
1. Make the machine safe. Refer to (PIL 01-03). secure.
2. Open the engine compartment cover. Refer to 16. Operate the engine, until the oil pressure low
(PIL 06-06). warning light has extinguished.
Figure 93. 17. Check for oil leakage.

18. When the oil has cooled, check the oil level again
and if necessary top up with clean engine oil.
H
F
C
D
C Drain plug
D O-ring
H Seal
F Filter
3. Place a suitable container below the sump drain
plug.
4. Remove the sump drain plug and its O-ring.
5. Drain the engine oil.
6. Clean and install the drain plug with a new O-ring.
7. Tighten the drain plug to the correct torque value.
Torque: 40–60N·m
8. Remove the filter canister, if necessary use a
chain wrench.
9. Clean the seal face of the filter head.
10. Smear the seal on the new filter canister with
clean engine oil.
11. Screw the filter canister on until it just contacts
the filter head.
12. Turn the filter canister at least a further 3/4 of a
turn.
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Clean 9. When the pressure washing is complete, move

the machine away from the wash area, or
Notice: Clean the engine before you start engine alternatively, clean away the material washed
maintenance. Obey the correct procedures. from the machine.
Contamination of the fuel system will cause
damage and possible failure of the engine. 10. Before working on specific areas of the engine,
use a compressed air jet to dry off any moisture.
Notice: The engine and other components could When the area is dry, use a soft clean brush to
be damaged by high pressure washing systems. remove any sand or grit particles that remain.
Special precautions must be taken if the machine
is to be washed using a high pressure system. 11. When removing components, be aware of any
Make sure that the alternator, starter motor and dirt or debris that may be exposed. Cover any
any other electrical components are shielded open ports and clean away the deposits before
and not directly cleaned by the high pressure proceeding.
cleaning system. Do not aim the water jet directly
Additional cleaning must be carried out prior to
at bearings, oil seals or the engine air induction
working on the high pressure fuel system. Refer to
system.
Fuel System, General, Clean.
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 connected. If connectors are open
install 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 brush to soak
off mud or dirt.
7. Apply an approved cleaning and degreasing
agent with a brush. Obey the manufacturers
instructions.
8. Use a pressure washer to remove the soft dirt
and oil. Important: DO NOT aim the water jet
directly at oil seals or electrical and electronic
components such as the engine electronic
control unit (ECU), alternator or fuel injectors. DO
NOT place the jet nozzle closer than the specified
distance to any part of the engine.
Distance: 600mm
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Check (Level)
1. Open the engine compartment cover. Refer to
(PIL 06-06).
2. Make sure that the oil level is between the
maximum and minimum marks on the dipstick.
Figure 94.
A Dipstick
B Filler
3. If necessary, fill the recommended oil through
filler to the maximum level.
4. Install the filler cap and the dipstick.
5. Make sure that they are fully inserted and
tightened.
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Remove and Install
Remove 22. Loosen and remove the brake master cylinder

reservoir retaining bolts.
23. Do not remove the pipes attached to the master
2. Open the engine compartment cover. Refer to cylinder reservoir but put the reservoir out of the
(PIL 06-06). way.
3. Isolate the battery. Refer to (PIL 33-03). 24. Make sure that the fluid level does not drain
down.
4. Remove retaining bolts and then lift off the front
grille. 25. Label and remove all electrical connections, the
number of connectors will vary depending on the
5. Remove retaining bolts from both sides and lift ancillary equipment fitted to the engine. Typical
off the front nose guard. electrical connectors are:
6. Disconnect the hydraulic oil cooler hoses from 25.1. Starter motor
the hydraulic oil cooler.
25.2. Alternator
7. Plug and cap open ports to prevent ingress of
25.3. Coolant temperature sender
dirt.
25.4. Engine oil pressure switch
8. Make sure that the adaptor must be held with a
spanner whilst installing or removing the hose. 25.5. Engine temperature sender
9. It may be easier to remove the top hose 26. Loosen and disconnect the fuel lines from the fuel
connection once the cooler has been removed sedimenter.
from the machine.
27. Plug all the open orifices to prevent ingress of dirt
10. Drain the cooling system. and loss of fuel.
11. Remove the transmission oil cooler hoses. 28. Loosen and remove the retaining bolts for the fuel
sedimenter.
12. Remove the radiator top hose and bottom hose.
29. Remove the sedimenter.
13. Make a suitable alignment mark to allow correct
repositioning of the radiator shroud. 30. If installed, loosen and disconnect the ether cold
start fuel line from the engine. Plug and cap open
14. Remove retaining bolts and lift off the fan guard. orifices to prevent ingress of dirt and loss of fluid.
15. Remove retaining bolts (both sides) and lift 31. Disconnect the throttle linkage from the arm on
off the radiator sub-assembly including radiator, the fuel injection pump.
hydraulic and transmission coolers, and shroud.
32. Leave at least one of the locking nuts in position,
16. Make sure that the engine fan is not get this will ensure that the engine revs are set
damaged. correctly when reassembling.
17. Support the subassembly with suitable lifting 33. Loosen and remove the rear propshaft to
equipment. gearbox retaining bolts.
18. If required, the shroud, radiator and coolers can 34. On 4WD machines, loosen and remove the front
be removed as individual items. propshaft to gearbox retaining bolts.
19. Loosen and remove the exhaust silencer 35. Remove the access plate located at the base of
retaining bolts, remove the silencer. the gearbox.
20. Loosen and remove the retaining clamp for the 36. Through the access hole, loosen and remove
air filter intake hose. the torque converter to engine flywheel retaining
bolts (turn the flywheel to align bolts with access
21. Remove the air intake filter. Use tape to close hole).
the opening in the air intake manifold, this will
prevent ingress of dirt. 37. Disconnect the gearshift lever from the top of the
gearbox.
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38. Use a suitable trolley jack and support the weight 44. Make sure that the converter stays mounted on
of the gearbox. the gearbox shaft.
39. Attach a `cradle' to the trolley jack that will evenly 45. Support the engine with suitable lifting
support the weight of the gearbox. equipment.
40. Use a suitable stand and support the weight of 46. Take the weight of the engine on the hoist.
the engine.
47. Loosen and remove the engine mounting bolts
41. Loosen and remove the gearbox mounting bolts. (both sides).
42. Remove the gearbox to engine retaining bolts. 48. Lift the engine clear of the machine.
43. Pull the transmission and converter clear of the 49. Put the engine on a suitable stand, the
engine. correct dismantling and assembly procedures
are detailed in the KOEL engine service manual.
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Figure 95.
Q Q
A
S
B
H
A Bolt B Bolt
C Hydraulic oil cooler hoses D Adaptor
E Transmission oil cooler hoses H Brake vacuum hose
S Bolt Q Bolt
Install 2. Make sure that the drive tangs are correctly

located in the gearbox pump, When mating the
1. The installation procedure is the opposite of the gearbox/torque converter to engine.
steps. 3. It is vitally important that the torque converter
is installed at the gearbox and engine flywheel
correctly.
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4. Failure to locate the converter correctly will result

in damage to the gearbox oil pump on engine
start up.
5. When you are satisfied that the torque converter
is located correctly, use the access hole in the
bottom of the gearbox to install and tighten the
flexi-plate to engine flywheel retaining bolts.
6. Rotate the flywheel to align the next bolt hole.
7. Install and tighten all retaining bolts.
8. When installing the radiator sub-assembly,
including radiator, cooler and shroud take care
not to damage the engine fan.
9. Align the shroud using alignment mark.
10. Make sure that the front nose guard and the
engine cover are correctly aligned.
11. Fill the cooling system using correct mixture of
water/ anti-freeze.
12. Check engine, coolant and brake oil levels.
13. Make sure that the brake vacuum hose is
reconnected at the brake vacuum pump.
14. When connecting the battery, connect the earth
(black) lead last.
15. Make sure that the engine idle speed is correct,
adjust as required, refer to Technical Data.
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Store and Recommission 11. Seal the exhaust and intake ducts to prevent
contamination.
Consumables
Description Part No. Size 12. Clean the engine.
Cleaner/Degreaser 4104/1557 0.4L Refer to: PIL 15-00-00.
- General purpose
solvent based parts 13. Apply protective paints on non-painted parts.
cleaner 14. Loosen the alternator belt.
Engine Storage (up to 6 months) 15. Cover the engine with a proper protective sheet
to prevent it from dampness and atmospheric
Before you store the engine make sure that: contaminants.
• The environment is not humid or exposed to Engine Starting After Storage

bad weather.
• The storage place is not near an electrical 1. Remove the protective sheet.
panel.
• Prevent storing the engine in direct contact with 2. Use a cloth soaked in degreasing fluid to remove
the ground. the protective treatment from the external parts.
Consumable: Cleaner/Degreaser - General
1. Cover the engine with a proper protective sheet
purpose solvent based parts cleaner
to prevent it from dampness and atmospheric
contaminants. 3. Inject lubricating oil (not more than 2cm³) into the
intake ducts.
Engine Storage (over 6 months)
4. Adjust the alternator belt tension.
1. Follows the precautions mentioned in the above Refer to: PIL 15-18-00.
procedure.
5. Refuel the machine.
2. Fill the engine housing with protective oil up to
the maximum level. 6. Make sure that the oil and the coolant are up to
the maximum level.
3. Refuel the machine with fuel additives for long
storage. 7. Start the engine and run it at idle speed for the
specified duration.
4. For machines with expansion tank:
Duration: 2min
4.1. Make sure that the coolant is up to the
maximum level. 8. Bring the engine to 75% of the maximum rated
speed for the specified duration.
5. For machines without expansion tank:
Duration: 5–10min
5.1. Fill the coolant until the pipes inside the
9. Stop the engine.
radiator are covered by specified distance.
Distance: 5mm 10. While the oil is still hot, drain the protective oil in
a suitable container.
5.2. Do not overfill the radiator, but leave
sufficient space for the fuel to expand. 11. Put new oil up to the maximum level.
6. Start the engine and run it at idle speed for the 12. Replace the filters (air, oil, fuel).
specified duration.
13. Drain the cooling circuit completely and put new
Duration: 2min coolant up to the maximum level.
7. Bring the engine to 75% of the maximum rated
speed for the specified duration. Important: Over time, lubricants and filters lose their
properties, so it is important to consider whether they
Duration: 5–10min need replacing, also based on the criteria mentioned
in the maintenance schedules.
8. Turn off the engine.
If the engine is not to be used for an extended period,
9. Drain the fuel tank completely.
the protective treatment procedure must be repeated
10. Spray engine oil (SAE 10W40) on the exhaust within 730d of the previous one.
and intake manifolds.
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18 - Engine Belt
18 - Engine Belt
Contents Page No.
15-18-00 General ........................................................................................................................... 15-19

15-18-03 Drive Belt ....................................................................................................................... 15-21
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Notes:
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15 - Engine
18 - Engine Belt
00 - General
Introduction .................................................... 15-19 The crankshaft pulley is used to drive the coolant
Health and Safety .......................................... 15-20 pump through a drive belt. In addition to the coolant
pump the drive belt also drives the alternator.
The belt is maintained at a constant tension by
the alternator. 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 they include:
• Alternator
• Cooling fan
• Coolant pump
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15 - Engine
18 - Engine Belt
00 - General
Health and Safety

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.
engine cover open.
Notice: A drive belt that is loose can cause damage
to itself and/or other engine parts.
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15 - Engine
18 - Engine Belt
03 - Drive Belt
03 - Drive Belt Health and Safety

Notice: A drive belt that is loose can cause
Health and Safety .......................................... 15-21 damage to itself and/or other engine parts.
Check (Condition) .......................................... 15-22
Adjust ............................................................ 15-22
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15 - Engine
18 - Engine Belt
03 - Drive Belt
Check (Condition) Adjust
At the recommended service interval, visually inspect 1. Make the machine safe. Refer to (PIL 01-03).
the drive belt for damage.
2. Isolate the battery. Refer to (PIL 33-03).
3. Loosen the alternator.
3.1. Loosen pivot fastening bolt 1 and bolt 2.
2. Stop the engine and let it cool down.
3.2. Loosen tension adjustment link fastening
3. Replace the drive belt if it has cracks or if it is bolt 3 and bolt 4.
frayed or has pieces of material missing.
Figure 96.
D
A
B
A Bolt 1
B Bolt 2
C Bolt 3
D Bolt 4
4. Adjust the fan belt.
4.1. With the help of the marked straight edge,
press the belt inward as far as possible.
4.2. Make sure that the reading coinciding with
the undisturbed string should be specified
value.
Dimension: 10–15mm
4.3. If the tension is not within the limit adjust it
with the help of tension adjusting lever by
lowering or raising the alternator.
4.4. When the desired tension is achieved,
firmly clamp the alternator in position by
tightening all bolts.
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15 - Engine
18 - Engine Belt
03 - Drive Belt
Figure 97.
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15 - Engine
21 - Oil Filter
21 - Oil Filter
Contents Page No.
15-21-00 General ........................................................................................................................... 15-25
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15 - Engine
21 - Oil Filter
00 - General
Introduction .................................................... 15-25 The oil filter is a spin on type which screws on to the
Health and Safety .......................................... 15-26 filter head. The oil filter and cooler are incorporated in
a housing that is bolted to the side of the crankcase.
The housing allows transfer of lubricating oil from the

crankcase to the oil cooler and the oil filter head.
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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.
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15 - Engine
24 - Air Filter
24 - Air Filter
Contents Page No.
15-24-00 General ........................................................................................................................... 15-29

15-24-03 Outer Element ................................................................................................................ 15-32
15-24-09 Dust Valve ...................................................................................................................... 15-33
15-24-60 Pre-Cleaner .................................................................................................................... 15-34
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Notes:
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15 - Engine
24 - Air Filter
00 - General
Introduction .................................................... 15-29
Health and Safety .......................................... 15-30
Introduction
Check (Condition) .......................................... 15-30 Engine performance and durability will be severely
Remove and Install ....................................... 15-31 affected if the quality of the air intake is poor.
A dirty and blocked air filter will reduce the amount

of air entering the combustion chamber which can
cause engine misfiring, 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.
This is a dry-type air filter with a replaceable paper

filter cartridge.
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15 - Engine
24 - Air Filter
00 - General
Health and Safety Check (Condition)

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.
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15 - Engine
24 - Air Filter
00 - General
Remove and Install
Note: Do not attempt to wash or clean the elements, 2. Open the engine compartment cover. Refer to
they must only be renewed. (PIL 06-06).
Note: A new inner element must be installed at least 3. Depress the clips and lift off the cover.
every other time the outer element is changed. As a
reminder, mark the inner element with a felt tipped 4. Remove the outer element. Take care not to tap
pen each time the outer element is changed. or knock the element.
5. If the inner element is to be changed, lift up and
A typical air filter is shown below.
pull to remove the inner element.
Remove
Figure 98.
A Outer element B Inner element
Install
steps.
2. Clean inside the housing, and cover, make sure
that the air holes are clear.
3. Install the cover and fasten the latch. Make sure
that the dust valve is at the bottom.
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24 - Air Filter
03 - Outer Element
03 - Outer Element
Clean
Cleaning of outer filter element is to be done only

when, restriction indicator shows a red signal. For
cleaning, proceed as follows:
1. Remove the outer element. Refer to (PIL 15-24).

2. Do not remove the inner element (safety
element).
3. Use a damp cloth to wipe out excess dust in the
air cleaner and end cover.
4. Thorough cleaning of the element with
compressed air is recommended. Clean the
element from inside to outside using pressurised
air.
5. Too much air pressure can break the fibre paper
and destroy the element.
6. Knocking or tapping the filter is not
recommended. This will cause damage to the
filter which will result in dust entry into the engine.
7. Carefully check properly cleaned element for
damage before installing. If there is any crack in
the element, the light will pass through it, replace
the element.
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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 - 33 9813/8500-2 15 - 33
15 - Engine
24 - Air Filter
60 - Pre-Cleaner
60 - Pre-Cleaner
Clean
1. Remove the wingnut.
2. Lift the cover.
3. Carefully remove the dust bowl.
4. Remove the dust.
5. Make sure that the dust does not fall into the air
filter intake.
6. Clean the dust bowl.
7. Remove oil or grease by washing in hot water
with a little detergent.
8. Dry the dust bowl.
9. Carefully set the dust bowl in position.
10. Install the wingnut.
11. Tighten the wingnut .
Figure 99.
A
A Wingnut
B Cover
C Dust bowl
15 - 34 9813/8500-2 15 - 34
15 - Engine
57 - Oil Filler
57 - Oil Filler
Contents Page No.
15-57-00 General ........................................................................................................................... 15-37
15 - 35 9813/8500-2 15 - 35
Notes:
15 - 36 9813/8500-2 15 - 36
15 - Engine
57 - Oil Filler
00 - General
00 - General
Health and Safety

Notice: The oil level must be checked with the
machine level, otherwise a false indication of the
amount of oil will be given.
15 - 37 9813/8500-2 15 - 37
15 - Engine
72 - Alternator
72 - Alternator
Contents Page No.
15-72-00 General ........................................................................................................................... 15-39
15 - 38 9813/8500-2 15 - 38
15 - Engine
72 - Alternator
00 - General
Introduction .................................................... 15-39 The alternator is a three phase generator having a
Health and Safety .......................................... 15-40 rotating field winding and static power windings.
Check (Condition) .......................................... 15-40
When the ignition switch is turned on, the current
from the battery flows by way of the No Charge
warning light to the field winding. This creates
a magnetic field which supplements the residual
magnetism in the rotor poles. As the engine is
started, the FEAD (Front End Accessory Drive)
belt drives the rotor and the alternating current is
generated in the power windings as they are cut by
the rotating magnetic field. Output is controlled by a
solid state regulator which varies the field current in
accordance with electrical demand.
15 - 39 9813/8500-2 15 - 39
15 - Engine
72 - Alternator
00 - General

• Ensure that the battery negative terminal is
connected to the earthing cable. Charging Circuit Test
• Never make or break connections to the battery
or alternator, or any part of the charging circuit 1. Make sure that all the battery and alternator
whilst the engine is running. Disregarding this connections are in place, secure and making
instruction will result in damage to the regulator good metal - to - metal contact, especially the
or rectifying diodes. earth connections to chassis and engine.
• Main output cables are 'live' even when the 2. Adjust the alternator drive belt tension if
engine is not running. Take care not to earth necessary and make sure that the battery is well
connectors in the moulded plug if it is removed charged.
from the alternator.
• During arc welding on the machine, protect the 3. Turn the ignition switch to the ON position. Oil
alternator by removing the moulded plug (or if pressure and ''No Charge'' warning lights should
separate output cables installed, remove the glow. If any light fails, re-check the connections.
cables).
• If slave starting is necessary, connect the 4. Start the engine; all warning lights should
second battery in parallel without disconnecting extinguish rapidly. If the ''No Charge'' warning
the vehicle battery from the charging circuit. light remains ON, re-check the alternator drive
The slave battery may then be safely removed belt tension and that the battery is charged. If
after a start has been obtained. Take care to the oil pressure warning remains on stop the
connect batteries positive to positive, negative engine Immediately and investigate the engine
to negative. lubrication system.
Check 1
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 100.
Check 2
The following checks should be made using an
analogue (moving pointer) type Multimeter.
15 - 40 9813/8500-2 15 - 40
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 101. 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 102.
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 102. 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 - 41 9813/8500-2 15 - 41
15 - Engine
72 - Alternator
00 - General
12.6. Open or short circuited power (stator)

windings.
13. To check for a fault, disconnect the capacitor and
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.
15 - 42 9813/8500-2 15 - 42
15 - Engine
75 - Starter Motor
75 - Starter Motor
Contents Page No.
15-75-00 General ........................................................................................................................... 15-45
15 - 43 9813/8500-2 15 - 43
Notes:
15 - 44 9813/8500-2 15 - 44
15 - Engine
75 - Starter Motor
00 - General
Introduction .................................................... 15-45 The electric starter motor is either a permanent-
Health and Safety .......................................... 15-46 magnet or a series-parallel wound direct current
Check (Condition) .......................................... 15-46 electric motor with a starter solenoid mounted on to
Remove and Install ....................................... 15-48 it. When the current from the battery is applied to the
solenoid, through the key-operated ignition switch,
the solenoid engages a lever that pushes out the
drive pinion on the starter driveshaft and meshes the
pinion with the starter ring gear on the flywheel of the
engine.
The solenoid also closes high current contacts for the

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

use, the electrical components are designed only
to operate for a time period of 30 seconds before
overheating.
15 - 45 9813/8500-2 15 - 45
15 - Engine
75 - Starter Motor
00 - General

WARNING Make the machine safe before
working on it. Park the machine on level ground Before carrying out the multimeter tests, check
and lower the loader arm. Stop the engine and the battery condition and make sure that all the
remove the ignition key. Make sure the park brake applicable electrical connections are clean and tight.
is engaged. Disconnect the battery to prevent the Make sure that the starter motor fixing bolts are
engine being started. Block all four wheels. tightened to the correct torque.
Notice: Before carrying out arc welding on the To prevent the engine starting during the tests make
machine, disconnect the battery and alternator to sure that the applicable engine stop fuse is removed.
protect the circuits and components. The battery
must still be disconnected even if a battery Check the readings in the following sequence using
isolator is installed. a multimeter. Unless otherwise stated, the readings
Notice: Do not isolate the machine electrics must be taken with the ignition switch held in the
when the engine is running, this may cause start position (HS) and the controls set to enable
damage to the machine electrics. 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
system before carrying out the tests.
Do not operate the starter motor for more than 20s at

one time. Let the starter motor cool for at least 2min
between starts.
1. Connect the multimeter across the battery

terminals.
Figure 103.
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 - 46 9813/8500-2 15 - 46
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 105. 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 107.
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 - 47 9813/8500-2 15 - 47
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.
6. Connect the voltmeter between battery positive
Remove
and the starter main terminal. With the starter 1. Disconnect the battery leads. Make sure you
switch off, the voltmeter should indicate battery disconnect the earth lead first.
voltage, but it should fall to practically zero when
the switch is turned to the on position, maximum Refer to: PIL 33-03-00.
permissible reading
2. Disconnect the starter motor electrical
Voltage: 0.25V connections.
Figure 108. 3. Support the starter motor and remove the
mounting bolts.
4. Disengage the pinion from the flywheel gear
teeth and remove the stater motor.
Figure 110.
B
A
A Starter main terminal

7. If the reading is above the maximum permissible
voltage, a high resistance is present in the
insulated lead or in the solenoid. Connect the
multimeter between the battery positive and
solenoid connection. If the multimeter now reads
zero with the switch closed, the fault is in the
solenoid.
Figure 109.
B
A Stater Motor
B Bolts
Install
1. Put the starter motor in position and align the
pinion in the flywheel gear teeth.
H Battery positive and solenoid connection
2. Install the mounting bolts.
8. Finally install the engine stop fuse.
3. Connect the electrical connections.
4. Connect the battery terminals. Make sure you
connect the earth lead last.
15 - 48 9813/8500-2 15 - 48
15 - Engine
75 - Starter Motor
00 - General

Item Nm
B 45
15 - 49 9813/8500-2 15 - 49
15 - Engine
87 - Switch
87 - Switch
Contents Page No.
15-87-18 Air Filter Vacuum ............................................................................................................ 15-51
15 - 50 9813/8500-2 15 - 50
15 - Engine
87 - Switch
18 - Air Filter Vacuum
18 - Air Filter Vacuum
Operation
The vacuum filter service indicator is installed on the

air cleaner or air induction piping so that it has access
to clean filtered air (between the air filter and the
engine).
The air filter service indicator is a simple device that

accurately detects any restrictions in the air induction
system.
As the air filter gets choked and restriction increases,

the red position indicator moves in the clear window
and locks at a point in between the zone. When
it reaches and locks in the zone, the air filter
should be cleaned or changed as mentioned in the
maintenance section and the indicator should be set
to zero.
Set the indicator by pushing the reset button on the

top of the indicator.
Figure 111.
C
A Indicator
B Zone
C Reset button
15 - 51 9813/8500-2 15 - 51
15 - Engine
90 - Air Intake
90 - Air Intake
Contents Page No.
15-90-00 General ........................................................................................................................... 15-53
15 - 52 9813/8500-2 15 - 52
15 - Engine
90 - Air Intake
00 - General
00 - General
Check (Condition)
15 - 53 9813/8500-2 15 - 53
Notes:
15 - 54 9813/8500-2 15 - 54
Contents Page No.
18-00 Fuel and Exhaust System

18-00-00 General ............................................................................................................................. 18-3
18-03 Tank
18-03-00 General ............................................................................................................................. 18-9
18-06 Level Sender
18-06-00 General ........................................................................................................................... 18-15
18-09 Filter
18-09-00 General ........................................................................................................................... 18-17
18-12 Water Separator
18-12-00 General ........................................................................................................................... 18-21
18-24 Exhaust
18-24-00 General ........................................................................................................................... 18-23
18-24-03 Inlet Manifold .................................................................................................................. 18-25
18-24-04 Outlet Manifold ............................................................................................................... 18-27
18-96 Fuel Pipe
18-96-00 General ........................................................................................................................... 18-29
9813/8500-2
2017-08-16
Acronyms Glossary
DEF Diesel Exhaust Fluid

EGR Exhaust Gas Recirculation
NOx Nitrogen Oxide
SCR Selective Catalytic Reduction
9813/8500-2
2017-08-16
Contents Page No.
18-00-00 General ............................................................................................................................. 18-3
18 - 1 9813/8500-2 18 - 1
Notes:
18 - 2 9813/8500-2 18 - 2
00 - General

Health and Safety ........................................... 18-3 Fuel
Clean ............................................................... 18-4 Fuel is flammable, keep naked flames away from the
Bleed ............................................................... 18-6 fuel system. Stop the engine immediately if a fuel
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
injury if you do not follow these precautions.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear personal protective equipment.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help
immediately.
WARNING! Do not open the high pressure fuel
causes high fuel pressure. High pressure fuel spray
can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow these
instructions will lead to dirt entering the fuel system.
Dirt in the fuel system will seriously damage the fuel
injection equipment and could be expensive to repair.
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 - 3 9813/8500-2 18 - 3
00 - General
Clean • Gases - Air, sulphur dioxide etc. which can

create corrosive compounds if dissolved in the
fluid.
Cleanliness Requirements
These contaminants can appear during
Important: Additional cleaning must be carried out manufacture, assembly, operation and maintenance.
prior to working on the high pressure fuel system.
It is extremely important the high pressure fuel The fuel filter is rated at 5 micron = 0.005mm
components and the adjacent parts of the engine (0.0002in). Listed are a few typical comparisons of
are meticulously cleaned before any components are micron size:
removed. Refer to: Effects of Contamination.
Figure 112.
Before starting work on the high pressure fuel
system, make sure that the working environment
is suitable. Refer to: Maintenance Environment,
Common Rail Fuel Injection.
1. Obey all fuel system health and safety

information. C
Refer to: PIL 18-00-00. B
2. Clean the machine, prior to completing any

maintenance work. A
3. Clean the engine.
Refer to: PIL 15-00-00. A 8 microns
B 70 microns
4. Remove the hoses, electrical harnesses and C 100 microns
ancillaries to improve access and expose any
remaining trapped dirt close to the relevant high • Red Blood Cell = 8 microns (0.008mm,
pressure components. 0.000315in).
• Human Hair = 70 microns (0.07mm, 0.00275in).
5. Wash away any remaining dirt or debris and then • Grain of Salt = 100 microns (0.1mm,
dry the area using a compressed air jet. When 0.00394in).
the area is dry use a soft clean brush to remove • The smallest particle visible to the naked eye is
sand or grit particles that remain. 40 microns (0.00157in) approximately.
Effects of Contamination The fuel filter must be changed in accordance with
the applicable service schedule and procedures. The
While the requirement for a good level of cleanliness water in fuel sensor must be maintained to make sure
is well known and common practice, the introduction of correct operation at all times.
of high pressure common rail fuel injection
necessitates working to new levels of cleanliness. The potential for engine damage due to fuel
contamination is much greater when using common
Once inside the system, fuel circuit contaminants rail injection technology than with mechanical
greatly affect the performance and life of the fuel injection systems. This is because common rail
injection equipment. For example, contaminants in requires components with smaller manufacturing
the fuel pump will develop internal wear to cause tolerances, especially the fuel injectors. In addition,
internal leakage and hence lower discharges. Use common rail operates at much higher fuel pressures,
of poor quality fuels and poor maintenance could over five times that of mechanical systems.
also lead to contaminants entering the fuel injectors.
There is a possibility of catastrophic equipment Similar pressures are used by commercial water
failure if debris should prevent the injectors from fully jet cutting machines to cut metal. Fortunately clean
closing. The main contaminants can be classified as diesel fuel has lubricating qualities that prevents
follows: erosion of components but it is obvious that
contaminated fuel will cause serious damage at such
• Solid Particles - sand, fibres, metallic particles, high pressures.
welding scale, sealing materials and wear
particles etc.
• Liquid - usually water and incompatible oils and
greases.
18 - 4 9813/8500-2 18 - 4
00 - General
Maintenance Environment, Common Rail • Wear a new disposable environmental type suit
Fuel Injection when working on the fuel system. If it becomes
contaminated with mud, move away from the
Depending on circumstances engine maintenance engine and change into a new suit.
may be required in various working environments. • Use clean latex gloves (non-powdered).
Obviously procedures are best carried out in a • Before you start work make sure that all the
dedicated workshop equipped with a suitable clean required replacement parts and tools are on
room, but in practice this is not always possible. site. Make sure that the replacement parts are
still sealed inside their packaging.
Maintenance procedures requiring removal or • Put caps on all exposed ports and orifices
replacement of fuel system components, particularly immediately. Do not leave them open.
high pressure components, require special • High pressure fuel pipes MUST BE RENEWED
precautions to make the working environment if any pipe joint is loosened or disconnected. DO
suitable, reducing the risk of contamination to an NOT re-use the original pipe.
absolute minimum.
Vehicle Maintenance Workshop
Use the following guidelines to make sure you reduce
the chances of fuel system contamination when Unless the workshop has a dedicated `sealable
working in different environments: clean room' work bay, precautions must still be taken.
Worksite - Open to weather • Clean the engine. Clean the engine in the
dedicated area and then move it to the
This repair site is not an acceptable location. Only workshop.
in extreme circumstances should a machine be • Clean the floor area around the machine.
repaired on an open site. Use the guidelines below: • Erect clean plastic sheeting to shelter the
engine from any wind and the possibility of
• Clean the engine. If the machine is on hard debris such as dirt and dust falling from above.
standing, clean away the material washed from • Make sure that workshop doors to the outside
the engine. are kept closed. A gust of wind through an open
• Place suitable clean boards on the ground door will easily blow sand particles into the air.
around the machine. • Make sure your work wear is clean, non-flocking
• Erect clean plastic sheeting to shelter the and lint free. If in doubt wear a new disposable
engine from wind and rain. environmental type suit.
• Wear a new disposable environmental type suit • Use clean latex gloves (non-powdered).
when working on the fuel system. If the suit • Before you start work make sure that all the
becomes contaminated with mud, move away required replacement parts and tools are on
from the engine and change into a new suit. site. Make sure that the replacement parts are
• Use clean latex gloves (non-powdered). still sealed inside their packaging.
• Before you start work make sure that all the • Put caps on all exposed ports and orifices
required replacement parts and tools are on immediately. Do not leave them open.
site. Make sure that the replacement parts are • High pressure fuel pipes MUST BE RENEWED
still sealed inside their packaging. if any pipe joint is loosened or disconnected. DO
• Put caps on all exposed ports and orifices NOT re-use the original pipe.
immediately. Do not leave them open.
• High pressure fuel pipes MUST BE RENEWED
if any pipe joint is loosened or disconnected. DO
NOT re-use the original pipe.
Worksite - Closed to weather from above
This repair site is the least acceptable condition,

if possible move the machine to a more suitable
environment. Use the guidelines below:
• Clean the engine. Clean the floor of all material

washed from the engine.
• Place suitable clean boards on the ground
around the machine.
• Erect clean plastic sheeting to shelter the
engine from the wind and the possibility of
debris such as dirt and dust falling from above.
18 - 5 9813/8500-2 18 - 5
00 - General
Bleed Figure 114.
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.
D
Air in the fuel system could cause misfiring or failure
to start. Air will enter the fuel system if any part of the
system has been drained or disconnected.
To bleed the system do the steps that follow:

2. Loosen the air vent screw, located on the fuel
filter.
C
Figure 113.
C Feed pump
D Vent screw
B 6. Loosen the connecting union nuts at the
injectors.
7. Crank the engine until air free fuel flows from the
connections.
Important: If the engine continues to run roughly,

check again for air in the fuel system. If the fault
persists contact your nearest JCB dealer.
If the engine runs smoothly for a short time, and then

begins to run roughly or stops, check all seals and
connections especially in the low pressure side of the
system.
A
A Fuel filter
B Air vent screw
3. Operate the fuel lift pump (feed pump) until fuel
oil flows without air bubbles.
4. Tighten the air vent screw on the fuel filter.
5. Similarly bleed the pump by opening the vent
screw on top of it and tighten it after removing air
locks.
18 - 6 9813/8500-2 18 - 6
03 - Tank
03 - Tank
Contents Page No.
18-03-00 General ............................................................................................................................. 18-9
18 - 7 9813/8500-2 18 - 7
Notes:
18 - 8 9813/8500-2 18 - 8
03 - Tank
00 - General
Introduction ...................................................... 18-9 The fuel tank is a safe container for storing flammable
Remove and Install ....................................... 18-10 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 - 9 9813/8500-2 18 - 9
03 - Tank
00 - General
Remove and Install
Consumables 6.1. Remove the rear fender extension from the

Description Part No. Size machine, if attached.
JCB High Strength 4102/0551 0.05L 7. Disconnect the fuel feed and return hoses from
Threadlocker the fuel tank. Refer to Figure 115.
JCB Threadseal 4102/1951 0.05L
7.1. Put labels on the fuel feed and return hoses
Remove to help identification.
1. Make the machine safe. Refer to (PIL 01-03). 8. Disconnect the fuel sender electrical harness
connector from the fuel tank. Refer to Figure 115.
1.1. Obey the safety instructions.
9. Remove the bolts that attach the steps to the fuel
2. Disconnect the battery. Refer to (33-03). tank.
3. Get access to the fuel tank. Refer to Figure 115. 9.1. Use a suitable device to support the steps,
before you remove the bolts.
4. Drain the fuel from the fuel tank. Refer to Figure
9.2. Remove the steps from the fuel tank.
115.
10. Remove the bolts that attach the fuel tank to the
4.1. Put a suitable clean container below the fuel
chassis frame. Refer to Figure 115.
tank.
4.2. Remove the drain plug from the fuel tank. 10.1. Use a suitable device to support the fuel
Refer to Figure 115. tank, before you remove the bolts.
10.2. Remove the fuel tank from the machine.
5. Remove the plastic trim from the machine.
6. Remove the bolts that are attached to the rear
fender extension.
18 - 10 9813/8500-2 18 - 10
03 - Tank
00 - General
Figure 115.
E
D
B
A
A Drain plug B Suction hose

C Harness connector - fuel sender D Pipe stub
E Bolt
18 - 11 9813/8500-2 18 - 11
03 - Tank
00 - General
Install
procedure.
2. If a new fuel tank is being installed, remove the
fuel level sender from the old tank and install it
to the new tank.
3. Make sure that the fuel return and feed hoses are
attached to the correct connectors.
4.1. Apply sealant to the threads of the drain
plug.
Consumable: JCB Threadseal
4.2. Replace the drain plug O-ring with a new
one.
5.1. Apply sealant to the threads of the bolts.
Consumable: JCB High Strength
Threadlocker
6. Fill the fuel tank with clean fuel.
7. Make sure that all the fuel tank connections are
tightened correctly.
7.1. Check the connections for leakage.

Item Nm
A 85
E 83
18 - 12 9813/8500-2 18 - 12
06 - Level Sender
06 - Level Sender
Contents Page No.
18-06-00 General ........................................................................................................................... 18-15
18 - 13 9813/8500-2 18 - 13
Notes:
18 - 14 9813/8500-2 18 - 14
06 - Level Sender
00 - General
00 - General 4. Apply JCB Threadlocker and Sealer to all the

bolts.
Remove and Install Consumable: JCB Threadlocker and Sealer

(Medium Strength)
Consumables
5. Tighten the bolts to the specified correct torque
value.
JCB Threadlocker 4101/0250 0.01L
and Sealer (Medium Torque: 7N·m
4101/0251 0.05L
Strength)
Remove
2. Remove the fuel tank from the machine to get
access to remove the fuel level sender unit. Refer
to (PIL 18-03).
3. Disconnect the electrical harness connector from
the fuel sender.
4. Remove the bolts that attach the fuel level sender
flange to the fuel tank. Refer to Figure 116.
5. Carefully lift the fuel level sender out of the tank
aperture. Refer to Figure 116.
5.1. Remove the fuel level sender unit from the
fuel tank.
Figure 116.
A
D
C
A Fuel tank
B Fuel level sender unit
C Bolts
D Gasket
Install
procedure.
2. Examine the gasket to make sure it is clean and
in good condition.
2.1. Replace the gasket, if necessary.
3. When you install the fuel level sender, make sure
that the float arm is orientated towards the front
of the machine.
18 - 15 9813/8500-2 18 - 15
09 - Filter
09 - Filter
Contents Page No.
18-09-00 General ........................................................................................................................... 18-17
18 - 16 9813/8500-2 18 - 16
09 - Filter
00 - General
Introduction .................................................... 18-17 The fuel filter consists of a paper element folded in
Operation ....................................................... 18-18 such a way as to give a very large surface area. It is
Drain and Fill ................................................. 18-18 most important that the fuel filter is changed regularly
in accordance with the machine service schedule.
Use only the correct specification filters.
18 - 17 9813/8500-2 18 - 17
09 - Filter
00 - General
Operation Drain and Fill
Fuel is supplied to the fuel pump by a fuel lift pump 1. Make the machine safe. Refer to (PIL 01-03).
(feed pump) incorporated in the fuel pump itself. A
water separator and a coarse filter (mud filter) are 2. Open the engine cover. Refer to (PIL 06-06-06).
used in the fuel line from tank to feed pump. A dual 3. Loosen the drain plug at the bottom of the filter
fuel filter consisting of an efficient 'pre' and 'micro' bowls.
filter elements are used in the fuel line from feed
pump to fuel pump. 4. Loosen the center bolts and remove the bowls.
Figure 117.
A Fuel filter
B Center bolts
Mud Filter
Change the element of the mud filter. Also clean the
inside of the filter bowl using diesel. If a bowl type
strainer (instead of mud filter) is installed to your
engine, clean the bowl type strainer with diesel oil.
18 - 18 9813/8500-2 18 - 18
12 - Water Separator
Contents Page No.
18-12-00 General ........................................................................................................................... 18-21
18 - 19 9813/8500-2 18 - 19
Notes:
18 - 20 9813/8500-2 18 - 20
00 - General
00 - General
Drain and Fill
Drain the water separator every 50h or earlier if water

contamination is excessive.
If the water separator is not drained periodically,

water may rust internal engine components and
render them unserviceable.

2. Open the engine cover. Refer to (PIL 06-06-06).
3. Remove the drain plug from the bottom of the
filter to drain the water.
4. When the water is drained off, install the drain
plug.
Figure 118.
A Drain plug
18 - 21 9813/8500-2 18 - 21
24 - Exhaust
24 - Exhaust
Contents Page No.
18-24-00 General ........................................................................................................................... 18-23

18-24-03 Inlet Manifold .................................................................................................................. 18-25
18-24-04 Outlet Manifold ............................................................................................................... 18-27
18 - 22 9813/8500-2 18 - 22
24 - Exhaust
00 - General
Introduction .................................................... 18-23 The exhaust system is used to guide exhaust gases
Health and Safety .......................................... 18-24 away from the controlled combustion inside the
Check (Condition) .......................................... 18-24 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 - 23 9813/8500-2 18 - 23
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
engine cover open.
18 - 24 9813/8500-2 18 - 24
24 - Exhaust
03 - Inlet Manifold
03 - Inlet Manifold Introduction

Introduction .................................................... 18-25 On compression ignition (diesel) engines, the inlet
Check (Condition) .......................................... 18-26 manifold (also called the intake manifold) is the
part of the air intake system that distributes air for
combustion to the cylinders via each inlet port in
the cylinder head. The design of the manifold is
important to make sure that air is distributed as
evenly as possible under all engine speed and load
conditions.
18 - 25 9813/8500-2 18 - 25
24 - Exhaust
03 - Inlet Manifold
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
18 - 26 9813/8500-2 18 - 26
24 - Exhaust
04 - Outlet Manifold
04 - Outlet Manifold
Check (Condition)
1. Check the manifold mating faces for signs of
damage and distortion.
2. Check the manifold casting for signs of cracks.
3. Renew the manifold if there are any signs of
defect.
4. Visually inspect for leaks at the exhaust manifold.
Make sure all gaskets are in good condition,
replace as required.
18 - 27 9813/8500-2 18 - 27
96 - Fuel Pipe
96 - Fuel Pipe
Contents Page No.
18-96-00 General ........................................................................................................................... 18-29
18 - 28 9813/8500-2 18 - 28
96 - Fuel Pipe
00 - General
Introduction .................................................... 18-29 Important: The high pressure fuel pipes must be
Health and Safety .......................................... 18-30 replaced every time they are removed. If you install
the original pipes, it will cause leaks at the fuel pipe
connections.
High Pressure Pipe

The high pressure pipes are thick walled and
seamless tubes made of steel. The high pressure
fuel pipes supply pressurised fuel from the high
pressure fuel pump to the fuel rail. From the rail, fuel
is supplied to the electronic injectors through the high
pressure pipes.
The ends of the tubes are formed with conical nipples

for proper installation in the sealing cones on the fuel
rail and on the injector port.
Low Pressure Pipe

During fuel injection some fuel bleeds off the
electronic injectors and is sent back to the tank
through the low pressure pipes. The return fuel
from the high pressure fuel pump is also transferred
through the low pressure pipe.
All the low pressure return fuel is collected at a

common fuel distributor and is sent to the tank
through the low pressure pipes.
The low pressure fuel pipe also supplies low

pressure fuel from the tank to the high pressure pump
through the fuel filter.
18 - 29 9813/8500-2 18 - 29
96 - Fuel Pipe
00 - General
Health and Safety

WARNING Do not open the high pressure fuel
causes high fuel pressure. High pressure fuel
spray can cause serious injury or death.
Notice: Do not allow dirt to enter the fuel system.
Before disconnecting any part of the fuel system,
thoroughly clean around the connection. When a
component has been disconnected, for example
a fuel pipe, always install protective caps and
plugs to prevent dirt ingress. Failure to follow
these instructions will lead to dirt entering the
fuel system. Dirt in the fuel system will seriously
damage the fuel injection equipment and could be
expensive to repair.
18 - 30 9813/8500-2 18 - 30
21 - Cooling System
Contents Page No.
21-00 Cooling System

21-00-00 General ............................................................................................................................. 21-3
21-03 Cooling Pack
21-03-00 General ........................................................................................................................... 21-11
21-09 Pump
21-09-00 General ........................................................................................................................... 21-19
21-12 Thermostat
21-12-00 General ........................................................................................................................... 21-23
21-93 Hose
21-93-00 General ........................................................................................................................... 21-29
9813/8500-2
2017-09-21
Acronyms Glossary
CAC Charge Air Cooler

ECM Engine Control Module
9813/8500-2
2017-09-21
21 - Cooling System
00 - Cooling System
00 - Cooling System
Contents Page No.
21-00-00 General ............................................................................................................................. 21-3
21 - 1 9813/8500-2 21 - 1
Notes:
21 - 2 9813/8500-2 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
Fault-Finding .................................................... 21-5 kept at its normal operating temperature to achieve
Drain and Fill ................................................... 21-7 maximum efficiency. It is the function of the cooling
system to allow the engine to reach this temperature
Check (Leaks) ................................................. 21-7 quickly and then maintain it.
Check (Level) .................................................. 21-8
21 - 3 9813/8500-2 21 - 3
21 - Cooling System
00 - Cooling System
00 - General
Health and Safety

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the
cap, hot coolant can spray out and burn you.
Make sure that the engine is cool before you work
on the cooling system.
CAUTION Antifreeze can be harmful. Obey the
manufacturer's instructions when handling full
strength or diluted antifreeze.
21 - 4 9813/8500-2 21 - 4
21 - Cooling System
00 - Cooling System
00 - General
Fault-Finding
Fault
Coolant - Loss. Table 7. Page 21-5
Coolant - Over Temperature. Table 8. Page 21-5
Coolant - Under Temperature. Table 9. Page 21-6
Coolant - Contaminated. Table 10. Page 21-6
Table 7. 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 8. 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.
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 8. Coolant - Over Temperature.

Cause Remedy
Incorrect coolant level (low). Check the level.
See Also: Table 7. Coolant - Loss.
External radiator matrix blocked with dirt or chaff. Clean exterior or radiator matrix.
Air flow to the radiator inadequate or restricted. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Coolant pump or fan drive belts loose. Check/correct belt tension.
Radiator hose collapsed, restricted or leaking. Check/replace hose.
Oil level overfilled. Check oil level.
Cooling system pressure cap incorrect or faulty. Replace cap with the correct rating for the system.
Over concentration of anti-freeze. Remove part of the coolant from cooling system and
replace with water.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, incorrect or missing. Check/replace the thermostat.
Air or combustion gases in the cooling system. Make sure the fill rate is not exceeded and the
correct vented thermostat is installed. If aeration
continued, check for a compression leak through the
head gasket.
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 - 5 9813/8500-2 21 - 5
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 (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 injector worn or malfunctioning. Check the electronic fault codes. Check the electrical
connections at the injectors.
Table 9. Coolant - Under Temperature.

Cause Remedy
Air flow across the radiator excessive. Check/repair fan shroud, anti-recirculation sealing,
shutters, fan sensors, fan speeds as required.
Temperature sensor gauge faulty. Check the electronic fault codes. Verify that the
gauge and temperature sensor are accurate.
Thermostat faulty, (open - not sealing). Check/replace the thermostat.
Coolant not flowing by temperature sensor. Check/clean coolant passages. A total coolant loss
may result in the gauge showing low temperature
initially. In which case, check the level.
Table 10. 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 7. Coolant - Loss.
gasket, head and crankcase.
21 - 6 9813/8500-2 21 - 6
21 - Cooling System
00 - Cooling System
00 - General
Drain and Fill Check (Leaks)

Consumables
Description Part No. Size Before you start the machine, inspect the system for
Antifreeze HP/ 4006/1101 5L leaks:
Coolant ASTM D6210 4006/1120 20L 1. Make the machine safe.
Concentrate 4006/1103 200L
Readymix Antifreeze 4006/1110 5L
HP/Coolant ASTM 4006/1115 20L 2. Get access to the cooling pack.
D6210 50/50 4006/1125 200L 3. Check under the cooling pack and cooling hoses
for signs of leaks.
Visually check the coolant level daily.
4. Repair or replace any damaged components
Check the quality of the antifreeze mixture and before starting the machine.
change it according to the service schedule.
1. Open the engine compartment cover. Refer to

(PIL 06-06).
2. Make sure that the coolant level should be
between the MIN and the MAX marks on coolant
reservoir.
3. If the level in the expansion bottle is low, then
continue with steps 4 to 9.
4. Carefully loosen the cap just enough to let any
pressure escape.
5. Remove the cap when all pressure is released.
6. Fill with pre-mixed water/antifreeze until it
reaches the correct level.
7. Fill the expansion tank, using the necessary anti-
freeze solution, to the level indicated.
Consumable: Antifreeze HP/Coolant ASTM
D6210 Concentrate
Consumable: Readymix Antifreeze HP/Coolant
ASTM D6210 50/50
7.1. Note: Only the domestic machines use the
Readymix Antifreeze (JCB Ready to use)
coolant.
8. Run the engine for a while to raise the coolant to
working temperature and pressure.
9. Stop the engine and checks for leaks.
21 - 7 9813/8500-2 21 - 7
21 - Cooling System
00 - Cooling System
00 - General
Check (Level)
Refer to: PIL 01-03.
2. Get access to the coolant expansion tank.
3. Check the level of coolant in the coolant
expansion tank. If necessary remove the filler
cap and top up to the level indicated.
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 - 8 9813/8500-2 21 - 8
21 - Cooling System
03 - Cooling Pack
03 - Cooling Pack
Contents Page No.
21-03-00 General ........................................................................................................................... 21-11
21 - 9 9813/8500-2 21 - 9
Notes:
21 - 10 9813/8500-2 21 - 10
21 - Cooling System
03 - Cooling Pack
00 - General
Introduction .................................................... 21-11 The cooling pack contains the following major
Clean ............................................................. 21-12 components:
Disassemble and Assemble .......................... 21-16 • Radiator.
• Cooling fan.
• CAC (Charge Air Cooler).
• Condenser for air-conditioning (if installed).
• Oil cooler (if installed).
21 - 11 9813/8500-2 21 - 11
21 - Cooling System
03 - Cooling Pack
00 - General
Clean
The cooling pack is located in front of the engine,

the pack consists of the engine cooling radiator,
hydraulic oil cooler, intercooler and air-conditioning
condenser (optional). If the cooler tubes/fins get
clogged (by dirt and flies etc.) the radiator and
coolers will be less efficient.
1. Remove the front grille.

2. Brush off all debris from the cooler tubes and fins.
Make sure the loosened material is brushed out
of the cooler enclosure.
2.1. When cleaning the matrix make sure that
the brush follows the same direction as the
fins are to avoid damaging them. Damaged
fins will reduce the cooling efficiency of the
matrix.
3. Install the front grille.
Machines with air conditioning have a condenser

matrix installed in front of the oil cooler, the fins
of the condenser matrix may get clogged. In this
case, clean the tubes/fins of the condenser matrix as
described above.
Figure 119.
21 - 12 9813/8500-2 21 - 12
21 - Cooling System
03 - Cooling Pack
00 - General
Remove and Install
Remove 7.1. Put a label on the hoses to help installation.

7.2. Disconnect the radiator top and bottom
1. Make the machine safe with the loader arm
hoses.
raised.
Refer to: PIL 01-03-12. 7.3. Plug all the open ports and hoses to prevent
contamination.
8. Remove the setscrews 1 (x2) and clips 2 (x2).
9. Remove the bolts 1 (x4) and washers 1 (x4) from
3. Open the engine compartment cover. the sealing plate.
10. Remove the setscrews 2 (x3) and washers 2 (x3)
4. Remove the side grille. from the baffle plate.
5. Remove the front grille housing. 11. Support the cooling pack assembly and remove
the bolts 2 and nuts 1 from each side of the
6. Drain the engine coolant. cooling pack.
Refer to: PIL 21-00. 12. Attach a suitable lifting equipment to the cooling
pack.
7. Loosen the clips 1 (x2) that attaches the radiator
top and bottom hoses to the engine. 13. Remove the cooling pack from the machine.
21 - 13 9813/8500-2 21 - 13
21 - Cooling System
03 - Cooling Pack
00 - General
Figure 120.
K
J
N
M
F
G
A Cooling pack B Hoses

C Clip 1 D Setscrews 1
E Clips 2 F Bolts 1
G Washers 1 H Sealing plate
J Setscrews 2 K Washers 2
L Baffle plate M Bolts 2
N Nuts 1
21 - 14 9813/8500-2 21 - 14
21 - Cooling System
03 - Cooling Pack
00 - General
Install
1. The installation is the opposite of the removal
procedure. Additionally do the following steps.
2. Top up the engine cooling system to the correct
level.
3. Operate the engine at idle speed.
3.1. Check the oil coolers, and the engine
cooling system for leaks.
4. Stop the engine.
4.1. Check the coolant and hydraulic oil are at
the correct levels. If necessary, add fluid to
the correct level.
21 - 15 9813/8500-2 21 - 15
21 - Cooling System
03 - Cooling Pack
00 - General

1. Remove the cooling pack.
2. Disassemble the individual components as
necessary.
21 - 16 9813/8500-2 21 - 16
21 - Cooling System
09 - Pump
09 - Pump
Contents Page No.
21-09-00 General ........................................................................................................................... 21-19
21 - 17 9813/8500-2 21 - 17
Notes:
21 - 18 9813/8500-2 21 - 18
21 - Cooling System
09 - Pump
00 - General
Introduction .................................................... 21-19 The coolant pump is a centrifugal type located in the
Component Identification ............................... 21-20 front of the crankcase, driven by the engine drive belt.
The impeller rotates to circulate the coolant through

the cooling system. The pump shaft bearing and seal
are not renewable.
21 - 19 9813/8500-2 21 - 19
21 - Cooling System
09 - Pump
00 - General
Figure 121.
A Water pump
B Water intake
21 - 20 9813/8500-2 21 - 20
21 - Cooling System
12 - Thermostat
12 - Thermostat
Contents Page No.
21-12-00 General ........................................................................................................................... 21-23
21 - 21 9813/8500-2 21 - 21
Notes:
21 - 22 9813/8500-2 21 - 22
21 - Cooling System
12 - Thermostat
00 - General
Introduction .................................................... 21-23 The thermostat is installed on the cylinder head. It is
Component Identification ............................... 21-24 located between the engine and the radiator in the
Operation ....................................................... 21-25 cooling circuit.
Check (Condition) .......................................... 21-26
The function of the thermostat is to block the flow of
Check (Operation) ......................................... 21-26 coolant to the radiator until the engine has warmed
up to a sufficient temperature.
When the engine is cold, no coolant flows through

the engine. Once the engine reaches its operating
temperature, refer to Cooling System - Technical
Data, the thermostat opens. By letting the engine
warm up as quickly as possible, the thermostat
reduces engine wear, deposits and emissions. Refer
to: PIL 21-00-00.
21 - 23 9813/8500-2 21 - 23
21 - Cooling System
12 - Thermostat
00 - General
Figure 122. Thermostat
A Cylinder head B Water outlet cover

C Thermostat D Gasket
E Air bleeding hole
21 - 24 9813/8500-2 21 - 24
21 - Cooling System
12 - Thermostat
00 - General
Operation diameter orifice allows trapped air to be expelled

from the system.
The thermostat is a wax element type and is Figure 124.

configured for by-pass blanking. The thermostat 7 3
functions as follows:
8 11
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
plate up against its seat, closing the outlet port to the 9
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 1
housing inlet port into the bypass gallery.
Figure 123. 2
7 3
6
8 10
11 5
4
1 Thermostat
2 Spring
3 Top valve plate
4 Bottom valve plate
9 5 Wax pellet
1 6 Diaphragm
7 Actuating rod
8 Outlet port to the radiator top hose
2 9 Inlet port thermostat housing
10 Outlet port bypass gallery
11 1mm diameter orifice
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
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 - 25 9813/8500-2 21 - 25
21 - Cooling System
12 - Thermostat
00 - General
Check (Condition) Check (Operation)

1. If the thermostat is suspected of being faulty, A period of 3–5min before the thermostat valve starts
perform a thermostat test, to confirm its to operate is normal because of the time required to
serviceability. heat soak the thermostat.
2. Note that the thermostat is a non-serviceable 1. Make sure that the engine is safe to work on. If
item. If the thermostat is faulty or damaged it the engine has been running, let it cool before
must be renewed. you start the service work.
3. Inspect the seal for damage or splits. If necessary 2. Remove the thermostat housing and the
replace the seal. Make sure that the seal is thermostat. Refer to Figure 125.
correctly installed.
Figure 125.
A Thermostat housing
B Thermostat
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 126.
21 - 26 9813/8500-2 21 - 26
21 - Cooling System
12 - Thermostat
00 - General
Figure 126.
4. Use a thermometer to measure the temperature

of the coolant.
5. When the coolant reaches the operating range of
the thermostat the valve should start to open, the
movement of the valve plate should be evident.
6. Record the starts to open temperature, the fully
open temperature and the amount of valve lift
when fully open.
21 - 27 9813/8500-2 21 - 27
21 - Cooling System
93 - Hose
93 - Hose
Contents Page No.
21-93-00 General ........................................................................................................................... 21-29
21 - 28 9813/8500-2 21 - 28
21 - Cooling System
93 - Hose
00 - General
Introduction .................................................... 21-29 The engine cooling hoses are essential parts of
Health and Safety .......................................... 21-30 the cooling system. They carry the liquid coolant
Check (Condition) .......................................... 21-30 between the engine and the radiator/cooling pack.
21 - 29 9813/8500-2 21 - 29
21 - Cooling System
93 - Hose
00 - General

when the coolant is hot. When you remove the 1. Visually inspect the engine and related cooling
cap, hot coolant can spray out and burn you. components for:
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 - 30 9813/8500-2 21 - 30
24 - Brake System
Contents Page No.
24-00 Brake System

24-00-00 General ............................................................................................................................. 24-3
24-03 Service Brake
24-03-00 General ............................................................................................................................. 24-7
24-03-01 Master Cylinder .............................................................................................................. 24-17
24-03-39 Piston ............................................................................................................................. 24-23
24-03-50 Light Switch .................................................................................................................... 24-25
24-18 Park Brake
24-18-00 General ........................................................................................................................... 24-27
24-18-18 Caliper ............................................................................................................................ 24-31
24-18-21 Disc ................................................................................................................................ 24-34
9813/8500-2
2017-09-12
Acronyms Glossary

9813/8500-2
2017-09-12
24 - Brake System
00 - Brake System
00 - Brake System
Contents Page No.
24-00-00 General ............................................................................................................................. 24-3
24 - 1 9813/8500-2 24 - 1
Notes:
24 - 2 9813/8500-2 24 - 2
24 - Brake System
00 - Brake System
00 - General
Introduction ...................................................... 24-3
Health and Safety ........................................... 24-4
Service Brakes
The service brakes are housed inside the rear axle
centre case and act on the rear axle half shafts.
The brakes comprise of two oil immersed, multi-plate
friction packs, which are operated hydraulically by
dual foot pedals and compensating master cylinders.
The first part of the brake pedal travel is for 'inching',
and then further travel operates the service brakes
fully.
Although the machine has only two brake packs in

the rear axle (2-wheel braking), 4-wheel braking is
achieved because the transmission is permanently
in 4WD (Four Wheel Drive). In this way all 4 wheels
are effectively braked via the machine transmission.
Park Brake
The independent park brake is installed on the
rear axle transfer gearbox (drop-box), and acts on
the output yoke of the front propshaft. The brake
comprises a caliper and a disc, which is hydraulically
operated from a lever in the cab.
The park brake lever incorporates a sensor switch,

which provides an electrical interlock to prevent the
operator engaging `Forward' or `Reverse' drive when
the park brake is on.
24 - 3 9813/8500-2 24 - 3
24 - Brake System
00 - Brake System
00 - General
Health and Safety the test has been completed, make sure all brake
system components are installed and the system is
operating correctly.
Brake Fluid
WARNING! Before testing the park brake make sure
Use of incorrect brake fluid will cause serious
the area around the machine is clear of people.
damage to the seals of the braking system. This will
result in brake failure. WARNING! If the machine starts to move during the
park brake test, immediately apply the foot brake and
Service Brake Bleeding
reduce the engine speed.
Before bleeding the service brake system, park on
WARNING! If the machine starts to move during the
level ground and set the park brake to on. Put blocks
service brake test, immediately reduce the engine
on both sides of the wheels on one axle to prevent
speed and apply the park brake.
the machine rolling. Stop the engine and disconnect
the battery so that the engine cannot be started. If WARNING! Do not use a machine with a faulty park
you do not take these precautions the machine could brake.
run over you. WARNING! Non approved modifications to drive
Park Brake Maintenance ratios, machine weight or wheel and tyre sizes may
adversely affect the performance of the park brake.
Before working on the park brake, park on level
ground and put blocks on both sides of all wheels WARNING! Oil on the brake disc will reduce brake
to prevent the machine rolling. Stop the engine and effectiveness. Keep oil away from the brake disc.
disconnect the battery so that the engine cannot be Remove any oil from the disc with a suitable solvent.
started. If you do not take these precautions the Read and understand the solvent manufacturer's
machine could run over you. safety instructions. If the pads are oily, install with the
new pads.
WARNING! Faulty brakes can kill. If you have to
top up the brake reservoir frequently, get the brake
system checked by your JCB Dealer. Do not use the
machine until the fault has been put right.
has wheels use blocks to prevent unintentional WARNING! The park brake must not be used to
movement. slow the machine from travelling speed, except in an
emergency, otherwise the efficiency of the brake will
Brake Dust
be reduced. Whenever the park brake has been used
Brake pads generate dust, which if inhaled may in an emergency the brake friction components must
endanger health. Wash off the caliper assemblies be renewed and the other components inspected.
before commencing work. Clean hands thoroughly
Notice: Over adjustment or failure to disengage the
after completing the work.
park brake properly will cause excessive wear of the
Brake Dust park brake mechanism.
Brake shoes generate dust, which if inhaled
may endanger health. Make sure that dust is
removed correctly, particularly before installing
new components. Clean hands thoroughly after
completing the work.
Springs
Always wear personal protective equipment when
dismantling assemblies containing components
under pressure from springs. This will protect against
eye injury from components accidentally flying out.
Notice: Using incorrect fluid could damage the
system. See Fluids, Capacities and Lubricants for
the correct fluid. The fluid can harm your skin. Wear
rubber gloves. Cover cuts or grazes.
WARNING! Before working on the brake system,
make sure that the machine is on solid level ground.
Put blocks on all wheels to prevent the machine
rolling.
WARNING! Do not use the machine with any part of
its brake system disconnected or inoperative. When
24 - 4 9813/8500-2 24 - 4
24 - Brake System
03 - Service Brake
03 - Service Brake
Contents Page No.
24-03-00 General ............................................................................................................................. 24-7

24-03-01 Master Cylinder .............................................................................................................. 24-17
24-03-39 Piston ............................................................................................................................. 24-23
24-03-50 Light Switch .................................................................................................................... 24-25
24 - 5 9813/8500-2 24 - 5
Notes:
24 - 6 9813/8500-2 24 - 6
24 - Brake System
03 - Service Brake
00 - General
00 - General Technical Data

Technical Data ................................................. 24-7
Component Identification ................................. 24-8
Fault-Finding .................................................. 24-10
Check (Level) ................................................ 24-13
Bleed ............................................................. 24-13
Disassemble and Assemble .......................... 24-14
Table 11. Service Brakes

Type JCB Oil-Immersed Multi-Plate Discs
Actuation Hydraulic
Location Rear axle centre casing
Hydraulic Piston Diameter 166mm
Friction plates (3 per brake pack)
Outside Diameter 166mm
Inside Diameter 102.5mm
Lining area per plate 26751mm²
Master Cylinder
Number of cylinders 2
Type Compensated master cylinder
Piston diameter (each) 22.22mm
24 - 7 9813/8500-2 24 - 7
24 - Brake System
03 - Service Brake
00 - General
Main Component Identification
Figure 127.
6 7 8 10
1
2
5 11
Item Description
Table 12.
3 Brake carrier
Item Description 4 Driveshaft
1 Counter plates 5 Stub axle arm
2 Friction plates
24 - 8 9813/8500-2 24 - 8
24 - Brake System
03 - Service Brake
00 - General
Item Description
6 Brake piston
7 Reaction pin
8 Brake piston housing
10 Drive head housing
11 Differential unit
24 - 9 9813/8500-2 24 - 9
24 - Brake System
03 - Service Brake
00 - General
Fault-Finding
Fault
One or more brakes do not apply (Brake travel not excessive, brakes not Table 13. Page 24-10
pulling to one side).
Pedal travel excessive (but not touching floor). Table 14. Page 24-10
Applying one brake (pedals unlocked) also partially engages the other Table 15. Page 24-10
brake.
Pedal hard to operate. Table 16. Page 24-10
Pedal touches floor under constant pressure - no fluid loss. Table 17. Page 24-10
Pedal touches floor under constant pressure and fluid loss. Table 18. Page 24-11
Pulling to one side when pedals locked together. Table 19. Page 24-11
Poor braking (not pulling to one side). Table 20. Page 24-11
Brake not releasing. Table 21. Page 24-11
Poor braking when hot. Table 22. Page 24-12
Excessive brake noise in operation. Table 23. Page 24-12
Fluid loss when the machine is standing. Table 24. Page 24-12
Table 13. One or more brakes do not apply (Brake travel not excessive, brakes not pulling to one side).
Cause Remedy
Master cylinder fault. Check the master cylinder in single and coupled
pedal modes to identify the fault area. Repair as
necessary.
Friction and counter plate distortion. Check friction and counter plates.
Table 14. Pedal travel excessive (but not touching floor).

Cause Remedy
Air in the hydraulic system. Check the fluid tank level. Check for fluid and air
leaks. Rectify as necessary.
Leak in hydraulic system. Check for fluid loss at master cylinder and brake
piston, all pipes and fittings for loose connections.
Rectify as required.
Friction and counter plate distortion. Renew friction and counter plates - Both sides.
Table 15. Applying one brake (pedals unlocked) also partially engages the other brake.
Cause Remedy
Valve stem seal inside (non active) master cylinder Replace the master cylinder piston.
piston not sealing.
Table 16. Pedal hard to operate.

Cause Remedy
Tightness at pedal pivot. Inspect the pedal pivot. Free-off and lubricate the
pilot pivot.
Fluid contamination and seal damage. Flush the system and replace all the hydraulic seals.
Misaligned push rod or pedal. Check and rectify as necessary.
Kinked or crushed brake pipes. Check and replace the brake pipework.
Table 17. Pedal touches floor under constant pressure - no fluid loss.
Cause Remedy
necessary.
Friction and counter plate distortion. Renew friction and counter plates - Both sides.
Air in hydraulic system. Check the fluid tank level. Check for fluid and air
leaks. Rectify as necessary.
24 - 10 9813/8500-2 24 - 10
24 - Brake System
03 - Service Brake
00 - General
Table 18. Pedal touches floor under constant pressure and fluid loss.
Cause Remedy
External fluid leaks. Visually check the brake circuit for fluid loss, repair
as necessary.
Internal fluid leaks. Do the leak check of the brake piston seal.
Table 19. Pulling to one side when pedals locked together.

Cause Remedy
Compensating feature not working. Inspect the master cylinder compensating operation.
Check if there is a blockage in bridging pipe. Service
as required.
Braking system inoperative on one side. Unlatch the pedals to test circuits individually.
Friction plates worn beyond limits or distorted on one Renew the friction and the counter plates - Both the
side. sides.
Badly adjusted push rods. Adjust push rod to minimum specified dimension.
Dimension: 1mm
Servo operating rod out of adjustment. Adjust the servo operating rod.
Annular piston fault. Check the annular piston and repair as necessary.
Table 20. Poor braking (not pulling to one side).

Cause Remedy
Friction plates worn beyond limits or distorted. Replace the friction and the counter plates - Both
sides of relevant axle.
necessary.
Annular piston fault. Check the annular piston and repair as necessary.
Incorrect or low axle oil. Fill the axle with the correct type of oil.
Table 21. Brake not releasing.

Cause Remedy
Brake pedal spring fault. Install a new spring.
Master cylinder fault (plunger stuck in bore). Check the master cylinder in single and coupled
necessary.
Blocked hole in master cylinder tank cap. Install a new tank cap.
Brake pedal free travel incorrect. Adjust pedal free travel.
Fluid contamination and seal damage. Flush the system and renew hydraulic seals.
Annular brake piston(s) binding in axle. Check that the correct brake fluid is used (incorrect
fluid can swell the annular brake piston seals). Check
the annular brake piston seals are in good condition.
Check that the annular brake piston rotates freely
in its housing with no seals installed. Check that
the annular brake piston seal retracts the piston
approximately to specified dimension.
Dimension: 0.5mm
Kinked or crushed brake pipes. Check and replace the pipes as necessary.
Friction and counter plates not free on splines or Check the friction and the counter plates for free
dowels. movement - Both sides of the relevant axle. If
necessary, replace the friction and the counter
plates.
24 - 11 9813/8500-2 24 - 11
24 - Brake System
03 - Service Brake
00 - General
Table 22. Poor braking when hot.

Cause Remedy
Moisture in the system vapourising when the axle is Disassemble the axle and clean the annular piston
hot. to remove the moisture. Remove the master cylinder
and check for corrosion, repair as necessary. Flush
the hydraulic brake system.
Table 23. Excessive brake noise in operation.

Cause Remedy
Deterioration of axle oil or wrong type of axle oil. Change the axle oil.
Axle oil loss. Fill the axle with the correct oil and check for leaks.
Friction plates worn beyond limits. Replace the friction plates and the counter plates.
Friction and counter plates in poor condition. Check for the distortion or the surface pitting and
roughness of the friction and the counter plates.
Make a note that the annular grooving of the counter
plates is acceptable.
Table 24. Fluid loss when the machine is standing.

Cause Remedy
Severe damage or slight cut or nick in the brake Disassemble the axle and replace the seal.
piston seal (Confirm that the fault is as indicated by
checking that the brake pedal does not touch the
floor under constant pressure.)
24 - 12 9813/8500-2 24 - 12
24 - Brake System
03 - Service Brake
00 - General
Check (Level) Bleed

1. Make the machine safe. Refer to (PIL 01-03). WARNING: Use of incorrect fluid will cause serious
damage to the seals which could in turn cause brake
2. Open the engine cover and remove the side failure.
panel. Refer to (PIL 06-06).
3. Visually check the level. The correct fluid level is
marked on the tank. 2. Apply the park brakes.
Figure 128. 3. Block one pair of wheels at both sides.
A 4. Fill the master brake cylinder tank with the correct
fluid.
5. Make sure that throughout the bleeding process
the level is not allowed to fall below the
"MINIMUM" mark.
6. Unlatch the pedals.
7. Bleed the right hand master cylinder as follows:
7.1. Attach a tube to the right hand brake bleed
screw.
B 7.2. Make sure that the free end of the tube is
immersed in the fluid contained in a suitable
container.
A Tank cap
7.3. Open the brake bleed screw and apply full
B Tank
pedal strokes to the right hand brake pedal
4. If necessary add fluid, Make the machine safe until all air is expelled.
with the lift arm raised. Refer to (PIL 01-03). 7.4. Close the brake bleed screw with the pedal
fully depressed.
5. Remove the tank cap.
8. Bleed the left hand master cylinder as follows:
5.1. If the system has fallen a long way below
the MAX mark, check the system for 8.1. Do the step 7.1 to step 7.4 with the left hand
damaged components. bleed screw and the left pedal.
6. Carefully fill the recommended fluid until it 9. Bleed the bridge pipe as follows:
reaches the correct level.
9.1. Attach a tube to either the left or right hand
7. Install the tank cap. If there is a fluid spill, clean brake bleed screw.
the area.
9.2. Make sure that the free end the tube is
immersed in fluid contained in a suitable
container.
9.3. Make sure that the brake pedals are locked
together.
9.4. Open the bleed screw and apply full pedal
strokes to the brake pedals until all air is
expelled.
9.5. Close the bleed screw with the pedals fully
depressed.
10. Repeat the procedures as necessary.
11. Top up the tank to the "FULL" mark.
24 - 13 9813/8500-2 24 - 13
24 - Brake System
03 - Service Brake
00 - General
Consumables 6. Remove the brake pack.

7. Remove the circlip.
JCB Gear Oil HP 4000/0505 20L
4000/0503 200L 8. The wear limit of friction plates is to the depth of
JCB Multi-Gasket 4102/1212 0.05L the cross hatching.
JCB Threadlocker 4101/0250 0.01L 9. Check all plates for flatness and damage.
and Sealer (Medium 4101/0251 0.05L
Strength) 10. Scoring of the counter plates to a certain limit is
permissible.
Disassembly 11. Install a new brake pack, if it is damaged.
Note: Make sure that only one side at a time is 12. Make sure that you do not install new plates
disassembled to prevent damage to the bearings and individually.
preserve the crown wheel and the backlash settings.
13. Remove all the three reaction pins and check
The axle must be removed from the machine when them for damage.
you disassemble the rear axle brakes.
14. Before you remove the brake housing and the
Before you disassemble the rear axle brakes, it is piston assembly make sure that you support
mandatory to mark the components for alignment the differential with the driveshaft or any other
and to identify the right hand and left hand side, to suitable support.
make suer that it is correctly assembled at the time
of assembly. 15. Mark the brake piston housing and the
drivehead.
1. Use a heavy duty (6 point) socket to remove the
bolt. 16. Remove the capscrews.
2. Carefully remove the stub axle arm from the 17. Remove the brake housing and the piston
drivehead. assembly.
3. If necessary, tap the case with a soft faced 18. Remove the brake piston from the brake housing.
hammer and remove all traces of the old sealant 19. Remove and discard the seal 1 and seal 2.
from the mating faces.
20. Check the housing bore for damage and scoring.
4. The brake pack consist of three friction plates
and four counter plates. There are two counter 21. Nicks or cuts in the seals may be the reason for
plates, one at each end of the brake pack, which loss of brake fluid.
are not attached to the plate carrier.
5. If it is necessary to install the plates again then
make a note of their position and correct the
orientation.
24 - 14 9813/8500-2 24 - 14
24 - Brake System
03 - Service Brake
00 - General
Figure 129.
K J
L
N
P
M Q
G F B E C D
A Bolt B Counter plate

C Plate carrier D Circlip
E Reaction pin F Cross hatching
G Oil flow holes H Suitable support for differential
J Brake piston housing K Drivehead housing
L Capscrew M Nut
N Seal 1 P Brake piston
Q Seal 2
24 - 15 9813/8500-2 24 - 15
24 - Brake System
03 - Service Brake
00 - General
Assembly Consumable: JCB Threadlocker and Sealer

(Medium Strength)
1. Remove all traces of the old sealant from the
mating faces of the drive head and the brake 21. Put the stub axle on to the drivehead. Make sure
piston housing. that they are aligned correctly.
2. Install a new seal 1 and seal 2. Make sure they 22. Install the bolt and tighten the bolt to the correct
seat squarely in their grooves. torque value.
3. Carefully push the brake piston into the brake Table 25. Torque Values
piston housing. Item Description Nm
4. Apply JCB Multigasket to the drivehead mating A Bolt 98
face and then install the brake piston housing L Capscrew 46
assembly.
Consumable: JCB Multi-Gasket
5. Make sure that the brake piston housing is
aligned correctly.
6. Install the capscrews, tighten the screws to the
correct torque value.
7. Remove the differential support.
8. Soak the new friction plates in JCB Special Gear
Oil before assembly.
Consumable: JCB Gear Oil HP
9. Assemble the three friction plates and four
counter plates onto the brake carrier.
10. If the original brake pack is reused then place the
plates to their original position.
11. Install the circlip.
12. Make sure that brake pack oil flow holes must be
aligned with each other when being installed to
the brake pack carrier.
13. Put the three reaction pins into their grooves and
lubricate them.
14. Push the pins fully into their location holes in the
housing.
15. Install the three reaction pins into their grooves
and secure them. Press the pins fully into location
holes in the housing.
16. Install one counter plate into the housing,
lubricate it and then the other counter plate.
17. If the old counter plates are re installed then put
them into their original position.
18. Fully press the brake pack in the housing.
19. Apply JCB multigasket to the mating surface of
the drivehead.
20. Apply sealant to the bolt thread.
24 - 16 9813/8500-2 24 - 16
24 - Brake System
03 - Service Brake
01 - Master Cylinder
01 - Master Cylinder Operation

Operation ....................................................... 24-17 The compensatory master cylinders overcome the
Remove and Install ....................................... 24-19 problem of unequal wear between the right and left
Disassemble and Assemble .......................... 24-22 brake. The units incorporate both master cylinder
and compensator valve.
Each brake has its own master cylinder, brake

pedals, servo units and associated pipework. Both
the master cylinders have one common tank.
Figure 130.
E
Q
B P D
M K
A J N G R F C
H
A Master cylinder 1 B Master cylinder 2

C Brake pedal 1 D Brake pedal 2
E Tank F Rod
G Plunger H Valve seal
J Valve stem K Brake pack 1
L Brake pack 2 M Service port
N Valve 1 P Valve 2
Q Bridge pipe R Drillings
Pedals Locked - Normal Operation flows to the brake pack through the service port and
the associated pipework.
When the brake pedals are pushed down (the brake
pedals are mechanically locked together), the rod The master cylinder 2 operates in the same way to
pushes the plunger down the bore of the master feed the brake pack 2.
cylinder. The pressurised oil acting on the centre
valve seal through the valve stem causes the seal With the valve stem at the maximum travel, further
to close off the tank supply port. As the plunger movement of the plunger causes valve1 to lift off its
continues to move down the bore, the pressurised oil seat. Both the master cylinders are interconnected
through a bridge pipe, therefore hydraulic pressure
in both cylinders will be equal.
24 - 17 9813/8500-2 24 - 17
24 - Brake System
03 - Service Brake
If the brake pack 1 and brake pack 2 have worn

equally, then the amount of oil displacement between
the cylinders will be minimal and the brakes will be
applied evenly.
Pedals Locked - Compensating

Operation
When the brake pedals are pushed down (the brake
pedals are mechanically locked together), actuation
of the brake pack 1 and the brake pack 2 is as
described in 'Pedals Locked - Normal Operation'. If
however, the brakes have not worn equally, then the
amount of fluid displaced from each master cylinder
will vary and some form of compensation is required.
The pedal application moves the plungers down

the bores of the master cylinder 1 and the master
cylinder 2. The linings of the brake pack 1 are
brought into contact before the linings of brake pack
2 because they have not worn as severely.
If further displacement took place at the linings,

brake pack 1 would be applied before brake
pack 2. Therefore the master cylinder 1 begins to
compensate for master cylinder 2.
The fluid is displaced from master cylinder 1 to

master cylinder 2 through the bridge pipe until
the pressures are equalised. In this condition both
compensating valves are open and both brakes are
applied evenly.
Pedals Unlocked - Normal Operation

When a single brake pedal is pushed down, the rod
pushes the plunger down the bore of the master
cylinder. The pressurised oil acting on the centre
valve seal through the valve stem causes the seal
to close off the tank supply port. As the plunger
continues to move down the bore, pressurised oil
flows to the brake pack1 through the service port and
associated pipework, thus braking one wheel only.
With the valve stem at the maximum travel, further

movement of the plunger causes valve 1 to lift off its
seat. The fluid is displaced through the drillings from
the active master cylinder 1 through the bridge pipe
to the passive master cylinder 2. The valve 2 in the
passive cylinder is held on its seat by the displaced
pressurised fluid.
24 - 18 9813/8500-2 24 - 18
24 - Brake System
03 - Service Brake
Remove and Install
Remove 6.1. Put caps on the open ports and pipe ends
to prevent contamination.
7. Remove the master cylinders from the machine
Refer to: PIL 01-03-27. one at a time.
2. Remove the front steering console from inside 8. Disconnect the bridging pipe, axle feed pipe
the cab. and the brake tank supply pipe from the master
3. Get access to the brake pedal levers. cylinder.
4. Remove the actuating rod clevis pins that are 8.1. Put caps on the open pipes and ports to
attached to the brake pedals. prevent contamination.
4.1. Disconnect the piston rods from the brake 9. Remove the bolts that are attached to the master
pedals. cylinder.
5. Get access to the brake pipes from outside the 10. Remove the master cylinder from the machine.
cab. 11. Put labels on the master cylinders to aid
6. Remove the brake pipe unions. identification i.e. left side or right side.
24 - 19 9813/8500-2 24 - 19
24 - Brake System
03 - Service Brake
Figure 131.
D
F
E
J
G
B
H
A
L K C
M
N
A Pedal levers B Clevis pin

C Unions D Bridging pipe
E Axle feed pipe F Tank supply pipe
G Bolts H Pedals
J Stop bolt K Rod clevis
L Clevis locknut M Actuating rod
N Distance
Install 3. Make sure that both the brake pedals are at the
same level. If they are not at the same level, do
1. The installation procedure is the opposite of the the steps below.
steps. 3.1. Remove the locknut and turn the stop bolt
to align the brake pedals correctly.
2. Check the brake pedals adjustment before you
3.2. Tighten the locknut.
install the master cylinder(s). Do the steps below.
4. Install the master cylinders to their original
2.1. Remove the pedals and check for their
positions.
alignment.
24 - 20 9813/8500-2 24 - 20
24 - Brake System
03 - Service Brake
5. Do not remove or adjust the actuating rod clevis

pins.
6. If you remove the clevis pin(s) to install the new
master cylinder(s), measure the position of the
pin location hole relative to the cylinder body.
7. When you connect the actuating rod clevis to the
brake pedal lever, make sure that the clevis pin
aligns without moving the actuating rod or brake
pedal.
7.1. If necessary, loosen the clevis locknut and
turn the actuating rod until the clevis pin
aligns with the brake pedal.
7.2. Tighten the clevis locknut.
8. Bleed the brake system.
9. Install the pedals and check for straight line
braking.
9.1. If satisfactory straight line braking cannot be
achieved.

Item Nm
G 30
24 - 21 9813/8500-2 24 - 21
24 - Brake System
03 - Service Brake
The brake master cylinders are non-serviceable

parts and must not be disassembled. If a brake
master cylinder is suspected as being faulty it must
be replaced as a complete assembly.
Figure 132.
A Brake master cylinder
24 - 22 9813/8500-2 24 - 22
24 - Brake System
03 - Service Brake
39 - Piston
39 - Piston Figure 133.
Check (Leaks)
Special Tools D
Hand Pump Pressure 892/00223 1
Test
Pressure Gauge (0-70 892/00346 1 A
Bar) B
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.
Important: This check must be carried out only when

the axle is cold.

2. Remove the brake piston feed pipe. A Brake piston feed pipe
3. Put a cap on the open ends of the pipe to avoid B Brake piston port
contamination. D Hand pump
4. Fill the brake piston housing with the specified 5.2. The hand pump must be filled with the
hydraulic oil. specified hydraulic oil. Do not exceed the
specified pressure value.
5. Check the piston seal for damage: Pressure: 69bar (1,000.0psi)
5.1. Install the hand pump with the specified 5.3. Pressurise the brake piston housing with
pressure gauge. Refer to Figure 133. the hand pump.
Special Tool: Hand Pump Pressure Test 5.4. If the pressure falls off rapidly, or if no
(Qty.: 1) pressure reading can be obtained, the
Special Tool: Pressure Gauge (0-70 Bar) seal is severely damaged and needs
(Qty.: 1) replacement with a new one.
6. Check the piston seal for small cuts or nicks:
6.1. Install an adaptor installed with a piece of
clear tube to the brake piston port. Refer to
Figure 134.
24 - 23 9813/8500-2 24 - 23
24 - Brake System
03 - Service Brake
39 - Piston
Figure 134.
A
B
A Brake piston feed pipe

B Brake piston port
C Tube
6.2. Make sure that you keep the tube vertical
when you do the test.
6.3. Attach the tube to the side of the machine
with a tape.
6.4. Fill the tube unit approximately three
quarters full with a specified hydraulic oil.
6.5. Check if the level has dropped below the
original marked, after the specified duration.
If it has, then the brake piston seal for the
slights cuts or generally for wear.
Duration: 0.5h
7. Do the steps 2 to step 6.5 for the opposite brake
piston seal.
8. Install the brake piston feed pipe.
9. Bleed the brake system.
24 - 24 9813/8500-2 24 - 24
24 - Brake System
03 - Service Brake
50 - Light Switch
50 - Light Switch
Adjust
1. Turn the ignition key to the ON position, do not
start the engine.
2. With the brake pedal in the return position, install
the switch inwards fully until the body touches the
brake lever.
3. Remove out one full turn to ensure the brake
pedal lever can only engage the switch plunger
and not foul the body.
4. Tighten the locknut to the correct torque value.
5. Press the brake panel and check the correct
operation of the brake lights.
Figure 135.
A Switch
B Locknut
24 - 25 9813/8500-2 24 - 25
24 - Brake System
18 - Park Brake
18 - Park Brake
Contents Page No.
24-18-00 General ........................................................................................................................... 24-27

24-18-18 Caliper ............................................................................................................................ 24-31
24-18-21 Disc ................................................................................................................................ 24-34
24 - 26 9813/8500-2 24 - 26
24 - Brake System
18 - Park Brake
00 - General
00 - General Operation
Operation ....................................................... 24-27 This machine is equipped with a hydraulic parking
Check (Operation) ......................................... 24-28 brake built into the transmission. The parking brake
Adjust ............................................................ 24-29 is electrically selected by means of a switch located
on the control panel.
By default the parking brake comes on when the

engine is not running. As soon as the engine is
started the transmission pump flow disengages the
parking brake.
In the event of breakdown of the engine/transmission

the parking brake can be manually released.
Release the park brake manually

1. Remove the bolt.
2. Remove the spacer.
3. Tighten the bolt without the spacer.
4. Thread in the bolt until the parking brake is fully
released.
5. Make sure that the spacer is installed as soon as
the engine /transmission is functional.
Figure 136.
A B
A Bolt
B Spacer
24 - 27 9813/8500-2 24 - 27
24 - Brake System
18 - Park Brake
00 - General
Check (Operation) Figure 137.
Make sure that all the routine health and safety D

precautions are observed before operating the
machines.

2. Fully apply the park brake. P
3. Make sure that the two brake pedals are locked B
together. A
4. Start the engine and raise the lift arm to the

appropriate travelling position.
5. Select low speed range. E
5
0
10
R PM x 100
00000 00
15
AUX
20
6. Push down hard on the foot brake pedal.
30
25
C
7. Select forward drive on the drive selector switch.
0-I
- II
- III
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: A Park brake lever

8.1. Move the park brake lever fractionally B Foot brake pedals
forward until the warning light on the C Speed range switch
instrument panel goes OFF. D Drive selector switch
E Warning light - instrument panel
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 2000RPM (Revolutions
Per Minute). The machine should not move.
8.4. Do not do this test for more than the
specified duration.
Duration: 20s
8.5. Reduce the engine speed to idle and put the
gear lever in neutral.
8.6. Move the park brake lever to the fully ON
position from its partially applied position.
8.7. Lower the lift arm and stop the engine.
8.8. If the machine moved during this test, adjust
the park brake and repeat the test.
24 - 28 9813/8500-2 24 - 28
24 - Brake System
18 - Park Brake
00 - General
Adjust
If the park brake caliper assembly has been 2. Disengage the park brake (lever in horizontal
dismantled or the brake pads renewed, then the position).
caliper must be set as follows:
1. Make sure that the caliper assembly is set

central to the park brake disc within the specified
distance.
Distance: 0.5mm
Figure 138.
G
F
E
A Handle grip B Pin

C Face D Adjusting nut
E Clevis F Adjusting nut
24 - 29 9813/8500-2 24 - 29
24 - Brake System
18 - Park Brake
00 - General
G Dowel pin
3. Turn the handle grip half a turn in a clockwise 7.9. If the machine moved inspect the caliper /
direction. pads, reset as described above.
4. Cable length - Adjustment 7.10. Seal kits are no longer available for
the master cylinders, the only servicing
4.1. Remove the dowel pin. permitted is a major repair kit which
comprises of a full piston assembly.
4.2. Remove the clevis from the caliper.
7.11. A faulty master cylinder and piston
4.3. Set the caliper lever to the specified assembly must be replaced with new
distance from the face by adjusting the ones.
cable length at adjusting nut.
4.4. Install the clevis.
4.5. Tighten the clevis to the correct torque
value.
Torque: 27N·m
5. Cable lever -Adjustment
5.1. Remove the dowel pin.
5.2. Remove the clevis from the caliper.
5.3. Set the caliper lever to the specified
distance from the face by adjusting nut.
6. Make sure that the park brake switch is correctly
adjusted.
7. Test the park brake.
7.1. Make sure that the park brake is fully
engaged.
7.2. The park brake electrically disconnects
the transmission drive; this prevents the
machine from being driven with the park
brake on.
7.3. Therefore, in order to complete the test,
move the park brake lever fractionally
forward until the warning light is just
extinguished; hold the lever in this position
for the duration of the test.
7.4. Do not move the lever too far forward,
otherwise the park brake will not be fully
operational.
7.5. Make sure the brake pedals are locked
together, push down hard on the brake
pedals and select forward drive.
7.6. Slowly release the brake pedals.
7.7. If the machine has not moved use the
accelerator to gradually increase the engine
speed to 1500 RPM (Revolutions Per
Minute) -the machine should not move.
7.8. Do not test the machine for more than
specified value.
Duration: 20s
24 - 30 9813/8500-2 24 - 30
24 - Brake System
18 - Park Brake
18 - Caliper
18 - Caliper Check (Condition)

Check (Condition) .......................................... 24-31 1. Disassemble the caliper. Refer to (PIL 24-18).
2. Clean and dry all the parts.
3. Check all the parts are free from excessive wear,
damage or corrosion.
3.1. Remove any light scores or stains.
3.2. Replace the corroded or deeply scored
parts.
4. You must always replace both brake pads if the
parking brake is used in an emergency.
5. Check if the spring is broken or distorted.
6. Check the condition of the disc surface.
7. Replace the disc if badly warped, pitted or worn.
8. Assemble the caliper. Refer to (PIL 24-18).
24 - 31 9813/8500-2 24 - 31
24 - Brake System
18 - Park Brake
18 - Caliper
Consumables Disassemble
JCB Threadlocker and 4101/0550 0.01L 1. Remove the park brake caliper from the machine.
Sealer (High Strength) Refer to (PIL 24-18).
4101/0552 0.2L
Special HP Grease 4003/2017 0.4kg 2. Use the alphabetical sequence shown on the
4003/2006 12.5kg illustration as a guide to disassembly. Refer to
Figure 139.
4003/2005 50kg
Figure 139.
A
P H C
Q
G
D
R
U N F
U
M J
E
K
S
A Spring B Nut
C Brake pads D Nut
E Lock nut F Spherical washer
G Rod H Pin pivot
24 - 32 9813/8500-2 24 - 32
24 - Brake System
18 - Park Brake
18 - Caliper
J Lever K Pivot seat

L Safety clip M Retaining pin
N Bolt P Arm
Q Retaining pin R Safety clip
S Body T Plate caliper
U Bolt
3. The tension of the spring must be released.

4. Apply and keep hand pressure to pivot seat.
5. Remove the M10 lock nut and the spherical
washer.
6. Allow the spring to open out to its full travel by
slowly releasing the hand pressure on the pivot
seat.
Assemble
the disassembly procedure. Additionally do the
following steps.
2. Replace the pads if the thickness of the friction
lining is less than the specified value.
Dimension: 3mm
3. Lightly apply grease to all pivots and working
surfaces.
4. Make sure that the park brake caliper assembly
centreline is aligned with the brake disc
centreline within the specified dimension.
Distance: 0.5mm
4.1. Install the shims between the mounting
bracket and the caliper bracket as
necessary.
5. Tighten the nut sufficiently to allow the lever to
move freely with minimum side clearance.
6. Apply sealant to the threads of the bolts.
Consumable: JCB Threadlocker and Sealer
(High Strength)

Item Nm
U 118
D 6
24 - 33 9813/8500-2 24 - 33
24 - Brake System
18 - Park Brake
21 - Disc
21 - Disc Introduction
Introduction .................................................... 24-34 A disc brake is a wheel brake that slows the rotation
Remove and Install ....................................... 24-35 of the wheel by the friction caused by pushing brake
pads against a brake disc with a set of calipers.
24 - 34 9813/8500-2 24 - 34
24 - Brake System
18 - Park Brake
21 - Disc
Remove and Install
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
1. If installed remove the park brake caliper. disc is clean and free from wear or damage.
2. Bend back the stake nut locking ring. 2. If necessary install a new oil seal. Lubricate the
lips of the seal.
3. Clean the brake disc and the gearbox around the
brake disc. Make sure no contamination enters 3. Install the brake disc onto the output shaft.
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.
7. Do not use a steel hammer, damage can occur

to the output shaft bearing.
24 - 35 9813/8500-2 24 - 35
24 - Brake System
18 - Park Brake
21 - Disc
Figure 140.
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 - 36 9813/8500-2 24 - 36
Contents Page No.
25-00 Steering System

25-00-00 General ............................................................................................................................. 25-3
25-03 Priority Valve
25-03-00 General ........................................................................................................................... 25-11
25-06 Steer Unit/Valve
25-06-00 General ........................................................................................................................... 25-17
25-12 Column
25-12-00 General ........................................................................................................................... 25-29
9813/8500-2
2017-09-08
Acronyms Glossary
2WS Two Wheel Steer

LS Load Sense
9813/8500-2
2017-09-08
Contents Page No.
25-00-00 General ............................................................................................................................. 25-3
25 - 1 9813/8500-2 25 - 1
Notes:
25 - 2 9813/8500-2 25 - 2
00 - General
Introduction ...................................................... 25-3
Health and Safety ........................................... 25-4
2WS System
Operation ......................................................... 25-5 The main components of the 2WS (Two Wheel Steer)
Fault-Finding .................................................... 25-6 steering system are:
Bleed ............................................................... 25-8
• Priority valve.
• LS (Load Sense) steer unit.
• Double acting power track rod ram.
25 - 3 9813/8500-2 25 - 3
00 - General
Health and Safety

Engine/Steering Failure
If the engine or steering fails, stop the machine as
quickly as possible. Do not operate the machine until
the fault has been corrected.
movement.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear personal protective equipment.
fluid. If fluid penetrates your skin, get medical help
immediately.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
hose line must be vented. Make sure the hose
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be
started while the hoses are open.
WARNING! When getting access for maintenance
work, make sure no-one is in a position to be caught
and/or crushed by the wheels when the steering
wheel is turned.
25 - 4 9813/8500-2 25 - 4
00 - General
Operation
The main components of the steering system are: steer unit, which then directs the oil to the steer ram
until the required steering lock is achieved.
• Priority valve.
• Load sensing steer unit. When the steering lock is held, the pressure signal
• Hydraulic tank. ceases, flow from the hydraulic pump is now
• Steer ram. distributed to the main hydraulic circuit through the
priority valve.
When the steering wheel is turned, a pressure
demand is sensed at the priority valve through the The maximum steering system pressure is controlled
load sensing line. Then the oil from the hydraulic by a relief valve located in the steer unit.
pump is distributed through the priority valve to the
Figure 141.
A B
P2
A Priority valve (Gear pump machines) B Priority valve (Variable flow machines)
C Steer unit D Power track rod ram - front
E Load sensing line P2 Hydraulic pump - secondary
25 - 5 9813/8500-2 25 - 5
00 - General
Fault-Finding
Fault
Steering wheel difficult to turn Table 29. Page 25-6
Steering wheel turns on its own Table 30. Page 25-6
Machine does not turn when the steering wheel is turned Table 31. Page 25-6
Table 29. Steering wheel difficult to turn

Cause Remedy
Tyres not inflated to correct pressure Inflate the tyres to the correct pressure.
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 the component Check the hoses and the connections for leaks.
connections
Air in the hydraulic system Bleed the load sense line. Refer to (PIL 30-00).
Low pump flow Check the pump flow, if required, Service or replace
pump.
Steer relief valve set incorrectly Check the pressure setting of the steer unit relief
valve, adjust as required.
Worn or damaged parts in the steer control valve Remove and inspect the steer control valve.
Priority valve not operating correctly Check if the priority valve is sticking, rectify as
required. Check the load sense line from the steer
unit to the priority valve for signs of leaking or poor
connection.
Mechanical failure Check for damaged axle components, such as rams,
track rods, linkages.
Table 30. Steering wheel turns on its own

Cause Remedy
Dirt in the steer control unit (causing the sleeves to Clean and inspect the steer unit.
stick open)
Steer control valve centering springs damaged, Check the steer unit.
broken or missing
Steer control valve - Incorrect position of the rotor to Disassemble the steer control valve, correct as
the shaft slot required. Refer to (PIL 25-06).
Table 31. Machine does not turn when the steering wheel is 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 the component Check the hoses and the connections for leaks.
connections
Air in the hydraulic system Bleed the load sense line. Refer to (PIL 30-00).
Low pump flow Check the pump flow, if required, Service or replace
pump.
Steer relief valve set incorrectly Check the pressure setting of the steer unit relief
valve, adjust as required.
Worn or damaged parts in the steer control valve Remove and inspect the steer control valve.
Priority valve not operating correctly Check if the priority valve is sticking, rectify as
required. Check the load sense line from the steer
unit to the priority valve for signs of leaking or poor
connection.
25 - 6 9813/8500-2 25 - 6
00 - General
Cause Remedy
Mechanical failure Check for damaged axle components, such as rams,
track rods, linkages.
Steer column splined shaft not fully engaged in steer Check the shaft engagement.
valve
Power track rod failure Check the power track rod for signs of damage or
leaks.
25 - 7 9813/8500-2 25 - 7
00 - General
Bleed
2 Wheel Steer Machines

When any hydraulic steering component is
disconnected or removed, the system must be bled
before driving the machine.
1. Operate the engine at 1500 RPM (Revolutions

Per Minute).
2. Turn and hold the steering wheel fully in both
directions:
2.1. Turn the steering wheel to the left, until the
front wheels are fully locked to the left.
2.2. Turn the steering wheel to the right, until the
front wheels are fully locked to the right.
2.3. Turn the steering wheel to the left, until
the front wheels are in the straight ahead
position.
3. Stop the engine.
4. Check the hydraulic tank fluid level and add the
hydraulic fluid, if required. Refer to (PIL 30-00).
25 - 8 9813/8500-2 25 - 8
03 - Priority Valve
03 - Priority Valve
Contents Page No.
25-03-00 General ........................................................................................................................... 25-11
25 - 9 9813/8500-2 25 - 9
Notes:
25 - 10 9813/8500-2 25 - 10
03 - Priority Valve
00 - General
Introduction .................................................... 25-11 The priority valve is an integral part of the steer valve.
Component Identification ............................... 25-12
Operation ....................................................... 25-13 There are four connections to the valve as follows:
• From hydraulic pump.

• To steering valve.
• To valve block.
• Pilot connection from the steering valve.
25 - 11 9813/8500-2 25 - 11
03 - Priority Valve
00 - General
Figure 142.
A
A Steer valve
B Priority valve
25 - 12 9813/8500-2 25 - 12
03 - Priority Valve
00 - General
Operation
Neutral The pressure is directed through an internal drilling,

onto the end of the priority valve spool. This creates
The oil from the hydraulic services pump enters the a high pressure differential across the spool, causing
priority valve. it to move down against the force of the spring. This
allows the oil from the pump inlet port to flow into the
When the steering is not being operated, the internal gallery to supply the loader services.
flow to the steering circuit is dead ended by the
closed centre steer unit and no pressure demand is
generated in the load sense line.
Figure 143.
E
M
D
A
G
C
A R
A Inlet port B Steer unit

C Load sense line D Integral drilling
E Priority valve spool F Spring
G Integral gallery L Tank
M Loader services
25 - 13 9813/8500-2 25 - 13
03 - Priority Valve
00 - General
Turning When the steering lock is reached, the pressure

signal in the load sense line from the steering unit
When the steering wheel is turned, a pressure ceases, restoring the pressure differential across the
demand is generated in the load sense line from the spool. The spool moves back and allows the oil from
steering unit. the pump inlet port to supply the loader services.
The pump output flow available is always greater
The pressure is then applied to the spring end of than the actual flow required to operate the steering
the priority valve spool. This reduces the pressure system, therefore flow to the loader services is never
differential across the spool, causing it to move up completely cut off.
under spring force. This allows oil from the pump inlet
port to flow out of the priority port to the steering unit, The maximum steering system pressure is set by
which in turn directs the flow to the corresponding relief valve housed inside the steering unit.
end of the power track rod ram until the required
steering lock is reached.
Figure 144.
E
M
A H
K
L
J
L
A
R
A Inlet port B Steer unit

C Load sense line E Priority valve spool
H Priority port J Power track rod ram
K Relief valve L Tank
25 - 14 9813/8500-2 25 - 14
03 - Priority Valve
00 - General
M Loader services
25 - 15 9813/8500-2 25 - 15
06 - Steer Unit/Valve
Contents Page No.
25-06-00 General ........................................................................................................................... 25-17
25 - 16 9813/8500-2 25 - 16
00 - General

Technical Data ............................................... 25-17 Table 32.
Operation ....................................................... 25-18
Description Data
Check (Pressure) .......................................... 25-23
Valve Type Dynamic signal, load
Remove and Install ....................................... 25-24 sensing, Non-reaction
Disassemble and Assemble .......................... 25-26 Displacement of Gerotor 125 cc/r
Maximum system pres- 190bar (2,753.6psi)
sure
Maximum back pressure 10bar (144.9psi)
Maximum system oper- 106°C (222.7°F)
ating temperature
Maximum difference be- 28°C (82.4°F)
tween steer unit and
system temperature
Input torque - Powered 1.3–2.2N·m
Input torque - Non-pow- 136N·m
ered
25 - 17 9813/8500-2 25 - 17
00 - General
Operation
Neutral
Figure 145.
L
T
R
P
A Non-return valve B Inner spool

C Outer sleeve D Centering spring
P Inlet port T Tank port
Oil from the priority valve enters the steering unit by the centring springs. The steering unit is 'closed
through the inlet port, opening the non-return valve. centre' therefore the flow from the priority valve is
When the steering wheel is stationary, the inner spool dead ended by the steering unit.
and outer sleeve are held in the neutral position
25 - 18 9813/8500-2 25 - 18
00 - General
Left Turn
Figure 146.
J
B
E
L
T
LS
P
B Inner spool C Outer sleeve

E Relief valve F Stator
J Track rod ram LS Load sense port
The illustration shows the flow through the steering metering unit is linked to the spools by a cross pin.
unit in a left-hand turn condition. Turning the steering As the steering is operated the oil is diverted by the
wheel rotates the inner spool a few degrees relative inner spool into the stator.
to the outer sleeve, and sends a pressure signal
(demand) to the relief valve, and through the load The rotor lobes pump the oil out to one side of the
sense port back to the priority valve. power track rod ram, turning the rear wheels to the
left. At the same time, the oil displaced from the
The relative movement between the inner spool and other side of the power track rod ram returns to tank
the outer sleeve directs oil pressure through 6 of through the steer unit.
the 12 holes in the bottom of the outer sleeve. The
25 - 19 9813/8500-2 25 - 19
00 - General
Right Turn
Figure 147.
J
B
L
T
B Inner spool F Stator

J Track rod ram
The illustration shows the flow through the steering that the oil is diverted by the inner spool to the other
unit in a right-hand turn condition. The operation is side of the stator and the power track rod ram.
identical to that described for a left-hand turn, except
25 - 20 9813/8500-2 25 - 20
00 - General
Right Turn, Unassisted
Figure 148.
J
B
L
T
R
G
P
B Inner spool C Outer sleeve

F Stator G Non-return valve
J Track rod ram LS Load sense port
The illustration shows the circuit operation with the As there is no supply from the pump, oil from one
engine stopped. Turning the steering wheel rotates side of the power track rod rams (supplemented by
the inner spool until the cross pin engages with and exhaust oil if necessary) is used to feed the other side
rotates the outer sleeve, metering oil to the stator, through the non-return valve.
and pumping it out to the power track rod ram under
manual pressure only.
25 - 21 9813/8500-2 25 - 21
00 - General
Shock Valve
Figure 149.
L
T
R
X
P Y
A
A Non-return valve 1 H Shock valve

P Inlet port T Tank port
X Non-return valve 2 Y Non-return valve 3
In normal operation, oil from the priority valve enters

the steering unit through the inlet port, opening a
spring loaded non-return valve 1. The flow is directed
by the steering unit to achieve the desired turn (right-
hand shown).
In the event of a pressure shock wave being

generated in the system by an outside force,
the shock valve vents this pressure to exhaust
preventing damage to the steering unit.
The non-return valve 2 is held on its seat by the

generated pressure and the non-return valve 1
closes to prevent the shock wave being fed back to
the pump. Some of the excess flows through the non-
return valve 3 to the opposite side of the power track
rod ram to prevent cavitation.
25 - 22 9813/8500-2 25 - 22
00 - General
Check (Pressure) 8.1. Make sure that the steering wheel is held
in the full lock position when you read the
Special Tools pressure gauge.
9. Remove the plug from the hydraulic steer unit
Pressure Gauge (0-400 892/00279 1 to adjust the set pressure, if necessary. Refer to
Bar) Figure 151.
Check (Pressure) 10. Use an Allen key to adjust the screw until you get
the correct set pressure. Refer to Figure 151.
Figure 151.
E
to (PIL 33-03).
4. Turn the steering wheel to the full left and full
right lock positions several times to remove the
hydraulic system pressure. D
5. Get access to the test adaptor on the hydraulic
pump, from below the machine.
6. Connect a Pressure Gauge to the test adaptor.
Refer to Figure 150.
Special Tool: Pressure Gauge (0-400 Bar) (Qty.:
1)
Figure 150. C
A C Steer unit/valve
D Allen key
E Plug
A Test adaptor
B Pressure gauge
7. Operate the engine at 1500 RPM (Revolutions
Per Minute) and turn the steering to the full lock
position.
8. Check the pressure gauge reading which must
equal the relief valve pressure. Refer to (PIL
25-00).
25 - 23 9813/8500-2 25 - 23
00 - General
Remove and Install
Remove 4. Cap all the open ports to prevent contamination.
1. Make the machine safe with the lift arm lowered. 5. Put a label on the hoses to help installation.
Refer to: PIL 01-03-27. 6. Support the steer unit from outside of the
operator station.
2. Turn the steering wheel to the left, and to the right
several times to vent the system pressure. 7. Remove the bolt (x4) from inside the operator
station.
3. Disconnect all the hydraulic hoses from the steer
unit. 8. Lift the steer unit from the machine.
Figure 152.
A Steer unit B Bolt (x4)
25 - 24 9813/8500-2 25 - 24
00 - General
Install
steps.
2. Make sure that the hoses are connected to the
correct ports.
3. Bleed the steering system.
4. If a new steer unit has been installed, then the
system relief valve must be tested for the correct
pressure setting.
5. Make sure that all the hydraulic adaptors that are
installed have a bonded sealing washer applied
to the threads of the adaptor.
25 - 25 9813/8500-2 25 - 25
00 - General
Disassembly of the steer valve is not recommended.

If the valve is suspected as being faulty it must be
replaced as a complete unit.
25 - 26 9813/8500-2 25 - 26
12 - Column
12 - Column
Contents Page No.
25-12-00 General ........................................................................................................................... 25-29
25 - 27 9813/8500-2 25 - 27
Notes:
25 - 28 9813/8500-2 25 - 28
12 - Column
00 - General
Introduction .................................................... 25-29 The steering column connects the steering wheel to
Disassemble and Assemble .......................... 25-30 the steering mechanism.
25 - 29 9813/8500-2 25 - 29
12 - Column
00 - General
Consumables 3. Bend the retaining tabs backwards to remove the

Description Part No. Size upper bearing.
JCB High Strength 4102/0551 0.05L 4. Remove the bolts and the nut.
Threadlocker
5. Remove the steering column from the flexible
Use the alphabetical sequence shown on the coupling.
illustration as a guide to disassembly.
Assemble
Disassemble
1. Remove the front instrument housing and the the disassembly procedure. Additionally do the
steering column pedestal cover to get access to following steps.
the steering column.
2. To avoid excessive side loading on the steer
2. Put labels on the electrical connections before valve, assemble the steering column, flexible
you disconnect the components installed on the coupling, extension shaft and the steer valve with
housing. a minimum of misalignment before you tighten
the secure bolts and clamps.
25 - 30 9813/8500-2 25 - 30
12 - Column
00 - General
Figure 153.
A
AC
AD AB
D
B AB
C AE
E
J
H K G`
N
M
P F
L
AA
Z
AA U
Y
Q
AG S
T
R
AF
V Z
Y
X
P Upper bearing R Nut

L Bolt N Steering column
AA Flexible coupling Z Extension shaft
Q Lower bearing J Space
U Washer H Tension pin
Y E-clip
3. Press the bearing until flush with end of the outer 5. Achieve the minimum end-float by selecting a
column. groove in the gap.
4. Press the bearing until it can be secured by the 6. Install additional spacing washers above the set
retaining tabs. pin, if necessary.
25 - 31 9813/8500-2 25 - 31
12 - Column
00 - General
7. Install the tension pin offset so that one end

engages with the direction indicator automatic
cancel button.
8. Make sure that the extension shaft is correctly
installed in the flexible coupling.
9. The coupling bolt must be engaged with the cut-
out in the shaft.
10. Remove all dirt from the spindle socket of the
steering valve before you install the column
assembly.
11. Install the E-clip as close as possible to the
splines on the extension shaft.
12. Insert the extension shaft spline into the steer
valve splined socket.
13. Make sure that there is a specified gap between
the splines shaft and socket.
Dimension: 0.5–1.5mm
14. The shaft must not touch the bottom of the
splined socket.
15. Apply lock and seal to the threads of the bolts
before installation.
Consumable: JCB High Strength Threadlocker
25 - 32 9813/8500-2 25 - 32
27 - Driveline
Contents Page No.
27-00 Driveline
27-00-00 General ............................................................................................................................. 27-3
27-03 Manual Gearbox
27-03-00 General ............................................................................................................................. 27-5
27-03-06 Clutch - Forward/Reverse .............................................................................................. 27-51
27-03-07 Clutch - 2WD/4WD ......................................................................................................... 27-58
27-03-39 Filter ............................................................................................................................... 27-67
27-03-78 Direct Shift Turret ........................................................................................................... 27-68
27-20 Axle
27-20-00 General ........................................................................................................................... 27-73
27-22 Drivehead
27-22-00 General ........................................................................................................................... 27-87
27-22-06 Crownwheel .................................................................................................................. 27-105
27-22-09 Pinion Gear .................................................................................................................. 27-107
27-27 Hub
27-27-00 General ......................................................................................................................... 27-111
27-29 Wheel
27-29-00 General ......................................................................................................................... 27-137
27-33 Tyre
27-33-00 General ......................................................................................................................... 27-145
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-149
27-51 Driveshaft
27-51-00 General ......................................................................................................................... 27-151
27-51-15 Shaft Hub Side ............................................................................................................. 27-153
9813/8500-2
2017-09-25
Acronyms Glossary
2WD Two Wheel Drive

DTI Dial Test Indicator
LSD Limited Slip Differential
PMV Pressure Maintenance Valve
PTFE Polytetrafluoroethylene
SAE Society of Automotive Engineers
9813/8500-2
2017-09-25
27 - Driveline
00 - Driveline
00 - Driveline
Contents Page No.
27-00-00 General ............................................................................................................................. 27-3
27 - 1 9813/8500-2 27 - 1
Notes:
27 - 2 9813/8500-2 27 - 2
27 - Driveline
00 - Driveline
00 - General
00 - General
Health and Safety

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 9813/8500-2 27 - 3
27 - Driveline
03 - Manual Gearbox
03 - Manual Gearbox
Contents Page No.
27-03-00 General ............................................................................................................................. 27-5

27-03-06 Clutch - Forward/Reverse .............................................................................................. 27-51
27-03-07 Clutch - 2WD/4WD ......................................................................................................... 27-58
27-03-39 Filter ............................................................................................................................... 27-67
27-03-78 Direct Shift Turret ........................................................................................................... 27-68
27 - 4 9813/8500-2 27 - 4
27 - Driveline
03 - Manual Gearbox
00 - General
Introduction ...................................................... 27-5 A manual gearbox is a type of transmission used in
Technical Data ................................................. 27-6 motor vehicle applications. It uses a driver operated
Component Identification ................................. 27-8 clutch, engaged and disengaged by a foot pedal,
Fault-Finding .................................................. 27-13 for regulating torque transfer from the engine to the
transmission and a gear lever operated by hand.
Clean ............................................................. 27-22
Check (Condition) .......................................... 27-22 A typical JCB manual transmission is called Synchro
Check (Level) ................................................ 27-23 Shuttle, of which the following types exist:
Check (Pressure) .......................................... 27-24
• SS500
Calibrate ........................................................ 27-29 • SS600
Disassemble and Assemble .......................... 27-33 • SS620
• SS700
• SS750
27 - 5 9813/8500-2 27 - 5
27 - Driveline
03 - Manual Gearbox
00 - General
Technical Data
Table 33.
Description Combined torque converter, reverser, and gearbox unit. Synchromesh manual
gear selection. Electro-hydraulic selection of forward and reverse.
Weight (dry) 2WD (Two Wheel Drive) 170kg
4WD (Four Wheel Drive) 170kg
Gear Ratio
Std Ratio Low ratio
1st 5.56:1 6.56:1
2nd 3.45:1 4.06:1
3rd 1.83:1 1.90:1
4th 1.00:1 1.00:1
Torque Converter
Torque Converter Diame- 310mm
ter
Torque Multiplication at 2.52:1 3.01:1
Stall
Table 34.
Converter Pressures (in neutral) bar (psi)
Converter In at 50°C (121.9°F) 1000 RPM (Revolutions Per 1.5 - 2.5
Minute)
2000 RPM 5.3 - 6.7
Converter In at 100°C (211.9°F) 1000 RPM 0.5 - 1.3
2000 RPM 4.1 - 4.9
Converter Out at 50°C (121.9°F) 1000 RPM 0.8 - 1.6
2000 RPM 3.0 - 4.0
Converter Out at 100°C (211.9°F) 1000 RPM 0.3 - 0.9
2000 RPM 2.1 - 2.9
Table 35.
Lubrication Pressures (in neutral) bar (psi)
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 RPMrev/min 1.3 - 2.1
Main Line Pressure (in neutral) bar (psi)
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 (121.9°F) 1000 RPM 7.7 - 11.0
2000 RPM 13.9 - 20.0
Cooler at 100°C (211.9°F) 1000 RPM 5.2 - 8.2
2000 RPM 14.5 - 17.5
Pump at 50°C (121.9°F) 1000 RPM 11.5 - 15.5
27 - 6 9813/8500-2 27 - 6
27 - Driveline
03 - Manual Gearbox
00 - General
2000 RPM 24.0 - 33.0

Clutch Pressures All clutch pressures should be the same as Mainline
Pressure to within 0.7bar (10.1psi)
27 - 7 9813/8500-2 27 - 7
27 - Driveline
03 - Manual Gearbox
00 - General
Unit Identification The gearbox serial number is stamped on the unit

identification plate as shown. When you make an
There is more than one gearbox design variant. The order for parts replacement, always give the details
SS700 type 2 variant described in this section is mentioned on the unit identification plate. In the case
identified as having an enclosed layshaft rear case. of gear replacements, always check the part number
Make sure you refer to the correct procedure before stamped on the gear, and the number of teeth.
you disassemble or assemble the gearbox.
Figure 155.
Figure 154.
B
B Identification plate
A Layshaft rear case
27 - 8 9813/8500-2 27 - 8
27 - Driveline
03 - Manual Gearbox
00 - General
Figure 156. 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 - 9 9813/8500-2 27 - 9
27 - Driveline
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)
27 - 10 9813/8500-2 27 - 10
27 - Driveline
03 - Manual Gearbox
00 - General
Sectional Drawing
Figure 157. 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
27 - 11 9813/8500-2 27 - 11
27 - Driveline
03 - Manual Gearbox
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
27 - 12 9813/8500-2 27 - 12
27 - Driveline
03 - Manual Gearbox
00 - General
Fault-Finding
Fault
The transmission is noisy Table 36. Page 27-13
The transmission is overheating Table 37. Page 27-15
The transmission will not pull Table 38. Page 27-17
There is no drive in one or both directions Table 39. Page 27-19
The transmission is jumping out of gear Table 40. Page 27-20
The transmission is sticking in gear Table 41. Page 27-21
The gear ratios are crash changing Table 42. Page 27-21
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 36. 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.
No Check 16.
27 - 13 9813/8500-2 27 - 13
27 - Driveline
03 - Manual Gearbox
00 - General
Check Action
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.
27 - 14 9813/8500-2 27 - 14
27 - Driveline
03 - Manual Gearbox
00 - General
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 37. 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.
27 - 15 9813/8500-2 27 - 15
27 - Driveline
03 - Manual Gearbox
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.
27 - 16 9813/8500-2 27 - 16
27 - Driveline
03 - Manual Gearbox
00 - General
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 38. The transmission will not pull

Check Action
No Check 5.
damage.
No Check 7.
27 - 17 9813/8500-2 27 - 17
27 - Driveline
03 - Manual Gearbox
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.
27 - 18 9813/8500-2 27 - 18
27 - Driveline
03 - Manual Gearbox
00 - General
Check Action
No Check 32.
No Check 33.
Table 39. 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.
27 - 19 9813/8500-2 27 - 19
27 - Driveline
03 - Manual Gearbox
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 40. 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.
27 - 20 9813/8500-2 27 - 20
27 - Driveline
03 - Manual Gearbox
00 - General
Check Action
damage.
No Check 12.
No Check 14.
No Check 15.
Table 41. The transmission is sticking in gear

Check Action
No Check 2.
No Check 4.
No Check 5.
Table 42. The gear ratios are crash changing

Check Action
No Check 2.
No Check 3.
27 - 21 9813/8500-2 27 - 21
27 - Driveline
03 - Manual Gearbox
00 - General
Clean Check (Condition)

Consumables
Description Part No. Size Before assembling the gearbox make sure that a
Cleaner/Degreaser 4104/1557 0.4L thorough inspection of all components is carried out.
- General purpose Remember that although a failed component may
solvent based parts be easy to identify, the cause of that failure may be
cleaner less easy to trace. It is also possible that a failed
component may have caused damage to other areas
of the gearbox.
Clean the exterior of the gearbox assembly as
follows: 1. Carefully remove all traces of gasket compound
from components as follows:
1. Make sure that all open ports and orifices are
effectively plugged. 1.1. Front and rear case mating faces.
2. Remove any deposits of dirt, grit and oil from 1.2. Front case and torque converter housing
the outer cases using a suitable degreaser and mating faces.
water.
2. Clean the inside of the case using a suitable
Consumable: Cleaner/Degreaser - General degreasing agent.
3. Carefully inspect all gears, bearings and shafts
3. Dry the cases. for signs of excessive wear or damage. If wear
or damage is evident, the components must be
renewed.
4. Make sure that all oil way cross drillings in the
cases, shafts and gears are clear and free from
debris. Blocked oil ways are a common cause of
bearing failure. Use an air line to blow through
cross drillings.
If failure of the forward and reverser clutch or

power take-off clutch is suspected, see the relevant
dismantling and assembly procedure.
27 - 22 9813/8500-2 27 - 22
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03 - Manual Gearbox
00 - General
Check (Level)
Check (Level)
3. Open the engine cover. Refer to (PIL 06-06).
4. Before you complete a check of the oil level,
you must wait for the specified time on the
instructional label. Refer to Figure 158.
Duration: 20s
5. Remove the gearbox dipstick.
6. Check the gearbox oil level.
6.1. Make sure that the gearbox oil level
is between the end of the dipstick and
maximum mark on the dipstick.
7. If necessary, add the recommended oil through
the dipstick tube into the gearbox.
8. Check the oil level on the dipstick.
9. Install the dipstick.
Figure 158.
A
A Instructional label
B Dipstick gauge
C Dipstick
27 - 23 9813/8500-2 27 - 23
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03 - Manual Gearbox
00 - General
Check (Pressure)
Special Tools 5. Make sure that the mainline pressure shown in

Description Part No. Qty. the pressure gauge is of the specified value.
Flowmeter 892/00229 1 Refer to (PIL 27-03).
Flow Test Adaptor 892/00237 1 6. With the transmission in neutral, repeat the step
Assembly 5 and note the gauge reading with the engine
Load Valve 892/00270 1 running at 2000 RPM.
Digital Hydraulic 998/11051 1
7. Stop the engine and remove the test gauge.
Pressure Test Kit
8. If the mainline pressure is low, refer to (PIL
WARNING Fine jets of fluid at high pressure can 27-03).
penetrate the skin. Keep face and hands well
clear of fluid under pressure and wear personal 9. A high pressure reading could indicate a faulty
protective equipment. Hold a piece of cardboard pressure maintenance valve.
close to suspected leaks and then examine the
cardboard for signs of fluid. If fluid penetrates your Clutch Pressure (forward clutch given in
skin, get medical help immediately.
example)
WARNING Take care when disconnecting
hydraulic hoses and fittings as the oil will be hot. 1. Stop the engine.
WARNING Make the machine safe before 2. Make the machine safe. Refer to (PIL 01-03).
working on it. Park the machine on level ground
and lower the loader arm. Stop the engine and 3. Connect a pressure gauge of the specified value
remove the ignition key. Make sure the park brake to the forward clutch pressure test connector
is engaged. Disconnect the battery to prevent the or reverse clutch pressure test connector as
engine being started. Block all four wheels. necessary.
Pressure: 0–20bar (0.0–289.9psi)
Before you do any of the transmission pressure/flow Special Tool: Digital Hydraulic Pressure Test Kit
tests, make sure that the oil level is correct and at (Qty.: 1)
normal operating temperature.
4. Start the engine and run at 1000 RPM.
The test points can be left in place after testing.
Remove the blanking plugs as required and install 5. Apply the park brake and the foot brake firmly
the test points. If the test points are to be left in place, and select forward. Make sure that the clutch
apply Loctite 242 on the threads before installation. pressure shown in the pressure gauge is of the
Torque tighten the test points to 28N·m specified value. Refer to (PIL 27-03).
5.1. If the mainline pressure value is low,
To test the complete transmission, the following
the then the forward and reverse clutch
procedures are listed in a logical sequence. Make
pressure values should also be high.
sure you do the procedures in the same sequence.
For specific tests, refer to (PIL 27-03). 5.2. If the mainline pressure value is high,
the then the forward and reverse clutch
Mainline Pressure pressure values should also be high.
1. Stop the engine. 6. With the transmission in neutral, repeat the step
5 and note the gauge readings with the engine
2. Make the machine safe. Refer to (PIL 01-03). running at 2000 RPM.
3. Connect a pressure gauge of the specified value 7. Stop the engine and remove the test gauge.
to the test connector.
7.1. If the clutch pressure is low, the clutch could
Pressure: 0–20bar (0.0–289.9psi) be leaking. A leaking clutch is easier to
Special Tool: Digital Hydraulic Pressure Test Kit detect when the engine is running at idle.
(Qty.: 1) While idling, check the clutch pressure as
in step 5. If the clutch pressure is lower
4. Start the engine and run at 1000 RPM
than the specified value, the clutch could be
(Revolutions Per Minute) with the transmission in
leaking. Before you disassemble the clutch,
neutral.
refer to (PIL 27-03).
27 - 24 9813/8500-2 27 - 24
27 - Driveline
03 - Manual Gearbox
00 - General
7.2. A high clutch pressure could indicate a are as per the specified value. Refer to (PIL
faulty pressure maintaining valve. 27-03).
6. With the transmission in neutral, repeat the step
Pump flow 5 and note the gauge readings with the engine
1. Stop the engine. running at 2000 RPM.
2. Make the machine safe. Refer to (PIL 01-03). 7. Stop the engine and remove the test gauges.
3. Remove the transmission filter. Refer to (PIL 8. Install the hoses to the original position.
27-03).
8.1. If the pressure is low, refer to (PIL 27-03).
4. Screw in the adaptor 1 on to the threaded spigot. 8.2. A high pressure along with a low flow could
Special Tool: Flow Test Adaptor Assembly (Qty.: be due to a blocked oil cooler.
1)
Converter In Pressure
5. Install the test adaptor 2 and secure with the
adaptor 3. 1. Stop the engine.
6. Connect the flow meter. 2. Make the machine safe. Refer to (PIL 01-03).
Special Tool: Flowmeter (Qty.: 1) 3. Connect a pressure gauge of the specified value
7. Start the engine and run at 1000 RPM with the to the test point.
transmission in neutral. Pressure: 0–10bar (0.0–144.9psi)
Special Tool: Digital Hydraulic Pressure Test Kit
7.1. The flow meter will indicate the pump flow. (Qty.: 1)
4. Start the engine and run at 1000 RPM with the
8. With the transmission in neutral, repeat the step transmission in neutral.
7 and note the gauge readings with the engine
running at 2000 RPM. 5. Make sure that the converter in pressure
indicated in the pressure gauge is of the specified
9. Stop the engine and remove the test adaptors. value. Refer to (PIL 27-03).
10. Install the filter. Refer to (PIL 27-03). 5.1. A high or low reading could be due to a
faulty converter relief valve or due to a
11. If the pump flow is low, refer to the low pump flow
problem with the pump.
fault, refer to (PIL 27-03).
6. Remove the pressure test gauge.
Converter Out Pressure / Oil Cooler Flow
Rate Converter Relief (Safety) Valve Pressure
1. Stop the engine. 1. Stop the engine.
2. Make the machine safe. Refer to (PIL 01-03). 2. Make the machine safe. Refer to (PIL 01-03).
3. Connect a pressure gauge of the specified value 3. Connect a pressure gauge of the specified value
and flow meter to the converter out line. to the test point.
Special Tool: Flowmeter (Qty.: 1) Pressure: 0–10bar (0.0–144.9psi)
Special Tool: Digital Hydraulic Pressure Test Kit Special Tool: Digital Hydraulic Pressure Test Kit
(Qty.: 1) (Qty.: 1)
3.1. The flow meter must have a low back 4. Install a load valve to the converter out line.
pressure, otherwise an incorrect reading
Special Tool: Load Valve (Qty.: 1)
will be shown.
4. Start the engine and run at 1000 RPM with the Notice: Make sure the load valve is in the fully
transmission in neutral. open position (adjusting knob screwed fully out)
before starting the pressure test. Failure to do
5. The pressure gauge indicates the converter out this could damage the pump.
pressure and the flow meter indicates the oil
cooler flow rate. Make sure that both the readings
27 - 25 9813/8500-2 27 - 25
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03 - Manual Gearbox
00 - General
5. Make sure that the pressure is not more than the Lubrication Pressure
specified value. Damage to the converter seals
may occur. 1. Stop the engine.
Pressure: 7.6bar (110.1psi) 2. Make the machine safe. Refer to (PIL 01-03).
6. Start the engine and run at 1000 RPM with the 3. Connect a suitable pressure gauge to the return
transmission in neutral. line from the oil cooler to the transmission.
7. Slowly screw down the load valve while Special Tool: Digital Hydraulic Pressure Test Kit
observing the gauge reading. (Qty.: 1)
8. Make sure that the gauge reading rises to the 4. Start the engine and run at 1000 RPM with the
converter relief (safety) valve setting. Refer to transmission in neutral.
(PIL 27-03).
5. Make sure that the lubrication pressure indicated
8.1. If the reading is higher, then the converter in the pressure gauge is of the specified value.
relief valve is faulty. Refer to (PIL 27-03).
8.2. If the reading is lower, the pump seal could 6. With the transmission in neutral, repeat the step
be leaking or could be due to a faulty 5 and note the gauge readings with the engine
converter relief valve. running at 2000 RPM.
9. Stop the engine and remove the test gauges. 7. Stop the engine and remove the pressure gauge.
10. Install the hoses to the original position.
27 - 26 9813/8500-2 27 - 26
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03 - Manual Gearbox
00 - General
Figure 159.
G
J
X Y Z
H
A Main line pressure B Forward clutch pressure

C Reverse clutch pressure D Converter inlet / Converter relief valve pressure
E Converter outlet pressure F Pump flow (remove filter and install adaptors)
G Lubrication pressure H Cooler flow (flow meter in line from transmission
to cooler)
J Load valve W Flow meter
27 - 27 9813/8500-2 27 - 27
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03 - Manual Gearbox
00 - General
X Adaptor 1 Y Test adaptor 2

Z Adaptor 3
27 - 28 9813/8500-2 27 - 28
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03 - Manual Gearbox
00 - General
Calibrate Figure 160.
Special Tools
Spacer Kit 459/70378 1
Drive Coupling 892/00812 1
Spanner
End Float Setting Tool 990/00083 1
Shafts (End Float Measurement)

After replacement of the gearbox shafts, check A
the end float measurements. The component
manufacturing system makes sure that the end C
float is controlled within specified limits. To check
for correct assembly and installation of the shafts,
measure the end float dimensions as follows:
End float adjustment (Layshaft)

1. Remove the 2WD (Two Wheel Drive)/4WD (Four
Wheel Drive) unit, if it is installed. B
2. Screw a suitable M8 bolt into the end of the A Bolt
layshaft. B Spacer
3. Rotate the shaft and at the same time pull up on C DTI (Dial Test Indicator)
the bolt. 6. If the gearbox is assembled with new
4. Measure the layshaft end float and it must be components such as bearings or cases, the
within the specified limit. end float measurement may be more than the
specified limit mentioned in the step 4.
7. If necessary adjust the end float.
5. The layshaft and its associated components are
manufactured with a "set right" system. If the 7.1. Remove the front and rear case.
components are assembled correctly, the shaft 7.2. Remove the layshaft.
end float must be within the specified limit. Refer
to: 4. 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.
27 - 29 9813/8500-2 27 - 29
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03 - Manual Gearbox
00 - General
D
G Torque converter housing
2. Install the service tool on the main shaft end C
bearing and spacer 1 with the bolt 1. Refer to:
Refer to Figure 162. E
Special Tool: End Float Setting Tool (Qty.: 1)
3. Tighten the bolt 1 to the correct torque value. C DTI
D End float setting tool
4. Measure the main shaft end float and it must be E Spacer 1
within the specified limit. F Bolt 1
Dimension: 0.03–0.08mm 8. The main shaft and its associated components
5. Rotate the shaft when you take the measurement are manufactured with a "set right" system. If the
to install the bearings fully. components are assembled correctly, the shaft
end float must be within the specified limit. Refer
6. Set the pointer of the DTI on the chamfer of the to: 4.
shaft, not on the end face. This will make sure
that a constant reading is given. 9. If the gearbox is assembled with new
components such as bearings or cases, the
7. An M8 bolt installed on the end of the main shaft, end float measurement may be more than the
can be used to push and pull the shaft. specified limit mentioned in the step 4.
10. If necessary adjust the end float.
10.1. Remove the end float setting tool followed
by the spacer 1.
10.2. Measure the spacer 1.
10.3. If necessary, Use the end float
measurement to select and install the
correct size spacer1 from the kit.
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.
27 - 30 9813/8500-2 27 - 30
27 - Driveline
03 - Manual Gearbox
00 - General

AX
H C
AV
AW
BB
C DTI AV Retaining nut

H Forward reverse unit shaft AW Washer 2
AX Yoke
4. The forward reverse shaft and its associated BB Oil seal
components are manufactured with a "set right"
system. If the components are assembled 2. Transfer gear- output shaft end float check. Refer
correctly, the shaft end float must be in the to Figure 165.
specified limit. Refer to: 1.
2.1. Install the special tool sleeve which
5. If there is no float, or too much end float, separate temporarily replace the output yoke and
the cases and check that the bearings inner and attached with special tool nut and tighten
outer cups are installed correctly. the nut to the correct torque value.
6. If the forward reverse shaft and clutch 2.2. Check for the end float while tightening nut.
assemblies are disassembled, then check that 2.3. If there is no end float then check that the
the assembly has been carried out correctly. bearing cups are pushed fully into the case.
Transfer gear- output shaft end float check. 2.4. Refer to the parts catalogue for the correct
bearing installation.
1. If installed, follow below steps. Refer to Figure
164. 2.5. Install the special tool so that the fork end
can engage in the special tool nut and then
1.1. If necessary, Unstake the nut. Whilst tighten the bolt 2.
holding the output yoke with the drive
2.6. Install a DTI.
coupling spanner tool, remove the output
shaft nut and the washer 2 below it. From 2.7. Set the torque wrench to the specified
below support the output shaft and lift off the value and then measure the end float while
yoke. rotating the output shaft.
Special Tool: Drive Coupling Spanner (Qty.: Torque: 35N·m
1)
2.8. To select the right size spacer 3 do the step
1.2. Prise out the oil seal and discard it. from 2.9 to 2.11.
27 - 31 9813/8500-2 27 - 31
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03 - Manual Gearbox
00 - General
Figure 165. 3.1. Lubricate between the seal lips before

installing the new oil seal. The seal is not
K C 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
N shown in figure.
J
3.4. Install a new retaining nut and tighten the
nut to the correct torque value.
M
Figure 166.
AX
AV
AW
L
C DTI
J Special sleeve tool BB
K Special tool nut
L Bolt 2
M Support pillar
N Torque wrench
2.9. Subtract the end float obtained in step 2.7 AV Retaining nut
from the solid spacer thickness value (13.70 AW Washer 2
mm). AX Yoke
BB Oil seal
2.10. Subtract 0.120mm to allow for theoretical
bearing tolerance and pre-load. 3.5. If the correct size spacer is selected the
rolling torque must be the specified value
2.11. If the there is no spacer of the thickness when the retaining nut is fully tightened.
valued derived in step 2.10 use the next
smallest spacer. Torque: 2N·m
2.12. Remove the special nut and sleeve, also 3.6. If the rolling torque is too high, install the
remove the rear bearing and the 13.70 mm next larger size spacer. If there is end float,
solid spacer. install the next smaller size spacer.
2.13. Install the correct size spacer. Do not 3.7. Use a square-ended staking tool to carefully
install the oil seal at this stage. Make sure stake the nut into the slot.
that the outer bearing is not damaged.
Table 43. Spacer Selection Example
2.14. Install the sleeve and initially tighten the
nut to the correct torque value. Check that Value
there is no end float and rolling torque Service Spacer 13.70
is less than 1.5 Nm (1.0 lb-ft). If the Subtract end float 0.41
rolling torque exceeds 1.5 Nm (1.0 lb-ft), Total 13.29
check that the output shaft is assembled
Subtract tolerance and 0.12
correctly.
preload
2.15. If the rolling torque is too high, install the Result 13.17
next larger size spacer 3. If there is end
Use next smallest spac- 13.15
float, install the next smaller size spacer 3.
er
2.16. Remove the special nut and sleeve.
3. If removed, follow the below steps. Refer to
Figure 166. Item Description Nm
F Bolt 1 56
AV Retaining nut 300
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03 - Manual Gearbox
00 - General
Disassemble and Assemble Figure 167.
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
Strength) E D
Lifting Equipment D Bolt 1

E Pump 1
equipment. You must identify the weight of the item to 1.3. Remove the pump 1 from the gearbox.
enough and suitable for the job. Make sure that lifting 2. Some applications do not have a gearbox driven
equipment is in good condition and complies with all main hydraulic pump. if there is no gearbox
local regulations. driven pump start from: 3.
Cleanliness is of the utmost importance when 3. Remove the circlip 1 and then remove the pump
servicing the gearbox. All precautions to prevent any 1 drive shaft with its bearing. Refer to Figure 168.
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 167.
1.1. Support the pump 1.
1.2. Remove the bolt 1.
27 - 33 9813/8500-2 27 - 33
27 - Driveline
03 - Manual Gearbox
00 - General
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 170.
F
F Circlip 1 Figure 170.
G Pump 1 drive shaft
H Shaft sealing ring
J Bearing 1
4. Remove and discard the shaft sealing ring. Refer
to Figure 168.
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 169.
CX Bolt 2
10. Remove all the bolts 3 and lift off the pump 2 from
the input shaft. Refer to Figure 171.
11. Remove and discard the pump 2 sealing washer.
27 - 34 9813/8500-2 27 - 34
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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 171. 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 171. 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 172. 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 172. Refer to Figure 172.
18. On a 4WD clutch transmission, do the following: 20. Remove all the bolt 4 and remove the gear shift
Refer to Figure 172. turret. Refer to Figure 172.
18.1. Remove the 2WD and 4WD clutch 21. Remove the gasket 1. Refer to Figure 172.
hydraulic pipe.
22. If installed, remove the baffle plate. Refer to
18.2. Remove the 2WD and 4WD clutch Figure 172.
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 172.
of assembly.
24. Remove the plug 1. Refer to Figure 173.
18.4. Remove the valve cartridge from the case.
27 - 35 9813/8500-2 27 - 35
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03 - Manual Gearbox
00 - General
25. Remove the pressure maintenance valve spool, Figure 174.

and spring 1. Refer to Figure 173. AU AT
Figure 173.
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 173. 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 174.
Figure 173.
32. Remove all the bolt 6 and lift off the rear case.
28. Remove the plug 2. Refer to Figure 174. Refer to Figure 174.
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 174. together with their associated bearing. Refer to
Figure 174.
30. Remove the plug 3. Refer to Figure 174.
34. Remove the selector detent plugs. Refer to
Figure 175.
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 175.
27 - 36 9813/8500-2 27 - 36
27 - Driveline
03 - Manual Gearbox
00 - General
Figure 175. Figure 176. 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 176.
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
175. Figure 176.
38. Remove the selector forks. Refer to Figure 175. 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 177.
plunger. Refer to Figure 175.
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 177.
175.
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 176. 3 together. Refer to Figure 177.
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 177.
sure that they are installed correctly with
the mating cups at the time of assembly.
27 - 37 9813/8500-2 27 - 37
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03 - Manual Gearbox
00 - General
Figure 177. Special Tool: Drive Coupling Spanner (Qty.: 1)

AE 54. Prise out the oil seal and discard it. Refer to
AG
Figure 178.
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 178.
AF AJ
Figure 178.
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 177. AY Output shaft assembly
AZ Outer bearing
49. Remove the main shaft. Refer to Figure 177. 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 177. 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 178.
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 177. the centre of the output shaft transfer gear. Refer
to Figure 178.
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 177. disassembly. Refer to Figure 179.
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 178.
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03 - Manual Gearbox
00 - General
the synchro hubs and cups in their original Figure 180.

relationship.
CM CW CT
Special Tool: Bearing Press (Qty.: 1)
58.2. Remove the needle roller bearings.
Figure 179. 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 180. 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 181.
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.
27 - 39 9813/8500-2 27 - 39
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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 182.
3. Layshaft- assembly. Refer to Figure 183.
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 183. Figure 184. 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 185.
4. Main shaft assembly- blocking pin type 6. Transfer gear- output shaft assembly. Refer to
synchroniser. Refer to Figure 184. Figure 185.
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.
27 - 41 9813/8500-2 27 - 41
27 - Driveline
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 186.
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 186.
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 186.
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 187.
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 187.
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 186.
8. Use a service tool to locate the seal and install
the output yoke. Refer to Figure 186.
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 186.
27 - 42 9813/8500-2 27 - 42
27 - Driveline
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 187.
18. Carefully lower the forward reverse shaft unit into
the case. Refer to Figure 187. 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 187. 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 188. 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 188. 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 188.
case. Refer to Figure 188.
25. Install the idler gear to the spindle, while tilting
23. Install the idler gear spacer. Refer to Figure 188. the main shaft to one side. Refer to Figure 188.
26. Install the upper thrust washers and bearing 2
assembly. Refer to Figure 188.
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 189.
29. Carefully lower the layshaft assembly into the
case. Refer to Figure 189.
27 - 43 9813/8500-2 27 - 43
27 - Driveline
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 189. 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 189. assembly
32. Install the selector forks into there original 37. Make sure that the each gear is engaged
location. Refer to Figure 190. correctly. Refer to Figure 190.
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 190. to Figure 190.
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 190.
correct torque value. Refer to Figure 190. 40. Lift the selector rod to select the 4th gear. Refer
Consumable: JCB Threadlocker and Sealer to Figure 190.
(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 190.
selector detent plug and then tighten the selector Special Tool: Selector Shaft Lock Screw (Qty.: 1)
detent plug correctly. Refer to Figure 190.
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 190.
detent assembly, do not apply sealant to the plug Special Tool: Main Shaft Adjuster (Qty.: 1)
at this stage. Refer to Figure 190.
27 - 44 9813/8500-2 27 - 44
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 193.
mating surface of the front case. Refer to Figure
191. 48. Make sure that the main shaft locates with the
output shaft. Refer to Figure 193.
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. 193.
50. Rotate the output shaft back and forth to engage
Figure 191. the gears on the layshaft. Refer to Figure 193.
BZ BW Figure 193.
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 191.
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 192.
Figure 192. 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 193.
52. Apply sealant to all the bolt 6 and tighten the bolt
6 to the correct torque value. Refer to Figure 193.
(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 193.
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)
27 - 45 9813/8500-2 27 - 45
27 - Driveline
03 - Manual Gearbox
00 - General
55. Tighten the selector detent plug correctly. Refer Figure 195.
to Figure 193.
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 194. CL
Figure 194.
CL Gearbox cover mating surface

62. Install the torque converter housing. Apply
sealant to the bolt 2. Refer to Figure 196.
Figure 196.
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 195.
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 197.
65. At the time of installation make sure that the
pump 2 is aligned with the mounting holes. Refer
to Figure 197.
27 - 46 9813/8500-2 27 - 46
27 - Driveline
03 - Manual Gearbox
00 - General
Figure 197. 74. Use a new gasket and mount the pressure
maintenance valve body on the case. Refer to
B A Figure 198.
Figure 198.
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 197. AB Spring 1
67. Tighten the bolt 3 to the correct torque value. AC Pressure maintenance valve body
Refer to Figure 197. 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 198. 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 198. 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 198. to the correct torque value. Refer to Figure 198.
Consumable: JCB Threadlocker and Sealer Consumable: JCB Threadlocker and Sealer
(Medium Strength) (Medium Strength)
71. Tighten the plug 2 correctly. Refer to Figure 198. 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 198.
spring 3. Refer to Figure 198.
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 198. 198.
(Medium Strength) 78. Apply sealant to the plug 1 and tighten the plug 1
to the correct torque value. Refer to Figure 198.
(Medium Strength)
27 - 47 9813/8500-2 27 - 47
27 - Driveline
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 198. leverage point. Refer to Figure 199.
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 199.
89. Tighten the screw to the correct torque value.
81. Install the solenoid valve onto the pressure Refer to Figure 199.
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 199. value. Refer to Figure 199.
Torque: 24N·m
82. Apply sealant to the capscrews. Refer to Figure
199. 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 200.
83. Tighten the capscrews to the correct torque
value. Refer to Figure 199. Figure 200.
84. Install the 2WD / 4WD solenoid control valve.

BT
85. Make sure that its electrical connector block is
phased correctly. Refer to Figure 199.
86. Make sure that you do not hold the component
by its electrical connector block. Refer to Figure
199.
Figure 199.
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 201.
93. Make sure that the turret assembly is in the
correct orientation. Refer to Figure 201.
M Capscrew (x4)
P Screw
Q Clamp
R 2WD / 4WD solenoid control valve
S Electrical connector block
T Hydraulic pipe
27 - 48 9813/8500-2 27 - 48
27 - Driveline
03 - Manual Gearbox
00 - General
Figure 201. 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 202.
103.1.Install a new sealing ring on the pump 1
drive shaft.
Figure 202.
N Bolt4 (x4)
94. Make sure that the turret selector mechanism G
engages correctly with the gearbox selector
forks. Refer to Figure 201. H
95. Apply sealant to the bolt 4 and secure the turret
assembly with the bolt 4. Refer to Figure 201.
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 201. G Pump 1 drive shaft
97. Check the gear selection. Refer to Figure 201. 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 - 49 9813/8500-2 27 - 49
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 - 50 9813/8500-2 27 - 50
27 - Driveline
03 - Manual Gearbox
06 - Clutch - Forward/Reverse
06 - Clutch - Forward/Reverse Check (Condition)

Check (Condition) .......................................... 27-51 Carry out a visual inspection of the friction and
Calibrate ........................................................ 27-52 counter plates:
Counter plates
1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored
must be replaced with a new set.
Friction plates
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
27 - 51 9813/8500-2 27 - 51
27 - Driveline
03 - Manual Gearbox
Calibrate Disassemble and Assemble
End Float Setting Disassembly

1. Use a DTI (Dial Test Indicator) to measure the 1. Carefully remove the piston ring seals. Refer to
end float of the pressure end plate. Manual Gearbox, Piston Ring Seal, Remove and
Install (PIL 27-03-45). Refer to Figure 204.
2. The pressure end plate end float should be within
the specified limit. Figure 204.
A
Figure 203.
A
A
B
A Piston ring seal

B Clutch end bearing
3. If it is necessary to adjust the end float, to bring
it within the specified limit mentioned in step 2, 2. If the piston ring seals are excessively worn then
install shims between the retaining circlip and the check for burrs or damage on the shaft grooves.
pressure end plate. If necessary remove burrs with a fine grade
abrasion paper and oil. Refer to Figure 204.
3. Use a puller to remove the clutch end bearing.
4. Remove the thrust bearing 1 and the thrust
washer 1. Refer to Figure 205.
Figure 205.
D
C
D
C Thrust bearing 1
D Thrust washer 1
E Gear and splined hub assembly
27 - 52 9813/8500-2 27 - 52
27 - Driveline
03 - Manual Gearbox
5. Remove the gear and the splined hub assembly Figure 207.
with the needle roller bearing and the spacer.
K
6. Make sure that you have note the location of the
spacer for its correct assembly. Refer to Figure
205.
L
7. Remove the thrust bearing 2 and the thrust
washer 2. Refer to Figure 206.
Figure 206. M
G
F
G
K Friction plate
L Counter plate
M Disc spring
12. Remove the disc spring. Refer to Figure 207.
13. Put the clutch assembly in a suitable press to
compress the piston spring then remove the
circlip. Refer to Figure 208.
Figure 208.
F Thrust bearing 2
G Thrust washer 2
H Friction and counter plates retaining circlip
J Pressure end plate
8. Remove the friction and counter plate retaining
circlip. Refer to Figure 206.
9. Remove the pressure end plate. Refer to Figure
206.
10. Remove the friction plates and the counter
plates. Keep them together in set. Refer to Figure
207.
11. Do not mix the plates with those from other
14. Lift off the spring retaining plate. Refer to Figure
clutches assemblies. Refer to Figure 207.
209.
15. Remove the spring. Refer to Figure 209.
27 - 53 9813/8500-2 27 - 53
27 - Driveline
03 - Manual Gearbox
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 211.
21. Do the step from 3 to 20 again, to disassemble
the opposite side clutch.
N Spring retaining plate
P Spring Before you assemble the clutch assembly check
Q Oil baffle the condition of the clutch assembly. Refer to
Manual Gearbox, Clutch- Forward/Reverse, Check
16. Remove the oil baffle plate. Refer to Figure 209. Condition (PIL 27-03-06).
17. Turn the assembly over and hit the clutch shaft Assembly
gently on a piece of aluminium (or wooden) block
to loosen the piston. Refer to Figure 210. 1. Install new O-rings to the piston and shaft.
Lubricate the piston with oil and push fully into the
Figure 210. bore of the clutch housing. Refer to Figure 212.
Figure 212.
R Piston
18. If the piston does not loosen when you hit the
S Piston O-ring
clutch shaft is on aluminium (or wooden) block,
T Shaft O-ring
then the hand pump air down the shaft oil inlet
hole. Refer to Figure 210. 2. Install the oil baffle and the piston spring. Refer
to Figure 213.
19. Remove the piston. Refer to Figure 211.
3. Make sure that the spring seats in the piston.
27 - 54 9813/8500-2 27 - 54
27 - Driveline
03 - Manual Gearbox
K
N
P
L
Q
M
N Spring retaining plate K Friction plate

P Spring L Counter plate
Q Oil baffle M Disc spring
4. Install the spring retaining plate. Refer to Figure 7. Install the counter plates and friction plates
213. alternately, start with a counter plate and finish
with a friction plate. Refer to Figure 215.
5. Compress the spring and install the circlip. Refer
to Figure 214. 8. Install the pressure end plate. Refer to Figure
216.
Figure 214.
9. Make sure that the chamfered face is installed,
facing the clutch pack. Refer to Figure 216.
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 215.
27 - 55 9813/8500-2 27 - 55
27 - Driveline
03 - Manual Gearbox
Figure 216. 13. The pressure end plate end float should be within
the specified limit.Refer to Figure 217.
H Dimension: 3.2–4.4mm
J 14. If it is necessary to adjust the end float, to bring it
within specified limit mentioned in step 13, install
shim between the retaining circlip and pressure
end plate. Refer to Figure 217.
15. Install the thrust washer 2 and thrust bearing 2.
H Figure 218.
J
G
F
G
H Friction and counter plates retaining circlip

J Pressure end plate
10. Make sure that the teeth are not aligned with the
lubrication slots in the housing. Refer to Figure
216.
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 F Thrust bearing 2
clutch pack is free to operate smoothly. Refer to G Thrust washer 2
Figure 216.
16. Carefully use a thin rod (or screwdriver) to align
12. Use a DTI (Dial Test Indicator) to measure the the teeth of the clutch plates. Install the gear and
end float of the pressure end plate. Refer to splined hub. Refer to Figure 219.
Figure 217.
17. Install the spacer followed by the needle roller
Figure 217. bearing.
18. Make sure that the space is installed first.
19. Install the thrust washer 1 and thrust bearing 1.
27 - 56 9813/8500-2 27 - 56
27 - Driveline
03 - Manual Gearbox
Figure 219.
D
C
D
C Thrust bearing 1
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 220.
Figure 220.
A
A
A
B
A Piston ring seal

B Clutch end bearing
21. Install new piston ring seals. Refer to Manual
Gearbox, Piston Ring Seal, Remove and Install
(PIL 27-03-45). Refer to Figure 220.
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 - 57 9813/8500-2 27 - 57
27 - Driveline
03 - Manual Gearbox
07 - Clutch - 2WD/4WD
07 - Clutch - 2WD/4WD Introduction

Introduction .................................................... 27-58 Refer to Driveline, Manual Gearbox, Clutch-
Component Identification ............................... 27-59 Forward/Reverse, Introduction (PIL 27-03-06).
27 - 58 9813/8500-2 27 - 58
27 - Driveline
03 - Manual Gearbox
Figure 221. 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
27 - 59 9813/8500-2 27 - 59
27 - Driveline
03 - Manual Gearbox
G PTFE (Polytetrafluoroethylene) Piston ring seal H O-ring

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
27 - 60 9813/8500-2 27 - 60
27 - Driveline
03 - Manual Gearbox
Special Tools 7. If necessary only remove and replace the bearing

Description Part No. Qty. from the drive clutch assembly.
Drive Coupling 892/00812 1 8. Carefully remove the piston seal ring.
Spanner
9. If the piston ring seal is damaged or excessively
Consumables worn then check for burrs or damage on the shaft
Description Part No. Size groove.
10. If necessary remove the burrs with a fine grade
JCB Threadlocker 4101/0250 0.01L abrasion paper and oil.
Strength) 11. Use a puller tool to remove the 4WD output gear
with its bearing 1, needle roller bearings and the
Before you disassemble the 2WD (Two Wheel Drive) thrust washer 1.
and 4WD (Four Wheel Drive) clutch units, drain the
gearbox oil. 12. Remove the thrust washer. Note: the thrust
washer and thrust washer 1 are not
Disassembly interchangeable.
1. Use a spanner to hold the output yoke and 13. Remove the circlip 1 and if installed remove the
remove the bolt. shims. Keep the shims as an assembly set.
Special Tool: Drive Coupling Spanner (Qty.: 1) 14. Remove the pressure end plate, the clutch pack
friction plates and the counter plates. Keep them
2. Remove the output yoke. together in a set.
3. Use the output yoke as a stand. 15. Do not mix these plates with the plates from other
clutches.
4. Carefully remove and discard the oil seal. Make
sure that the seal housing is not damaged at the 16. If only the clutch pack is to be removed then do
time of removal. the step 1 to 15 only.
5. Remove all the bolts that attach the 4WD case to 17. Use a suitable press and a cut away tube as
the gearbox. Lift off the 4WD case. shown, to compress the spring and remove the
circlip.
6. Remove the 2WD and 4WD clutch from the
gearbox.
27 - 61 9813/8500-2 27 - 61
27 - Driveline
03 - Manual Gearbox
Figure 222.
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 - 62 9813/8500-2 27 - 62
27 - Driveline
03 - Manual Gearbox
Figure 223. 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 - 63 9813/8500-2 27 - 63
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 - 64 9813/8500-2 27 - 64
27 - Driveline
03 - Manual Gearbox
Assembly Figure 225.

the disassembly procedure. Additionally do the
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 224.
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
27 - 65 9813/8500-2 27 - 65
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03 - Manual Gearbox
components are assembled correctly, the shaft

end float should be in be in the specified limit.
21. Rotate the shaft by hand and make sure that it
runs smoothly.
22. Pull the shaft up and down to find any excessive
end float. If there is excessive end float or the
shaft runs roughly, disassemble the unit and
check for correct assembly.
23. Install a new oil seal.
24. Install the Output yoke and then install the bolt.
25. Tighten the bolt to the correct torque value.

Item Description Nm
A Bolt 395
E Bolt 1 56
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39 - Filter
39 - Filter
Introduction
The transmission filter is designed to filter all the

contamination that is generated through use to
the required level of cleanliness. The filter must
be serviced to the requirements of the machine
maintenance schedules.
27 - 67 9813/8500-2 27 - 67
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78 - Direct Shift Turret
78 - Direct Shift Turret Introduction

Introduction .................................................... 27-68 The gear lever turret connects the gear lever and the
Component Identification ............................... 27-69 gearbox.
27 - 68 9813/8500-2 27 - 68
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03 - Manual Gearbox
Figure 226.
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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Disassemble 4. Remove the circlip.
1. Remove the gear lever. 5. Slowly release the pressure from the top lever
and remove it, together with the bush, washer
2. Slacken the worm drive clips. Remove the rubber and spring 6.
gaiter.
6. Rotate the spring 8 so as to disengage from the
CAUTION! Beware of spring pressure acting on retaining tabs inside the gear lever turret. Be
the bush when the circlip is removed. aware that the spring may suddenly disengage
while still under pressure. Repeat this operation
3. Use a suitable press or clamp to carefully press until all the coils are disengaged and the spring
the top lever down to compress the spring 6, to can be removed.
release pressure on the circlip 1.
7. Remove the retainer and the lower lever.
Figure 227.
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

procedure. During the replacement procedure do the
following work: 1. Lubricate liberally the working surfaces before
assembling.
2. Make sure that the O-ring is free from damage.
Install the O-ring correctly.
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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.
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20 - Axle
Contents Page No.
27-20-00 General ........................................................................................................................... 27-73
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00 - General
Introduction .................................................... 27-73 Axles are an integral component of a wheeled
Technical Data ............................................... 27-74 vehicle. The axle transmits a driving torque to the
Component Identification ............................... 27-75 wheel, as well as maintaining the position of the
Drain and Fill ................................................. 27-77 wheels relative to each other and to the vehicle body.
Check (Level) ................................................ 27-78
Lubricate ........................................................ 27-79
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Technical Data

Table 47. SD55 Axle (without brakes)
Description Data
Type JCB spiral bevel input with epicyclic hub reduction
Type of brakes None
Installation Centre pivot
Weight (dry, with no steer rams 354kg approximately
and without wheels)
Hub reduction 5.4 : 1
Input type Yoke
Oscillation 5°
Toe - in 0°
Castor angle 0°
Camber angle 1°
King - pin inclination 0°
Ratios 18 inch wheels 20 inch wheels
Overall 16.2 : 1 18.6 : 1
Crownwheel and pinion 3:1 3:1
Crownwheel teeth 33 33
Pinion teeth 11 11
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For: 55 Series (1 Piece Axle), 4WD The axle has a single piece case which houses the
................................................... Page 27-75 differential and half shafts. The axle is pivot mounted
For: Dead Steer, 2WD ............... Page 27-76 to the chassis.
(For: 55 Series (1 Piece Axle), 4WD)

The illustration shows a typical steer drive rear axle.
Figure 228.
A B
F
G
J
K
C
D
E
H
A Yoke connection to propshaft B Pinion

C Crownwheel D Differential unit
E Drive shaft F Universal coupling
G Reduction gear hub H Steer swivel trunnion bearings
J Axle pivot K Oil fill and level plug
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00 - General
(For: Dead Steer, 2WD)
Figure 229.
A B
A
B
D
A Hub B Swivel
C Pivot D Track rod
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Drain and Fill (For: 55 Series (3 piece Axle))

For: 55 Series (1 Piece Axle) ..... Page 27-77 The axle oil is used to lubricate the brake
For: 55 Series (3 piece Axle) ..... Page 27-77 components and cool the brake plates.
It is important that the oil is changed regularly as

(For: 55 Series (1 Piece Axle)) specified in the service schedules. Refer to: PIL
78-24-06.
The axle oil is used to lubricate the brake
components and cool the brake plates. The lubricating properties of the oil will reduce as a
result of brake wear.
It is important that the oil is changed regularly as
specified in the service schedules. Refer to: PIL 1. Park the machine on level ground so that the 'OIL
78-24-06. LEVEL' mark on one hub is at the bottom.
The lubricating properties of the oil will reduce as a 2. Engage the park brake.
result of brake wear.
3. Set the transmission to neutral.
4. Lower the attachments to the ground.
2. Place a container of suitable size below the drain
plug to collect the oil. 6. Place a container of suitable size below the fill
plug of the hub to collect the oil.
3. Remove the drain plug and its seal.
Figure 231.
4. Allow the oil to drain out completely.
A
4.1. The drain plug is magnetic. Clean the drain
plug.
4.2. Metallic particles should be carefully B
removed.
5. Install the drain plug and the seal.
7. Clean the area around the fill/level plug, then D
remove the plug and the sealing washer.
8. Fill with the recommended oil through the fill/level
hole. C
9. Clean and install the fill/level plug along with the

seal.
10. Tighten the fill/level plug to the correct torque
value. A Wheel
B Hub
Figure 230. C Drain plug
A D Level mark
7. Remove the fill plug from the hub.
plug.
8.2. Metallic particles should be carefully
B removed.
A Fill/level plug
B Drain plug 9. Clean and install the fill/level plug of the hub.
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10. Position the other wheel of the rear axle so that Check (Level)
the 'OIL LEVEL' mark on the hub is at the bottom.
Do the steps 6 thru 9.
11. Place a container of suitable size below the drain
plug to collect the oil. Notice: The oil level must be checked with the
machine level, otherwise a false indication of the
Figure 232. amount of oil will be given.

2. Clean the area around the fill/level plug.
A 3. Remove the plug and the sealing washer.
4. Oil should be level with the bottom of the hole.
5. Add the recommended oil if necessary.
B
6. Clean and install the plug and the washer.
Figure 233.
A
A Fill/level plug
B Drain plug
12. Remove the drain plug.
plug. B
13.2. Metallic particles should be carefully A Fill/level plug
removed. B Drain plug
14. Install the drain plug.
15. Clean the area around the fill/level plug of the
axle, then remove the plug and the sealing
washer.
16. Fill with the recommended oil through the fill/level
hole.
17. Clean and install the fill/level plug of the axle
along with its seal.
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Lubricate Figure 235. Front Axle (4 Wheel Drive Machines)

A,B C,D
For: Dead Steer, 2WD ............... Page 27-79
For: 55 Series (1 Piece Axle), 4WD
................................................... Page 27-79
E
(For: Dead Steer, 2WD) A C
Lubricate
2. Turn the ignition switch to the OFF position. B D
A Grease point 1
3. Get access to the front axle. B Grease point 2
C Grease point 3
4. Apply grease to all the linkages and points of the D Grease point 4
axle. Refer to Figure 234. E Grease point 5
Figure 234. Front Axle (2 Wheel Drive Machines)
B C D
A,F E,G
A E
F G
A Grease point 1
B Grease point 2
C Grease point 3
D Grease point 4
E Grease point 5
F Grease point 6
G Grease point 7
Lubricate
3. Get access to the front axle.
4. Apply grease to all the linkages and points of the
axle. Refer to Figure 235.
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00 - General
Remove and Install
For: 2DX [T3], Front .................. Page 27-80 2. Put chocks against the rear wheels.
For: 2DX [T3], Rear ................... Page 27-82
3. Remove the bolts with service tool to disconnect
the propshaft from the axle.
(For: 2DX [T3], Front)
Special Tool: Splined Bolt Socket (Qty.: 1)
Special Tools Refer to: PIL 27-47-00.
4. Loosen the wheel retaining nuts.
Splined Bolt Socket 892/00822 1
Slide Hammer Kit 993/68100 1 5. Lift the machine on each side as shown.
WARNING A raised and badly supported 6. Remove the front wheels.

machine can fall on you. Position the machine Refer to: PIL 27-29-00.
on a firm, level surface before raising one end.
Ensure the other end is securely chocked. Do 7. Put a jack underneath the balance point of the
not rely solely on the machine hydraulics or jacks axle and support the axle weight.
to support the machine when working under it.
Disconnect the battery, to prevent the machine 7.1. Note: the drivehead assembly is offset, the
being started while you are beneath it. balance point of the axle is not the centre of
the axle. Attach a cradle to the jack that will
WARNING A machine can roll off jacks and partially embrace the axle.
crush you unless the wheels have been blocked.
Always block the wheels at the opposite end of 8. Remove the nut and pivot pin retaining bolt.
the machine that is to be jacked. Do not work
underneath a machine supported only by jacks. 9. Use the special tool to remove the pivot pin.
Always support a jacked-up machine on axle Special Tool: Slide Hammer Kit (Qty.: 1)
stands before working underneath it.
10. Remove the spacers.
Remove 11. Lower the jack so that the axle is clear of the
mounting yoke and remove the axle.
27 - 80 9813/8500-2 27 - 80
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00 - General
Figure 236.
B
G F
E
D
A Safety strut B Bolt

C Steer ram hose D Wheel nut
E Jack F Nut
G Retaining bolt - pivot H Pivot pin
J Spacer
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00 - General
Install 3.1. Disengage the park brake. Refer to (PIL

24-18).
3.2. Get access to the parking brake bracket
removal procedure.
which is installed to the rear axle, from
2. Make sure that the end float of the axle is not below the machine.
more that the specified value. 3.3. Loosen the bulkhead nuts that attach the
Dimension: 0.5mm parking brake cable to the bracket. Refer to
Figure 237.
2.1. If required, use spacers in the front and rear
of the axle to attain the required end float. 3.4. Disconnect the cable from the brake caliper.
2.2. Use only one type (thickness) of spacer.
3.5. Use a cable tie to attach the cable.
3. Whenever a wheel has been removed, check the
wheel nut torque values every two hours until 4. Remove the universal bolts to disconnect the
they stay correct. drive shaft from the rear axle. Refer to Figure
237.
5. Disconnect the brake pipes from the brake piston
Torque: 70 ± 5N·m housings.
5.1. Put caps on the open pipes and ports to
Table 48. Spacer Thickness prevent contamination.
Part Number (Colour) Thickness
5.2. Put labels on the pipes to help identification
823/10401 (Grey) 3.5mm for installation.
823/10402 (Cream) 4mm
823/10403 (Yellow) 4.5mm 6. Remove the bolt that attaches the tee piece to
the rear axle housing. Refer to Figure 237.
823/10404 (Blue) 5mm
823/10405 (Red) 5.5mm 6.1. Remove the tee piece from the rear axle
823/10406 (Black) 6mm housing. Refer to Figure 237.
7. If the drivehead is installed with the differential
(For: 2DX [T3], Rear) lock, remove the hydraulic pipe from the
drivehead. Refer to Figure 237.
Consumables
Description Part No. Size 8. Loosen the rear road wheel retaining nuts.
JCB Threadlocker and 4101/0550 0.01L
Sealer (High Strength) 8.1. Make sure that the front wheels are
4101/0552 0.2L
blocked, before you loosen the rear wheel
retaining nuts.
WARNING A raised and badly supported
machine can fall on you. Position the machine 8.2. Use the wooden blocks to block the front
on a firm, level surface before raising one end. wheels.
Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks 9. Use the stabiliser legs to raise the rear end of
to support the machine when working under it. the machine with the wheels and tyres above the
Disconnect the battery, to prevent the machine ground.
being started while you are beneath it.
10. Use the screw jacks to support the rear end of
WARNING If, for whatever reason, a wheel stud the machine. Refer to Figure 237.
is renewed, all the studs for that wheel must be
changed as a set, since the remaining studs may 11. Remove the rear road wheels from the machine.
have been damaged.
12. Put a jack below the balance point (at centre) of
the axle and support the axle weight. Refer to
Remove Figure 237.
1. Make the machine safe. Refer to (PIL 01-03). 12.1. Attach a cradle to the jack that will partially
hold the axle.
to (PIL 33-03). 13. Remove the nut, washer and retaining bolt that
are attached to the axle mounts. Refer to Figure
3. Do the steps below for the Synchro Shuttle 237.
machines only.
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20 - Axle
00 - General
13.1. Make a note that some machines may be 14. Lower the jack to remove the rear axle from the
installed with the packers below the axle axle mounts.
mounts on both sides, depending on the
wheel combinations. 15. Remove the rear axle.
Figure 237.
G
F
H
L J
P
K
A
C
B Q
N
M
A Bracket B Bulkhead nuts

C Cable D Bolts
E Brake pipes F Bolt
G Tee piece H Hydraulic pipe - drivehead
J Wheel nuts K Screw jacks
L Jack M Nuts
N Washers P Bolts - axle mounts
Q Packers
27 - 83 9813/8500-2 27 - 83
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00 - General
Install
procedure.
2. Apply JCB Threadlocker and Sealer to the
threads of the retaining bolts.
(High Strength)
2.1. Tighten the retaining bolts to the correct
specified torque value.
Torque: 607N·m
3. Tighten the wheel nuts to the correct specified
torque value.
Torque: 680N·m
3.1. Tighten the wheel nuts in a diagonal
sequence.
4. Do a torque check of the wheel nuts when you
install the wheel.
4.1. Check the wheel nuts torque every
specified duration until they stay correct.
Duration: 2h
5. Tighten the universal joint bolts to the correct
specified torque value.
Torque: 79N·m
6. Bleed the brake system. Refer to (PIL 24-00).
7. Check and adjust the park brake of the Synchro
Shuttle machines only. Refer to (PIL 24-18).
27 - 84 9813/8500-2 27 - 84
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22 - Drivehead
22 - Drivehead
Contents Page No.
27-22-00 General ........................................................................................................................... 27-87

27-22-06 Crownwheel .................................................................................................................. 27-105
27-22-09 Pinion Gear .................................................................................................................. 27-107
27 - 85 9813/8500-2 27 - 85
Notes:
27 - 86 9813/8500-2 27 - 86
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22 - Drivehead
00 - General
Introduction .................................................... 27-87 The axle drivehead transmits drive from the input
Component Identification ............................... 27-88 coupling yoke to the driveshafts through the
Disassemble and Assemble .......................... 27-93 differential unit.
27 - 87 9813/8500-2 27 - 87
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00 - General
For: 55 Series (1 Piece Axle) ..... Page 27-88 Figure 239.

For: 55 Series (3 Piece Axle) ..... Page 27-91
(For: 55 Series (1 Piece Axle))
Unit Identification
The axle serial number is stamped on the unit
order for parts replacement, always give the details
mentioned on the unit identification plate. In the case
of gear replacements, always check the part number
stamped on the gear, and the number of teeth.
Figure 238.
A Identification plate
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22 - Drivehead
00 - General
Figure 240.
4 5
2 3 6 7 8
Item Description
5 Bevel gears
Table 49.
6 Side nut locking pin
Item Description
7 Differential housing
1 Coupling yoke
8 Crownwheel
2 Driveshaft
3 Side nut
4 Pinion
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00 - General
Location Drawing (448/00040)
Figure 241.
15 10
14
12
13
1
2
11
3
4
5
Item Description
Table 50. 4 Spacer
Item Description 5 Bearing (taper roller)
1 Drivehead carrier 6 Pinion seal
2 Bearing (taper roller) 7 Coupling yoke
3 Shim 8 Stake nut
27 - 90 9813/8500-2 27 - 90
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00 - General
Item Description identification plate. In the case of gear replacements,

10 Bolt-Verbus Ripp always check the part number stamped on the gear,
and the number of teeth.
11 Crown wheel and pinion
assembly Figure 242.
12 Bearing (taper roller)
13 Side nut
14 Side nut locking pin
15 Differential assembly
(For: 55 Series (3 Piece Axle))
Unit Identification A

identification plate. When ordering replacement
parts, always quote the details on the unit A Identification plate
27 - 91 9813/8500-2 27 - 91
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00 - General
Location Drawing (448/00063)
Figure 243.
1 15 11 10 16
14
13
12
2
3
5 4
6
7
8
Item Description
Table 51. 10 Bolt Verbus-ripp
Item Description 11 Crownwheel and pinion
assembly
1 Drive case
13 Side nut
3 Shim
14 Brake piston
4 Spacer
15 Differential assembly
16 Brake piston housing
6 Pinion seal
7 Coupling yoke
8 Stake nut
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00 - General
For: 55 Series (1 Piece Axle) ..... Page 27-93 7. Remove the bearing outer race 1 and bearing
For: 55 Series (3 Piece Axle) ..... Page 27-98 outer race 2 from the drivehead carrier bores.
8. Drive off the taper roller bearing cone 1 from the
(For: 55 Series (1 Piece Axle)) crownwheel differential case half.
Special Tools 9. Remove the differential assembly from the
Description Part No. Qty. carrier.
Spanner 10. Mark the position of the drive yoke on the splined
Setting Tool Kit 892/00918 1 shaft.
Spacer Kit 921/52600 1 11. Use the special tool to prevent the drive yoke
Spacer Kit 921/53300 1 from rotating and remove the pinion nut.
Torque Wrench 993/70111 1 Special Tool: Drive Coupling Spanner (Qty.: 1)
(10-100Nm)
Support Bracket 997/11000 1 12. Remove the drive yoke.
13. Remove the pinion shaft from the drivehead
Consumables carrier.
JCB Multi-Gasket 4102/1212 0.05L 14. Prise the pinion oil seal out of the bore.
JCB Threadlocker 4101/0250 0.01L 15. Remove the pinion tail bearing.
Strength) 16. If necessary, remove the bearing outer race 3.
Disassembly 17. If necessary, remove the bearing cup from

the opposite side of the drivehead carrier and
The drivehead consists of the drivehead carrier remove the pinion shims.
and pinion assembly, and the differential unit. A 18. Remove the spacer and the taper roller bearing
separate disassembly procedure is given for each cone 3 from the pinion.
sub assembly.
Disassemble the differential unit (If
Disassemble the Drivehead Carrier
necessary)
1. Drain the oil from the axle centre case.
1. For LSD (Limited Slip Differential) Refer to Front
2. Completely remove both hub assemblies with the Differential, Disassemble and Assemble.
driveshafts.
2. Remove the differential assembly retaining bolt
3. Mark the installation position of the drivehead and separate the case half 1 and case half 2.
carrier with respect to the axle case.
3. Remove the side gears and the thrust washer 1
4. Remove the drivehead carrier retaining bolt and (2 off each).
then remove the drivehead carrier from the axle
4. Remove the bevel gears and thrust washer 2 (4
case.
off each) from the trunnion pins.
5. Clean the drivehead carrier and axle case mating
5. Remove the taper roller bearing cone 2 from the
faces.
differential case half.
6. Pull out the tension pin 1 and tension pin 2, and
6. Remove the Verbus-ripp bolts.
remove the castellated nut 1 and castellated nut
2. 7. Remove the crownwheel from the differential
case half.
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00 - General
Figure 244.
D K L
T
M
Q
G E C
P
R W N
S
F
H J
V
A
B
AG
U
AD
AE
Z
AF
AC
AB
AA
X Y
27 - 94 9813/8500-2 27 - 94
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22 - Drivehead
00 - General
housing halves are also matched. Do not use

unmatched halves.
Table 52.
Item Description Assemble the differential unit (if necessary)
A Drivehead carrier retain- 1. For LSD Refer to Front Differential, Disassemble
ing bolt and Assemble.
B Drivehead carrier
C Tension pin 1 2. Assemble the trunnion pin, bevel gear 1 and the
bevel gear 2 then the thrust washer 1 and thrust
D Tension pin 2 washer 2 into differential half case 2.
E Castellated nut 1
F Castellated nut 2 3. Put the differential half case 1 onto the half case
2. Make sure you align them properly.
G Bearing outer race 1
H Bearing outer race 2 4. Apply sealant to the differential assembly
J Taper roller bearing retaining bolt and then install it.
cone 1 Consumable: JCB Threadlocker and Sealer
K Differential assembly (Medium Strength)
L Differential assembly re-
taining bolt 5. Tighten the bolt to the correct torque value.
M Case half 1 6. Check the gears for free rotation.
N Case half 2
7. Use new Verbus-ripp bolts to install the
P Side gear
crownwheel.
Q Thrust washer 1
R Bevel gear 8. Tighten the bolt to the correct torque value. Refer
S Thrust washer 2 to table1.
T Taper roller bearing Assemble the drivehead carrier
cone 2
U Verbus-ripp bolt 1. Measure the correct thickness for the seam.
V Crownwheel Refer to Front Drivehead, Pinion Gear- Calibrate.
W Trunnion pin Refer to: PIL 27-22-09.
X Pinion nut
2. Install the shim behind the new bearing cup.
Y Drive yoke
Z Pinion shaft 3. Install the new pinion head bearing cone onto the
AA Pinion oil seal pinion.
AB Pinion tail bearing 4. Install the pinion and bearings into the drivehead
AC Bearing outer race 3 case.
AD Bearing cup
5. Install the largest available solid spacer (14.20
AE Drive pinion shim mm).
AF Spacer
AG Taper roller bearing
cone 3 6. Apply a coat of oil and then install the pinion tail
bearing.
Assembly 7. Do not install the oil seal at this stage.
The procedure below refers to the following aspects 8. Install the special tool sleeve and the special
of the drivehead assembly, which are covered pinion shaft adaptor from the setting kit.
separately in detail.
Special Tool: Setting Tool Kit (Qty.: 1)
• Pinion depth setting
• Crownwheel and pinion meshing 9. Tighten the adaptor to the correct torque value.
10. Make sure that the pinion is free to rotate and
Both the crownwheel and pinion and the bevel gear
there is end float, this will prevent any damage
1 and bevel gear 2 are matched and should be
to the bearing. If the pinion is not free to rotate
replaced as a set, if any of their components are
or there is no end float at this stage check the
damaged or excessively worn. The two differential
27 - 95 9813/8500-2 27 - 95
27 - Driveline
22 - Drivehead
00 - General
bearing is installed properly. Also check that the Figure 246.

correct size spacer is installed.
11. Use two (M10x30) nuts and bolts to install the
special bracket on the drivehead housing.
Special Tool: Support Bracket (Qty.: 1) AN
Figure 245.
AM
AL
AJ
AK
AH
AM DTI
AN Torque wrench
16. Set the torque wrench to the specified value and
measure the end float while you rotate the shaft.
Torque: 35N·m
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
AH Special tool sleeve
AJ Adaptor 17. To select the right size spacer do the following
AK Special bracket steps. Refer to Table 55.
AL Support pillar 17.1. Subtract the end float obtained in step
12. Install the special support pillar on the bracket so 16 from the solid spacer thickness value
that the fork end engages with the adaptor. (14.20 mm).
17.2. Subtract 0.04mm to allow for theoretical
13. Make sure that the fork is centrally located on the bearing tolerance and pre-load.
adaptor.
17.3. The result is the size of spacer to be
14. If necessary, align the bracket again. installed from the solid spacer setting kit.
15. Install a DTI (Dial Test Indicator). Make sure that Special Tool: Spacer Kit (Qty.: 1)
the DTI is mounted on the drivehead and not on 17.4. If there is no spacer of this size, then install
the bracket. the next nearest size spacer.
18. Remove the sleeve and the temporary spacer.
19. Install the correct size spacer from the solid
spacer setting kit.
20. Make sure that you do not damage the outer
bearing.
21. Again install the sleeve and then install the
adaptor.
27 - 96 9813/8500-2 27 - 96
27 - Driveline
22 - Drivehead
00 - General
22. Tighten the adaptor to the correct torque value, 41. Measure the backlash between the crownwheel
to protect against bearing damage while spacer and the pinion and it should be within the
selection is verified making sure the pinion is free specified limit.
to rotate. Length/Dimension/Distance: 0.17–0.28mm
23. Check there is no end float and the pinion is free 42. When altering the backlash adjust both the
to turn smoothly by hand. castellated nut in equal amounts.
24. Remove the adaptor and then install the nut. 43. When the backlash and pre-load are both
25. Make sure that the rolling torque is less than 2.0 correct, install the tension pin 1 and tension pin 2.
Nm, if the rolling torque exceeds 2.0 Nm, then 44. Check the tooth marks to verify that the
check that the shaft is assembled correctly or not. crownwheel and the pinion are set correctly.
26. If the pinion is not free to rotate, check the correct 45. Apply JCB Multigasket to the mating faces of the
size spacer has been installed. drivehead carrier and the axle case.
27. If the rolling torque measured at step 25 is Consumable: JCB Multi-Gasket
too high, install the next larger size spacer. If
the rolling torque is too low, install the next 46. Install the drivehead carrier to the axle case with
smallest size spacer. If a correct spacer is not the crownwheel towards the short driveshaft.
available from the range, check that drivehead is
assembled correctly. 47. Install the drivehead carrier retaining bolts.
28. Remove the adaptor and the sleeve. 48. Tighten the bolt to the correct torque value.
29. Lubricate the seal lips and then install the new 49. Reassemble both driveshafts and hub
oil seals. assemblies.
30. Install the coupling yoke and the new stake nut.
Table 53. Torque Settings (55 Series)
31. Gradually tighten the stake nut up to the specified Item Description Nm
torque value, while occasionally rotating the
coupling yoke. A Drivehead carri- 98
er retaining bolt
Torque: 250N·m U Verbus-ripp bolt 94
32. If the correct size spacer is selected then the
pinion rolling torque should with in the specified
limit. Table 54. Torque Settings (70 and 80 Series)
Torque: 2.3–3.4N·m Item Description Nm

A Drive head car- 166
33. The nut tightening torque value can be increased rier retaining
to a maximum of 300 Nm but the pinion rolling bolt
torque does not exceed the maximum of 3.4 Nm. U 'Verbus Ripp' 200
bolt
34. Finally stake the nut into the slot.
35. Install the differential assembly onto the
drivehead carrier. Table 55. Spacer Selection Example
Value
(1)
36. Push the taper roller bearing onto the spigot of

the differential half case2. Temporary spacer size 14.20
Subtract end float 0.25
37. Install the bearing outer race 1 and bearing outer Total 13.95
race 2.
38. Install the castellated nut 1 and castellated nut 2 preload
to the drivehead carrier. Result 13.91
39. Do not install the tension pin 1 and tension pin 2 Use next smallest spac- 13.90
at this stage. er
(1) All the values are in millimetre (mm).
40. Adjust the castellated nut to give an increase in
input pinion rolling torque of between 1.36 and
2.5 Nm more than that specified in Step25.
27 - 97 9813/8500-2 27 - 97
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22 - Drivehead
00 - General
Table 56. Torque Values 2. Mark the brake piston housing and the drivehead
for their correct assembly with respect to each
Item Description Nm
other. Refer to Figure 247.
L Differential assembly 46
retaining bolt 3. Remove the brake piston housing. Refer to
AJ Adaptor 50 Figure 247.
4. Remove the differential side nut locking pin to
(For: 55 Series (3 Piece Axle)) allow for readjustment on assembly. Refer to
Special Tools Figure 248.
Description Part No. Qty. Figure 248.
Spanner C
Setting Tool Kit 892/00918 1
Torque Wrench 993/70111 1
(10-100Nm)
Support Bracket 997/11000 1
Disassembly
When the drivehead is installed on the machine it
cannot be disassembled. It is recommended that you
remove the complete axle.
The crownwheel and pinion are matched and should C Side nut locking pin
be replaced as a pair, if either of them are damaged
or excessively worn. 5. Remove the other brake piston housing if it is
damaged, but its locking pin must be removed
The two differential case halves are also matched as to allow the side load adjustment on assembly.
are the differential side gears and planet gears, do Refer to Figure 248.
not use unmatched halves or gears.
6. Lift off the crownwheel/ differential assembly.
1. Place the drivehead with the crownwheel at the Refer to Figure 249.
top and then remove the capscrews. Refer to
Figure 247.
D
B A
A Capscrew D Crownwheel/ differential assembly

B Brake piston housing
7. If it is necessary to remove the brake piston
housings then mark the crownwheel end of the
27 - 98 9813/8500-2 27 - 98
27 - Driveline
22 - Drivehead
00 - General
drivehead case to make sure that they are Figure 251.

correctly assembled at the time of assembly.
K L
8. Use the spanner to lock the drive yoke and then
remove the stake nut and the yoke. Refer to
Figure 250.
Special Tool: Drive Coupling Spanner (Qty.: 1)
9. Use a soft faced hammer to hit the pinion end
shaft until the pinion is free from its front bearing
and then remove the pinion. Refer to Figure 250.
10. Remove the pinion seal and the outer bearing
cone. Refer to Figure 250.
Figure 250.
K Inner bearing cone
H L Pinion spacer
J 16. Remove the inner bearing cone. Refer to Figure

251.
E 17. Disassembly of the differential unit. Refer to
Figure 252.
17.1. Remove the bolts.
17.2. Lift off the top half housing.
G Figure 252.
F
M
E Pinion
F Pinion seal
G Outer bearing cone R
H Inner bearing cup N
J Shim
S
11. If necessary, drive out the pinion inner bearing
cup and shims. Refer to Figure 250.
P
12. Discard the shims. Refer to Figure 250. Q
13. Do the step 11 to remove the outer bearing cup.

14. There are no shims for the outer bearing cup.
15. Remove the pinion spacer. Refer to Figure 251.
M Bolt
N Top half housing
P Spherical washer 1
Q Spherical washer 2
R Differential bearing cone
S Differential gear
27 - 99 9813/8500-2 27 - 99
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22 - Drivehead
00 - General
17.3. Remove the differential gears, the 8. Tighten the bolt to the correct torque value. Refer
spherical washer 1 and spherical washer to Figure 253.
2.
9. Check the gears for free rotation. Refer to Figure
17.4. Remove the differential bearing cones. 253.
Assembly 10. Install the new inner bearing cone on to the

pinion. Refer to Figure 254.
1. If necessary, install a new crownwheel to the
differential case half. Figure 254.
2. Install the crownwheel retaining bolt.

K L
3. Tighten the bolt to the specified torque value.
Torque: 94N·m
4. Assemble the differential gear and the spherical
washer 1 and spherical washer 2 into the bottom
half of the differential housing. Refer to Figure
253.
5. Install the differential bearing cones. Refer to
Figure 253.
6. Put the top half of the differential housing on
to the differential and make sure that you have
aligned it correctly. Refer to Figure 253. K Inner bearing cone
L Pinion spacer
Figure 253.
11. Install the largest available solid spacer
(14.20mm) from the solid spacer setting kit. Refer
M to Figure 254.
12. Find the correct thickness for the shims. Refer to
Front Drivehead, Pinion Gear- Calibrate. Refer to
Figure 254.
R Refer to: PIL 27-22-09.
N
13. Install the shims behind the pinion inner bearing
S cup. Refer to Figure 255.
P 14. Use a puller tool to make sure that the inner

Q bearing cup is installed in square. Do not use a
hammer. Refer to Figure 255.
15. Install the outer bearing cup. Refer to Figure 255.
16. Put the pinion into its bore. Refer to Figure 255.
M Bolt
N Top half housing
P Spherical washer 1
Q Spherical washer 2
R Differential bearing cone
S Differential gear
7. Apply Loctite 242 to the threads of the bolts and
then install them. Refer to Figure 253.
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22 - Drivehead
00 - General
H
T
J
E U
G
F
V
E Pinion
F Pinion seal
G Outer bearing cone W
H Inner bearing cup
J Shim
1
17. Before you put the pinion into the bore, make T Pinion shaft adaptor
sure that it is matched with the crownwheel. U Special tool sleeve
Refer to Figure 255. V Special bracket
W Bolt (M10x30)
18. The code numbers etched on the pinion end
face and the crownwheel perimeter should be the 25. If the pinion is not free to rotate or there is no end
same. Refer to Figure 255. float at this stage check the bearing is installed
correctly. Refer to Figure 256.
19. Install the pinion outer bearing cone. Refer to
Figure 255. 26. Make sure that the correct size spacer is
installed. Refer to Figure 256.
20. Do not install the oil seal at this stage. Refer to
Figure 255. 27. Use two bolts (M10x30) to install the special
bracket to the drivehead housing. Refer to Figure
21. Install the special tool sleeve and the special 256.
pinion shaft adapter. Refer to Figure 256.
Special Tool: Support Bracket (Qty.: 1)
Special Tool: Setting Tool Kit (Qty.: 1)
28. Install the special tool support pillar to the bracket
22. Tighten the adaptor to the correct torque value. so that the fork end engages in adaptor. Refer to
Refer to Figure 256. Figure 256.
23. Make sure that the pinion is free to rotate and 29. Make sure that the fork is centrally located on the
there is end float. Refer to Figure 256. adaptor. Refer to Figure 256.
24. End float will prevent the bearing from damage. 30. If necessary, align the bracket again. Refer to
Refer to Figure 256. Figure 256.
31. Install a DTI. Refer to Figure 257.
32. Make sure that the DTI is installed on the
drivehead not on the bracket. Refer to Figure
257.
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22 - Drivehead
00 - General
Figure 257. 38. Install the sleeve. Refer to Figure 256.

39. Tighten the adaptor to the specified value, to
Z protect against bearing damage while spacer
selection is verified and make sure that the pinion
is free to rotate. Refer to Figure 256.
Y
Torque: 50N·m
40. Check there is no end float and pinion is free to
turn smoothly by hand. Refer to Figure 256.
X 41. Remove the adaptor and install the stake nut.
42. Check that rolling torque is less than 2.0 Nm. If
the rolling torque exceeds 2.0 Nm, check that the
shaft is assembled correctly. Refer to Figure 256.
43. If the pinion is not free to rotate then check the
correct size spacer is installed or not. Refer to
Figure 256.
44. If rolling torque measured at step 42 is too high
then install the next larger size spacer. If the
rolling torque is too low then install the next
smallest size spacer. Refer to Figure 256.
X Support pillar 45. If a correct spacer is not available from the range,
Y DTI check that drivehead is assembled correctly.
Z Torque wrench Refer to Figure 256.
33. Set the torque wrench to the specified value and 46. Remove the stake nut and the sleeve. Refer to
measure the end float while you rotate the shaft. Figure 256.
47. Lubricate the seal lips and then install the new oil
Torque: 35N·m seal. Refer to Figure 258.
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1) Figure 258.
34. Correct size solid spacer selection. Refer to
Figure 257. Refer to Table 57.
34.1. To select the correct size spacer, subtract
the end float obtained at step 33 from the
solid spacer size (14.20 mm). AA
AB
34.2. Also subtract 0.04 mm to allow for
theoretical bearing tolerance and pre load. AC
34.3. The result is the size of spacer to be
installed from the solid spacer kit.
34.4. If there is no spacer of this size, fit the next
nearest size spacer from the spacer kit.
35. Remove the sleeve and the temporary spacer.
Refer to Figure 256. AA Oil seal
AB Coupling yoke
36. When you remove the temporary spacer make AC Stake nut
sure that the outer bearing is not damaged. Refer
to Figure 256. 48. Install the coupling yoke and the new stake nut.
37. Install the correct size spacer from the spacer kit.
27 - 102 9813/8500-2 27 - 102

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22 - Drivehead
00 - General
49. Gradually tighten the stake nut to the minimum Figure 260.
specified torque value, occasionally rotate the
coupling yoke. Refer to Figure 258.
D
Torque: 250N·m
50. If the correct size spacer is selected, the rolling
torque should be within the specified torque
value including the seal drag. Refer to Figure
258.
Torque: 2.3–3.4N·m
51. When the torque value is correct, use a square-
ended staking tool to stake the nut to the pinion
shaft. Refer to Figure 258.
52. The stake nut tightening torque value can be
increased to a maximum of 300 Nm if the pinion
rolling torque does not exceed the maximum of
3.4 Nm. Refer to Figure 258.
Figure 259.
D Crownwheel/ differential assembly

57. Install the other side brake piston housing onto
the drivehead. Refer to Figure 261.
Figure 261.
AD
B A
53. If the brake piston housing is removed then install

one at the opposite end to the crownwheel. Refer
to Figure 261.
54. Apply Loctite 574 to the drivehead mating face,
then install the brake piston housing. Refer to
Figure 261.
55. Make sure that the mark made between the
drivehead and the brake piston housing at the
time of disassembly is aligned. Refer to Figure A Capscrew
261. B Brake piston housing
C Side nut locking pin
56. Install the crownwheel/ differential assembly into ADDifferential side nut
the drivehead. Refer to Figure 260.
58. Install the capscrews. Refer to Figure 261.
59. Tighten the capscrews to the correct torque
value. Refer to Figure 261.
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22 - Drivehead
00 - General
60. Adjust the differential side nuts to give a bearing Table 58. Torque Values
pre-load of the specified value.
Item Description Nm
Torque: 1.13–2.26N·m M Bolt 46
61. Measure the pre-load by taking another rolling T Pinion shaft adaptor 50
torque reading and subtracting the torque figure AC Stake nut 250
measured at step 50. The difference is the A Capscrew 56
bearing pre-load.
62. Measure the crownwheel backlash, it should be
within the specified limit.
63. Adjust the differential side nuts by equal amounts
when you change the backlash.
64. When the backlash and pre-load are both
correct, install the side nut locking pins. Refer to
Figure 261.
65. Check the tooth marks to make sure that
the crownwheel and pinion are set correctly.
Refer to Front Drivehead, Crownwheel- Check
(Operation).
Figure 262.
Table 57. Spacer Selection Example

Value
(1)
Temporary spacer size 14.20

Subtract end float 0.25
Total 13.95
pre-load
Result 13.91
Use next smallest spac- 13.90
er
(1) All the values are in millimetre (mm).
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27 - Driveline
22 - Drivehead
06 - Crownwheel
06 - Crownwheel Introduction
Introduction .................................................. 27-105
Check (Operation) ....................................... 27-106
(For: 4WD)
A crown wheel is a rotating gear wheel with teeth set
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.
27 - 105 9813/8500-2 27 - 105

27 - Driveline
22 - Drivehead
06 - Crownwheel
Check (Operation) Figure 265.
(For: 4WD)
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 263.
2. Pinion too deeply in mesh. Move the crown wheel

towards the pinion to correct the backlash.
Figure 264.
3. Pinion too far out of mesh. Move the crown wheel

away from the pinion to correct the backlash.
27 - 106 9813/8500-2 27 - 106

27 - Driveline
22 - Drivehead
09 - Pinion Gear
09 - Pinion Gear Introduction

Introduction .................................................. 27-107
Calibrate ...................................................... 27-108
(For: 4WD)
A pinion gear is a small gear that meshes with a
larger crownwheel. They are mainly used in vehicles
to maintain a forward movement.
27 - 107 9813/8500-2 27 - 107

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: 4WD) 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 268.
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 59. 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 266. 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 60. 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 267. 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 61. 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
27 - 108 9813/8500-2 27 - 108

27 - Driveline
27 - Hub
27 - Hub
Contents Page No.
27-27-00 General ......................................................................................................................... 27-111
27 - 109 9813/8500-2 27 - 109

Notes:
27 - 110 9813/8500-2 27 - 110

27 - Driveline
27 - Hub
00 - General
Introduction .................................................. 27-111 The hub is the part of the axle where the wheel
Component Identification ............................. 27-112 is mounted and where the axle shaft (if installed)
Drain and Fill ............................................... 27-118 passes through.
Check (Level) .............................................. 27-119
Some hubs are not driven and rotate due to motion
Disassemble and Assemble ........................ 27-120 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 - 111 9813/8500-2 27 - 111

27 - Driveline
27 - Hub
00 - General
For: Dead Steer ...................... Page 27-112

For: PD55 ................................ Page 27-113
For: PD40 ................................ Page 27-115
(For: Dead Steer)
Figure 269.
11 14
7 17
9 10 12 13
5
6 16
27 - 112 9813/8500-2 27 - 112

27 - Driveline
27 - Hub
00 - General
(For: PD55)
Table 62.
Item Description
1 Grease cap Figure 270.
2 Split pin
3 Slotted nut G H
4 Thrust washer
5 Bearing
6 Stub axle
7 Hub A
9 Bearing
10 Oil seal B
11 Swivel hub
12 Seal C
13 Bush
14 Grease nipple
16 Sleeve J
17 Wheel stud
K
D
E L
F M
Table 63.
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
H Hub swivel
J Driveshaft
K Oil seal
L Wheel bearing (inner)
M Wheel bearing (outer)
27 - 113 9813/8500-2 27 - 113

27 - Driveline
27 - Hub
00 - General
Sectional Drawing
Figure 271.
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 64. 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 - 114 9813/8500-2 27 - 114

27 - Driveline
27 - Hub
00 - General
(For: PD40) Figure 273.
Unit Identification
order for parts replacement, always give the details
mentioned on the unit identification plate. In the case
of gear replacements, always check the part number
Figure 272.
Figure 274.
F G
D K
E L
27 - 115 9813/8500-2 27 - 115

27 - Driveline
27 - Hub
00 - General
Item Description
F Bearing carrier
Table 65.
G Hub swivel
Item Description
H Driveshaft
A Annulus ring
J Oil seal
B Planet gear assembly
K Wheel bearing (inner)
(x3)
L Wheel bearing (outer)
C Thrust pad
D Planet gear carrier
E Wheel stud (x5)
Sectional Drawing
Figure 275.
22 10 12 13 5 7 9 3 4 1
23
24
26
27
28
29
33
11 11 31 34 57 35
Item Description
Table 66. 4 Oil seal
Item Description 5 Bearing carrier
1 Swivel hub 7 Annulus carrier
3 Bearing (taper roller) 9 Dowels
27 - 116 9813/8500-2 27 - 116

27 - Driveline
27 - Hub
00 - General
Item Description
10 Bolt Verbus-ripp
11 Spacer (x2)
12 Annulus ring
13 Circlip (internal)
22 Planet gear
23 Planetary hub carrier
24 Bearing (needle roller)
27 Thrust pad
28 Driveshaft
31 O-ring
33 Drain plug
34 Bearing (needle roller)
35 Oil seal
57 Cover plate
27 - 117 9813/8500-2 27 - 117

27 - Driveline
27 - Hub
00 - General
Drain and Fill 2. Fill the hubs with the recommended axle oil
through the plug hole.
3. The oil level must be with the bottom surface of
(For: PD55, 4WD) the plug hole.
Drain 4. Clean the hub plug.
1. Make the machine safe. Refer to (PIL 01-03). 5. Install the hub plug.
2. Set the machine level with the wheels above the

ground.
2.1. Use the suitable lifting equipments to lift the
machine axles at the same level.
3. Do the hub oil drain and fill procedure on one
wheel at a time.
4. Turn the wheel manually to get the hub oil level
mark to the vertical position with the hub plug at
the bottom.
5. Put a suitable size of container below the hub
plug to collect the oil.
6. Remove the hub plug to drain the oil.
7. Allow sufficient time to drain the oil from the hub.
8. Complete the above steps for the other wheels.
Figure 276.
A
A Wheel
B Hub
C Plug
D Level mark
Fill
1. Set the hub oil level mark to the horizontal
position.
1.1. Turn the wheel manually to get the hub oil
level mark to the horizontal position.
27 - 118 9813/8500-2 27 - 118

27 - Driveline
27 - Hub
00 - General
Check (Level) 9. Remove the hub plug.

10. Check the oil level of the hub.
(For: PD55, 4WD) 10.1. The hub oil level must be with the bottom
surface of the plug hole.
Check the hub oil level of one wheel at a time.
Complete the steps below to check the hub oil. 10.2. If necessary, add the recommended axle
oil.
11. Clean the hub plug before you install it.
2. Set the machine level with the wheels above the
ground. 12. Install the hub plug.
2.1. Use suitable lifting equipment to lift the

machine axles to the same level.
3. Set the hub oil level mark to the horizontal
position.
3.1. Turn the wheel manually to get the hub oil
level mark to the horizontal position.
3.2. The specified tolerance is permitted above
or below the oil level mark horizontal
position.
Figure 277.
A
D C
A Wheel
B Hub
C Plug
D Level mark
E Tolerance 5mm
4. Apply the park brake.
5. Set the transmission to the neutral position.
6. Lower the attachments to the ground.
8. Clean the area around the hub plug.
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27 - Driveline
27 - Hub
00 - General
For: 2WD, Dead Steer ............. Page 27-120 Description Part No. Size
For: PD55, 4WD ...................... Page 27-122 Special MPL-EP 4003/1501 0.4kg
For: PD40 ................................ Page 27-128 Grease 4003/1506 12.5kg
4003/1510 50kg
(For: 2WD, Dead Steer)
Special Tools Disassembly
1. Disassemble the hub as per the numerical
Shim Kit 445/04700 1 sequence shown in the illustration.
Bearing Press 892/00179 1
2. A suitable press is required to remove and
Consumables replace the stub axle.
Description Part No. Size Special Tool: Bearing Press (Qty.: 1)
Strength)
27 - 120 9813/8500-2 27 - 120

27 - Driveline
27 - Hub
00 - General
Figure 278.
13
9
10
17 16
12
18
11
21
22
15
14
20
19
4 7
3
8
1
6 5
1 Grease cap 2 Split pin

3 Castle nut 4 Thrust washer
5 Hub 6 Bearing 1
7 Oil seal 8 Bearing 2
9 Bolt 10 Pivot pin
11 Nut 12 Pin
13 King pin 14 Stub axle carrier
15 Bearing 3 16 Shim
17 Seal 18 Bush 1
19 Seal 20 Bush 2
21 Sleeve 22 Stub axle
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27 - Driveline
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00 - General
Assemble disassembled without removing the axle. Refer to

Figure 285.
1. Assembly is the opposite of the removal
sequence. Obey the instructions given below 1. Drain the oil from the hub.
during assembly.
2. Remove the screws.
1.1. When you install the bushes 1 and 2 the
open ends of the grease grooves should 3. Remove the planet gear carrier from the bearing
face the axle beam. carrier.
1.2. Add shims as required to give a clearance of 4. Remove and discard the O-ring.
the specified value between the axle beam
and the bearing3. 5. Remove the planet gears only if they are
damaged. Note: Planet gears can only be
Dimension: 0–0.1mm replaced as an assembly which contains the
Special Tool: Shim Kit (Qty.: 1) gear, bearing, and two L-shaped circlips. Refer
1.3. Apply sealant on the threads of the bolt. to Figure 279. and Refer to Figure 284.
Consumable: JCB Threadlocker and Sealer Figure 279.
(Medium Strength)
F
1.4. Fill the hubs with grease and between the
lips of the seals. D
G
Consumable: Special MPL-EP Grease
B
1.5. Set the bearings 1 and 2 by rotating the hub
in each direction while tightening the nut.
1.6. When the correct torque setting has been
achieved, back off one flat of the nut and
then install the split pin.

Item Nm
3 40
9 30 B Planet gear carrier
D Planet gear
(For: PD55, 4WD) G Driveshaft thrust pad
F External circlip 1
Special Tools
Description Part No. Qty. 5.1. Remove the external circlip 1.
Heavy Duty Socket 892/00333 1 5.2. Remove the planet gear.
19mm A/F x 3/4 in 5.3. The driveshaft thrust pad is drilled and
Drive tapped for removal purposes. Use a
Wheel Hub Service Kit 892/01092 1 suitable M6 screw to extract the thrust pad
Reaction Plate M14 998/M1374 4 from inside the planet gear carrier.
Studs
6. Remove the external circlip 2.
Reaction Plate 998/M1375 1
7. Remove the sun gear from the driveshaft.
Disassemble
8. To remove the verbus-ripp bolts it is necessary
WARNING A raised and badly supported to remove the spacer (if installed). Rotate the
machine can fall on you. Position the machine spacer with a suitable drift to align the holes in
on a firm, level surface before raising one end. the spacer with the space between the bolts.
Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks 9. Use two dowels and two heel bars to remove the
to support the machine when working under it. spacer as shown. Refer to Figure 280.
Disconnect the battery, to prevent the machine
The illustrations in this procedure show the axle

removed from the machine but the hubs can be
27 - 122 9813/8500-2 27 - 122

27 - Driveline
27 - Hub
00 - General
Figure 280. 11.2. Install the four M14 studs and nuts on
the annulus carrier. Some annulus carriers
J have two tapped holes for use with jacking
K screws. Use two high grade M14 bolts
as jacking screws to remove the annulus
carrier.
Special Tool: Reaction Plate (Qty.: 1)
Special Tool: Reaction Plate M14 Studs
(Qty.: 4)
11.3. Engage the reaction plate.
AF 11.4. Adjust the studs to maintain a clearance
between the reaction plate and the
H driveshaft.
11.5. Install a three leg puller. Engage the puller
legs through the holes in the annulus
carrier.
H External circlip 2 11.6. Use the puller to remove the annulus

J Spacer carrier along with the annulus ring from the
K Verbus-ripp bolt axle stub shaft.
AFSun gear 11.7. Make sure that the dowels remain either
in the annulus carrier or in the stub shaft.
10. Remove the verbus-ripp bolts with a heavy duty Note: It is normal for fretting to occur on
socket. the mating surfaces between the axle stub
Special Tool: Heavy Duty Socket 19mm A/F x 3/4 shaft and annulus carrier. Do not attempt
in Drive (Qty.: 1) to repair it.
10.1. Note: the verbus-ripp bolts are very tight 12. Remove the internal circlip to separate the
and care must be taken not to distort the annulus ring from the annulus carrier.
bolt heads. Use an extension bar as short
as possible. Discard the verbus-ripp bolts 13. Remove the outer wheel bearing and the bearing
after removal. carrier as follows:
11. Remove the annulus carrier along with the 13.1. Attach the legs of the bearing puller
annulus ring as follows: Refer to Figure 281. onto two diametrically opposite wheel
studs and put the reaction tube over the
Figure 281. driveshaft. Refer to Figure 282.
Special Tool: Wheel Hub Service Kit (Qty.:
1)
AG 13.2. The reaction tube must be used otherwise
damage to the driveshaft and driveshaft
bearings will occur.
AJ
13.3. On five wheel stud axles, the modified
wheel studs from the Wheel Hub Service
Kit must be used. Bolt to two diametrically
opposite holes provided on the bearing
carrier.
13.4. Slowly turn the screw until the bearing
AH carrier and the outer wheel bearing are
released from the axle stub shaft.
AG M14 studs and nuts 13.5. If the wheel hub starts to rotate use a
AH Reaction plate suitable bar to prevent further rotation.
AJ 3 Leg puller
13.6. If the screw becomes hard to turn, tap the
11.1. Put marks on the stub shaft and annulus back of the bearing carrier with a soft faced
carrier to identify their relative angular mallet to help release the bearing.
position during installation.
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00 - General
Figure 282. 15. Remove the inner wheel bearing as follows:

W Y
Figure 284.
X
Q
Q Bearing carrier W
W Reaction tube
X Screw
Y Bar
W Reaction tube
14. Remove and discard the outer part of the X Screw
combination oil seal by cutting the outer seal with
a sharp chisel. Take care not to damage the seal 15.1. Clamp the plates around the inner wheel
seat on the axle stub shaft. Refer to Figure 283. bearing.
Figure 283. 15.2. Attach the puller rods and put the reaction
tube over the driveshaft.
15.3. The reaction tube must be used otherwise
Z
15.4. Slowly turn the screw until the inner wheel
bearing is released from the axle stub
shaft.
15.5. Remove and discard the inner part of the
combination oil seal.
16. If installed do not remove the dirt shield.
T Combination oil seal

Z Chisel
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27 - Hub
00 - General
Figure 285.
F
D
V
E P
V
C N
L
B
J K
AF
G T
R U
S
A
A Screw B Planet gear carrier

C O-ring D Planer gear
E Bearing F External circlip 1
G Driveshaft thrust pad H External circlip 2
J Spacer K Verbus-ripp bolt
L Annulus carrier M Annulus ring
N Internal circlip P Dowel
Q Bearing carrier R Outer wheel bearing
S Inner wheel bearing T Combination oil seal
U Dirt shield (If installed) V L-shaped circlip
AF Sun gear
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Assemble Figure 288.
1. Install the outer wheel bearing cup into the AA

bearing carrier.
2. Install the inner wheel bearing cup and cone into
the bearing carrier.
3. Use the seal dolly 892/00891 from the Wheel
Hub Service Kit to install a new combination oil
seal. The seal dolly has two sides 'A' and 'B' B
marked for identification. Do not lubricate the
seal before installation. Refer to Figure 286.
Figure 286. Q
AA
A
Q Bearing carrier
AASeal dolly
5. Install the seal on the dolly.
B
6. Use a soft-faced mallet to drive the seal squarely
AA Seal dolly into the bearing carrier until the dolly flange is up
against the carrier. Refer to Figure 289.
4. Make sure you use the correct side of the seal
dolly as follows: Figure 289.
4.1. For axles with a steel dirt shield use side 'A'
of the seal dolly. Refer to Figure 287.
Figure 287. AA
AA U
A
Q Bearing carrier
AASeal dolly
7. Attach the bearing press extension shaft onto the
Q
end of the axle stub with four verbus-ripp bolts.
Figure 290.
Q Bearing carrier
U Dirt shield
AA Seal dolly
4.2. For axles without a steel dirt shield use side
'B' of the seal dolly. Refer to Figure 288.
K Verbus-ripp bolts
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00 - General
8. Lightly apply oil on the inner wheel bearing cone. 22. Install the new verbus-ripp bolts.
9. Position the bearing carrier (complete with inner 23. Do not tighten the verbus-ripp bolts at this stage.
bearing) onto the axle stub over the extension
shaft. 24. Measure the seal drag rolling force:
10. Assemble the bearing press as shown. Refer to Figure 292.

Figure 291.
Figure 291.
BB
R AC BA
AD
AB BA Cord
BB Spring balance
R Outer wheel bearing 24.1. Install the planet gear carrier.

AB Handle 24.2. Do not install the sun gear.
AC Thrust washers (x2)
AD Reaction tube 24.3. Wrap a cord around the planet gear carrier
flange and attach a spring balance to it as
11. Slide the reaction tube over the extension shaft shown. Refer to Figure 292.
(the wide opening towards the bearing).
24.4. Pull the spring balance so that the hub
12. Make sure that the bearing and bearing carrier rotates, do this several times to let the seal
are properly positioned against the axle stub. bed in and record the reading.
24.5. Remove the planet gear carrier.
13. Attach the handle and make sure that the
thrust bearing is installed between the two thrust 25. Tighten the verbus-ripp bolts to the correct torque
washers. value.
14. Slowly turn the handle to press the inner wheel 26. Measure the rolling force:
bearing correctly into position, then remove the
handle and reaction tube. 26.1. Install the planet gear carrier.
15. Install the outer wheel bearing cone into the 26.2. Do not install the sun gear.
bearing carrier. 26.3. Wrap a cord around the planet gear carrier
16. Assemble the reaction tube and handle onto the
shown.
extension shaft.
17. Slowly turn the handle to press the outer bearing rotates and record the reading.
correctly into position until the free play is
removed. 26.5. To calculate the rolling force, subtract
the seal drag force (24.4) from the value
18. Remove the handle and reaction tube. obtained in the step 26.4.
19. Assemble the annulus ring onto the annulus 26.6. The rolling force should be within the
carrier and then install the internal clip. specified range.
Torque: 2–22N·m
20. Make sure that the dowels are correctly installed.
26.7. If the values are outside the limits specified
21. Attach the annulus assembly to the axle stub then check if the seal is installed correctly,
shaft in the same angular position based on the
marks made during installation.
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and/or replace the wheel bearings if 30.1. Note: The sun gear must be installed with
necessary. the 1.5mm x 45° chamfer inboard.
26.8. Remove the planet gear carrier. 31. Install a new O-ring, and then install the planet
gear carrier onto the bearing carrier. Make sure
27. Press the driveshaft thrust pad (chamfered side
that the two tapped holes are in line with those
faces downwards) into the recess in the planet
on the bearing carrier.
gear carrier.
32. Do not strike the centre of the planet gear
28. Install the new planet gears in the position of any
carrier during installation as this may dislodge the
that were removed during disassembly. Refer to
driveshaft thrust pad.
Figure 292.
33. Apply sealant to the threads of the screws. Refer
28.1. Important: Make sure that you install the
to Figure 295.
planet gears in the correct orientation.
Install the large radius end of the bearing Figure 295.
over the pin first. Refer to Figure 293.
Q
Figure 293.
AE
A
A Screw
AE Large radius end 34. Install the screw to attach the planet gear carrier.
28.2. Secure the planet gears with external 35. Tighten the screws to the correct torque value.
circlip 1.
36. Fill the hub with the correct grade oil.
Figure 294.
F Table 68. Torque Values
Item Nm
D
G A 56
B K 320
(For: PD40)
Special Tools
Heavy Duty Socket 892/00333 1
19mm A/F x 3/4 in
Drive
Wheel Hub Service Kit 892/01092 1
B Planet gear carrier Disassemble

D Planet gear
G Driveshaft thrust pad WARNING A raised and badly supported
F External circlip 1 machine can fall on you. Position the machine
on a firm, level surface before raising one end.
29. Install the spacer (If installed). Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks
30. Install the sun gear onto the driveshaft and to support the machine when working under it.
secure with the external circlip 2. Disconnect the battery, to prevent the machine
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27 - Hub
00 - General
as possible. Discard the verbus-ripp bolts

The illustrations in this procedure show the axle after removal.
removed from the machine but the hubs can be
disassembled without removing the axle. Refer to 8. Remove the annulus carrier along with the
Figure 296. annulus ring as follows: Refer to Figure 297.
1. Drain the oil from the hub. Figure 297.
2. Remove the screws that attach the planet gear

carrier.
V
3. Remove the planet gear carrier from the bearing
carrier.
4. Remove and discard the O-ring.
5. Remove the planet gears only if they are
damaged, Note: Planet gears can only be
replaced as an assembly which contains the gear
and the bearing. Refer to Figure 296.
Figure 296.
F V
D V M14 bolts (jacking screws)
G
8.1. Put marks on the stub shaft and annulus
B
carrier to identify their relative angular
position during installation.
8.2. Install two high grade M14 bolts as jacking
screws on the annulus carrier.
8.3. Remove the annulus carrier with the
annulus ring from the axle stub shaft.
8.4. Make sure that the dowels remain either
in the annulus carrier or in the stub shaft.
Note: It is normal for fretting to occur on the
B Planet gear carrier mating surfaces between the axle stub shaft
D Planet gear and annulus carrier. Do not attempt to repair
G Driveshaft thrust pad it.
F External circlip1
9. Remove the internal circlip to separate the
5.1. Remove the external circlip1. annulus ring from the annulus carrier.
5.2. Remove the planet gear. 10. Remove the outer wheel bearing and the bearing
carrier as follows:
5.3. The driveshaft thrust pad is drilled and
tapped for removal purposes. Use a 10.1. Attach the legs of the bearing puller
suitable M6 screw to extract the thrust pad onto two diametrically opposite wheel
from inside the planet gear carrier. studs and put the reaction tube over the
driveshaft. Refer to Figure 298.
6. Remove the external circlip2 and the spacers (if
installed). Special Tool: Wheel Hub Service Kit (Qty.:
1)
7. Remove the verbus-ripp bolts with a heavy duty
socket. 10.2. The reaction tube must be used otherwise
Special Tool: Heavy Duty Socket 19mm A/F x 3/4 bearings will occur.
in Drive (Qty.: 1)
10.3. On five wheel stud axles, the modified
7.1. Note: the verbus-ripp bolts are very tight wheels studs from the Wheel Hub Service
and care must be taken not to distort the Kit must be used. Bolt to two diametrically
bolt heads. Use an extension bar as short opposite holes provided on the bearing
carrier.
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00 - General
10.4. Slowly turn the screw until the bearing 12. Remove the inner wheel bearing as follows:
carrier and the outer wheel bearing are Refer to Figure 300.
released from the axle stub shaft.
Figure 300.
10.5. If the wheel hub starts to rotate use a
suitable bar to prevent further rotation.
10.6. If the screw becomes hard to turn, tap the
back of the bearing carrier with a soft faced
mallet to help release the bearing. X
Figure 298.
W Y
W
W Reaction tube
X Screw
12.1. Clamp the plates around the inner wheel
X bearing.
Q
12.2. Attach the puller rods and put the reaction
Q Bearing carrier tube over the driveshaft.
W Reaction tube
X Screw 12.3. The reaction tube must be used otherwise
Y Bar damage to the driveshaft and driveshaft
11. Remove and discard the outer part of the
combination oil seal by cutting the outer seal with 12.4. Slowly turn the screw until the inner wheel
a sharp chisel. Take care not to damage the seal bearing is released from the axle stub
seat on the axle stub shaft. Refer to Figure 299. shaft.
12.5. Remove and discard the inner part of the
Figure 299. combination oil seal.
13. If installed do not remove the dirt shield.
T Combination oil seal

Z Chisel
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27 - Hub
00 - General
Figure 301.
F
D
E P
C
N
B L
J K
G
T
R U
S
A
A Screw B Planet gear carrier

C O-ring D Planer gear
E Bearing F External circlip1
G Driveshaft thrust pad H External circlip2
J Spacer K Verbus-ripp bolt
L Annulus carrier M Annulus ring
N Internal circlip P Dowel
Q Bearing carrier R Outer wheel bearing
S Inner wheel bearing T Combination oil seal
U Dirt shield (If installed)
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Assemble Figure 304.
1. Install the outer wheel bearing cup into the AA

bearing carrier.
2. Install the inner wheel bearing cup and cone into
the bearing carrier.
3. Use the seal dolly 892/00891 from the wheel hub
service kit to install a new combination oil seal.
The seal dolly has two sides 'A' and 'B' marked B
for identification. Do not lubricate the seal before
installation. Refer to Figure 302.
Special Tool: Wheel Hub Service Kit (Qty.: 1)
Q
Figure 302.
AA
A
Q Bearing carrier
AASeal dolly
5. Install the seal on the dolly.
B 6. Use a soft-faced mallet to drive the seal squarely

into the bearing carrier until the dolly flange is up
against the carrier. Refer to Figure 304.
AA Seal dolly
Figure 305.
4. Make sure you use the correct side of the seal
dolly as follows:
4.1. For axles with steel dirt shield use side 'A'
of the seal dolly. Refer to Figure 303.
AA
Figure 303.
AA U
Q
A Q Bearing carrier
AASeal dolly
7. Attach the bearing press extension shaft onto the
end of the axle stub with four verbus-ripp bolts.
Q Refer to Figure 306.
Figure 306.
Q Bearing carrier
U Dirt shield
AA Seal dolly
4.2. For axles without a steel dirt shield use side
'B' of the seal dolly. Refer to Figure 304.
K
K Verbus-ripp bolts
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00 - General
8. Lightly apply oil on the inner wheel bearing cone. 22. Install the new verbus-ripp bolts.
9. Position the bearing carrier (complete with inner 23. Do not tighten the verbus-ripp bolts at this stage.
bearing) onto the axle stub over the extension
shaft. 24. Measure the seal drag rolling force:
10. Assemble the bearing press as shown. Refer to Figure 308.

Figure 307.
Figure 307.
BB
R AC BA
AD
AB BA Cord
BB Spring balance
R Outer wheel bearing 24.1. Install the planet gear carrier.

AB Handle 24.2. Wrap a cord around the planet gear carrier
AC Thrust washers (x2) flange and attach a spring balance to it as
AD Reaction tube shown.
11. Slide the reaction tube over the extension shaft 24.3. Pull the spring balance so that the hub
(the wide opening towards the bearing). rotates, do this several times to let the seal
bed in and record the reading.
12. Make sure that the bearing and bearing carrier
are properly positioned against the axle stub. 24.4. Remove the planet gear carrier.
13. Attach the handle and make sure that the 25. Tighten the verbus-ripp bolts to the correct torque
thrust bearing is installed between the two thrust value.
washers.
26. Measure the rolling force:
14. Slowly turn the handle to press the inner wheel
26.1. Install the planet gear carrier.
bearing correctly into position, then remove the
handle and reaction tube. 26.2. Wrap a cord around the planet gear carrier
15. Install the outer wheel bearing cone into the shown.
bearing carrier.
16. Assemble the reaction tube and handle onto the rotates and record the reading.
extension shaft.
26.4. To calculate the rolling force, subtract
17. Slowly turn the handle to press the outer bearing the seal drag force (24.3) from the value
correctly into position until the free play is obtained in the step 26.3.
removed. 26.5. The rolling force should be within the
specified range.
18. Remove the handle and reaction tube.
Torque: 2–22N·m
19. Assemble the annulus ring onto the annulus
carrier and then install the internal clip. 26.6. If the values are outside the limits specified
then check if the seal is installed correctly,
20. Make sure that the dowels are correctly installed. and/or replace the wheel bearings if
necessary.
21. Attach the annulus assembly to the axle stub
shaft in the same angular position based on the 26.7. Remove the planet gear carrier.
marks made during installation.
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00 - General
27. Install the spacers (if installed) and the external 31. Do not strike the centre of the planet gear
circlip2. carrier during installation as this may dislodge the
28. Press the driveshaft thrust pad (chamfered side
faces downwards) into the recess in the planet 32. Apply sealant to the threads of the screws. Refer
gear carrier. to Figure 311.
29. Install the new planet gears in the position of any Figure 311.
that were removed during disassembly. Refer to
Q
Figure 310.
29.1. Important: Make sure that you install the
planet gears in the correct orientation. B
Install the large radius end of the bearing
over the pin first. Refer to Figure 309.
Figure 309.
A
AE
A Screw
33. Install the screw to attach the planet gear carrier.
34. Tighten the screws to the correct torque value.
35. Fill the hub with the correct grade oil.
AE Large radius end Table 69. Torque Values

Item Nm
29.2. Secure the planet gears with the external
A 56
circlip1.
K 320
Figure 310.
F
D
G
B
B Planet gear carrier

D Planet gear
G Driveshaft thrust pad
F External circlip1
30. Install a new o-ring, and then install the planet
gear carrier onto the bearing carrier. Make sure
that the two tapped holes are in line with those
on the bearing carrier.
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29 - Wheel
Contents Page No.
27-29-00 General ......................................................................................................................... 27-137
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Notes:
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00 - General
Introduction .................................................. 27-137 On new machines, and whenever a wheel has been
Health and Safety ........................................ 27-138 removed, check the wheel nut torques every two
Remove and Install ..................................... 27-139 hours until they stay correct. Every day, before
starting work, check that the wheel nuts are tight.
Tighten the wheel nuts (in a diagonal sequence) to
the correct torque value, refer to Technical Data.
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00 - General
Health and Safety

WARNING If, for whatever reason, a wheel stud
is renewed, all the studs for that wheel must be
changed as a set, since the remaining studs may
have been damaged.
WARNING Wheels and tyres are heavy. Take
care when lifting or moving them. Store with care
to ensure that they cannot fall and cause injury.
WARNING An exploding tyre can kill. Inflated
tyres can explode if over-heated or over-inflated.
Follow the instructions given when inflating the
tyres. Do not cut or weld the rims. Use a tyre/
wheel specialist for all repair work.
WARNING Deflate the tyre you wish to change
before removing the wheel from the machine.
Air pressure in the tyres can cause the tyre and
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner
and outer wheel halves together when there is air
pressure in the tyre. Always wear safety glasses.
WARNING Wheels installed with semi-solid tyres
are heavy. Removing and installing them requires
special equipment and training. Have the work
carried out by your JCB dealer or a tyre specialist.
WARNING Do not install pneumatic tyres on a
wheel made for a solid tyre. Do not install a solid
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for
your machine, contact your local JCB dealer or a
trained specialist.
DANGER Run flat inserts may be installed in the
rear wheels. These must remain installed to the
rear wheels to ensure machine stability is not
compromised in the event of a deflated tyre.
Make sure that all tyres are inflated to the correct
pressure and have run flat inserts as required.
Where run flat inserts have been specified for use,
ensure that replacement wheels also have run flat
inserts to ensure the machine stability.
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27 - Driveline
29 - Wheel
00 - General
Remove and Install
For: 2DX [T3], 2WD, Front ....... Page 27-139 2. Install the lift arm safety strut. Refer to (PIL
For: 2DX [T3], 4WD, Front ....... Page 27-140 06-69)
For: 2DX [T3], Rear ................. Page 27-141 3. Follow the general safety precautions. Refer to
(PIL 01-03).
(For: 2DX [T3], 2WD, Front)
4. Make sure that the engine cannot be started.
care when lifting or moving them. Store with care 5. Put blocks under the rear wheels.
6. Loosen the five wheel nuts by half of one turn.
is renewed, all the studs for that wheel must be 7. Put a jack under the centre of the front axle. Use
changed as a set, since the remaining studs may the correct jack.
have been damaged.
8. Use the jack to lift the machine until both front
WARNING Whenever a wheel has been wheels are off the ground.
changed, check the nut torques every two hours.
When the nuts stay tight for 8h, the interval for 9. Put blocks under each end of the front axle.
checking can revert to the period stated in the
servicing schedule. 10. Hold the wheel and remove the wheel nuts.
11. Remove the wheel.
Remove
Figure 312.
A Wheel B Nuts
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27 - Driveline
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00 - General
Install WARNING Whenever a wheel has been

changed, check the nut torques every two hours.
1. Make sure that the mating surfaces of the wheel When the nuts stay tight for 8h, the interval for
and axle hub are clean. checking can revert to the period stated in the
servicing schedule.
removal procedure.
Remove
3. Tighten the nuts to the correct torque value.
4. When the installation is complete do the following Refer to (PIL 01-03).
step also:
2. Make sure that the engine cannot be started.
4.1. Check and make sure that the wheel nut
torques are correct after every two hours of 3. Put blocks under the rear wheels.
machine operation until they stay correct.
4. Loosen the four wheel nuts by half of one turn.
(For: 2DX [T3], 4WD, Front) 5. Put a jack under the centre of the front axle. Use
WARNING Wheels and tyres are heavy. Take the correct jack.
6. Use the jack to lift the machine until both front
wheels are off the ground.
is renewed, all the studs for that wheel must be 7. Put blocks under each end of the front axle.
changed as a set, since the remaining studs may
have been damaged. 8. Hold the wheel and remove the wheel nuts.
9. Remove the wheel.
Figure 313.
A Wheel B Nuts
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00 - General
Install 2. Make sure that the engine cannot be started.
1. Make sure that the mating surfaces of the wheel 3. Put blocks under the front wheels.
and axle hub are clean.
4. Loosen the eight wheel nuts by half of one turn.
removal procedure. 5. Put a jack under the centre of the rear axle. Use
the correct jack.
6. Use the jack to lift the machine until both rear
4. When the installation is complete do the following wheels are off the ground.
step also:
7. Put blocks under each end of the rear axle.
torques are correct after every two hours of 8. Hold the wheel and remove the wheel nuts.
machine operation until they stay correct. 9. Remove the wheel.
(For: 2DX [T3], Rear)
Remove
Figure 314.
A B
A Wheel B Nuts
27 - 141 9813/8500-2 27 - 141

27 - Driveline
29 - Wheel
00 - General
Install
steps.
2. Make sure that the mating surfaces of the wheel
and axle hub are clean.
4. When the installation is complete do the following
step also:
torques are correct after every two hours of
machine operation until they stay correct.
27 - 142 9813/8500-2 27 - 142

27 - Driveline
33 - Tyre
33 - Tyre
Contents Page No.
27-33-00 General ......................................................................................................................... 27-145
27 - 143 9813/8500-2 27 - 143

Notes:
27 - 144 9813/8500-2 27 - 144

27 - Driveline
33 - Tyre
00 - General

DANGER Make sure that all tyres are inflated
Health and Safety ........................................ 27-145 to the correct pressure. Refer to the machine
Technical Data ............................................. 27-146 operator manual.
Check (Condition) ........................................ 27-147 WARNING An exploding tyre can kill. Inflated
tyres can explode if over-heated or over-inflated.
Follow the instructions given when inflating the
tyres. Do not cut or weld the rims. Use a tyre/
wheel specialist for all repair work.
WARNING Do not use the machine with
damaged, incorrectly installed, incorrectly inflated
or excessively worn tyres. Recognise the speed
limitation of the tyres installed and do not operate
at more than their recommended maximum
speed.
WARNING Running tyres outside recommended
guidelines may result in failure of the tyres which
at high speeds may endanger life.
WARNING Deflate the tyre you wish to change
before removing the wheel from the machine.
Air pressure in the tyres can cause the tyre and
rim sections to explode causing serious injury or
death. Never loosen the nuts that hold the inner
and outer wheel halves together when there is air
pressure in the tyre. Always wear safety glasses.
WARNING Do not install pneumatic tyres on a
wheel made for a solid tyre. Do not install a solid
tyre on a wheel made for a pneumatic tyre. If
you are unsure of the correct specification for
your machine, contact your local JCB dealer or a
trained specialist.
WARNING When ordering tyres, you must
specify not only the tyre size but also the speed
designation. The correct tyres for the machine are
shown in the Operator's Manual. On no account
should you use tyres of other designations
without first gaining approval from the machine
manufacturer.
WARNING Remove the valve core to make sure
the tyre is fully deflated. If the tyre is not fully
deflated, unseen damage to the wheel and / or
tyre could cause the assembly to explode.
27 - 145 9813/8500-2 27 - 145

27 - Driveline
33 - Tyre
00 - General
Technical Data
For: 2DX [T3], 2WD ................. Page 27-146

For: 2DX [T3], 4WD ................. Page 27-146

Table 70.
Item Tyre Size Ply Road Tyre Pressures Worksite Tyre Pressures
1 7.5 x 16 16 5.5bar (79.7psi) 5.5bar (79.7psi)
8.25 x 16
2 14.9 x 24 12 2.1bar (30.4psi) 2.1bar (30.4psi)
3 12 x 24 (HD) 20 3bar (43.5psi) 3bar (43.5psi)

Table 71.
Item Tyre Size Ply Road Tyre Pressures Worksite Tyre Pressures
1 10 x 16.5 8 3.5bar (50.7psi) 3.5bar (50.7psi)
2 17.5L x 24 8 1.8bar (26.1psi) 1.8bar (26.1psi)
27 - 146 9813/8500-2 27 - 146

27 - Driveline
33 - Tyre
00 - General
Check (Condition) Figure 315.
Always drive with consideration for the condition

of the tyres. Incorrect tyre pressures will affect the
stability of the machine. Check the tyres daily for
the correct tyre pressure and signs of damage. For
example:
• Signs of distortion (bulges).

• Cuts or wear.
• Embedded objects (nails, etc.).
Install the valve caps firmly to prevent dirt from

entering the valve. Inspect for leaks when you check
the tyre pressures.
Inspect the tyre valve for leaks, when you check the
tyre pressures. 2. Prepare the equipment.
2.1. Use only an air supply system which
Tyre Inflation includes a pressure regulator. Set the
regulator no higher than 1.38 bar (20 psi)
Always try to maintain the tyre pressure to the
above the recommended tyre pressure.
recommended settings. Using a machine with under-
inflated tyres means: 2.2. Use an air hose fitted with a self-locking air
chuck and remote shut-off valve.
• Decreasing the machines stability.
• Higher tyre temperatures. 3. Add the air.
• Excessive strain of the tyre fabric.
• Causes bulging of the sidewalls. 3.1. Make sure that the air hose is correctly
• Shortens the tyres life. connected to the tyre valve. Clear other
people from the area. Stand behind the
Using the machine with over-inflated tyres is tread of the tyre while adding the air.
dangerous: 3.2. Inflate the tyre to the recommended
pressure. Do not over-inflate.
• It causes excessive tensile loads in the fabric:
this makes a tyre more susceptible to cuts and
punctures.
Do not cut or weld on the rim of an inflated tyre.
After checking or amending the tyre pressure always

replace and secure the valve cap.
Always deflate the tyre before removing foreign

obstacles from the tread.
Procedure
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 - 147 9813/8500-2 27 - 147

27 - Driveline
47 - Propshaft
47 - Propshaft
Contents Page No.
27-47-00 General ......................................................................................................................... 27-149
27 - 148 9813/8500-2 27 - 148

27 - Driveline
47 - Propshaft
00 - General
00 - General
Lubricate
Apply grease to all the points and linkages.
Figure 316. Front Driveshaft
A B
27 - 149 9813/8500-2 27 - 149

27 - Driveline
51 - Driveshaft
51 - Driveshaft
Contents Page No.
27-51-00 General ......................................................................................................................... 27-151

27-51-15 Shaft Hub Side ............................................................................................................. 27-153
27 - 150 9813/8500-2 27 - 150

27 - Driveline
51 - Driveshaft
00 - General
00 - General
Unit Identification Figure 317.

order for parts replacement, always quote the details
on the unit identification plate. In the case of
gear replacements, always check the part number
27 - 151 9813/8500-2 27 - 151

27 - Driveline
51 - Driveshaft
00 - General
Sectional Drawing
Figure 318.
2 26
29
3 15
Table 72.
Item Description
2 Planet gear carrier
3 O-ring
8 Thrust washer
9 Circlip (external) (if in-
stalled)
(1)
15 Bearing Carrier
26 Driveshaft
(1)
29 Sun gear
(1)
(1) Some axles have driveshafts with integral sun

gears.
27 - 152 9813/8500-2 27 - 152

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
15 - Shaft Hub Side
Remove and Install
Consumables 3. Lever the planet gear carrier off the bearing

Description Part No. Size carrier.
JCB Threadlocker 4101/0250 0.01L 4. Remove and discard the O-ring.
Strength) 5. For driveshafts with separate sun gear only.
Remove 6. If the driveshaft is to be replaced, remove the

circlip to allow the sun gear to slide off the
1. Drain the oil from the hub. driveshaft.
2. Remove the screws 1. 7. Remove the driveshaft from the axle.
Figure 319.
A
C F
A Screws 1 B Planet gear carrier

C Bearing carrier D O-ring
E Driveshaft F Sun gear
G Circlip
27 - 153 9813/8500-2 27 - 153

27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side
Install 11. Fill the hubs with new oil of the correct grade.
Follow the correct fill procedure.
In the event of fatigue or an overload related
driveshaft failure, it is recommended that both Table 73. Torque Values
driveshafts are replaced as damage may have Item Description Nm
occurred to the other driveshaft at the time of failure.
A Screws 1 56
steps.
2. Rotate the driveshaft slightly to locate the splines
with the brake and drivehead assembly.
3. If the splines cannot be aligned, release the
brake pack as follows:
3.1. Remove the lock nuts.
3.2. Screw in the two jacking bolts equally by
hand then turn them with a spanner until the
brake is released.
Figure 320.
H
H Jacking bolts
J Lock nuts
3.3. When the driveshaft is correctly located,
loosen the jacking bolts until the brake is on.
3.4. Loosen the bolts a little more and then
tighten the lock nuts.
4. Install a new O-ring.
5. If the sun gear was removed then install it with
1.5mm x 45 degree chamfer.
6. Install the circlip.
7. Install the planet carrier onto the bearing carrier
make sure that the two tapped holes are in line
with those on the bearing carrier.
8. Apply sealant and then install the screws 1.
(Medium Strength)
9. Tighten the screws 1 to the correct torque value.
10. When you install the planet gear carrier, do not
hit the centre of the carrier as it can displace the
27 - 154 9813/8500-2 27 - 154

Contents Page No.
30-00 General
30-00-00 General ............................................................................................................................. 30-3
30-00-49 Schematic Symbols .......................................................................................................... 30-8
30-00-50 Schematic Circuit ........................................................................................................... 30-12
30-03 Tank
30-03-00 General ........................................................................................................................... 30-21
30-03-12 Suction Strainer .............................................................................................................. 30-25
30-03-15 Level Indicator ................................................................................................................ 30-28
30-03-21 Filler Cap ........................................................................................................................ 30-29
30-04 Filter
30-04-00 General ........................................................................................................................... 30-33
30-04-09 Return Line .................................................................................................................... 30-34
30-11 Gear Pump
30-11-00 General ........................................................................................................................... 30-37
30-15 Cylinder / Ram
30-15-00 General ........................................................................................................................... 30-43
30-15-03 Shovel Lift ...................................................................................................................... 30-57
30-15-06 Lift Arm ........................................................................................................................... 30-60
30-15-12 Bucket Crowd ................................................................................................................. 30-63
30-15-15 Dipper ............................................................................................................................. 30-66
30-15-18 Boom .............................................................................................................................. 30-68
30-15-21 Swing .............................................................................................................................. 30-71
30-15-24 Stabiliser ......................................................................................................................... 30-83
30-21 Oil Cooler
30-21-00 General ........................................................................................................................... 30-87
30-50 Excavator Control Valve Block
30-50-00 General ........................................................................................................................... 30-91
30-51 Lift Arm Control Valve Block
30-51-00 General ........................................................................................................................... 30-97
30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-100
30-51-80 Spool ............................................................................................................................ 30-103
30-60 Directional Control Valve
30-60-00 General ......................................................................................................................... 30-109
30-75 Unloader Valve
30-75-00 General ......................................................................................................................... 30-113
30-93 Hose
30-93-00 General ......................................................................................................................... 30-117
30-97 Connectors
30-97-00 General ......................................................................................................................... 30-121
30-97-03 Quick Release Coupling .............................................................................................. 30-124
30-97-09 Adaptor ......................................................................................................................... 30-126
30-97-18 O-Ring Face Seal (ORFS) ........................................................................................... 30-128
9813/8500-2
2017-09-22
30-97-24 Push Lock Fitting ......................................................................................................... 30-130
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-131
9813/8500-2
2017-09-22
Acronyms Glossary
ARV Auxiliary Relief Valve

HBCV Hose Burst Check Valve
HPCO High Pressure Carry Over
MRV Main Relief Valve
ORFS O-Ring Face Seal
QRC Quick Release Coupling
SAE Society of Automotive Engineers
9813/8500-2
2017-09-22
Notes:
9813/8500-2
2017-09-22
00 - General
00 - General
Contents Page No.
30-00-00 General ............................................................................................................................. 30-3

30-00-49 Schematic Symbols .......................................................................................................... 30-8
30-00-50 Schematic Circuit ........................................................................................................... 30-12
30 - 1 9813/8500-2 30 - 1
Notes:
30 - 2 9813/8500-2 30 - 2
00 - General
00 - General
Introduction ...................................................... 30-3 The hydraulic system is a power transmission system
Health and Safety ........................................... 30-4 that uses the force of flowing liquids to transmit power
Technical Data ................................................. 30-5 to specific components in a machine.
Discharge and Pressurise ............................... 30-5
To help you trace specific hydraulic problems to a
Clean ............................................................... 30-6 faulty unit (valve, actuator, ram etc.), refer to Fault
Check (Level) .................................................. 30-7 finding. Refer to: PIL 30-00-00.
Once you have traced the faulty unit, refer to

the relevant section for removal, disassembly and
checking instructions.
To help identify circuits, valves, rams etc. mentioned

in the fault finding procedures. Refer to the hydraulic
schematic diagrams. Refer to: PIL 30-00-50.
• Before you begin fault finding, read the Health

and Safety Information. Refer to: PIL 30-00-00.
• Make simple checks before you remove or
disassemble a major component.
• Make sure that the hydraulic fluid is at the
correct working temperature 50°C (121.9°F).
• Whatever the fault, check the condition of the
hydraulic fluid. Drain and replace if necessary.
Refer to Hydraulic fluid quality in this procedure
and Hydraulic System - Clean. Refer to: PIL
30-00-00.
• Make sure you remove ALL contamination and
if possible identify its origin. It may be part of a
component from elsewhere in the circuit.
Hydraulic Fluid Quality

This machine uses a large volume of fluid in the
hydraulic system for power transmission, equipment
lubrication, rust prevention and sealing. According
to a survey conducted by a pump manufacturer,
seventy per cent of the causes of problems in
hydraulic equipment were attributable to inadequate
maintenance of the quality of the hydraulic fluid.
Therefore, it is obvious that control of the quality of
the hydraulic fluid helps prevent hydraulic equipment
problems and greatly improves safety and reliability.
Furthermore from an economic angle it extends the
life of the hydraulic fluid if quality is maintained.
Hydraulic Contamination
Once inside the system, hydraulic circuit
contaminants greatly affect the performance and life
of hydraulic equipment. For example, contaminants
in a hydraulic pump develop internal wear to cause
internal leakage and hence lower discharges. Wear
particles generated will circulate with the hydraulic
fluid to cause further deterioration in the performance
of this and other equipment. Contaminants also
enter principal sliding sections of the equipment
causing temporary malfunction, scuffing, sticking
30 - 3 9813/8500-2 30 - 3
00 - General
00 - General
and leakage and can lead to major problems. The Health and Safety
main contaminants can be classified as follows:
1. Solid Particles - Sand, fibres, metallic particles, Hydraulic Pressure

welding scale, sealing materials and wear Hydraulic fluid at system pressure can injure you.
particles etc. Before connecting or removing any hydraulic hose,
2. Liquid - Usually water and incompatible oils and hose line must be vented. Make sure the hose
greases. service line has been vented before connecting or
removing hoses. Make sure the machine cannot be
3. Gases - Air, sulphur dioxide etc. which can create
started while the hoses are open.
corrosive compounds if dissolved in the fluid.
WARNING! Fine jets of fluid at high pressure can
These contaminants can appear during penetrate the skin. Keep face and hands well clear of
manufacture, assembly and operation. pressurised fluid and wear protective glasses. If fluid
penetrates your skin, get medical help immediately.
WARNING! Take care when disconnecting hydraulic
hoses and fittings as the oil will be hot.
WARNING! Damaged hoses can cause fatal
accidents. Examine the hoses regularly. Do not use
the machine if a hose or hose fixture is damaged.
Notice: Do not allow dirt to enter the system. Before
disconnecting any part of the system, thoroughly
clean around the connection. When a component
has been disconnected, always install protective
caps and plugs to prevent dirt ingress.Failure to
follow these instructions will lead to dirt entering the
system. Dirt in the system will seriously damage
the systems components and could be expensive to
repair.
CAUTION! The temperature of the hydraulic oil will
be high soon after stopping the machine. Wait until it
cools before beginning maintenance.
30 - 4 9813/8500-2 30 - 4
00 - General
00 - General
Technical Data Discharge and Pressurise
Refer to the relevant PIL section of the Hydraulic 1. Make the machine safe with the lift arm lowered.
System for the correct Technical Data. Refer to: PIL 01-03-27.
2. Operate the controls to remove the hydraulic
pressure from the service hose lines. To release
the hydraulic pressure from the electrical and
servo operated services the battery must be
connected while you operate the controls.
2.1. For manually operated services, operate
the controls (several times) of the service(s)
to be disconnected.
2.2. For electrical and servo operated services,
turn the ignition key to the ON position.
2.3. Press the relevant console switch (to make
the relevant service active).
2.4. Operate the service several times to vent
the lines.
3. Carefully remove the hydraulic tank filler cap to
vent residual tank hydraulic pressure.
4. Install the hydraulic tank filler cap.
30 - 5 9813/8500-2 30 - 5
00 - General
00 - General
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 321.
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 - 6 9813/8500-2 30 - 6
00 - General
00 - General
Check (Level)
CAUTION Do not run the machine with the
hydraulic tank filler cap removed.

2. Look at the hydraulic fluid in the sight glass.
2.1. Check if the hydraulic fluid is cloudy, or if
there is water or air in the system.
Figure 322.
A
A Sight glass
3. The level of hydraulic fluid should be at the red
mark (or above).
4. If necessary, add the recommended hydraulic
fluid.
4.1. Release the pressure from the hydraulic
tank.
4.2. Open the hydraulic filler cap.
Figure 323.
A Hydraulic cap
B Seal
4.3. Use a suitable container to add the
hydraulic fluid through the filler port.
4.4. Check the level of hydraulic fluid.
30 - 7 9813/8500-2 30 - 7
00 - General
49 - Schematic Symbols
49 - Schematic Symbols Introduction

Introduction ...................................................... 30-8 Complex hydraulic components and circuits can
Diagram ........................................................... 30-9 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 - 8 9813/8500-2 30 - 8
00 - General
Diagram Table 77. Directional control valves

Symbol Description
Used to enclose sever-
Table 74. 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 75. 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 76. 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 - 9 9813/8500-2 30 - 9
00 - General
Table 78. Energy Transmissions Symbol Description

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 79. 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 - 10 9813/8500-2 30 - 10
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 - 11 9813/8500-2 30 - 11
00 - General
50 - Schematic Circuit
50 - Schematic Circuit Introduction

Introduction .................................................... 30-12 A schematic wiring diagram is a simplified pictorial
Diagram ......................................................... 30-13 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 - 12 9813/8500-2 30 - 12
00 - General
Diagram
Figure 324. .............................................................................................................................Page 30-15
30 - 13 9813/8500-2 30 - 13
Notes:
30 - 14 9813/8500-2 30 - 14
00 - General
Page 30-16 Figure 324. Page 30-17

G
J K
H
L1 T
L2 S
H2
H1 R
L3
L
Q
L4
P
E L5
D
N
C L6
B M
A L7
30 - 15 9813/8500-2 30 - 15
00 - General
Figure 324. (Part 1 of 2) Page Page
30-16 30-17
H1
Page 30-17
E
D
B
A
30 - 16 9813/8500-2 30 - 16
00 - General
30-16 30-17
L1 T
L2 S
H2
H1 R
L3
Page 30-16
L
Q
L4
P
L5
N
L6
M
L7
30 - 17 9813/8500-2 30 - 17
00 - General
A Hydraulic tank B Hydraulic oil cooler

C Return filter D Tandem gear pump
E Unloader valve F Steer valve
G Steering ram H Lift arm valve block - 2/3 spool
H1 Lift ram spool H2 Shovel ram spool
J Lift ram K Shovel ram
L Excavator valve block L1 Kingpost clamp spool
L2 Slew ram spool L3 Boom ram spool
L4 Stabiliser ram spool L5 Stabiliser ram spool
L6 Dipper ram spool L7 Bucket ram spool
M Bucket ram N Dipper ram
P Stabiliser ram Q Stabiliser ram
R Boom ram S Slew ram
T Kingpost clamps
30 - 18 9813/8500-2 30 - 18
03 - Tank
03 - Tank
Contents Page No.
30-03-00 General ........................................................................................................................... 30-21

30-03-12 Suction Strainer .............................................................................................................. 30-25
30-03-15 Level Indicator ................................................................................................................ 30-28
30-03-21 Filler Cap ........................................................................................................................ 30-29
30 - 19 9813/8500-2 30 - 19
Notes:
30 - 20 9813/8500-2 30 - 20
03 - Tank
00 - General
Introduction .................................................... 30-21 The hydraulic tank holds excess hydraulic oil to
Drain and Fill ................................................. 30-22 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 - 21 9813/8500-2 30 - 21
03 - Tank
00 - General
Drain and Fill

2. Remove the filler cap.
3. Put a suitable container below the drain plug of
the hydraulic tank.
4. Remove the drain plug and washer.
4.1. Let the fluid drain into the container.
5. Install the washer and drain plug.
Figure 325.
A
C
B
A Filler cap
B Drain plug
C Washer
7. Top up the hydraulic tank with the recommended
fluid to the correct level.
8. Install the filler cap and make sure it is tight.
9. Check the system for leaks.

Item Nm
B 85–100
30 - 22 9813/8500-2 30 - 22
03 - Tank
00 - General
Remove and Install
Consumables 5.1. Put caps on the open hoses and ports to

Description Part No. Size prevent contamination.
JCB High Strength 4102/0551 0.05L 5.2. Some machine variants may have different
Threadlocker return hose configurations at the hydraulic
tank. Make sure that all the hoses are
Remove disconnected.
1. Make the machine safe. 6. Loosen the clips that attach the suction hose to
the tank. Refer to Figure 326.
6.1. Remove the suction hose from the tank.
2. Remove the pressure from the hydraulic system.
Refer to: PIL 30-00-00. 7. Use suitable lifting equipment to support the
hydraulic tank.
3. Put a suitable container below the hydraulic tank
drain plug. 8. Remove the mount bolts (x4) and washers (x4)
that attach the tank to the chassis frame. Refer
4. Carefully remove the drain plug and drain the to Figure 326.
hydraulic oil from the tank (below the left side of
the machine). Refer to Figure 326. 8.1. Carefully remove the tank from the
machine.
5. Disconnect the hydraulic return hoses from the
tank. Refer to Figure 326.
Figure 326.
G
E F
D
B
C A
B C
A Drain plug B Return hoses

C Clips D Suction hose
E Bolts F Washers
G Sight glass H Cover plate
30 - 23 9813/8500-2 30 - 23
03 - Tank
00 - General
Install
steps.
2. Inspect the fluid level sight glass to make sure it
is clean and in good condition.
2.1. If necessary, replace the sight glass.
3. If the filter cover plate is removed for any reason,
use a new O-ring and sealing washers to install
the plate.
4. Use a new O-ring to install the drain plug.
4.1. Tighten the drain plug to the specified
torque value.
Torque: 85–100N·m
5. Apply JCB High Strength Threadlocker to all the
mount bolts.
Consumable: JCB High Strength Threadlocker
6. When you install the suction hose, make sure it is
correctly attached and routed on the tank spigot.
6.1. Make sure that the clearance between the
hose and the gearbox case is the specified
value.
6.2. Phase the clips at the specified angle apart.
Angle: 180°
7. Fill the tank with clean hydraulic fluid.
8. Operate the machine to the specified normal
temperature of the hydraulic fluid.
Temperature: 50°C (121.9°F)
9. Turn the ignition switch to the OFF position and
check for leaks.
30 - 24 9813/8500-2 30 - 24
03 - Tank
12 - Suction Strainer
12 - Suction Strainer Introduction

Introduction .................................................... 30-25 The suction strainer is a component used for trapping
Remove and Install ....................................... 30-26 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 - 25 9813/8500-2 30 - 25
03 - Tank
Remove and Install
Remove 6. Make sure that the area around the suction

strainer is clean.
7. Remove the clip that attaches the hydraulic
Refer to: PIL 01-03-27. suction hose to the hydraulic tank. Refer to
2. Get access to the hydraulic tank. Figure 327.
3. Remove the hydraulic tank filler cap. 7.1. Remove the hydraulic suction hose.
Refer to: PIL 30-03-21. 8. Use the specified dimension (Across/Flats)

spanner to remove the suction strainer from the
4. Put a suitable container below the hydraulic tank hydraulic tank. Refer to Figure 327.
drain plug.
Dimension: 65mm
5. Carefully remove the drain plug and drain the
hydraulic tank oil. 8.1. Remove the suction strainer and discard it.
Figure 327.
A Hydraulic tank B Clip

C Suction hose D Suction strainer
30 - 26 9813/8500-2 30 - 26
03 - Tank
Install
steps.
2. Install a new suction strainer to the hydraulic
tank.
2.1. Tighten the suction strainer to the correct
torque value.
Torque: 15–20N·m
3. Use the clip to attach the suction hose to the
hydraulic tank.
Torque: 100N·m
5. Fill the hydraulic tank with oil.
5.1. Tighten the hydraulic tank filler cap.
30 - 27 9813/8500-2 30 - 27
03 - Tank
15 - Level Indicator
15 - Level Indicator
Remove and Install

Consumables
JCB High Strength 4102/0551 0.05L
Threadlocker
Remove
1. Before you remove the sight glass, the tank must
be drained first until the fluid level is below the
tank aperture. Refer to (PIL 30-03).
2. Carefully remove the sight glass from the tank
aperture. Refer to Figure 328.
Figure 328.
G Sight glass
Install
steps.
2. Use a new O-ring to install the sight glass.
2.1. Apply JCB Threadlocker to the thread glass
threads.
Consumable: JCB High Strength
Threadlocker
2.2. Tighten the sight glass to the correct torque
value.
Torque: 50–55N·m
30 - 28 9813/8500-2 30 - 28
03 - Tank
21 - Filler Cap
21 - Filler Cap Introduction

Introduction .................................................... 30-29 The hydraulic tank breather (and filter) form an
Remove and Install ....................................... 30-30 integral part of the hydraulic tank filler cap. Replace
the cap (and breather filter) with a new one at the
recommended service interval.
The cap incorporates a side mounted barrel lock that

is operated by the ignition/door key. It is important
to note that the seal must be in good condition and
correctly installed in the cap.
30 - 29 9813/8500-2 30 - 29
03 - Tank
21 - Filler Cap
Remove and Install
Remove 3. Make sure that the area around the hydraulic

tank filler cap is clean. Refer to Figure 329.
4. Insert the key and turn counterclockwise to
Refer to: PIL 01-03-27. remove the filler cap. Refer to Figure 329.
2. Get access to the hydraulic tank filler cap. Refer 5. Remove the filler cap from the hydraulic tank.
to Figure 329.
Figure 329.
A Filler cap B Key

C Seal D Counterclockwise
E Clockwise
30 - 30 9813/8500-2 30 - 30
03 - Tank
21 - Filler Cap
Install
steps.
2. Insert the key into the filler cap and turn
counterclockwise.
3. Turn the cap on the hydraulic tank until you feel
the resistance and turn a further quarter of a turn.
4. Turn the key clockwise and remove the key.
5. Check the filler cap for correct installation.
5.1. If you rotate the cap without the key, it will
not remove.
6. Make sure that the seal is in good condition and
correctly installed in the cap.
30 - 31 9813/8500-2 30 - 31
04 - Filter
04 - Filter
Contents Page No.
30-04-00 General ........................................................................................................................... 30-33

30-04-09 Return Line .................................................................................................................... 30-34
30 - 32 9813/8500-2 30 - 32
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 - 33 9813/8500-2 30 - 33
04 - Filter
09 - Return Line
09 - Return Line
Remove and Install
WARNING Fine jets of fluid at high pressure can Remove

clear of pressurised fluid and wear protective 1. Make the machine safe. Refer to (PIL 01-03).
glasses. If fluid penetrates your skin, get medical
help immediately. 2. Remove the hydraulic tank filler cap.
3. Remove the nuts, cover plate and seal.
Figure 330.
J
C
G
H
D
E
L
F
C Nuts D Cover plate

E Seal F Element assembly
J Magnets G Seal
H Seal L Filter element
K Spring
4. Remove the complete element assembly and the 4. Attach the filler cap and make sure its tight.
seal.
5. Remove the nut and spring.
6. Remove the filter element from the spindle.
7. Clean the magnets.
Install
1. Install the new element and the new seals.
2. Install the cover plate in position, then tighten the
nuts.
3. Add the recommended hydraulic fluid to the
correct level.
30 - 34 9813/8500-2 30 - 34
11 - Gear Pump
11 - Gear Pump
Contents Page No.
30-11-00 General ........................................................................................................................... 30-37
30 - 35 9813/8500-2 30 - 35
Notes:
30 - 36 9813/8500-2 30 - 36
11 - Gear Pump
00 - General

Pump Specification Pump 1 Pump 2
Displacement 16cc 16cc
Working Pressure 180bar (2,608.7psi)
Rotation Clockwise
Pump flow rate @2200 70.4L/min
RPM (Revolutions Per
Minute)
30 - 37 9813/8500-2 30 - 37
11 - Gear Pump
00 - General
Figure 331.
A C D B
Q
S
J
N
U M L P
G
H K
A Flange B Cover
C Body 1 D Body 2
E Bolt F Washer
G Drive gear shaft H Driven gear 1
J Drive gear K Driven gear 2
L Connecting shaft M Seal 1
N Seal 2 P Bush
Q Balance plate R Seal 3
S Seal 4 T Seal 5
U Circlip
30 - 38 9813/8500-2 30 - 38
11 - Gear Pump
00 - General
Remove and Install
Consumables 4. Remove the bolts that attach the inlet hose flange
Description Part No. Size to the gear pump. Refer to Figure 332.
JCB Multi-Gasket 4102/1212 0.05L 4.1. Remove the inlet hose flange from the gear
JCB Threadlocker 4101/0250 0.01L pump body.
Strength) 4.2. Put caps on the open hose and port to
5. Remove the pump outlet hoses from the elbow
CAUTION This component is heavy. It must only connectors. Refer to Figure 332.
method and device. 5.1. Put caps on the open hoses and connectors
to prevent contamination.
Remove 6. Put a suitable sling around the pump body.
1. Make the machine safe. Refer to (PIL 01-03). 6.1. Make sure that the sling is in tension and
holds the weight of the gear pump, before
2. Remove the propshaft from the machine. Refer you remove the mount bolts.
to (PIL 27-48).
7. Remove the mount bolts that attach the pump to
3. Drain the hydraulic oil from the hydraulic tank. the gearbox.
8. Carefully remove the pump from the gearbox.
30 - 39 9813/8500-2 30 - 39
11 - Gear Pump
00 - General
Figure 332.
C D
A
A Gear pump B Outlet hose (pump section 1)

C Outlet hose (pump section 2) D Elbow connectors
E Bolts F Inlet hose with flange
30 - 40 9813/8500-2 30 - 40
11 - Gear Pump
00 - General
Install
procedure.
2. Clean all traces of the gasket compounds from
the pump and gearbox mount faces.
3. Apply a thin bead of JCB Multi-Gasket to the
gearbox mount face.
4. Engage the splined shaft of the pump into the
gearbox.
5. Apply JCB Threadlocker and Sealer to the pump
mount bolts.
(Medium Strength)
5.1. Attach the pump flange to the gearbox
mounting face.
6. Remove the caps from the outlet hoses and the
elbow connectors.
7. Connect the pump outlet hoses to the related
elbow connectors.
8. Apply JCB Threadseal to the threads of all the
hydraulic adaptors.
9. All the hydraulic adaptors that are installed with
the bonded sealing washers
10. Use the mount bolts to install the pump inlet hose
flange to the pump body.
11. Install the propshaft to the machine. Refer to (PIL
27-48).
12. Fill the recommended hydraulic oil to the correct
level. Refer to (PIL 30-00).
13. After the installation of the gear pump, replace
the suction strainer and return line filter. Refer to
(PIL 30-03 and PIL 30-04).
14. After the installation of the gear pump and before
you start the engine.
14.1. Operate the engine and check for leaks,
also check the MRV (Main Relief Valve)
operating pressure. Refer to (PIL 30-00).
30 - 41 9813/8500-2 30 - 41
15 - Cylinder / Ram
15 - Cylinder / Ram
Contents Page No.
30-15-00 General ........................................................................................................................... 30-43

30-15-03 Shovel Lift ...................................................................................................................... 30-57
30-15-06 Lift Arm ........................................................................................................................... 30-60
30-15-12 Bucket Crowd ................................................................................................................. 30-63
30-15-15 Dipper ............................................................................................................................. 30-66
30-15-18 Boom .............................................................................................................................. 30-68
30-15-21 Swing .............................................................................................................................. 30-71
30-15-24 Stabiliser ......................................................................................................................... 30-83
30 - 42 9813/8500-2 30 - 42
15 - Cylinder / Ram
00 - General
Introduction .................................................... 30-43 A hydraulic cylinder ram is a mechanical actuator
Health and Safety .......................................... 30-44 that is used to give a single directional force
Operation ....................................................... 30-46 through a single action stroke. It is used in many
Check (Condition) .......................................... 30-49 applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
Check (Operation) ......................................... 30-49 consists of a cylinder barrel, in which a piston
Disassemble and Assemble .......................... 30-50 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 - 43 9813/8500-2 30 - 43
15 - Cylinder / Ram
00 - General
Health and Safety Caution During Use

1. Use only under designated conditions.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 1.1. If hydraulic oil other than the designated oil
Before connecting or removing any hydraulic hose, is used, the seals quickly degenerate and
residual hydraulic pressure trapped in the service become damaged. If the relief valve is set at
hose line must be vented. Make sure the hose a value higher than specified, it may cause
service line has been vented before connecting or ram damage and is dangerous.
removing hoses. Make sure the engine cannot be 1.2. In high temperature environments (approx.
started while the hoses are open. 90°C and above) or low temperature
Lifting Equipment environments (below -20°C), seals quickly
become damaged. Special seal materials
You can be injured if you use incorrect or faulty lifting are necessary so check to see if the ram
equipment. You must identify the weight of the item to that you are using is suitable or not.
enough and suitable for the job. Make sure that lifting 1.3. The number one cause of ram oil leakage is
equipment is in good condition and complies with all rod damage. Be careful not to damage the
local regulations. rod.
WARNING! A raised and badly supported machine 2. Warm up sufficiently before beginning work.
can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other 2.1. In cold conditions the rod seals may
end is securely chocked. Do not rely solely on the be frozen, so if the ram is operated at
machine hydraulics or jacks to support the machine maximum pressure and maximum speed,
when working under it. Disconnect the battery, to the seals will be damaged.
prevent the machine being started while you are
2.2. There is a large amount of air in a new
beneath it.
ram or one which has been left for a long
time, so the ram will not operate smoothly.
Precautions for Installation Also, if pressure is applied suddenly without
bleeding the air, high temperatures will be
1. Precautions when installing the ram on the
generated due to adiabatic compression
machine.
and the seals may burn.
1.1. When installing and removing from the 2.3. Before beginning work, always move the
machine, suspend the ram safely. ram at full stroke with no load and expel air
1.2. Suspending the ram by the piping is not only from the cylinder.
dangerous, but can also cause damage to
3. When stopping or storing, do it at a safe and fixed
the cylinder.
position.
1.3. Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. 3.1. The installed ram cannot maintain the same
Also, the rod can be damaged and become position for a long period of time, because
unusable. the oil inside the ram may leak and the
hydraulic oil volume decreases as it cools.
2. Welding after installing the ram may result in Stop or store the machine in a safe and
damage. fixed position.
2.1. If electric welding is done even at a point Maintenance, Inspection Points

away from the ram, there may be sparking
inside the ram and it will become necessary 1. Carry out daily maintenance and inspection.
to replace the ram with a new one.
1.1. The key point for correct long-term
3. When painting the machine, mask the ram. If ram function is daily maintenance and
paint adheres to the rod surface or to the wiper inspection. Carry out maintenance and
ring and the ram is operated, the wiper ring will inspection so that the ram functions fully at
not function properly and foreign matter and paint all times. Always remove any mud, water,
can easily enter the ram. This will cause damage dust or oil film adhering to the rod and
to the seals, drastically shortening the life of the keep it in normal condition. However, when
ram. cleaning the wiper ring and seals, do not get
them wet with water but wipe clean with a
4. Install the ram only when it is clean.
rag. To prevent rust forming during storage,
the amount of exposed ram piston rod
30 - 44 9813/8500-2 30 - 44
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 - 45 9813/8500-2 30 - 45
15 - Cylinder / Ram
00 - General
Operation
Ram end damping As the ram closes to full retract, the probe engages
with the groove in the piston rod, the damping effect
When you operate the lift and extension rams, it can is caused as the orifice plate seats on the face of
cause a shake when the ram is at full travel. This the piston rod counterbore. The holes in the probe
could cause load instability and operator discomfort. control the speed of the ram by restricting the flow of
oil at a gradual rate until the ram is fully closed.
Ram- Cylinder end
A restrictor probe installed to the end of the cylinder,
aligns with a groove in the piston rod.
Figure 333. 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 - 46 9813/8500-2 30 - 46
15 - Cylinder / Ram
00 - General
Figure 334. 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 - 47 9813/8500-2 30 - 47
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 335.
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 336.
R S
R O-ring
S Extrusion ring
30 - 48 9813/8500-2 30 - 48
15 - Cylinder / Ram
00 - General
Maintenance and Inspection Operation

1. Always do the daily maintenance and inspection 1. The hydraulic ram should only be operated under
of the hydraulic rams. the designated conditions.
1.1. The key point for the correct long 1.1. If you use oil other than the recommended
term ram function is daily maintenance hydraulic oil, the seals can quickly
and inspection. Do the maintenance and degenerate and become damaged.
inspection to operate the rams satisfactorily.
1.2. If the relief valve is set at a value higher
1.2. Always remove any mud, water, dust or oil than the recommended, it may cause ram
film adhering to the rod and keep the ram in damage and it is dangerous.
normal condition.
1.3. In the higher (approximately 90°C and
1.3. Do not use water when you clean the wiper above) or lower (below -20°C) temperature
ring and seals, use a rag to clean. work environments, the seals quickly
become damaged.
1.4. To prevent rust formation during the
machine storage on the ram piston rod, the 1.4. To get the desired operation of the ram
amount of exposed time must be kept to a in these work environment, the seals are
minimum. made from special materials.
1.5. When you put the machine into storage for 1.5. The basic cause of ram oil leakage is rod
more than one week, apply a light coat of damage.
suitable grease or petroleum jelly to the
1.6. Be careful when you handle the ram rod
exposed part of the ram piston rod.
which must not be damaged.
2. Make sure that the genuine JCB parts are used
2. Operate the engine at idle speed to get the
when you replace the parts.
desired normal temperature of the hydraulic oil,
2.1. If you used parts other than genuine JCB before you start the ram operation.
parts, the desired results may not be
2.1. In cold conditions the rod seals may be
obtained. JCB recommend you to use only
frozen, and if you operate the ram at
genuine JCB parts.
maximum pressure and speed, the seals
3. Take care when you disassemble and assemble will be damaged.
the hydraulic ram. 2.2. A new ram has a large amount of trapped
air which may have been left for a long
3.1. If you disassemble the ram on the
time, if you operate such a ram, it will not
machine, it may be dangerous as possible
operate smoothly. If you apply pressure
movements of the ram may occur.
suddenly without bleeding the air from the
3.2. If you do not obey the cleanliness ram, high temperatures will be generated
procedures during the ram assembling, and the seals will burn.
foreign matter may enter the ram, and
2.3. Before you operate the ram, always move
damage to the ram and other hydraulic
the ram at full stroke with no load and bleed
equipments.
air from the ram cylinder.
3.3. Always obey the cleanliness procedures
when you assemble the hydraulic ram. 3. When you stop the ram operation, do it at a safe
and fixed position.
3.4. Always obey the correct torque tightening
instructions regarding the screwed parts for 3.1. The installed ram cannot maintain the same
the ram. If the torque value is applied too position for a long period of time, because
high or too low, it may cause damage. the oil inside the ram may leak and the
hydraulic oil volume decreases as it cools.
Keep the machine in a safe and fixed
position.
30 - 49 9813/8500-2 30 - 49
15 - Cylinder / Ram
00 - General
Consumables
Cleaner/Degreaser 4104/1557 0.4L
- General purpose
solvent based parts
cleaner
JCB Threadlocker and 4101/0550 0.01L
Sealer (High Strength) 4101/0552 0.2L
The procedures described below are applicable for

the following rams:
A
• Loader shovel ram
• Loader lift ram A Head end cover
• Bucket crowd ram
• Boom ram 6. Turn and pull the piston rod to remove from the
• Dipper ram ram cylinder. Refer to Figure 339.
Disassemble Figure 339.
1. Remove the hydraulic ram from the machine.

1.1. Put the hydraulic ram on the workbench.
2. Use a soft cloth to clean the hydraulic ram
cylinder.
2.1. Make sure that dirt and foreign matter do B
not enter inside the ram through the ports. B Piston rod
3. Hold the ram cylinder in the bench vice tightly 7. Put the piston rod on a V-block. Refer to Figure
with proper support. 340.
3.1. Use a cloth to wind around the ram cylinder 8. Insert a pipe in the rod end eye. Refer to Figure
surface to prevent any damage. 340.
4. Remove the seal from the head end cover. Refer Figure 340.
to Figure 337.
Figure 337. C
C Rod end eye

9. Remove the snap ring and the grub screw from
the rod piston. Refer to Figure 341.
5. Open the head end cover of the hydraulic ram

cylinder. Refer to Figure 338.
30 - 50 9813/8500-2 30 - 50
15 - Cylinder / Ram
00 - General
D H
D Snap ring
E Grub screw
10. Remove the piston bearing from the rod piston.
H Grub screw
Figure 342.
12. Remove the piston nut that attaches the piston to
the rod. Refer to Figure 344.
Figure 344.
J
J Piston nut
13. Remove and disassemble the piston. Refer to
G Piston bearing
Figure 345.
11. Remove the grub screw that attaches to the rod
piston. Refer to Figure 343.
30 - 51 9813/8500-2 30 - 51
15 - Cylinder / Ram
00 - General

K
K Piston
N Piston bearing
14. Remove the head end cover. Refer to Figure 346.
17. Use a bent screwdriver to remove the piston seal.
15. Use a bent screwdriver to remove the wiper seal Refer to Figure 348.
and the secondary rod seal. Refer to Figure 346.
Figure 348.
Figure 346.
P Piston seal
18. Remove the piston O-ring and the piston backup
ring. Refer to Figure 349.
L Wiper seal
M Secondary rod seal
16. Remove the piston bearing. Refer to Figure 347.
30 - 52 9813/8500-2 30 - 52
15 - Cylinder / Ram
00 - General

A B
R
Q
Q O-ring
R Backup ring
A Primary rod seal
19. Examine all the components and seals for B Head end cover
damage.
5. Put the rod seal guide ring into the head end
Assemble cover. Refer to Figure 350.
1. Use JCB Cleaner and Degreaser to clean all the Figure 351.
components. C
Consumable: Cleaner/Degreaser - General
1.1. Make sure that all the threads are free from
grease, hydraulic oil and sealant.
2. Make sure that the lubricants used during
assembly do not come into contact with the JCB
Threadlocker and Sealer (High Strength).
(High Strength)
3. For the correct installation of the seals to the end
cap and piston head.
Refer to: PIL 30-15. C Seal guide ring
4. Put the primary rod seal into the head end cover. 6. Put the secondary rod seal and the wiper seal
Refer to Figure 350. into the head end cover. Refer to Figure 352.
30 - 53 9813/8500-2 30 - 53
15 - Cylinder / Ram
00 - General
7. Put the piston O-rings into the piston grooves.

Refer to Figure 353. G Piston seal
Figure 353. 9. Make sure that the screwdriver does not have
sharp edges which is used to install the seals.
10. Put the piston O-ring and the backing ring inside
the piston head. Refer to Figure 355.
Figure 355.
H J
H O-ring
J Backing ring
11. Use a cotton cloth to clean the piston rod. Refer
to Figure 356.
Figure 356.
F O-rings
8. Put the piston seal into the piston groove. Refer
to Figure 354.
K Piston rod
30 - 54 9813/8500-2 30 - 54
15 - Cylinder / Ram
00 - General
12. Install the retainer into the piston rod. Refer to Figure 360.
Figure 357.
Figure 357.
L
N
N Nylon nut
L Retainer 17. Tighten the piston. Refer to Figure 361.
13. Put the head end cover on the piston rod Figure 361.
threaded end. Refer to Figure 358.
Figure 358.
A
A Head end cover 18. Tighten the grub screw and seal the joint. Refer
14. Use a rubber mallet to tap the head end cover. to Figure 362.
14.1. Lightly tap the head end cover to install the Figure 362.
cover.
15. Install the piston to the piston rod. Refer to Figure
359.
Figure 359.
P
M
P Grub screw
19. Tighten the grub screw and assemble the snap
ring. Refer to Figure 363.
M Piston
16. Tighten the nylon nut to the correct specified
torque value. Refer to Table 82.Refer to Figure
360.
30 - 55 9813/8500-2 30 - 55
15 - Cylinder / Ram
00 - General
Q R
Q Grub screw
R Snap ring
20. Install the piston bearing and apply oil on the tube
assembly. Refer to Figure 364.
Figure 364.
S
Table 82. Nylon Nut Torque Values

Ram Torque Value
Loader shovel ram 412–461N·m
Loader lift ram 539–588N·m
Bucket crowd ram 1,078–1,176N·m
Boom ram 1,765–1,961N·m
Dipper ram 1,667–1,683N·m
S Piston bearing
21. Install the piston rod assembly in the tube. Refer
to Figure 365.
Figure 365.
22. Tighten the head end cover. Refer to Figure 366.

Figure 366.
A Head end cover

23. Seal the head end cover. Refer to Figure 367.
30 - 56 9813/8500-2 30 - 56
15 - Cylinder / Ram
03 - Shovel Lift
03 - Shovel Lift
Remove and Install

A
method and device.
Remove
2. Release the hydraulic pressure from the system
by operating the system controls.
2.1. If a HBCV (Hose Burst Check Valve)
is installed on the ram, the system will
not vent. Extreme caution must be used
when releasing the hydraulic connections -
release the connections one turn and allow A Ram hoses
the pressure to dissipate.
5. Attach the lifting straps to the shovel lift ram,
3. Put labels on the hoses and then remove the make sure that the weight of the ram is supported
shovel ram hoses. by the sling.
4. Put caps on all the open ports to prevent 6. Remove the pivot pin from the ram rod end as
contamination and loss of fluid. follows:
6.1. Remove the circlips (x2) and shims (x2)
from both ends of the pivot pin.
6.2. Use the slide hammer kit to remove the
pivot pin.
7. Remove the pivot pin from the ram cylinder end
as follows:
7.1. Remove the circlips (x2) and shims (x2)
from both ends of the pivot pin.
7.2. Use the slide hammer kit to remove the
pivot pin.
7.3. Make sure that you remove the spacers
(x2).
8. Remove the shovel lift ram.
30 - 57 9813/8500-2 30 - 57
15 - Cylinder / Ram
03 - Shovel Lift
Figure 369.
B C
D
E
E
C B
B C
D
C B
B Circlip C Shim
D Pivot pin E Spacer
30 - 58 9813/8500-2 30 - 58
15 - Cylinder / Ram
03 - Shovel Lift
Install
1. The Installation procedure is the opposite of the
removal procedure.
2. Apply mineral oil (4001/0500) on the pivot pins.
30 - 59 9813/8500-2 30 - 59
15 - Cylinder / Ram
06 - Lift Arm
06 - Lift Arm
Remove and Install

Consumables
EP Hammer Grease 4003/2107 0.4kg
4003/2106 12.5kg
Remove
1. Make the machine safe with the lift arms raised.
2. Make sure that the lift arms are supported
properly.
3. Switch OFF the engine and release the hydraulic
system pressure from the lift arm end by
operating the lift arm controls back and forth
several times.
6. Remove the pivot pin retaining bolt and then
Refer to: PIL 30-00-00. remove the pivot pin 1 with the shims 1.
3.1. If a HBCV (Hose Burst Check Valve) 7. Remove the bolts that attaches the C-shaped
is installed on the ram, the system will locking bracket.
when releasing the hydraulic connections - 8. Remove the C-shaped locking bracket.
release the connections one turn and allow
the pressure to dissipate. 9. Remove the blind grommet, circlip, shims 2 and
the spacer.
4. Put labels on the hoses and then remove the lift
ram hoses. 10. Use the slide hammer kit to remove the pivot pin
2.
4.1. Put plugs on all the open ports to prevent
contamination and loss of fluid. Special Tool: Slide Hammer Kit (Qty.: 1)
5. Attach the lifting straps to the lift ram, make sure 11. Remove the lift ram.
that the weight of the ram is supported by the
sling.
30 - 60 9813/8500-2 30 - 60
15 - Cylinder / Ram
06 - Lift Arm
Figure 371.
B C
J
K
E F
A Hydraulic hose B Retaining bolt

C Shim 1 D Pivot pin 1
E Bolt (x2) F C-Bracket
G Blind grommet H Circlip
J Shim 2 K Pivot pin 2
30 - 61 9813/8500-2 30 - 61
15 - Cylinder / Ram
06 - Lift Arm
Install
removal procedure.
2. Apply a coat of anti-rust lubricant on the pivot
pins.
3. Apply grease on the mainframe bores.
Consumable: EP Hammer Grease
30 - 62 9813/8500-2 30 - 62
15 - Cylinder / Ram
12 - Bucket Crowd
12 - Bucket Crowd
Remove and Install
Special Tools 4. Put caps on the open hoses and ports to prevent
Description Part No. Qty. contamination.
Slide Hammer Kit 993/68100 1 5. Attach suitable lifting straps to the bucket crowd
ram, make sure that the weight of the ram is
CAUTION This component is heavy. It must only supported by the sling.
method and device. 6. Carefully remove the pivot pin retaining nut and
the bolt.
Remove 7. Use the slide hammer kit to remove the pivot pin.
1. Make the machine safe. Special Tool: Slide Hammer Kit (Qty.: 1)
8. Carefully remove the shims.
2. Release the hydraulic pressure from the system.
Refer to: PIL 30-00-00. 9. Remove the bucket crowd ram.
3. Put labels on the hoses, and then remove the 10. Make sure you do not damage the bucket link
bucket crowd ram hoses. levers.
Figure 372.
B
B
A
E D E C
D
C
B
A Ram hoses B Nut

C Bolt D Pivot pin
30 - 63 9813/8500-2 30 - 63
15 - Cylinder / Ram
12 - Bucket Crowd
E Shim
30 - 64 9813/8500-2 30 - 64
15 - Cylinder / Ram
12 - Bucket Crowd
Install
removal procedure.
2. Apply grease to the ram cylinder side pivot pin.
30 - 65 9813/8500-2 30 - 65
15 - Cylinder / Ram
15 - Dipper
15 - Dipper
Remove and Install
Special Tools when releasing the hydraulic connections -

Description Part No. Qty. release the connections one turn and allow
Slide Hammer Kit 993/68100 1 the pressure to dissipate.
3. Put labels and then remove the dipper ram
CAUTION This component is heavy. It must only hoses.
method and device. 4. Put caps on the open hoses and ports to prevent
contamination.
Remove 5. Attach the lifting straps to the dipper ram, make
sure that the weight of the ram is supported by
1. Make the machine safe. the sling.
6. Carefully remove the pivot pin retaining nut and
2. Release the hydraulic pressure from the system. the bolt.
Refer to: PIL 30-00-00. 7. Use the slide hammer kit to remove the pivot pin.
2.1. Note: If a HBCV (Hose Burst Check Valve) Special Tool: Slide Hammer Kit (Qty.: 1)
is installed on the ram, the system will Refer to: PIL 06-30-00.
8. Remove the dipper ram.
Figure 373.
A
C
B
C
B
A Ram hoses B Nut

C Bolt D Pivot pin
30 - 66 9813/8500-2 30 - 66
15 - Cylinder / Ram
15 - Dipper
Install
procedure.
30 - 67 9813/8500-2 30 - 67
15 - Cylinder / Ram
18 - Boom
18 - Boom
Remove and Install
Special Tools 7. Release the hydraulic pressure from the system.

Description Part No. Qty. Refer to: PIL 30-00-00.
7.1. Note: If a HBCV (Hose Burst Check Valve)
CAUTION This component is heavy. It must only is installed on the ram, the system will
be removed or handled using a suitable lifting not vent. Extreme caution must be used
method and device. when releasing the hydraulic connections -
release the connections one turn and allow
the pressure to dissipate.
Remove
8. Put labels on the hoses and then remove the
1. Make the machine safe. boom ram hoses.
Refer to: PIL 01-03-27. 9. Put caps on the open hoses and ports to prevent
2. Remove the pivot pin retaining nut 1 and the bolt contamination.
1. 10. Attach the lifting straps to the boom ram, make
3. Remove the pivot pin with the slide hammer kit. sure that the weight of the ram is supported by
the sling.
Refer to: PIL 06-30-00. 11. Remove the pivot pin retaining nut 2 and the bolt
2.
4. Remove the grease nipple from the eye end of
the ram (through the access hole). 12. Use the slide hammer kit to remove the kingpost
end pivot pin.
5. Slowly retract the ram.
6. Remove the hose clamp.
13. Remove the boom ram.
30 - 68 9813/8500-2 30 - 68
15 - Cylinder / Ram
18 - Boom
Figure 374.
B E
C G
A F
A Nut 1 B Bolt 2
C Rod end pivot pin D Access hole
E Ram hoses F Nut 2
G Bolt 2 H Kingpost end pivot pin
30 - 69 9813/8500-2 30 - 69
15 - Cylinder / Ram
18 - Boom
Install
steps.
1.1. It will be necessary to extend the ram to
align and engage the boom pivot pin. As
the ram extends, the ram will tend to turn.
For this reason it is recommended that a
smaller diameter steel bar is used to locate
the boom ram at the kingpost casting. The
steel bar can be more readily removed to
allow for alignment of the boom pivot pin.
When the boom pivot pin has been correctly
aligned and installed, then install the correct
kingpost end pivot pin.
30 - 70 9813/8500-2 30 - 70
15 - Cylinder / Ram
21 - Swing
21 - Swing Operation
Operation ....................................................... 30-71
Slew Operation
Disassemble and Assemble .......................... 30-76 The illustration shows the right hand swing selected.
The lower port has been pressurised by the spool.
Oil flows from the parallel gallery, out past the ARV
(Auxiliary Relief Valve) to both the head side of the
left hand swing ram and the rod side of the right hand
swing ram.
The boom therefore swings to the right hand side of

the machine. Displaced oil from the rod side of the
left hand swing ram and from the head side of the
right hand swing ram flows back through the upper
service port and back to tank.
Figure 375.
D
A
A Parallel gallery B Lower service port

C ARV D Upper service port
30 - 71 9813/8500-2 30 - 71
15 - Cylinder / Ram
21 - Swing
Slew Ram End Damping Slew ARV and Anti-Cavitation Operation

As the ram nears the closed position, the damping The spool is in neutral but the momentum of the
rod seats in the cone, where it is held by the spring. swinging excavator end creates back pressure in the
The tapered flutes on the end of the rod produce head side of the right hand swing cylinder and in the
a restricting orifice, thus restricting the speed of the rod side of the left hand swing cylinder. This opens
oil being released from the ram. This provides a the ARV1 and dumps oil to exhaust. At this point the
cushioning effect between the piston and the dump cylinders cavitate and exhaust oil pressure causes
end of the ram, effectively damping out the shock ARV2 to open, allowing oil from the exhaust gallery
loads which would otherwise occur when the boom to fill the left hand cylinder.
reaches the end of its swing arc.
Figure 376.
D
A
A Ram
B Damping rod
C Cone
D Spring
30 - 72 9813/8500-2 30 - 72
15 - Cylinder / Ram
21 - Swing
Figure 377.
A B
A Spool B ARV1
C ARV2
30 - 73 9813/8500-2 30 - 73
15 - Cylinder / Ram
21 - Swing
Remove and Install
Special Tools 3.3. Turn the ignition switch to the OFF position
Description Part No. Qty. and remove the ignition key.
Slide Hammer Kit 993/68100 1 3.4. Slowly remove the hydraulic tank filler cap.
Slew the excavator to the left side to remove the right 4. Disconnect the hydraulic hoses from the slew
side ram, or to the right side to remove the left side ram.
ram.
4.1. Put caps on the open ports and hoses to
Remove
4.2. Put labels on the open hoses to help
1. Make the machine safe. identification.
5. Carefully remove the pivot pin retaining nut and
1.1. Obey the safety instructions. the bolt.
2. Remove the hydraulic pressure from the 6. Use the slide hammer kit to remove the slew ram
hydraulic system. Do the steps below for rod end pivot pin.
centremount machines. Special Tool: Slide Hammer Kit (Qty.: 1)
2.1. Stop the engine and remove the ignition
key. 7. Remove the retaining bolts and trunnion plate.
2.2. Operate the excavator control levers back 8. Carefully remove the slew ram from the machine.
and forth several times to remove the
hydraulic pressure. 9. Remove the thrust washers.
2.3. Slowly remove the hydraulic tank filler cap. 9.1. Take care when you remove the thrust
3. Remove the hydraulic pressure from the washers.
hydraulic system and the pilot circuit 9.2. Record the positions of the thrust washers
accumulator. Do the steps below for sideshift to help identification.
machines.
10. Remove the bearing bushes if they are damaged
3.1. Turn the ignition switch to the ON position. and replace with new.
Do not start the engine.
10.1. Make sure that the grease holes of the
3.2. Activate the joystick controls, operate the bushes align with their corresponding
joysticks several times to remove the holes in the rear frame.
hydraulic pressure from the servo system
and service rams.
30 - 74 9813/8500-2 30 - 74
15 - Cylinder / Ram
21 - Swing
Figure 378.
A Pivot pin bolt B Pivot pin (rod end)

C Retaining bolts D Trunnion plate
E Thrust washers F Bearing bushes
Install 3. Tighten the retaining bolts to the correct torque

value.
removal procedure. Additionally do the following 4. After installation, operate the excavator.
steps.
4.1. Make sure that the ram and kingpost are
2. Make sure that the pivot bores are clean before operating freely.
you install the pivot pins.
5. Apply grease to all the pivot pins after the ram
2.1. Apply a coat of clean hydraulic fluid to the installation.
pivot bores.
2.2. Make sure that the pivot pin retaining hole
aligns with the corresponding hole in the Item Nm
kingpost. C 565
30 - 75 9813/8500-2 30 - 75
15 - Cylinder / Ram
21 - Swing
Disassemble
1. Clean the cylinder with a clean cloth.
2. Position the cylinder in a bench vice. Use soft
jaws in the vice to prevent any damage on the
outer tube. Refer to Figure 379.
Figure 379. A
A
5. Remove the port cap. Refer to Figure 382.
Figure 382.
3. Mark a straight line on the trunnion and the tube

to help installation. Refer to Figure 380.
Figure 380.
B
B Port cap
6. Remove the plunger. Refer to Figure 383.
Figure 383.
4. Remove the hexagon socket setscrew. Refer to

Figure 381.
C Plunger
30 - 76 9813/8500-2 30 - 76
15 - Cylinder / Ram
21 - Swing
7. Loosen the trunnion in a counterclockwise 10. Remove the grub screw. Refer to Figure 387.
direction with a rubber mallet or a nylon rod and
hammer. Refer to Figure 384. Figure 387.
Figure 384.
G Grub screw
11. Mark a straight line on the piston and the piston
D Trunnion rod to help assembly. Refer to Figure 388.
8. Remove the trunnion along with the piston rod Figure 388.
assembly from the tube. Refer to Figure 385.
Figure 385.
D E
D Trunnion
E Piston rod assembly
9. Put the piston rod assembly on a clean bench 12. Hold the rod eye and loosen the piston. Refer to
and remove the piston bearing strip. Refer to Figure 389.
Figure 386.
Figure 389.
Figure 386.
13. Remove the piston from the piston rod. Refer to

Figure 390.
F Piston bearing strip
30 - 77 9813/8500-2 30 - 77
15 - Cylinder / Ram
21 - Swing

L M
H E
L Trunnion O-ring
M Back-up ring
17. Remove the metal gland wiper. Refer to Figure
394.
E Piston rod assembly Figure 394.

H Piston
14. Remove the piston rod from the trunnion. Refer
to Figure 391.
Figure 391.
D N Metal gland wiper

18. Remove the piston bearing strip. Refer to Figure
395.
Figure 395.
D Trunnion
15. Remove the snap ring of the metal gland wiper
and the rod seal with a bent screw driver. Refer
to Figure 392.
Figure 392.
J K
J Snap ring F Piston bearing strip

K Rod seal 19. Remove the piston seal. Refer to Figure 396.
16. Remove the trunnion O-ring and the back-up ring
with a bend screw driver. Refer to Figure 393.
30 - 78 9813/8500-2 30 - 78
15 - Cylinder / Ram
21 - Swing
Figure 396. 2. Install the trunnion O-ring and the back-up ring.
Figure 399.
M L
Q Piston seal
20. Remove the piston O-ring. Refer to Figure 397. L Trunnion O-ring
M Back up ring
Figure 397.
3. Install the metal guard and the snap ring. Refer
to Figure 400.
Figure 400.
N J
P J Snap ring
N Metal gland wiper
4. Make sure that the wiper and lips are facing
P Piston O-ring against the pressure side. Refer to Figure 401.
21. Examine all the components and seals for Figure 401.
damage.
Assemble
1. Install the rod seal. Refer to Figure 398.
Figure 398.
5. Install the piston O-ring in the piston groove.

K Refer to Figure 402.
K Rod seal
30 - 79 9813/8500-2 30 - 79
15 - Cylinder / Ram
21 - Swing
Figure 402. 8. Install the piston on the piston rod assembly.

P
Figure 405.
E H
P Piston O-ring
6. Install the piston seal on the piston O-ring. Refer H Piston
to Figure 403.
9. Make sure that the cushion ring is in the centre.
Figure 403. Refer to Figure 406.
Figure 406.
Q Piston seal
7. Apply petroleum jelly on the head end cover
or the trunnion O-ring and install the piston rod
assembly into the trunnion. Refer to Figure 404.
Figure 404. 10. Install the grub screw in the groove and seal the
joint. Refer to Figure 407.
E
Figure 407.
D
G
D Trunnion
E Piston rod assembly G Grub screw
30 - 80 9813/8500-2 30 - 80
15 - Cylinder / Ram
21 - Swing
11. Put the bearing strips in the groove of the piston. Figure 410.
Figure 408.
R E
F R Tube
F Piston bearing strip 14. Install the head end cover or trunnion on the tube.
12. Make sure that the two piston bearing strips slot
is in the opposite direction. Refer to Figure 409. Figure 411.
Figure 409.
R D
D Trunnion
R Tube
15. Tighten the head end cover or the trunnion and
13. Apply hydraulic oil inside the tube and install the align with the mark. Refer to Figure 412.
piston rod assembly inside the tube. Refer to
Figure 410.
30 - 81 9813/8500-2 30 - 81
15 - Cylinder / Ram
21 - Swing
Figure 412.
16. Install and seal the hexagon setscrew. Refer to

Figure 413.
Figure 413.
A Set screw
17. Install the port cap and the plunger. Refer to
Figure 414.
Figure 414.
B C
B Port cap
C Plunger
30 - 82 9813/8500-2 30 - 82
15 - Cylinder / Ram
24 - Stabiliser
24 - Stabiliser
Remove and Install
Special Tools Special Tool: Slide Hammer Kit (Qty.: 1)

8. Start the engine and slowly extend the stabiliser
Slide Hammer Kit 993/68100 1 ram so that the dump end of the ram protrudes
from the top of the outer leg section.
be removed or handled using a suitable lifting 9. Attach suitable lifting gear to the ram.
method and device.
9.1. Make sure that the weight of the ram is
supported by the sling and remove the
Remove bottom pivot pin.
1. Lower the stabiliser legs until the pads are at the 10. Stop the engine.
specified height from the ground.
11. Release the hydraulic pressure from the system.
11.1. Important: If a HBCV (Hose Burst Check
Valve) is installed on the ram, the system
3. Remove the bottom locking nut and bolt. will not de-pressurise. Extreme caution
must be used when releasing the hydraulic
4. Remove the bottom pivot pin and allow the connections - release the connections one
stabiliser foot to fall clear. turn and allow the pressure to release.
Special Tool: Slide Hammer Kit (Qty.: 1) 12. Put labels on the hoses for identification, then
remove the stabiliser hoses.
5. Lift the inner leg and temporarily install the pivot
pin through the inner leg and ram. 13. Put caps on the open hoses and ports to prevent
contamination.
6. Put a block of wood underneath the stabiliser leg.
14. Lift the ram with suitable lifting equipment.
7. Remove the circlips and drive out the top pivot
pin with spacing collars.
30 - 83 9813/8500-2 30 - 83
15 - Cylinder / Ram
24 - Stabiliser
Figure 415.
E
G
G
H
F
C A
B
D
A Nut B Bolt
C Bottom pivot pin D Stabiliser foot
E Circlip F Top pivot pin
G Spacing collars H Stabiliser hoses
30 - 84 9813/8500-2 30 - 84
15 - Cylinder / Ram
24 - Stabiliser
Install
removal procedure.
2. Use suitable lifting equipment to install the
stabiliser ram.
3. On completion make sure that the ram and leg
operate freely and do not foul.
30 - 85 9813/8500-2 30 - 85
21 - Oil Cooler
21 - Oil Cooler
Contents Page No.
30-21-00 General ........................................................................................................................... 30-87
30 - 86 9813/8500-2 30 - 86
21 - Oil Cooler
00 - General
00 - General
Remove and Install
The hydraulic oil cooler forms part of a combined 6. Lift off the front nose housing.
cooling pack assembly, which also incorporates the
transmission oil cooler. To remove the unit therefore 7. Disconnect the hydraulic hoses and the
it is necessary to disconnect the associated hoses transmission hoses.
from the transmission system.
8. Put a label on the hoses to help installation.
Remove 9. Plug all the open ports and hoses to prevent
contamination.
10. Remove the cooler mounting bolts.
2. Vent any residual hydraulic pressure that may be
in the system by operating the controls back and 11. Carefully lift the cooler matrix from the machine.
forth several times.
12. Make sure that not to displace or damage the
3. Remove the front grille. anti-recirculation foam around the radiator.
4. Open the engine compartment cover. Refer to 13. If the foam is not correctly installed the radiator
(PIL 06-06). and oil cooler will be less efficient.
5. Remove the bolts.
Figure 416.
D H
G
F
C B F
A E
E
A Hydraulic oil cooler B Transmission oil cooler

C Bolt D Front nose housing
E Hydraulic hose F Transmission hose
G Cooler mounting bolt H Anti-recirculation foam
Install 2. Run the engine and check for leaks.
1. The installation procedure is the opposite of the 3. Check the transmission oil level and top up to the
removal procedure. Additionally do the following correct level.
steps.
30 - 87 9813/8500-2 30 - 87
21 - Oil Cooler
00 - General
4. Check the hydraulic oil level and top up to the

correct level. Refer to (PIL 30-00).
30 - 88 9813/8500-2 30 - 88
50 - Excavator Control Valve Block
Contents Page No.
30-50-00 General ........................................................................................................................... 30-91
30 - 89 9813/8500-2 30 - 89
Notes:
30 - 90 9813/8500-2 30 - 90
00 - General

ARV (Auxiliary Relief Pressure Setting
Remove and Install ....................................... 30-93 Valve)
Boom ram head side 310bar (4,492.7psi)
Bucket ram head side 250bar (3,623.2psi)
Bucket ram rod side 250bar (3,623.2psi)
Dipper ram head side 250bar (3,623.2psi)
Dipper ram rod side 250bar (3,623.2psi)
Slew left and right 260bar (3,768.1psi)
30 - 91 9813/8500-2 30 - 91
00 - General
Figure 417.
J
H
C
B
P
Stabilizer
Stabilizer
Dipper
Crowd
Boom
Slew
FROM D4/2 Heat Exchanger
260 Bar 260 Bar 310 Bar 250 Bar 250 Bar 250 Bar 250 Bar 250 Bar
Clamp Tank Clamp Port
A Tie rods B Inlet pipe assembly

C Slew block assembly D Boom block assembly
E Stabilizer block assembly F Stabilizer block assembly
G Dipper block assembly H Crowd block assembly
J Outlet pipe assembly
30 - 92 9813/8500-2 30 - 92
00 - General
Remove and Install 6.2. Put labels on the hoses to help identification
for installation.
Consumables
6.3. Make sure that the routing of the hoses is
Description Part No. Size recorded before you disconnect the hoses
JCB Threadseal 4102/1951 0.05L from the valve block.
CAUTION This component is heavy. It must only 7. Loosen the retaining nuts that attach the valve
be removed or handled using a suitable lifting block to the chassis.
method and device.
8. Put a suitable sling around the valve block.
Remove 9. Make sure that the sling is in tension and holds

the weight of the valve block, before you remove
1. Make the machine safe. Refer to (PIL 01-03). the bolts and nuts. Refer to Figure 420.
2. Operate the valve block levers to remove the Figure 420.

hydraulic pressure from the system.
3. Remove the rear valance from the machine.
4. Remove the excavator control console to get
access to the valve block. Refer to Figure 418.
Figure 418.
A Excavator control console

5. Remove the clevis pins that attach the control
levers to the valve block spools. Refer to Figure 10. Remove the retaining nuts and bolts that are
419. attached to the valve block. Refer to Figure 421.
5.1. Disconnect all the control levers from the Figure 421.
valve block spools.
D
Figure 419.
D
B Clevis pins
6. Disconnect all the hoses that are attached to the E
valve block. C
6.1. Put caps on the open hoses and ports to C Retaining nuts
prevent contamination. D Bolts
E Valve block
30 - 93 9813/8500-2 30 - 93
00 - General
11. Lower the valve block to the ground.
Install
procedure.
2. Make sure that all the hydraulic hoses are
routed and connected in the correct positions as
recorded.
3. Apply JCB Threadseal to the threads of all the
hydraulic adaptors which are installed with the
bonded sealing washers.
4. Adjust the control levers to the correct positions.
5. After the valve block installation, check the ARV
(Auxiliary Relief Valve) for the set pressure. Refer
to (PIL 30-50-06).
30 - 94 9813/8500-2 30 - 94
51 - Lift Arm Control Valve Block
Contents Page No.
30-51-00 General ........................................................................................................................... 30-97

30-51-03 Main Relief Valve (MRV) .............................................................................................. 30-100
30-51-80 Spool ............................................................................................................................ 30-103
30 - 95 9813/8500-2 30 - 95
Notes:
30 - 96 9813/8500-2 30 - 96
00 - General

Technical Data ............................................... 30-97 Table 85. Lift arm valve block - 2 spool
Description bar (psi)
MRV (Main Relief Valve) 180 (2,608.7)
ARV (Auxiliary Relief
Valve)
Bucket ram head side 310 (4,492.7)
Bucket ram rod side 170 (2,463.8)
Table 86. Lift arm valve block - 3 spool

Description bar (psi)
MRV 180 (2,608.7)
ARV
Bucket ram head side 310 (4,492.7)
Bucket ram rod side 170 (2,463.8)
30 - 97 9813/8500-2 30 - 97
00 - General
Figure 422.
B
A
C
A Inlet assembly B MRV (Main Relief Valve)

C Lift arm block assembly D Shovel block assembly
E Outlet assembly
30 - 98 9813/8500-2 30 - 98
00 - General
Figure 423.
L K
J
H
G
F
F MRV G Inlet assembly

H Lift arm block assembly J Shovel block assembly
K Auxiliary block assembly L Outlet assembly
30 - 99 9813/8500-2 30 - 99
03 - Main Relief Valve (MRV)
Disassemble 5. Disassemble the MRV in the numerical

sequence shown. Refer to Figure 425.
6. Make sure of the following, when you
2. Discharge the hydraulic system. Refer to (PIL disassemble the MRV.
30-00).
6.1. Do not contaminate any of the MRV
3. Remove the lift arm control valve block from the components.
machine. Refer to (PIL 30-51).
6.2. Do not damage the spool.
4. Remove the MRV (Main Relief Valve) from the lift 6.3. Do not damage the seal grooves.
arm control valve block. Refer to Figure 424.
6.4. When you remove the O-rings and seals,
Figure 424. use an appropriately rounded tool that will
not cause any damage to the seal grooves.
A
6.5. Discard all the O-rings and back up rings.
6.6. Do not use worn or damaged components.
6.7. Inspect the valve components for
scratches, nicks or any other type of
damage, replace with new if required.
A MRV
30 - 100 9813/8500-2 30 - 100

Figure 425.
1
1 Plug assembly 2 Piston relief valve setting

3 Spring 4 Adjusting screw socket
5 Washer 6 Relief valve nut
30 - 101 9813/8500-2 30 - 101

Assemble
1. Make sure that all the parts are clean and free
from damage.
2. Lubricate all the parts with clean hydraulic fluid.
3. Assemble the MRV in the reverse numerical
sequence shown. Refer to Figure 424.
3.1. Replace all the O-rings and the back-up
rings.
3.2. Make sure that all the parts move freely.
3.3. Make sure that the O rings and the back-up
rings are installed the correct way around.
3.4. Tighten the nut to the correct torque value.
30 - 102 9813/8500-2 30 - 102

80 - Spool
80 - Spool
Figure 426. Inlet section
A To HPCO (High Pressure Carry Over) line B Inlet from top

C Main relief valve
30 - 103 9813/8500-2 30 - 103

80 - Spool
Figure 427. Lift arm section
B
A
F Loader
30 - 104 9813/8500-2 30 - 104

80 - Spool
Figure 428. Shovel section
H
B
G
A
J Shovel cylinder
30 - 105 9813/8500-2 30 - 105

80 - Spool
Figure 429. Outlet section
B
A
K HPCO outlet
30 - 106 9813/8500-2 30 - 106

60 - Directional Control Valve
Contents Page No.
30-60-00 General ......................................................................................................................... 30-109
30 - 107 9813/8500-2 30 - 107

Notes:
30 - 108 9813/8500-2 30 - 108

00 - General
00 - General
Introduction
Flow Control Valves Figure 433.
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 430.
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 431. 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 435.

movement of the spool would connect Port P1 to Port
P4, and Port P3 to Port P2.
30 - 109 9813/8500-2 30 - 109

00 - General
Figure 436. 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 - 110 9813/8500-2 30 - 110

75 - Unloader Valve
75 - Unloader Valve
Contents Page No.
30-75-00 General ......................................................................................................................... 30-113
30 - 111 9813/8500-2 30 - 111

Notes:
30 - 112 9813/8500-2 30 - 112

75 - Unloader Valve
00 - General

Technical Data ............................................. 30-113 Table 87.
Component Identification ............................. 30-114
Maximum working pres- 350bar (5,072.4psi)
sure
Maximum flow 150L/min
Setting valve 1 3.6bar (52.2psi) cracking
pressure
Setting valve 2 155bar (2,246.4psi)
30 - 113 9813/8500-2 30 - 113

75 - Unloader Valve
00 - General
Figure 437.
A Unloader valve
30 - 114 9813/8500-2 30 - 114

93 - Hose
93 - Hose
Contents Page No.
30-93-00 General ......................................................................................................................... 30-117
30 - 115 9813/8500-2 30 - 115

Notes:
30 - 116 9813/8500-2 30 - 116

93 - Hose
00 - General
Introduction .................................................. 30-117 Hydraulic hoses are used to connect different
Disconnect and Connect ............................. 30-118 components in the hydraulic circuit. The hoses
Check (Condition) ........................................ 30-119 are graded by pressure, temperature, and fluid
compatibility. Hoses are built up with rubber and steel
layers. A rubber interior is surrounded by multiple
layers of woven wire and rubber. The exterior is
designed for abrasion resistance. The bend radius
of a hydraulic hose is carefully designed into the
machine, since hose failures can be deadly, and
violating the hose's minimum bend radius will cause
failure. Hydraulic hoses generally have steel fittings
swaged on the ends.
30 - 117 9813/8500-2 30 - 117

93 - Hose
00 - General
Disconnect and Connect Figure 440.
Some attachments are hydraulically powered. The

following procedures show how to connect and
disconnect the hydraulic hoses safely.
Connecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Check the hoses and adaptors for damage. 5. Check for leaks:
4. Connect the hoses: 5.1. Start the machine.
4.1. Make sure that the hose is not twisted. 5.2. Operate the related controls to increase the
Pressure applied to a twisted hose can pressure in the hydraulic system.
cause the hose to fail or the connections to 5.3. Stop the machine then remove the key.
loosen.
5.4. Check for indications of leakage at the hose
Figure 438. connections. Correct, as necessary.
Disconnecting the Hydraulic Hoses

2. Discharge the hydraulic system pressure.
3. Disconnect the hoses.
4.2. Make sure that the hose does not touch 4. Check the hoses and adaptors for damage.
hot parts. High ambient temperatures can
cause the hose to fail. 5. If necessary, install the blanking caps.
4.3. Make sure that the hose does not touch 6. Check for leaks:
parts which can rub or cause abrasion.
6.1. Start the machine.
4.4. Use the hose clamps (where possible) to
support long hose runs and keep the hoses 6.2. Operate the related controls to increase the
away from moving parts, etc. pressure in the hydraulic system.
Figure 439. 6.3. Stop the machine then remove the key.
6.4. Check for indications of leakage at the hose
connections. Correct, as necessary.
4.5. To allow for length changes when the hose

is pressurised, do not clamp at the bend.
The curve absorbs the change.
30 - 118 9813/8500-2 30 - 118

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
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 - 119 9813/8500-2 30 - 119

97 - Connectors
97 - Connectors
Contents Page No.
30-97-00 General ......................................................................................................................... 30-121

30-97-03 Quick Release Coupling .............................................................................................. 30-124
30-97-09 Adaptor ......................................................................................................................... 30-126
30-97-18 O-Ring Face Seal (ORFS) ........................................................................................... 30-128
30-97-24 Push Lock Fitting ......................................................................................................... 30-130
30-97-27 Rapid Assembly Hose Fitting ....................................................................................... 30-131
30 - 120 9813/8500-2 30 - 120

97 - Connectors
00 - General
00 - General
Technical Data
O-Ring Face Seal UNF Threads on the BSP Adap- BSP Adap- Hexagon Torque
ORFS Fittings tor Size tor Size (A/F) Value
Inch mm mm N·m
3/4 19.05 32mm 81N·m
Table 88. Torque Settings - ORFS
1 25.4 38mm 129N·m
UNF Thread Size Torque Value 1 1/4 31.75 50mm 206N·m
inch x pitch N·m
9/16 x 18 24–27N·m Table 90. Torque Settings - SAE Connections
11/16 x 16 40–44N·m SAE Hose SAE Port Hexagon Torque
13/16 x 16 55–60N·m Dash Size Thread (A/F) Value
1 x 14 60–66N·m Size
1 3/16 x 12 90–99N·m inch x mm N·m
pitch
1 5/16 x 12 115–126N·m
4 7/16 x 20 15.9mm 20–28N·m
1 7/16 x 12 125–138N·m
6 9/16 x 18 19.1mm 46–54N·m
1 11/16 x 12 170–187N·m
8 3/4 x 16 22.2mm 95–105N·m
2 x 12 200–220N·m
10 7/8 x 14 27mm 130–
140N·m
Adaptors Connected into Valve Blocks
12 1 1/16 x 12 31.8mm 190–
210N·m
Table 89. Torque Settings - BSP Adaptors 16 1 5/16 x 12 38.1mm 290–
310N·m
BSP Adap- BSP Adap- Hexagon Torque
tor Size tor Size (A/F) Value 20 1 5/8 47.6mm 280–
380N·m
Inch mm mm N·m
1/4 6.35 19mm 18N·m
3/8 9.525 22mm 31N·m
1/2 12.7 27mm 49N·m
5/8 15.875 30mm 60N·m
30 - 121 9813/8500-2 30 - 121

97 - Connectors
00 - General
Hoses installed into Adaptors
Figure 441.
B
C
A B C
A
A Adaptor B Hose
C O-ring D Dimension will vary depending upon the torque
applied.
Hoses installed into adaptors seal onto an `O' ring

which is compressed into a 45° seat machined into
the face of the adaptor port.
Table 91. BSP Hose - Torque Settings
BSP Hose Size Hexagon (A/F)
Nm kgf m lbf ft
in mm
1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8
1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9
3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5
1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9
5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9
3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8
1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9
1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5
1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8
Adaptors into Component Connections with Bonded Washers

Table 92. BSP Adaptors with Bonded Washers - Torque Settings
BSP Hose Size
Nm kgf m lbf ft
in
1/8 20.0 2.1 15.0
1/4 34.0 3.4 25.0
3/8 75.0 7.6 55.0
1/2 102.0 10.3 75.0
5/8 122.0 12.4 90.0
3/4 183.0 18.7 135.0
1 203.0 20.7 150.0
30 - 122 9813/8500-2 30 - 122

97 - Connectors
00 - General
BSP Hose Size

Nm kgf m lbf ft
in
1 1/4 305.0 31.0 225.0
1 1/2 305.0 31.0 225.0
Torque Stop Hose System
Figure 442.
B
C
A B C
A
A Adaptor B Hose
C O-ring D Shoulder
E Minimum dimension fixed by shoulder.
Torque-Stop hoses installed into adaptors seal onto the 'O' ring being damaged as a result of over
an `O' ring which is compressed into a 45° seat tightening, Torque-Stop hoses have an additional
machined into the face of the adaptor port. To prevent shoulder, which acts as a physical stop.
Table 93. BSP `Torque Stop' Hose - Torque Settings

BSP Hose Size Hexagon (A/F)
Nm kgf m lbf ft
in. mm
1/8 14.0 14.0 1.4 10.0
1/4 19.0 27.0 2.7 20.0
3/8 22.0 40.0 4.1 30.0
1/2 27.0 55.0 5.6 40.0
5/8 30.0 65.0 6.6 48.0
3/4 32.0 95.0 9.7 70.0
1 38.0 120.0 12.2 89.0
1 1/4 50.0 189.0 19.3 140.0
1 1/2 55.0 244.0 24.9 180.0
30 - 123 9813/8500-2 30 - 123

97 - Connectors
03 - Quick Release Coupling
03 - Quick Release Coupling Introduction

Introduction .................................................. 30-124 The flat face quick release couplings allow the
Disconnect and Connect ............................. 30-125 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 443.
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 - 124 9813/8500-2 30 - 124

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.
• 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 444.
C D E
C Ball
D Slot
E Sleeve
30 - 125 9813/8500-2 30 - 125

97 - Connectors
09 - Adaptor
09 - Adaptor Introduction
Introduction .................................................. 30-126 On a typical machine, some hydraulic components
Remove and Install ..................................... 30-127 may utilise Positional Type SAE (Society of
Automotive Engineers) Hydraulic Adaptors. When
you install a Positional Type Hydraulic Adaptor,
it is important to adopt the Remove and Install
procedure. 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 445.
A O-ring seal
B Locknut
C Washer
30 - 126 9813/8500-2 30 - 126

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 446.
Z Adaptor thread
6. Tighten the locknut to the correct torque value.

Item Nm
B 81
A O-ring seal
B Locknut
C Backing washer
4. Screw the adaptor into the port of the hydraulic
component as far as possible, so that all the
threads engage and the O-ring seal is correctly
seated against the sealing face.
5. Set the angular position of the adaptor as
required, then secure by tightening the locknut.
When installed correctly no more than one thread
should be visible at Z as shown.
30 - 127 9813/8500-2 30 - 127

97 - Connectors
18 - O-Ring Face Seal (ORFS)
18 - O-Ring Face Seal (ORFS) Introduction

Introduction .................................................. 30-128 The ORFS (O-Ring Face Seal) type fittings are
Remove and Install ..................................... 30-129 adaptors that are screwed into valve blocks, they
seal on to an O-ring which is compressed into a 45°
seat machined into the face of the tapped port.
30 - 128 9813/8500-2 30 - 128

97 - Connectors
18 - O-Ring Face Seal (ORFS)
The hose fittings are for flat face components for

resistance over torque. The ORFS (O-Ring Face
Seal) offers 100% reliability.
When you remove or install components, make sure

all of the hydraulic fittings are tightened to the correct
torque value during the assembly procedure.
To prevent damage to the ORFS during the assembly 4 Swivel nut - Hand tight
procedure it is important to use the double-spanner 5 Swivel nut - Torque tightened
method to tighten the fittings.
Figure 451.
Figure 448.
1 Torque spanner
D
2 Open ended combination spanner
Install
1. Always coat the ORFS with hydraulic oil before
installation.
2. The rubber ORFS is compressed into a precision
machined groove in the adaptor to form a tight
seal against a flat surface of the sleeve.
Figure 449. A Nut
3 B Sleeve
C ORFS
D Adaptor
3 ORFS
3. Use the swivel nut line marking. Tighten the nut
to the correct torque value to compress the fitting.
Refer to Technical Data.
30 - 129 9813/8500-2 30 - 129

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 452.
D A
C B
A Tube
B Collet
C O-ring
D Steel support tube
30 - 130 9813/8500-2 30 - 130

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 453.
A B C
E D
A Snap ring
B O-ring and back-up ring
C Tube
D Fitting body
E Hose
30 - 131 9813/8500-2 30 - 131

Notes:
30 - 132 9813/8500-2 30 - 132

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 ..................................................................................................................... 33-36
33-03 Battery
33-03-00 General ........................................................................................................................... 33-39
33-03-03 Isolator Switch ................................................................................................................ 33-48
33-09 Power Distribution
33-09-00 General ........................................................................................................................... 33-51
33-09-03 Fuse ............................................................................................................................... 33-53
33-12 Harness
33-12-00 General ........................................................................................................................... 33-57
33-12-03 Main Frame .................................................................................................................... 33-67
33-12-18 Side Console .................................................................................................................. 33-76
33-12-28 Exterior Roof .................................................................................................................. 33-93
33-24 Instruments
33-24-03 Instrument Panel .......................................................................................................... 33-101
33-27 Interior Switch
33-27-03 Multi-Purpose ............................................................................................................... 33-105
9813/8500-2
2017-09-25
Acronyms Glossary
CAN Controller Area Network

ECM Engine Control Module
9813/8500-2
2017-09-25
Contents Page No.
33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-8
33-00-90 Earth Point ..................................................................................................................... 33-36
33 - 1 9813/8500-2 33 - 1
Notes:
33 - 2 9813/8500-2 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
Check (Operation) ........................................... 33-7 safe with the battery isolated before you attempt to
disconnect any electrical connections or work in the
engine compartment.
33 - 3 9813/8500-2 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 9813/8500-2 33 - 4
00 - General
Fault-Finding
Fault
Battery Fault Table 95. Page 33-5
General Relay Fault Table 96. Page 33-5
Electrical Network - CAN (Controller Area Network) Bus system Table 97. Page 33-6
ECM Faults Table 98. Page 33-6
Table 95. Battery Fault

Cause Remedy
Battery Voltage Switch on the ignition key and check the battery
voltage with a multimeter. If the terminal voltage of
the battery is below 9 Volt or above 16 Volt, charge
or replace the battery.
Battery Connection Fault Disconnect the electrical connection from the battery.
Check for signs of corrosion or contamination in the
battery terminals, clean the terminals. Repair as
necessary.
If no fault is found proceed to ECM (Engine Control
Module) Connection Faulty.
ECM Connection Faulty Disconnect the harness from ECM and inspect.
Check seals are in place, check for signs of corrosion
or contamination.
If ECM pins are damaged, replace ECM and re-flash
appropriate calibration (see Re-flashing an ECM).
If harness is damaged, repair or replace as
necessary.
Check the resistance between the vehicle chassis
ground and ECM ground, if the resistance is high
repair the ECM ground.
If no fault is found proceed to 'Battery Charge Circuit
Fault'.
Battery Charge Circuit Fault Check the battery charge circuit, if the circuit is found
faulty repair as necessary.
If no fault is found raise a Techweb Helpdesk call.
Table 96. General Relay Fault

Cause Remedy
Relay Supply Voltage Fault Perform the relay test routine.
If relay supply voltage is found fault, proceed to
'Relay Connection Faulty'.
If relay supply voltage is OK, raise Techweb
Helpdesk Call.
Relay Connection Faulty Check the condition of relay to harness connection,
make sure the seals are in place, check for signs
of corrosion or contamination. Repair/replace as
necessary.
If no fault is found, proceed to ECM connection fault.
33 - 5 9813/8500-2 33 - 5
00 - General
Cause Remedy
ECM Connection Fault Disconnect the harness from engine ECM and
inspect. Check seals are in place, check for signs of
corrosion or contamination.
necessary.
Check the continuity and electrical insulation, repair
or replace as necessary.
If a relay fault is found, raise Techweb Helpdesk Call.
Table 97. 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 98. ECM Faults

Cause Remedy
ECM Overheat Identify the root cause and repair as necessary: – Air
intake problem – Engine too hot – Cooling fan failure
– Extreme hot soak.
If no fault is found proceed to ECM temperature fault.
ECM Temperature Fault Check the ECM temperature is consistent with
physical ECM temperature, if found faulty raise
Techweb Helpdesk call.
ECM General Fault Visually check the ECM pins and connections on the
wiring harness. If ECM pins are damaged, replace
ECM and re-flash appropriate calibration (see Re-
flashing an ECM).
If no fault is found proceed to ECM connection fault.
Check the conformity of ground connection of vehicle
chassis. If harness is damaged, repair or replace as
necessary.
necessary.
If no fault is found raise Techweb Helpdesk call.
33 - 6 9813/8500-2 33 - 6
00 - General
Examine the electrical circuits regularly for: Make sure that all the electrical equipment listed
below operate correctly.
• Damaged connectors.
• Loose connections. • Switches
• Chafing on the wiring harnesses. • Warning lights
• Corrosion. • Beacon
• Missing insulation. • Alarms
• Incorrect routing of the wiring harnesses. • Horn
• Wipers
Do not use the machine if one or more of these faults • Hourmeter
are found. You must make sure that the electrical • Battery
circuit is repaired immediately. • Lights
All defective equipment must be repaired before the

machine is used.
33 - 7 9813/8500-2 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 9813/8500-2 33 - 8
Figure 454.
/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 9813/8500-2 33 - 9
Figure 455. 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 9813/8500-2 33 - 10
Diagram
Figure 456. 335/Y3854 Issue 2 (Sheet 1 of 6).......................................................................Page 33-13

33 - 11 9813/8500-2 33 - 11
Notes:
33 - 12 9813/8500-2 33 - 12
Page 33-14 Figure 456. 335/Y3854 Issue 2 (Sheet 1 of 6) Page 33-15

7207/1302 STARTER MOTOR
-CH_C24
6.00 mm² 842 1/1
ST. SOL C
M6
7208/1107 696/01626 7208/1102 7208/1018

BATTERY -C22 -T1
70.00 mm² BLACK -C3 LUG LUG 70.00 mm² RED 1/1
B+
M10 M10
-FU17 15A
4.00 mm² 301C 33 37 2.50 mm² 312 BATT TO HIGH BEAM RELAY 7207/1514
TO
/3.B2 -CH_C22
1
M6 7207/1304
7208/1018 -T1
-FU18 15A
-T17 34 38 2.00 mm² 313 BATT TO LOW BEAM RELAY M10 -G2
M10 7207/1417
TO
/3.B2
1.00 mm² 170B IGN RLY 1
-CH_T1 TO
/5.E4 TO LIVELINKCONN
FROM SPLICE CH_SP050
16.00 mm² 200

M8 GND
2.00 mm² 611 -FU4
FROM
/2.D7 5A
4 8 1.00 mm² 170 1.00 mm² 170A IGN RLY 1
TO
/2.D1 TO SPEEDOMETER:3
-IP_SP360 7207/1419 ALTERNATOR
-FU3 5A -CH_C23
8.00 mm² 200A 3 7 1.00 mm² 104 IGN RLY 1 TO HAZARD SW :1 1/1 -B1 B+
TO
/3.D3 M8
-GND1
7232/0023
16.00 mm² 200
-FU2 10A -CH_C1
4.00 mm² 002J 2 6 1.00 mm² 126 IGN RLY 1 TO BRAKE RELAY 1/2
TO
/4.E5 ALT W
1
1/2
IGN RLY 1 TO SIDE SHIFT SW:2 2/2
1.00 mm² 101B TO
/4.C1 ALT D+ -G3
-FU1 15A 2/2
4.00 mm² 002H 1 5 1.50 mm² 101 1.00 mm² 101A IGN RLY 1 TO PARK BRAKE SW:2
TO
/4.D1 7219/0006 7219/0005
-IP_FB1 -IP_SP140 -CH_C19 -IP_C19 TO INSTRMNT CLUSTER
40/301747 ALT D+
IGN RELAY -1 7241/0054 -R4 1.00 mm² 407 0.50 mm² 407 TO
/2.C4
-R2 FUSEBOX DUMP RELAY 7/14 7/14
40/303388 2 TRANS SPLY TO FWD/ REV RELAY :10
-FU24 1.50 mm² 852 -CH_C19 -IP_C19
20A /4.E2
ALT WTO INSTRMNT CLUSTER
TO
4.00 mm² 002G 44 48 2.00 mm² 107D

-IP_SP040 2.00 mm² 107 5 4 1.00 mm² 412 1.00 mm² 412
7241/0062 7212/0060 332/E9928 -IP_SP010 TO
/2.C4
D TO CHASSIS W/H :13 11/14 11/14
-FP1 60A -MF_C2 -MF_MF2 -IP_C32
7207/1316 A C 1 3 -IP_SP200 TRANS DUMP
8.00 mm² 301 8.00 mm² 301 4.00 mm² 301A 4.00 mm² 002 1.50 mm² 107A 1.00 mm² 934B 1.00 mm² 934A
-T2 1/2 1/2
TO
/2.B4
1/2
-FP2 60A -IP_SP180
-MF_MF2 -IP_C32 8.00 mm² -IP_C25
1.00 mm² 934

M6 8.00 mm² 302 302 0.75 mm² 600C B E 0.75 mm² 133A
2/2 2/2 2/2 G J 7241/0060 -D2
TO LH COLUMN SW 7214/0068 7514/0010
-MF_FB1 F H 2.00 mm² 107B IGN RLY 1 DIODE -II
7241/0063 /4.F1
TO
-IP_C4
1.00 mm² 934 A B 1.00 mm² 936A
-IP_C22
7241/0058 1/4 2/4
C D
40/303388 -FU8 5A
TO INSTRMNT CLUSTER 40/303388
12 16 BATT
-R3 1.00 mm² 106C TO
/2.C1 -R5
IGN RELAY-2 Neutral Start Relay
D D 7212/0060 332/E9928
-IP_SP280 -FU7 10A
TO 4WD SW (SPLICE IP_SP350) -IP_C21 -CH_C21
4.00 mm² 302C A C 4.00 mm² 007 11 15 1.50 mm² 102 BATT A C 6.00 mm² 842
TO
/5.C1
2/2 2/2
B E TO SPLICE IP_SP250 B E
0.75 mm² 600C -FU6 0.50 mm² 600E 1.50 mm² 810B
10A /6.E4 TO
G J 4.00 mm² 007C 10 14 1.50 mm² 118 BATT TO HORN RELAY GND G J
TO
/4.E3
F H F H
-IP_C23 -FU5 15A

-IP_C33
4.00 mm² 007A 9 13 2.00 mm² 110 BATT TO RH COLUMN SW
7241/0058 TO
/3.F1 7241/0058
7218/0001 7218/0002 7232/0023 FACE FAN

-FU9 10A -IP_C17 -CB_C12 -CB_C5 TO SPLICE CB_SP040
0.75 mm² 600B GND TO FLASHER 4.00 mm² 007B 17 21 1.00 mm² 114 1.00 mm² 114 2/2 1/2 1.00 mm² 600H GND
TO
/3.C3 -B36 TO
/6.E1
6/8 6/8 2/2 1/2
701/Y1372 0.75 mm² 133D IGN TO REAR WL LAMP SW :2 40/301747 1.00 mm² 936C PARK BRAKE TO PARK BRAKE SW-2
TO
/4.A1 TO
/4.C5
IGN SW 0.75 mm² 133B
PARK RELAY
TO FRONT WL LAMP SW :2 TO PARK BRAKE SW
II START
0.75 mm² 133C IGN 7 1.00 mm² 936B 1.00 mm² 936 PARK BRAKE
7236/0003 TO
/4.B1 TO INSTRMNT CLUSTR
TO
/4.D1
0 OFF
PARK BRAKE 10 9
I ON
7234/0003 -IP_C3 -FU10 5A /2.E4 0.75 mm² 401 -IP_SP210

-IP_C1 TO HEADLAMP SW :5
TO
6.00 mm² 302A 4.00 mm² 001 18 22 1.00 mm² 133F 0.75 mm² 133 IGN
-IP_SP260
TO
/3.E1 FROM LH COLUMN SW :5
1/4 5/6
-IP_SP060 TO SPLICE IP_SP250 GND 0.50 mm² 600L 6 8 1.50 mm² 810A 1.50 mm² 810 NEUTRAL
/6.D4 TO
/4.F2
FROM
-IP_SP130
6.00 mm² 004 -IP_C25
7/6 7241/0060
7232/0023
-FU16 15A -IP_SP070 -IP_C5 MOBILE CHARGER
4.00 mm² 302E 28 32 2.00 mm² 304 2.00 mm² 304A 2/2 -B14 1/2 2.00 mm² 600P GND TO SPLICE IP_SP252
TO
/6.F4
2/2 1/2
1.00 mm² 305 BATT TO DIAGNOSTIC CONN
TO
/5.F5 7232/0023
-IP_C6 RADIO
-FU15 3A
27 31 BATT TO INSTRUMENT CLUSTER 1/2 2/2 1.50 mm² 600R GND TO SPLICE IP_SP252
0.75 mm² 305A TO
/2.F1 1.50 mm² 304E -B15 TO
/6.F4
1/2 2/2
7201/0403 7201/0403
7218/0001 7218/0002 INTERIOR LIGHT
-IP_C17 -CB_C12 -CB_C10 -CB_C11
1.50 mm² 304C 1.50 mm² 304C 1/1 1/1 1/1 1/1 1.50 mm² 600C GND TO SPLICE CB_SP040
-B26 TO
/6.E1
5/8 5/8
-IP_FB1
7241/0062 7211/0026 7211/0025 7241/0054
-FP3 60A -MF_MF1 -IP_C31 -IP_SP240 -FU20 15A TO FRNT WRK LAMP RELAY
7207/1323 -MF_C3 8.00 mm² 303 8.00 mm² 303 4.00 mm² 303A 36 40 2.00 mm² 310 BATT
-T3
TO
/4.B3
1/2 1/1 1/1
M6
-FU19 15A TO REAR WRK LAMP RELAY
35 39 2.00 mm² 309 BATT TO
/4.A3
-MF_FB2
7241/0063
-FU21 15A
4.00 mm² 303C 41 45 2.00 mm² 300 BATT TO HAZARD SW :3
TO
/3.D3
-FU22 10A
42 46 1.50 mm² 306 BATT TO WIPER MOTOR :1
TO
/3.F4
-FU23 10A
43 47 1.50 mm² 311 IGN RLY 1 TO HEAD LAMP SW :1
TO
/3.E1
33 - 13 9813/8500-2 33 - 13
33-14 33-15
7208/1107 696/01626 7208/1102

70.00 mm² BLACK -C3 BATTERY -C22
LUG LUG 70.00 mm² RED
M10
-FU17 15A
4.00 mm² 301C 33 37 2.50 mm² 312
M6 7207/1304
7208/1018 -T1
-FU18 15A
-T17 34 38 2.00 mm² 313
M10 7207/1417
-CH_T1
M8
2.00 mm² 611 GND FROM SPLICE CH_SP050
FROM
/2.D7 -FU4 5A
4 8 1.00 mm² 170
-FU3 5A
8.00 mm² 200A 3 7 1.00 mm² 104
-GND1
16.00 mm² 200
-FU2 10A
4.00 mm² 002J 2 6 1.00 mm² 126
-FU1 15A
4.00 mm² 002H 1 5 1.50 mm² 101
-IP_FB1
IGN RELAY -1 7241/0054
-R2 FUSEBOX
40/303388 -FU24 20A
4.00 mm² 002G 44 48 2.00 mm² 107D
7241/0062 7212/0060 332/E9928 -IP_SP010
D
-FP1 60A -MF_C2 -MF_MF2 -IP_C32
7207/1316 8.00 mm² 301 8.00 mm² 301 4.00 mm² 301A A C 4.00 mm² 002
-T2 1/2 1/2 1/2
-FP2 60A -IP_SP180
M6 8.00 mm² 302
-MF_MF2 -IP_C32 8.00 mm² 302 0.75 mm² 600C B E 0.75 mm² 133A
2/2 2/2 2/2 G J
-MF_FB1 F H
7241/0063
-IP_C22
7241/0058
40/303388 -FU8 5A
-R3 12 16 1.00 mm²
IGN RELAY-2
D
-IP_SP280 -FU7 10A
4.00 mm² 302C A C 4.00 mm² 007 11 15 1.50 mm²
0.75 mm² 600C B E

-FU6 10A
G J 4.00 mm² 007C 10 14 1.50 mm²
F H
Page 33-15
-IP_C23 -FU5 15A
4.00 mm² 007A 9 13 2.00 mm²
7241/0058
-FU9 10A
0.75 mm² 600B GND TO FLASHER 4.00 mm² 007B 17 21 1.00 mm²
TO
/3.C3
701/Y1372
IGN SW 0.75 mm² 133B
II START
7236/0003
0 OFF
I ON
7234/0003 -IP_C3
-IP_C1 -FU10 5A
6.00 mm² 302A 4.00 mm² 001 18 22 1.00 mm² 133F
-IP_SP260 1/4 5/6
6.00 mm² 004

7/6
-FU16 15A
4.00 mm² 302E 28 32 2.00 mm²
1.00 mm²
-FU15 3A
27 31 0.75 mm²
-IP_FB1
7241/0062 7211/0026 7211/0025 7241/0054
-FP3 60A -MF_MF1 -IP_C31 -IP_SP240 -FU20 15A
7207/1323 -MF_C3 8.00 mm² 303 8.00 mm² 303 4.00 mm² 303A 36 40 2.00 mm²
-T3 1/2 1/1 1/1
M6
-FU19 15A
35 39 2.00 mm²
-MF_FB2
7241/0063
-FU21 15A
4.00 mm² 303C 41 45 2.00 mm²
-FU22 10A
42 46 1.50 mm²
-FU23 10A
43 47 1.50 mm²
33 - 14 9813/8500-2 33 - 14
33-14 33-15
7207/1302 STARTER MOTOR

-CH_C24
6.00 mm² 842 1/1
ST. SOL C
M6
7208/1018
-T1
1/1
B+
M10
-FU17 15A
37 2.50 mm² 312 BATT TO HIGH BEAM RELAY 7207/1514
TO
/3.B2 -CH_C22
1
-FU18 15A
38 2.00 mm² 313 BATT TO LOW BEAM RELAY M10 -G2
TO
/3.B2
1.00 mm² 170B IGN RLY 1
TO
/5.E4 TO LIVELINKCONN
16.00 mm² 200

-FU4 5A
8 1.00 mm² 170 1.00 mm² 170A IGN RLY 1
TO
/2.D1 TO SPEEDOMETER:3
-IP_SP360 7207/1419 ALTERNATOR
-FU3 5A -CH_C23
7 1.00 mm² 104 IGN RLY 1 TO HAZARD SW :1 1/1 -B1 B+
TO
/3.D3 M8
7232/0023
-FU2 10A -CH_C1
6 1.00 mm² 126 IGN RLY 1 TO BRAKE RELAY 1/2
TO
/4.E5 ALT W
1
1/2
IGN RLY 1 TO SIDE SHIFT SW:2 2/2
1.00 mm² 101B TO
/4.C1 ALT D+ -G3
-FU1 15A 2/2
5 1.50 mm² 101 1.00 mm² 101A IGN RLY 1 TO PARK BRAKE SW:2
TO
/4.D1 7219/0006 7219/0005
-IP_FB1 -IP_SP140 -CH_C19 -IP_C19 TO INSTRMNT CLUSTER
40/301747 ALT D+
7241/0054 -R4 1.00 mm² 407 0.50 mm² 407 TO
/2.C4
FUSEBOX DUMP RELAY 7/14 7/14
2 TRANS SPLY TO FWD/ REV RELAY :10
-FU24 1.50 mm² 852 -CH_C19 -IP_C19
20A /4.E2
ALT WTO INSTRMNT CLUSTER
TO
48 2.00 mm² 107D

-IP_SP040 2.00 mm² 107 5 4 1.00 mm² 412 1.00 mm² 412 TO
/2.C4
TO CHASSIS W/H :13 11/14 11/14
1 3 -IP_SP200 TRANS DUMP
1.50 mm² 107A 1.00 mm² 934B 1.00 mm² 934A TO
/2.B4
-IP_C25
1.00 mm² 934
7241/0060 -D2
TO LH COLUMN SW 7214/0068 7514/0010
2.00 mm² 107B IGN RLY 1 DIODE -II
/4.F1
TO
-IP_C4
1.00 mm² 934 A B 1.00 mm² 936A
1/4 2/4
C D
-FU8 5A
40/303388
12 16 1.00 mm² 106C BATT TO INSTRMNT CLUSTER -R5
TO
/2.C1
Neutral Start Relay
D 7212/0060 332/E9928
-FU7 10A
TO 4WD SW (SPLICE IP_SP350) -IP_C21 -CH_C21
11 15 1.50 mm² 102 BATT A C 6.00 mm² 842
TO
/5.C1
2/2 2/2
TO SPLICE IP_SP250 B E
-FU6 0.50 mm² 600E 1.50 mm² 810B
10A /6.E4 TO
10 14 1.50 mm² 118 BATT TO HORN RELAY GND G J

TO
/4.E3
F H
Page 33-14
-FU5 15A
-IP_C33
9 13 2.00 mm² 110 BATT TO RH COLUMN SW
TO
/3.F1 7241/0058
7218/0001 7218/0002 7232/0023 FACE FAN

-FU9 10A -IP_C17 -CB_C12 -CB_C5 TO SPLICE CB_SP040
17 21 1.00 mm² 114 1.00 mm² 114 2/2 1/2 1.00 mm² 600H GND
-B36 TO
/6.E1
6/8 6/8 2/2 1/2
0.75 mm² 133D IGN TO REAR WL LAMP SW :2 40/301747 1.00 mm² 936C PARK BRAKE TO PARK BRAKE SW-2
TO
/4.A1 TO
/4.C5
133B
PARK RELAY
IGN TO FRONT WL LAMP SW :2 7 PARK BRAKE TO PARK BRAKE SW
0.75 mm² 133C 1.00 mm² 936B 1.00 mm² 936
TO
/4.B1 TO INSTRMNT CLUSTR PARK BRAKE
TO
/4.D1
0.75 mm² 401 10 9 -IP_SP210
-FU10 5A /2.E4
TO HEADLAMP SW :5
TO
22 1.00 mm² 133F 0.75 mm² 133 IGN TO

/3.E1 FROM LH COLUMN SW :5
-IP_SP060 TO SPLICE IP_SP250 GND 0.50 mm² 600L 6 8 1.50 mm² 810A 1.50 mm² 810 NEUTRAL
/6.D4 TO
/4.F2
FROM
-IP_SP130
-IP_C25
7241/0060
7232/0023
-FU16 15A -IP_SP070 -IP_C5 MOBILE CHARGER
32 2.00 mm² 304 2.00 mm² 304A 2/2 -B14 1/2 2.00 mm² 600P GND TO SPLICE IP_SP252
TO
/6.F4
2/2 1/2
1.00 mm² 305 BATT TO DIAGNOSTIC CONN
TO
/5.F5 7232/0023
-IP_C6 RADIO
-FU15 3A
31 BATT TO INSTRUMENT CLUSTER 1/2 2/2 1.50 mm² 600R GND TO SPLICE IP_SP252
0.75 mm² 305A TO
/2.F1 1.50 mm² 304E -B15 TO
/6.F4
1/2 2/2
7201/0403 7201/0403
7218/0001 7218/0002 INTERIOR LIGHT
-IP_C17 -CB_C12 -CB_C10 -CB_C11
1.50 mm² 304C 1.50 mm² 304C 1/1 1/1 1/1 1/1 1.50 mm² 600C GND TO SPLICE CB_SP040
-B26 TO
/6.E1
5/8 5/8
-FU20 15A TO FRNT WRK LAMP RELAY

40 2.00 mm² 310 BATT TO
/4.B3
-FU19 15A TO REAR WRK LAMP RELAY

39 2.00 mm² 309 BATT TO
/4.A3
-FU21 15A
45 2.00 mm² 300 BATT TO HAZARD SW :3
TO
/3.D3
-FU22 10A
46 1.50 mm² 306 BATT TO WIPER MOTOR :1
TO
/3.F4
-FU23 10A
47 1.50 mm² 311 IGN RLY 1 TO HEAD LAMP SW :1
TO
/3.E1
33 - 15 9813/8500-2 33 - 15
33 - 16 9813/8500-2 33 - 16

INSTRUMENT CLUSTER
7239/0031 -B3
-IP_C2 1/36 0.75 mm² 805D LH IND FROM SPLICE IP_SP110
FROM FUSE FU15
FROM
/3.E3
0.75 mm² 305A 12/36 1/36
/1.B5 FROM
7212/0081
BATT 12/36 332/Y5501 7219/0005 7219/0006 TRNS OIL TEMP SW
-IP_SP340 -CH_C10
-IP_C19 -CH_C19 TO SPLICE CH_SP020
22/36 0.50 mm² 404A 1.00 mm² 404 1.00 mm² 404 1/2 1/2 -B20 2/2 2/2 1.00 mm² 600B GND TO
/6.C4
22/36 4/14 4/14 701/80324
FROM SPLICE IP_SP150 ILLUMN 0.75 mm² 828C 17/36 1.00 mm² 404B #183 TO LIVELINK CONN
/3.C2 FROM TO
/5.E4
17/36
TRANS OIL
FROM SPLICE IP_SP080 LOW BEAM 0.75 mm² 834A 19/36
7212/0081 PRESS SW
/3.B4 FROM
-CH_C7
19/36 0.50 mm² 405 -IP_C19 -CH_C19 1.00 mm² 405 1/2 1/2 -B18 2/2 2/2 1.00 mm² 600J GND TO SPLICE CH_SP020
2/36
TO
/6.B4
5/14 5/14
2/36
701/M7305
FROM HIGH BEAM RELAY HIGH BEAM 0.75 mm² 837A 29/36
/3.B4 FROM
29/36 3/36 0.75 mm² 861B RWL FROM SPLICE IP_SP100

FROM
/4.A5
3/36
7212/0081 WATER TEMP SW
-IP_SP320 -CH_C2
-IP_C19 -CH_C19 -B9 GND TO SPLICE CH_SP020
18/36 0.50 mm² 406A 1.00 mm² 406 1.00 mm² 406 1/2 1/2 2/2 2/2 1.00 mm² 600E TO
/6.C4
18/36 6/14 6/14 701/80317
1.00 mm² 406B #181 TO LIVELINK CONN

TO
/5.E4
PARK BRAKE FROM PARK AND DUMP RELAY -IP_FB1
4/36 0.75 mm² 401 FROM
/1.C6 7241/0054
SPEEDOMETER 4/36
-FU12 3A
7216/0052
-B5 0.50 mm² 804A HAZARD FROM HAZARD SW SP020 1.00 mm² 611C 1.00 mm² 612
TO LIVELINK
-IP_C39 5/36
FROM
/3.C3 TO
/5.F4
1.00 mm² 974 1/6 1/6 2/6 2/6 1.00 mm² 600AH GND TO SPLICE IP_SP250 20 24 GND
TO
/6.E4 5/36
333/Y3682
-IP_SP290 TO DIAGNOSTIC CONN
16/36 0.75 mm² 611A 2.00 mm² 611 TO
/5.F5
GND
FROM FUSE FU4 IGN RLY 1 FROM SPLICE IP_SP230 16/36
1.00 mm² 170A 3/6 3/6 4/6 4/6 0.50 mm² 830F ILLUMN
/1.F5 FROM FROM
/3.C2 -CH_C20
6/36 0.75 mm² 806B RH IND FROM RH COLUMN SW 2.00 mm² 611B
-IP_C20 2.00 mm² 611B
FROM
/3.E3
6/36 8/10 8/10
7/36 0.50 mm² 830C ILLUMN FROM SPLICE IP_SP230
FROM
/3.C2
7/36
7212/0044 FUEL SENSOR
7219/0001 7219/0002 7212/0128 -IP_SP330 -CH_C4
-CH_C30 SPEED SENSOR 20/36 0.50 mm² 408A 1.00 mm² 408
-IP_C19 -CH_C19 1.00 mm² 408 2/2 2/2 -B16 1/2 1/2 1.00 mm² 611A 2.00 mm² 611 GND TO BATTERY GROUND
-IP_C20 -CH_C20 8/14 8/14
TO
/1.F1
2/2 1/2 GND TO SPLICE CH_SP020 20/36
1.00 mm² 974 -B6 1.00 mm² 600P TO
/6.A4 332/Y7471 -CH_SP050
5/10 5/10 2/2 1/2
TO
/5.E4
7212/0081 ENG. OIL PR. SW
-CH_C3
10/36 0.50 mm² 403A
-IP_SP310 1.00 mm² 403
-IP_C19 -CH_C19 1.00 mm² 403 1/2 1/2 -B7 2/2 2/2 1.00 mm² 600C GND TO SPLICE CH_SP020
3/14 3/14
TO
/6.C4
10/36 40/303383
1.00 mm² 403B LH IND TO LIVELINK CONN

TO
/5.F4
WATER TEMP
7212/0081 SENSOR
-CH_C5
FROM FUSE FU8 BATT -IP_SP030 -IP_C19 -CH_C19 -B17 GND TO SPLICE CH_SP020
1.00 mm² 106C 0.75 mm² 106 9/36 13/36 0.50 mm² 409 1.00 mm² 409 1/2 1/2 2/2 2/2 1.00 mm² 600F
/1.D5 FROM
9/14 9/14
TO
/6.C4
9/36 13/36 40/302723
0.50 mm² 106B 14/36 0.75 mm² 855D FWL FROM SPLICE IP_SP170
FROM
/4.B5
14/36
-FU11
1.00 mm² 412B 19 3A 23 1.00 mm² 413 ALT W TO LIVELINK CONN
-R1
TO
/5.E4
40/303384
BUZZER
BUZZERD ALT W FROM ALT W TERMINAL
15/36 0.50 mm² 412A 1.00 mm² 412 FROM
/1.E7
A C
IGN 0.50 mm² 106A 15/36 -IP_SP300
7219/0005
28/36 0.50 mm² 407 ALT D+ FROM ALT D+ TERMINAL WARNING CLUSTER
FROM
/1.E7 -IP_C37
0.50 mm² 411B BGND E 28/36 FROM SPLICE IP_SP220 ILLUMN 0.50 mm² 829G 3/14
BUZ
/3.B2 FROM
-B2
G J 3/14
40/303385
F H FROM SPLICE IP_SP160 HIGH BEAM 0.75 mm² 837C 2/14
/3.B4 FROM
2/14
-IP_C26 FROM SPLICE IP_SP170 FWL
7241/0058 0.75 mm² 855B 7/14
/4.B5 FROM
7/14 1/14 0.50 mm² 600AA GND TO SPLICE IP_SP250

TO
/6.D4
-IP_SP270 FROM SPLICE IP_SP020 HAZARD 0.50 mm² 804C 6/14 1/14
/3.D3 FROM
0.75 mm² 411 11/36 6/14

11/36 FROM SPLICE IP_SP120 RH IND 0.75 mm² 806E 5/14
/3.E3 FROM
5/14
FROM SPLICE IP_SP110 LH IND 0.75 mm² 805E 4/14
/3.E3 FROM
4/14
0.50 mm² 411A 11/14
11/14
FROM SPLICE IP_SP100 RWL 0.75 mm² 861C 8/14
/4.A5 FROM
8/14
0.50 mm² 106B 12/14
12/14
7212/0128 DUMP SW
-IP_C19 -CH_C19 -CH_SP010 -CH_C8
FROM SPLICE IP_SP200 TRANS DUMP 1.00 mm² 934A 1.00 mm² 934A 1.00 mm² 934C 1/2 -B21 2/2 1.00 mm² 600T GND TO SPLICE CH_SP020
/1.E6 FROM TO
/6.A4
13/14 13/14 1/2 333/Y8382 2/2
7212/0128 SW TRANS DUMP

-CH_C9
1.00 mm² 934B 1/2 -B19 2/2 1.00 mm² 600H GND TO SPLICE CH_SP020
TO
/6.C4
1/2 333/Y8382 2/2
33 - 17 9813/8500-2 33 - 17
33-18 33-19
INSTRUMENT CLUSTER
7239/0031 -B3
-IP_C2 1/36 0.75 mm² 805D LH IND
FROM FUSE FU15
0.75 mm² 305A 12/36 1/36
/1.B5 FROM
BATT 12/36 332/Y5501

-IP_SP340
22/36 0.50 mm² 404A 1.00 mm²
22/36
FROM SPLICE IP_SP150 ILLUMN 0.75 mm² 828C 17/36 1.00 mm²
/3.C2 FROM
17/36
FROM SPLICE IP_SP080 LOW BEAM 0.75 mm² 834A 19/36

/3.B4 FROM
19/36 0.50 mm² 405

2/36
FROM HIGH BEAM RELAY HIGH BEAM 2/36

0.75 mm² 837A 29/36
/3.B4 FROM
29/36 3/36 0.75 mm² 861B RWL
3/36
-IP_SP320
18/36 0.50 mm² 406A 1.00 mm² 406
18/36
1.00 mm² 406B
4/36 0.75 mm² 401 PARK BRAKE

SPEEDOMETER 4/36
7216/0052 HAZARD
-IP_C39 -B5 0.50 mm² 804A
TO SPLICE IP_SP250 5/36
1.00 mm² 974 1/6 1/6 2/6 2/6 1.00 mm² 600AH GND TO
/6.E4 5/36
333/Y3682
16/36 0.75 mm² 611A
FROM FUSE FU4 IGN RLY 1 FROM SPLICE IP_SP230 16/36

1.00 mm² 170A 3/6 3/6 4/6 4/6 0.50 mm² 830F ILLUMN
/1.F5 FROM FROM
/3.C2
6/36 0.75 mm² 806B RH IND
6/36
7/36 0.50 mm² 830C ILLUMN
7/36
7219/0001 7219/0002 7212/0128 -IP_SP330

-CH_C30 SPEED SENSOR 20/36 0.50 mm² 408A 1.00 mm²
-IP_C20 -CH_C20
1.00 mm² 974 2/2 1/2 1.00 mm² 600P GND TO SPLICE CH_SP020 20/36
-B6 TO
/6.A4
5/10 5/10 2/2 1/2
1.00 mm²
10/36 0.50 mm² 403A

-IP_SP310 1.00 mm²
10/36
Page 33-19
1.00 mm²
FROM FUSE FU8 BATT 1.00 mm² 106C

-IP_SP030 0.75 mm² 106 9/36 13/36 0.50 mm² 409
/1.D5 FROM
9/36 13/36
0.50 mm² 106B 14/36 0.75 mm² 855D FWL
14/36
1.00 mm² 412B

-R1
40/303384
BUZZER
BUZZERD
15/36 0.50 mm² 412A 1.00 mm² 412
A C
IGN 0.50 mm² 106A 15/36 -IP_SP300
28/36 0.50 mm² 407
0.50 mm² 411B BGND BUZ
E 28/36
G J
F H
-IP_C26
7241/0058
-IP_SP270
0.75 mm² 411 11/36
11/36
FROM SPLICE IP_SP200 TRANS DUMP

/1.E6 FROM
33 - 18 9813/8500-2 33 - 18
33-18 33-19
LH IND FROM SPLICE IP_SP110

FROM
/3.E3
7219/0005 7219/0006 7212/0081 TRNS OIL TEMP SW

-IP_SP340 -CH_C10
-IP_C19 -CH_C19 TO SPLICE CH_SP020
1.00 mm² 404 1.00 mm² 404 1/2 1/2 -B20 2/2 2/2 1.00 mm² 600B GND TO
/6.C4
4/14 4/14 701/80324

TO
/5.E4
TRANS OIL
7212/0081 PRESS SW
-CH_C7
-IP_C19 -CH_C19 1.00 mm² 405 1/2 1/2 -B18 2/2 2/2 1.00 mm² 600J GND TO SPLICE CH_SP020
TO
/6.B4
5/14 5/14
701/M7305
RWL FROM SPLICE IP_SP100

FROM
/4.A5 7212/0081 WATER TEMP SW
-IP_SP320 -CH_C2
1.00 mm² 406 1.00 mm² 406 1/2 1/2 2/2 2/2 1.00 mm² 600E TO
/6.C4
6/14 6/14 701/80317

TO
/5.E4
PARK BRAKE FROM PARK AND DUMP RELAY -IP_FB1
FROM
/1.C6 7241/0054
-FU12 3A
HAZARD FROM HAZARD SW SP020 1.00 mm² 611C 1.00 mm² 612
TO LIVELINK
FROM
/3.C3 20 24
TO
/5.F4
GND
-IP_SP290 TO DIAGNOSTIC CONN

2.00 mm² 611 TO
/5.F5
GND
RH IND FROM RH COLUMN SW -IP_C20 -CH_C20

2.00 mm² 611B 2.00 mm² 611B
FROM
/3.E3
8/10 8/10
ILLUMN FROM SPLICE IP_SP230
FROM
/3.C2
7212/0044 FUEL SENSOR
-IP_SP330 -CH_C4
1.00 mm² 408
-IP_C19 -CH_C19 1.00 mm² 408 2/2 2/2 -B16 1/2 1/2 1.00 mm² 611A 2.00 mm² 611 GND TO BATTERY GROUND
8/14 8/14
TO
/1.F1
332/Y7471 -CH_SP050
TO
/5.E4
7212/0081 ENG. OIL PR. SW
-CH_C3
-IP_SP310 1.00 mm² 403
-IP_C19 -CH_C19 1.00 mm² 403 1/2 1/2 -B7 2/2 2/2 1.00 mm² 600C GND TO SPLICE CH_SP020
3/14 3/14
TO
/6.C4
40/303383
LH IND TO LIVELINK CONN

Page 33-18
1.00 mm² 403B TO

/5.F4
WATER TEMP
7212/0081 SENSOR
-CH_C5
1.00 mm² 409 1/2 1/2 2/2 2/2 1.00 mm² 600F
9/14 9/14
TO
/6.C4
40/302723
FWL FROM SPLICE IP_SP170
FROM
/4.B5
-FU11
1.00 mm² 412B 19 3A 23 1.00 mm² 413 ALT W TO LIVELINK CONN
TO
/5.E4
1.00 mm² 412 ALT W FROM ALT W TERMINAL

FROM
/1.E7
-IP_SP300
7219/0005
ALT D+ FROM ALT D+ TERMINAL WARNING CLUSTER
FROM
/1.E7 -IP_C37
FROM SPLICE IP_SP220 ILLUMN 0.50 mm² 829G 3/14
/3.B2 FROM
-B2
3/14
40/303385
FROM SPLICE IP_SP160 HIGH BEAM 0.75 mm² 837C 2/14
/3.B4 FROM
2/14
FROM SPLICE IP_SP170 FWL 0.75 mm² 855B 7/14
/4.B5 FROM
7/14 1/14 0.50 mm² 600AA GND TO SPLICE IP_SP250

TO
/6.D4
FROM SPLICE IP_SP020 HAZARD 0.50 mm² 804C 6/14 1/14
/3.D3 FROM
6/14
FROM SPLICE IP_SP120 RH IND 0.75 mm² 806E 5/14
/3.E3 FROM
5/14
FROM SPLICE IP_SP110 LH IND 0.75 mm² 805E 4/14
/3.E3 FROM
4/14
0.50 mm² 411A 11/14
11/14
FROM SPLICE IP_SP100 RWL 0.75 mm² 861C 8/14
/4.A5 FROM
8/14
0.50 mm² 106B 12/14
12/14
7212/0128 DUMP SW
-IP_C19 -CH_C19 -CH_SP010 -CH_C8
FROM SPLICE IP_SP200 TRANS DUMP 1.00 mm² 934A 1.00 mm² 934A 1.00 mm² 934C 1/2 -B21 2/2 1.00 mm² 600T GND TO SPLICE CH_SP020
/1.E6 FROM TO
/6.A4
13/14 13/14 1/2 333/Y8382 2/2
7212/0128 SW TRANS DUMP

-CH_C9
1.00 mm² 934B 1/2 -B19 2/2 1.00 mm² 600H GND TO SPLICE CH_SP020
TO
/6.C4
1/2 333/Y8382 2/2
33 - 19 9813/8500-2 33 - 19
33 - 20 9813/8500-2 33 - 20

RH COLUMN SW RH REAR COMBI LAMP
7214/0068 7216/0051
WIPER MOTOR -B22
-IP_C8 -CH_C11
-B27 TO SPLICE IP_SP251
7/14 1.50 mm² 982 2/4 -B32 4/4 1.50 mm² 600N GND 1.00 mm² 811C 2/6 REVERSE TO SPLICE CH_SP020
TO
/6.E6 7219/0001 7219/0002
7/14 2/4 4/4 2/6 GND
40/301771 -IP_C20 -CH_C20 -CH_SP040 GND 3/6 1.00 mm² 600L TO
/6.B4
12/14 1.50 mm² 840 3/4 1/4 1.50 mm² 306 BATT FROM FUSE FU22 FROM BRAKE RELAY #21 1.00 mm² 816 1.00 mm² 816 1.00 mm² 816A 4/6 3/6
FROM
/1.A5 /4.E6 FROM
4/10 4/10 BRAKE

7219/0005
12/14 3/4 1/4
-CH_C19
4/6 332/Y6096
FROM SPLICE IP_SP230 ILLUMN -IP_C19
FROM FUSE FU5 -IP_C7 /3.C2 1.00 mm² 830E 1.00 mm² 830 1.00 mm² 830 5/6 TAIL
-IP_SP050
FROM
BATT 10/14 10/14

2.00 mm² 110 1.50 mm² 110C 1/14 5/6
/1.D5 FROM
-IP_C20 -CH_C20
1/14 1.00 mm² 806D 1.00 mm² 806 1.00 mm² 806 6/6 RH IND
7/10 7/10
1.50 mm² 110B 4/14 -IP_SP120 6/6
4/14 11/14 1.00 mm² 806A 1.00 mm² 806
11/14
TO SPLICE IP_SP251 0.75 mm² 806B RH IND TO INSTRMNT CLUSTER:6
TO
/2.D4
GND LH REAR COMBI LAMP
/6.E6 TO
332/Y6914
7216/0051
0.75 mm² 806E RH IND TO WARNING CLUSTER:6 FROM REVERSE RELAY -CH_C12 -B23
TO
/2.B5
REVERSE 1.50 mm² 811 -IP_C20 -CH_C20 1.50 mm² 811 1.00 mm² 811B 2/6 REVERSE TO SPLICE CH_SP020
-SW3 /4.E4 FROM
701/60004 1/10 1/10 -CH_SP030 2/6 GND

7219/0013 GND 3/6 1.00 mm² 600Z TO
/6.B4
HEADLAMP SW 10/14 1.00 mm² 805 0.75 mm² 805D LH IND TO INSTRMNT CLUSTER:1 1.00 mm² 816B 4/6 3/6
-IP_C11 TO
/2.F4 BRAKE
0.50 mm² 830D 8 7 0.50 mm² 600X 10/14 4/6
FROM SPLICE IP_SP220 -IP_C20 -CH_C20 332/Y6095
8/10 7/10 0.75 mm² 805E LH IND TO WARNING CLUSTER:7 ILLUMN 1.00 mm² 829D 1.00 mm² 829 1.00 mm² 829 5/6 TAIL
TO
/2.B5 /3.B2 FROM
10/10 10/10
5/6
FROM FUSE FU23 7219/0005 7219/0006
IGN RLY1.50
1 mm² 311 2 -IP_SP110 -IP_C19 -CH_C19
1.00 mm² 805B 1.00 mm² 805 1.00 mm² 805 6/6 LH IND
/1.A5 FROM
1/14 1/14
2/10 3 14/14 1.00 mm² 803 6/6
FROM FUSE FU8 3/10 14/14 1.00 mm² 805C
IGN 0.75 mm² 133 5 9/14 0.75 mm² 833
/1.C5 FROM
7212/0081
5/10 6 0.75 mm² 127 8/14 9/14 REVERSE SOL TO SPLICE CH_SP020
-SW2 -CH_C14
6/10 8/14 13/14 0.75 mm² 836 701/60005 1.50 mm² 811D 1/2 1/2 2/2 2/2 1.50 mm² 600M GND
7219/0014 -B30 TO
/6.B4
13/14 HAZARD SW
-IP_C10
0.50 mm² 830A 8
8/10 TO SPLICE IP_SP251 7212/0127
10 1.00 mm² 600Y GND -CH_C13 REAR HORN TO SPLICE CH_SP020
FROM FUSE FU3 10/10
TO
/6.E6
1.50 mm² 828
IGN RLY1.00
1 mm² 104 1 1.00 mm² 811A 1/2 -B28 2/2 1.00 mm² 600V GND
/1.E4 FROM TO
/6.B4
1/10 2 1/2 2/2
2.00 mm² 802 332/Y7151
FROM FUSE FU21 BATT 2.00 mm² 300 3 2/10
/1.A5 FROM
3/10
1.00 mm² 805A 5 17 1.00 mm² 804

-D1 5/10 18 17/10
7514/0010 2.00 mm² 803A 7232/0023
7214/0068 NO PLATE LAMP RH
18/10
DIODE 1 -IP_C9 -CB_C2 TO SPLICE CB_SP040
B A -IP_SP090 GND
1.00 mm² 806C 1.00 mm² 804B 1.00 mm² 830A 1/2 -B4 2/2 1.00 mm² 600F TO
/6.F1
2/4 1/4 1/2 40/302606 2/2
D C -IP_SP020
1.50 mm² 828B 1.50 mm² 828A 2.00 mm² 855A 1.00 mm² 804
-IP_SP150 4/4 3/4
0.50 mm² 804C HAZARD TO WARNING CLUSTER:5
TO INSTRUMENT CLUSTER:17
TO
/2.B5 7232/0023 NO PLATE LAMP LH
0.75 mm² 828C ILLUMN -CB_C1 TO SPLICE CB_SP040
TO
/2.F1
0.50 mm² 804A HAZARD
TO INSTRMNT CLUSTER:5 1/2 GND
TO
/2.E4 1.00 mm² 830 -B5 2/2 1.00 mm² 600G TO
/6.F1
FROM IP_SP170 FWL 1/2 40/302606 2/2
/4.B5 FROM
40/303389 RH HEAD LAMP

7216/0051
0.50 mm² 830F ILLUMN TO SPEEDOMETER:4 FLASHER 7218/0001 7218/0002
-CB_C3 -B25
TO
/2.D2 -IP_C17 -CB_C12
D 1.00 mm² 830B 1.00 mm² 830C 1.00 mm² 830B 1/6 TO SPLICE CB_SP040
-FU13 7.5A -IP_SP230 7/8 7/8
SIDE LAMP
25 29 A C -CB_SP060 1/6 GND
1.00 mm² 830 0.50 mm² 830A 2.00 mm² 803B
GND 4/6 1.50 mm² 600E TO
/6.F1
1.00 mm² 837A 2/6 HIGH BEAM 4/6
TO GND SPLICE IP_SP250 GND B E 2/6
1.00 mm² 830B
/6.E4 TO 2.50 mm² 600D 2.00 mm² 802 40/302148
G J 1.00 mm² 834A 3/6 LOW BEAM
ILLUMN TO RH REAR COMBI LAMP FROM IGN RELAY 2 GND F H
1.00 mm² 830E 0.75 mm² 600B
-IP_C17 -CB_C12 3/6
TO
/3.F5 /1.C3 FROM
1.00 mm² 806 1.00 mm² 806 5/6 RH IND

ILLUMN TO INSTRMNT CLUSTER:7 -IP_C24 2/8 2/8
0.50 mm² 830C 7241/0058 5/6
TO
/2.D4
-FU14 7.5A
26 30 1.00 mm² 829
-IP_SP220 1.00 mm² 829A
0.50 mm² 829H ILLUMN TO

TO 4WD SW:8
/5.C1
40/302204
HIGH BEAM RELAY
2
FROM FUSE FU17 BATT 5 4 -IP_SP160
2.50 mm² 312 2.50 mm² 837 2.00 mm² 837B
/1.F4 FROM
TO INSTRMNT CLUSTER:29
1.00 mm² 829D ILLUMN TO LH REAR COMBI LAMP 1 3 0.75 mm² 600J GND TO SPLICE IP_SP250 0.75 mm² 837A HIGH BEAM
TO
/3.E5 TO
/6.D4 TO
/2.E1
TO WARNING CLUSTER:2 LH HEAD LAMP
0.50 mm² 829B ILLUMN TO FRONT WL SW :8 -IP_C34 0.75 mm² 837C HIGH BEAM
TO
/4.B1 7241/0060
TO
/2.C5 7216/0051
7218/0001 7218/0002 -CB_C4 -B24
ILLUMN TO PARK BRAKE SW:8 -IP_C17 -CB_C12
0.50 mm² 829E 1.00 mm² 829A 1.00 mm² 829A 1.00 mm² 829A 1/6 SIDE LAMP
TO
/4.D1 40/302204 3/8 3/8
1/6 40/302148
0.50 mm² 829G ILLUMN TO WARNING CLUSTER:1 LOW BEAM RELAY 0.75 mm² 834A LOW BEAMTO INSTR. CLUSTER:19 2.00 mm² 837B -IP_C17 -CB_C12
2.00 mm² 837 1.00 mm² 837B 2/6 TO SPLICE CB_SP040
TO
/2.C5 TO
/2.F1 1/8 1/8 HIGH BEAM
7 -CB_SP010 2/6 GND
FROM FUSE FU18 -CB_C12 GND 4/6 1.50 mm² 600A TO
/6.F1
BATT 2.00 mm² 313 10 9 2.00 mm² 834 2.00 mm² 834B 2.00 mm² 834B -IP_C17 2.00 mm² 834 1.00 mm² 834B 3/6 LOW BEAM 4/6
/1.F4 FROM
8/8 8/8
-IP_SP080 -CB_SP030 3/6
TO SLPLICE IP_SP250 GND 6 8 -IP_C17 -CB_C12 5/6
/6.D4 TO 0.75 mm² 600Z 0.75 mm² 833 1.00 mm² 805C
4/8
1.00 mm² 805 1.00 mm² 805 LH IND
4/8
5/6
0.50 mm² 829F ILLUMN TO SIDE SHIFT SW:8 -IP_C34
TO
/4.C1 7241/0060
0.50 mm² 829C ILLUMN TO REAR WL SW

TO
/4.B1
33 - 21 9813/8500-2 33 - 21
33-22 33-23
RH COLUMN SW
7214/0068 WIPER MOTOR
-IP_C8
-B27 TO SPLICE IP_SP251
7/14 1.50 mm² 982 2/4 -B32 4/4 1.50 mm² 600N GND TO
/6.E6
7/14 2/4 4/4
40/301771
12/14 1.50 mm² 840 3/4 1/4 1.50 mm² 306 BATT FROM FUSE FU22
FROM
/1.A5
12/14 3/4 1/4
7219/0005
FROM FUSE FU5 -IP_C7
BATT -IP_SP050
2.00 mm² 110 1.50 mm² 110C 1/14
/1.D5 FROM
1/14 1.00 mm² 806D

1.50 mm² 110B 4/14 -IP_SP120
4/14 11/14 1.00 mm² 806A 1.00 mm² 806
11/14
TO SPLICE IP_SP251 0.75 mm² 806B RH IND TO INSTRMNT CLUSTER:6
TO
/2.D4
GND
/6.E6 TO
332/Y6914
0.75 mm² 806E RH IND TO WARNING CLUSTER:6
TO
/2.B5
-SW3
701/60004
7219/0013
HEADLAMP SW 10/14 1.00 mm² 805 0.75 mm² 805D LH IND TO INSTRMNT CLUSTER:1
-IP_C11 TO
/2.F4
0.50 mm² 830D 8 7 0.50 mm² 600X 10/14
8/10 7/10 0.75 mm² 805E LH IND TO WARNING CLUSTER:7
TO
/2.B5
FROM FUSE FU23

IGN RLY1.50
1 mm² 311 2 -IP_SP110
1.00 mm² 805B
/1.A5 FROM
2/10 3 14/14 1.00 mm² 803

FROM FUSE FU8 3/10 14/14 1.00 mm² 805C
IGN 0.75 mm² 133 5 9/14 0.75 mm² 833
/1.C5 FROM
5/10 6 0.75 mm² 127 8/14 9/14 -SW2

6/10 8/14 13/14 0.75 mm² 836 701/60005
7219/0014
13/14 HAZARD SW
-IP_C10
0.50 mm² 830A 8
8/10
10 1.00 mm² 600Y
FROM FUSE FU3 10/10
1.50 mm² 828
IGN RLY1.00
1 mm² 104 1
/1.E4 FROM
1/10 2 2.00 mm² 802

FROM FUSE FU21 BATT 2.00 mm² 300 3 2/10
/1.A5 FROM
3/10
1.00 mm² 805A 5 17 1.00 mm² 804

-D1 5/10 18 17/10
7514/0010 2.00 mm² 803A
7214/0068
18/10
DIODE 1 -IP_C9
B A -IP_SP090
1.00 mm² 806C 1.00 mm² 804B
2/4 1/4
D C -IP_SP020
1.50 mm² 828B 1.50 mm² 828A 2.00 mm² 855A 1.00 mm² 804
-IP_SP150 4/4 3/4
0.50 mm² 804C HAZARD TO WARNING CLUSTER:5
TO INSTRUMENT CLUSTER:17
TO
/2.B5
0.75 mm² 828C ILLUMN TO
/2.F1
Page 33-23
0.50 mm² 804A HAZARD TO
/2.E4
FROM IP_SP170 FWL
/4.B5 FROM
40/303389
0.50 mm² 830F ILLUMN TO SPEEDOMETER:4 FLASHER
TO
/2.D2
D
-FU13 7.5A -IP_SP230
25 29 1.00 mm² 830 0.50 mm² 830A A C 2.00 mm² 803B
1.00 mm² 830B

TO GND SPLICE IP_SP250 GND 2.50 mm² 600D B E 2.00 mm² 802
/6.E4 TO
G J
ILLUMN TO RH REAR COMBI LAMP FROM IGN RELAY 2 GND F H
1.00 mm² 830E 0.75 mm² 600B
TO
/3.F5 /1.C3 FROM
ILLUMN TO INSTRMNT CLUSTER:7 -IP_C24

0.50 mm² 830C 7241/0058
TO
/2.D4
-FU14 7.5A
26 30 1.00 mm² 829
-IP_SP220 1.00 mm² 829A
0.50 mm² 829H ILLUMN TO

TO 4WD SW:8
/5.C1
40/302204
HIGH BEAM RELAY
2
2.50 mm² 312 2.50 mm² 837 2.00 mm² 837B
/1.F4 FROM
1.00 mm² 829D ILLUMN TO LH REAR COMBI LAMP 1 3 0.75 mm² 600J GND TO SPLICE IP_SP250 0.75 mm² 837A HIGH BEAM
TO
/3.E5 TO
/6.D4
TO WARNING CLUSTER:
0.50 mm² 829B ILLUMN TO FRONT WL SW :8 -IP_C34 0.75 mm² 837C HIGH BEAM
TO
/4.B1 7241/0060
0.50 mm² 829E ILLUMN TO PARK BRAKE SW:8

TO
/4.D1 40/302204
0.50 mm² 829G ILLUMN TO WARNING CLUSTER:1 LOW BEAM RELAY 0.75 mm² 834A LOW BEAM
TO
/2.C5
7
FROM FUSE FU18 BATT 2.00 mm² 313 10 9 2.00 mm² 834 2.00 mm² 834B
/1.F4 FROM
-IP_SP080
TO SLPLICE IP_SP250 GND 0.75 mm² 600Z 6 8 0.75 mm² 833
/6.D4 TO
0.50 mm² 829F ILLUMN TO SIDE SHIFT SW:8 -IP_C34

TO
/4.C1 7241/0060
0.50 mm² 829C ILLUMN TO REAR WL SW

TO
/4.B1
33 - 22 9813/8500-2 33 - 22
33-22 33-23
RH REAR COMBI LAMP

7216/0051
-CH_C11 -B22
1.00 mm² 811C 2/6 REVERSE TO SPLICE CH_SP020
7219/0001 7219/0002 GND
2/6 GND 3/6 1.00 mm² 600L
-IP_C20 -CH_C20 -CH_SP040
TO
/6.B4
FROM BRAKE RELAY #21 1.00 mm² 816 1.00 mm² 816 1.00 mm² 816A 4/6 3/6
/4.E6 FROM
4/10 4/10 BRAKE

-CH_C19
4/6 332/Y6096
FROM SPLICE IP_SP230 ILLUMN -IP_C19
1.00 mm² 830E 1.00 mm² 830 1.00 mm² 830 5/6 TAIL
/3.C2 FROM
10/14 10/14
5/6
-IP_C20 -CH_C20
1.00 mm² 806 1.00 mm² 806 6/6 RH IND
7/10 7/10
6/6
LH REAR COMBI LAMP

7216/0051
FROM REVERSE RELAY -CH_C12 -B23
REVERSE 1.50 mm² 811 -IP_C20 -CH_C20 1.50 mm² 811 1.00 mm² 811B 2/6 REVERSE TO SPLICE CH_SP020
/4.E4 FROM
1/10 1/10 -CH_SP030 2/6 GND

GND 3/6 1.00 mm² 600Z TO
/6.B4
1.00 mm² 816B 4/6 BRAKE 3/6
4/6 332/Y6095
FROM SPLICE IP_SP220 -IP_C20 -CH_C20
ILLUMN 1.00 mm² 829D 1.00 mm² 829 1.00 mm² 829 5/6 TAIL
/3.B2 FROM
10/10 10/10
5/6
7219/0005 7219/0006
-IP_C19 -CH_C19
1.00 mm² 805 1.00 mm² 805 6/6 LH IND
1/14 1/14
6/6
1.00 mm² 805C
7212/0081
REVERSE SOL TO SPLICE CH_SP020
-CH_C14
1.50 mm² 811D 1/2 1/2 2/2 2/2 1.50 mm² 600M GND
-B30 TO
/6.B4
TO SPLICE IP_SP251 7212/0127

1.00 mm² 600Y GND -CH_C13 REAR HORN TO SPLICE CH_SP020
10/10
TO
/6.E6
1.00 mm² 811A 1/2 -B28 2/2 1.00 mm² 600V GND TO
/6.B4
2.00 mm² 802 1/2 332/Y7151 2/2
2/10
1.00 mm² 804

17/10
2.00 mm² 803A 7232/0023
18/10 NO PLATE LAMP RH
-CB_C2 TO SPLICE CB_SP040
-IP_SP090 GND
1.00 mm² 830A 1/2 -B4 2/2 1.00 mm² 600F TO
/6.F1
1/2 40/302606 2/2
7232/0023 NO PLATE LAMP LH

-CB_C1 TO SPLICE CB_SP040
Page 33-22
1/2 GND
1.00 mm² 830 -B5 2/2 1.00 mm² 600G TO
/6.F1
1/2 40/302606 2/2
40/303389 RH HEAD LAMP

7216/0051
FLASHER 7218/0001 7218/0002
-CB_C3 -B25
-IP_C17 -CB_C12
D 1/6 TO SPLICE CB_SP040
1.00 mm² 830B
7/8 7/8
1.00 mm² 830C 1.00 mm² 830B SIDE LAMP
C -CB_SP060 1/6 GND
2.00 mm² 803B
GND 4/6 1.50 mm² 600E TO
/6.F1
1.00 mm² 837A 2/6 HIGH BEAM 4/6
E 2/6
2.00 mm² 802 40/302148
J 1.00 mm² 834A 3/6 LOW BEAM
H 3/6
-IP_C17 -CB_C12
1.00 mm² 806 1.00 mm² 806 5/6 RH IND
-IP_C24 2/8 2/8
7241/0058 5/6
-IP_SP160
2.00 mm² 837B
0.75 mm² 837A HIGH BEAM
TO
/2.E1
TO WARNING CLUSTER:2 LH HEAD LAMP
0.75 mm² 837C HIGH BEAM
TO
/2.C5 7216/0051
7218/0001 7218/0002 -CB_C4 -B24
-IP_C17 -CB_C12
1.00 mm² 829A 1.00 mm² 829A 1.00 mm² 829A 1/6 SIDE LAMP
3/8 3/8
1/6 40/302148
0.75 mm² 834A LOW BEAMTO INSTR. CLUSTER:19 2.00 mm² 837B -IP_C17 -CB_C12
2.00 mm² 837 1.00 mm² 837B 2/6 HIGH BEAM TO SPLICE CB_SP040
TO
/2.F1 1/8 1/8
-CB_SP010 2/6 GND
-CB_C12 GND 4/6 1.50 mm² 600A TO
/6.F1
2.00 mm² 834B 2.00 mm² 834B -IP_C17 2.00 mm² 834 1.00 mm² 834B 3/6 LOW BEAM 4/6
8/8 8/8
-IP_SP080 -CB_SP030 3/6
-IP_C17 -CB_C12 5/6
1.00 mm² 805C
4/8
1.00 mm² 805 1.00 mm² 805 LH IND
4/8
5/6
33 - 23 9813/8500-2 33 - 23
33 - 24 9813/8500-2 33 - 24

-R13
FORWARD RELAY
2 7219/0001 7219/0002 7212/0081 FORWORD SOL
-IP_C20 -CH_C20 -CH_C16
1.50 mm² 852A 5 4 1.50 mm² 812 1.50 mm² 812 1/2 1/2 2/2 2/2 1.50 mm² 600N GND TO SPLICE CH_SP020
-B38 TO
/6.B4
LH COLUMN SW 2/10 2/10
7219/0005 TO SPLICE IP_SP250
4/14 1 3 GND
FROM FUSE FU24 -IP_C12 1.50 mm² 809 0.50 mm² 600G TO
/6.D4
IGN RLY 1 7/14 4/14
/1.D5 FROM 2.00 mm² 107B -B35
7/14 -IP_C27
NEUTRAL TO NEUTRAL RELAY 7241/0060
6/14 1.50 mm² 810 TO
/1.C7
6/14
-R15
REVERSE RELAY
7 -R8
FROM TRANS DUMP RELAY TRANS SPLY 10 9 REVERSE TO REV SOL. LAMP BRAKE RELAY
1.50 mm² 852 1.50 mm² 811
/1.E6 FROM TO
/3.E5
332/Y6914 2
TO SPLICE IP_SP250 GND 6 8 FROM FUSE FU2 IGN RLY 1 5 4 #21 TO BRAKE LAMP
0.50 mm² 600H 1.00 mm² 126 1.00 mm² 816
/6.D4 TO
/1.E4 FROM TO
/3.F5 7212/0141 BRAKE SW
-IP_C13
-IP_C27 0.50 mm² 126A 1 3 0.50 mm² 877 1/2 -B39 2/2 0.50 mm² 600AC GND TO SPLICE IP_SP252
7241/0060
TO
/6.F6
10/14 1.50 mm² 808 2/2 40/303381 1/2
10/14 -IP_C28
7241/0060
-R9
-IP_SP190
TO SPLICE IP_SP251 11/14 1.00 mm² 921 HORN RELAY
7201/0403 7201/0403
GND 7 7219/0001 7219/0002 FRONT HORN
/6.F6 0.50 mm² 600AB 8/14 11/14
-IP_C20 -CH_C17 -CH_C18
-CH_C20
TO
8/14
FROM FUSE FU6 BATT 1.50 mm² 118 10 9 1.50 mm² 814 1.50 mm² 814 1/1 1/1 -B29 1/1 1.50 mm² 600A GND TO SPLICE CH_SP020
/1.D5 FROM TO
/6.C4
3/10 3/10 40/300611 1/1
1.00 mm² 921B 6 8 1.00 mm² 118A
-IP_C28
7241/0060 7212/0128
7219/0005 7219/0006
-CH_C15 REAR HORN SW
-IP_C19 -CH_C19
1.00 mm² 921A 1.00 mm² 921A 2/2 1/2 1.00 mm² 600R GND TO SPLICE CH_SP020
-SW7 TO
/6.B4
12/14 12/14 2/2 1/2
7219/0013 -B31
FROM SPLICE IP_SP220 -IP_C35 PARK BRAKE SW
ILLUMN 0.50 mm² 829E 8 7 0.50 mm² 600AF GND TO SPLICE IP_SP252
/3.B2 FROM TO
/6.E4
8/10 1 7/10
FROM FUSE FU1IGN RLY 1 7212/0081
1.00 mm² 101A 2 PARK BRAKE SOLENOID
/1.E5 FROM
-IP_C20 -CH_C20 -CH_C33
2/10 3 1.00 mm² 1936 1.00 mm² 1936 1.00 mm² 1936 1/2 1/2 -B44 2/2 2/2 1.00 mm² 600K GND TO SPLICE CH_SP020
TO
/6.C4
3/10 6/10 6/10 701/60051
FROM SPLICE IP_SP210 4 1.00 mm² 600V GND TO SPLICE IP_SP252
TO
/6.E4
PARK BRAKE 1.00 mm² 936 5 4/10
/1.C7 FROM
5/10 6
7212/0141
-IP_C38 PARK BRAKE SW - 2
FROM SPLICE IP_SP210 PARK BRAKE 1.00 mm² 936C 2/2 1/2 1.00 mm² 600AG GND TO SPLICE IP_SP250
-SW1 /1.C7 FROM
-B4 TO
/6.E6
701/60004 2/2 1/2
7219/0013 SIDE SHIFT SW
FROM SPLICE IP_SP220 -IP_C36
ILLUMN 0.50 mm² 829F 8 7 0.50 mm² 600AE GND TO SPLICE IP_SP252
/3.A2 FROM TO
/6.E4
8/10 7/10
FROM FUSE FU1 7212/0081

IGN RLY 1 1.00 mm² 101B 2 HYDRA CLAMP
/1.E5 FROM
-IP_C19 -CH_C19 -CH_C29
2/10 3 1.00 mm² 920 1.00 mm² 920 1/2 1/2 2/2 2/2 1.00 mm² 600X GND TO SPLICE CB_SP020
-B10 TO
/6.B4
3/10 14/14 14/14
5
6
-SW4
701/60004
FROM SPLICE IP_SP220 7219/0013 FRONT WL SW -R14
ILLUMN 0.50 mm² 829B
-IP_C14 8 7 0.50 mm² 600T GND TO SPLICE IP_SP252 FR WL RELAY
/3.B2 FROM TO
/6.E4 7232/0005
8/10 7/10 7 7213/0066 7213/0058 -CB_C6 FRONT WL RH
FROM FUSE FU20 BATT 10 9
-IP_SP170 -IP_C18 -CB_C13 -CB_SP050 GND TO SPLICE CB_SP040
/1.B5 FROM 2.00 mm² 310 2.00 mm² 855C 2.00 mm² 855 2.00 mm² 855 1.00 mm² 855B 2/2 -B41 1/2 1.00 mm² 600D TO
/6.F1
1/3 1/3
2/2 40/302608 1/2
FROM FUSE FU8IGN 2 TO SPLICE IP_SP250 6 8
0.75 mm² 133C 0.75 mm² 600K
/1.C5 FROM
/6.D4 TO
TO DIODE -1
2/10 3 0.75 mm² 116 GND 2.00 mm² 855A FWL TO
/3.C2 7232/0005
FRONT WL LH
3/10 -IP_C29 -CB_C7
5 7241/0060 FWL TO WARNING CLUSTER:4 GND TO SPLICE CB_SP040
0.75 mm² 855B 1.00 mm² 855A 2/2 -B40 1/2 1.00 mm² 600B
TO
/2.C5 TO
/6.F1
6 2/2 1/2
FWL TO INSTRUMET CLUSTER:14 40/302608
0.75 mm² 855D TO
/2.C4
7232/0005
-SW5 -CB_C9 REAR WL LH
701/60004 GND TO SPLICE CB_SP040
REAR WORK LT SW 1.00 mm² 861B 2/2 -B42 1/2 1.00 mm² 600J TO
/6.E1
FROM SPLICE IP_220 7219/0013 2/2
40/302608 1/2
ILLUMN -IP_C15 8 7 GND TO SPLICE IP_SP252 -R16
0.50 mm² 829C 0.50 mm² 600U
/3.A2 FROM TO
/6.E4
8/10 7/10 RR WL RELAY
7232/0005
2 -CB_C8 REAR WL RH
FROM FUSE FU19 BATT 5 4 -IP_SP100 -IP_C18 -CB_C13 GND TO SPLICE CB_SP040
FROM FUSE FU8 /1.B5 FROM 2.00 mm² 309 2.00 mm² 861A 2.00 mm² 861 2.00 mm² 861 1.00 mm² 861A 2/2 -B43 1/2 1.00 mm² 600P TO
/6.E1
IGN 0.75 mm² 133D 2 2/3 2/3 -CB_SP020 2/2 1/2
/1.C5 FROM
40/302608
2/10 3 0.75 mm² 117 1 3 0.75 mm² 600M GND TO SPLICE IP_SP250
TO
/6.D4
3/10 0.75 mm² 861B RWL TO INSTRUMENT CLUSTER:3
TO
/2.E4
5 -IP_C29
6 7241/0060 RWL TO WARNING CLUSTER:11
0.75 mm² 861C TO
/2.B5
33 - 25 9813/8500-2 33 - 25
33-26 33-27
-R13
FORWARD RELAY
2
1.50 mm² 852A 5 4 1.50 mm² 812

LH COLUMN SW
7219/0005 TO SPLICE IP_SP250
4/14 1 3 GND
FROM FUSE FU24 -IP_C12 1.50 mm² 809 0.50 mm² 600G TO
/6.D4
IGN RLY 1 7/14 4/14
/1.D5 FROM 2.00 mm² 107B -B35
7/14 -IP_C27
NEUTRAL TO NEUTRAL RELAY 7241/0060
6/14 1.50 mm² 810 TO
/1.C7
6/14
-R15
REVERSE RELAY
7
FROM TRANS DUMP RELAY TRANS SPLY 10 9 REVERSE TO REV SOL. LAMP
1.50 mm² 852 1.50 mm² 811
/1.E6 FROM TO
/3.E5
332/Y6914
TO SPLICE IP_SP250 GND 6 8 FROM FUSE FU2
0.50 mm² 600H
/6.D4 TO
/1.E4
-IP_C27
7241/0060
10/14 1.50 mm² 808
10/14
-R9
-IP_SP190
TO SPLICE IP_SP251 11/14 1.00 mm² 921 HORN RELAY
GND 0.50 mm² 600AB 8/14 11/14 7
/6.F6 TO
FROM FUSE FU6

8/14 BATT 1.50 mm² 118 10 9 1.50 mm² 814
/1.D5 FROM
1.00 mm² 921B 6 8 1.00 mm² 118A
-IP_C28
7241/0060
-SW7 1.00 mm² 921A
7219/0013
FROM SPLICE IP_SP220 PARK BRAKE SW
-IP_C35
ILLUMN 0.50 mm² 829E 8 7 0.50 mm² 600AF GND TO SPLICE IP_SP252
/3.B2 FROM TO
/6.E4
8/10 1 7/10
FROM FUSE FU1IGN RLY 1 2
1.00 mm² 101A
/1.E5 FROM
2/10 3 1.00 mm² 1936 1.00 mm² 1936

3/10
FROM SPLICE IP_SP210 4 1.00 mm² 600V GND TO SPLICE IP_SP252
TO
/6.E4
PARK BRAKE 1.00 mm² 936 5 4/10
/1.C7 FROM
5/10 6
Page 33-27
-SW1
701/60004
7219/0013 SIDE SHIFT SW
ILLUMN 0.50 mm² 829F 8 7 0.50 mm² 600AE GND TO SPLICE IP_SP252
/3.A2 FROM TO
/6.E4
8/10 7/10
FROM FUSE FU1

IGN RLY 1 1.00 mm² 101B 2
/1.E5 FROM
2/10 3 1.00 mm² 920

3/10
5
6
-SW4
701/60004
FROM SPLICE IP_SP220 7219/0013 FRONT WL SW -R14
ILLUMN 0.50 mm² 829B
-IP_C14 8 7 0.50 mm² 600T GND TO SPLICE IP_SP252 FR WL RELAY
/3.B2 FROM TO
/6.E4
8/10 7/10 7
FROM FUSE FU20 BATT 10 9
-IP_SP170
2.00 mm² 310 2.00 mm² 855C
/1.B5 FROM
FROM FUSE FU8IGN 2 TO SPLICE IP_SP250 6 8

0.75 mm² 133C 0.75 mm² 600K
/1.C5 FROM
/6.D4 TO
2/10 3 0.75 mm² 116 GND
3/10 -IP_C29
5 7241/0060
6
-SW5
701/60004
REAR WORK LT SW
FROM SPLICE IP_220 7219/0013
ILLUMN -IP_C15 8 7 GND TO SPLICE IP_SP252 -R16
0.50 mm² 829C 0.50 mm² 600U
/3.A2 FROM TO
/6.E4
8/10 7/10 RR WL RELAY
2
FROM FUSE FU8 /1.B5 FROM 2.00 mm² 309 2.00 mm² 861A
IGN 0.75 mm² 133D 2
/1.C5 FROM
2/10 3 0.75 mm² 117 1 3 0.75 mm² 600M GND TO SPLICE IP_SP250
TO
/6.D4
3/10
5 -IP_C29
6 7241/0060
33 - 26 9813/8500-2 33 - 26
33-26 33-27
7219/0001 7219/0002 7212/0081 FORWORD SOL

-IP_C20 -CH_C20 -CH_C16
1.50 mm² 812 1/2 1/2 2/2 2/2 1.50 mm² 600N GND TO SPLICE CH_SP020
-B38 TO
/6.B4
2/10 2/10
TO SPLICE IP_SP250
/6.D4
-R8
TO REV SOL. LAMP BRAKE RELAY
/3.E5
2
FROM FUSE FU2 IGN RLY 1 5 4 #21 TO BRAKE LAMP
1.00 mm² 126 1.00 mm² 816
/1.E4 FROM TO
/3.F5 7212/0141 BRAKE SW
-IP_C13
0.50 mm² 126A 1 3 0.50 mm² 877 1/2 -B39 2/2 0.50 mm² 600AC GND TO SPLICE IP_SP252
TO
/6.F6
2/2 40/303381 1/2
-IP_C28
7241/0060
7201/0403 7201/0403
7219/0001 7219/0002 FRONT HORN
-IP_C20 -CH_C17 -CH_C18
-CH_C20 -B29 GND TO SPLICE CH_SP020
1.50 mm² 814 1/1 1/1 1/1 1.50 mm² 600A TO
/6.C4
3/10 3/10 40/300611 1/1
7212/0128
7219/0005 7219/0006
-CH_C15 REAR HORN SW
-IP_C19 -CH_C19
1.00 mm² 921A 2/2 1/2 1.00 mm² 600R GND TO SPLICE CH_SP020
TO
/6.B4
12/14 12/14 2/2 1/2
-B31
7212/0081
PARK BRAKE SOLENOID
-IP_C20 -CH_C20 -CH_C33
1.00 mm² 1936 1/2 1/2 -B44 2/2 2/2 1.00 mm² 600K GND TO SPLICE CH_SP020
TO
/6.C4
6/10 6/10 701/60051
7212/0141
Page 33-26
-IP_C38 PARK BRAKE SW - 2

FROM SPLICE IP_SP210 PARK BRAKE 1.00 mm² 936C 2/2 1/2 1.00 mm² 600AG GND TO SPLICE IP_SP250
/1.C7 FROM
-B4 TO
/6.E6
2/2 1/2
7212/0081
HYDRA CLAMP
-IP_C19 -CH_C19 -CH_C29
1.00 mm² 920 1/2 1/2 2/2 2/2 1.00 mm² 600X GND TO SPLICE CB_SP020
-B10 TO
/6.B4
14/14 14/14
7232/0005
7213/0066 7213/0058 -CB_C6 FRONT WL RH
-IP_SP170 -IP_C18 -CB_C13 -CB_SP050 GND TO SPLICE CB_SP040
2.00 mm² 855 2.00 mm² 855 1.00 mm² 855B 2/2 -B41 1/2 1.00 mm² 600D TO
/6.F1
1/3 1/3
2/2 40/302608 1/2
FWL TO DIODE -1
2.00 mm² 855A TO
/3.C2 7232/0005
FRONT WL LH
-CB_C7
FWL TO WARNING CLUSTER:4 2/2 1/2 GND TO SPLICE CB_SP040
0.75 mm² 855B TO
/2.C5 1.00 mm² 855A -B40 1.00 mm² 600B TO
/6.F1
2/2 1/2
FWL TO INSTRUMET CLUSTER:14 40/302608
0.75 mm² 855D TO
/2.C4
7232/0005
-CB_C9 REAR WL LH
GND TO SPLICE CB_SP040
1.00 mm² 861B 2/2 -B42 1/2 1.00 mm² 600J TO
/6.E1
2/2 1/2
40/302608
7232/0005
-CB_C8 REAR WL RH
-IP_SP100 -IP_C18 -CB_C13 GND TO SPLICE CB_SP040
2.00 mm² 861 2.00 mm² 861 1.00 mm² 861A 2/2 -B43 1/2 1.00 mm² 600P TO
/6.E1
2/3 2/3 -CB_SP020 2/2 40/302608 1/2
TO SPLICE IP_SP250
/6.D4
0.75 mm² 861B RWL TO INSTRUMENT CLUSTER:3
TO
/2.E4
0.75 mm² 861C RWL TO WARNING CLUSTER:11

TO
/2.B5
33 - 27 9813/8500-2 33 - 27
33 - 28 9813/8500-2 33 - 28

DIAGNOSTIC SKT 7219/0098 7219/0002 7219/0001
-LH_C001 -LH_SP020 -LH_C005 -IP_C005
A/9 A/9 1.00 mm² 611B 2.00 mm² 611 2.00 mm² 611 GND FROM INST. PANEL (IP_SP290)
1/10 1/10
FROM
/2.E6
-LH_SP010 -LH_C005 -IP_C005 BATT FROM FUSE FU15
B/9 B/9 1.00 mm² 305B 1.00 mm² 305 1.00 mm² 305
3/10 3/10
FROM
/1.C5
7219/0018
LIVELINK
C/9 C/9 -LH_C004
1.00 mm² 611A 10/12
D/9 D/9 10/12
1.00 mm² 305A 4/12
-B1 E/9 E/9 4/12

FROM FUSE FU12 GND 1.00 mm² 612 -IP_C005 -LH_C005 1.00 mm² 612 5/12
/2.E6 FROM
7/10 7/10
5/12
FROM SPLICE IP_SP310 LH IND 1.00 mm² 403B -IP_C005 -LH_C005 1.00 mm² 403B 1/12
/2.D5 FROM
5/10 5/10
1/12
FROM SPLICE IP_SP340 #183 -IP_C005 -LH_C005
0.50 mm² CANHA
0.50 mm² CANSA
12/12
0.50 mm² CANLA
1.00 mm² 404B 1.00 mm² 404B

/2.F4 FROM
9/10 9/10
12/12
FROM SPLICE IP_SP320 #181 1.00 mm² 406B -IP_C005 -LH_C005 1.00 mm² 406B 3/12
/2.E4 FROM
4/10 4/10
3/12
FROM SPLICE IP_SP330 #183 1.00 mm² 408B -IP_C005 -LH_C005 1.00 mm² 408B 9/12
/2.D5 FROM
10/10 10/10
9/12
FROM FUSE FU11 ALT W 1.00 mm² 413 -IP_C005 -LH_C005 1.00 mm² 413 7/12
/2.C5 FROM
6/10 6/10
7/12
FROM FUSE FU4 IGN RLY 1 1.00 mm² 170B -IP_C005 -LH_C005 1.00 mm² 107B 8/12
-MC1:SH1 /1.F5 FROM
2/10 2/10
8/12
GND
11/12
11/12
2/12 -B2
2/12
NO CONNECTOR
LEAD CUT -C11
1/1 CUT END
GND
-MC4:SH1
0.50 mm² CANHC
0.50 mm² CANSC

0.50 mm² CANLC
-LH_C002 7213/0031
-LH_SP031 7213/0031 -LH_C003
-CAN1 A/3 0.50 mm² CANHB 0.50 mm² CANHE
-LH_SP030 0.50 mm² CANHD A/3 -CAN2
C B A
C B A
727/00002 -LH_SP040 727/00002
B/3 0.50 mm² CANLB 0.50 mm² CANLE 0.50 mm² CANLD B/3
CAN TERM CAN TERM
-LH_SP041 RESISTOR 2
RESISTOR 1 GND GND -LH_SP050 GND
0.50 mm² CANSJ 0.50 mm² CANSE 0.50 mm² CAN SD
NO CONNECTOR -MC2:SH1 -LH_SP054 -MC5:SH1 NO CONNECTOR

-C10
LEAD CUT 0.75 mm² 611C -MC3:SH1 LEAD CUT
1/1 1/1
CUT END
-C9
CUT END
-SW6
7219/0013
4WD SW
ILLUMN 0.50 mm² 829H 8 7 0.50 mm² 600BB GND TO SPLICE IP_SP250
/3.B2 FROM TO
/6.C4
8/10 7/10
1
-IP_SP350 7219/0001 7219/0002 7212/0081
FROM FUSE FU7 BATT 1.50 mm² 102 1.00 mm² 102A 2 4WD
/1.D5 FROM
-IP_C20 -CH_C20 -CH_C31
2/10 3 1.00 mm² 878 1.00 mm² 878 1/2 1/2 2/2 2/2 1.00 mm² 600W GND TO SPLICE CH_SP020
-B3 TO
/6.A4
3/10 9/10 9/10
-R11
AUX CKT RELAY
2 7219/0005 7219/0006 7212/0081 AUX SOL CONN
-IP_C19 -CH_C19 -CH_C32
1.00 mm² 102C 5 4 1.00 mm² 103 1.00 mm² 103 1/2 1/2 2/2 2/2 1.00 mm² 600D GND TO SPLICE CH_SP020
-B4 TO
/6.A4
2/14 2/14
1.00 mm² 102B 1 3 1.00 mm² 700
7212/0128
-IP_C42 -IP_C41 AUX CIRCUIT SW.
7241/0060 GND TO SPLICE IP_SP251
1.00 mm² 700 1/2 -B7 2/2 1.00 mm² 600F TO
/6.E6
1/2 2/2
33 - 29 9813/8500-2 33 - 29
33-30 33-31
DIAGNOSTIC SKT 7219/0098 7219/0002 7219/0001

-LH_C001 -LH_SP020 -LH_C005 -IP_C005
A/9 A/9 1.00 mm² 611B 2.00 mm² 611 2.00 mm²
1/10 1/10
-LH_SP010 -LH_C005 -IP_C005
B/9 B/9 1.00 mm² 305B 1.00 mm² 305 1.00 mm²
3/10 3/10
C/9 C/9
D/9 D/9
-B1 E/9 E/9

FROM FUSE FU12 GND 1.00 mm² 612
/2.E6 FROM
FROM SPLICE IP_SP310 LH IND 1.00 mm² 403B

/2.D5 FROM
FROM SPLICE IP_SP340 #183
0.50 mm² CANHA

0.50 mm² CANSA
0.50 mm² CANLA

1.00 mm² 404B
/2.F4 FROM
FROM SPLICE IP_SP320 #181 1.00 mm² 406B

/2.E4 FROM
FROM SPLICE IP_SP330 #183 1.00 mm² 408B

/2.D5 FROM
FROM FUSE FU11 ALT W 1.00 mm² 413

/2.C5 FROM
FROM FUSE FU4 IGN RLY 1 1.00 mm² 170B

-MC1:SH1 /1.F5 FROM
GND
-LH_C002 7213/0031
-LH_SP031
-CAN1 A/3 0.50 mm² CANHB 0.50 mm² CANHE
C B A
727/00002
B/3 0.50 mm² CANLB 0.50 mm² CANLE
CAN TERM
-LH_SP041
RESISTOR 1 GND GND
0.50 mm² CANSJ 0.50 mm² CANSE
-MC2:SH1 -LH_SP054 -MC5:SH1
Page 33-31
NO CONNECTOR
LEAD CUT 0.75 mm² 611C
1/1
-C9
CUT END
-SW6
7219/0013
4WD SW
ILLUMN 0.50 mm² 829H 8 7 0.50 mm² 600BB GND TO SPLICE IP_SP250
/3.B2 FROM TO
/6.C4
8/10 7/10
1
-IP_SP350 7219/0001 7219/0002
FROM FUSE FU7 BATT 1.50 mm² 102 1.00 mm² 102A 2
/1.D5 FROM
-IP_C20 -CH_C20
2/10 3 1.00 mm² 878
3/10 9/10 9/10
-R11
AUX CKT RELAY
2 7219/0005 7219/0006
-IP_C19 -CH_C19
1.00 mm² 102C 5 4 1.00 mm² 103
2/14 2/14
1.00 mm² 102B 1 3 1.00 mm² 700
-IP_C42
7241/0060
33 - 30 9813/8500-2 33 - 30
33-30 33-31
7219/0001
-IP_C005
2.00 mm² 611 GND FROM INST. PANEL (IP_SP290)
FROM
/2.E6
-IP_C005 1.00 mm² 305 BATT FROM FUSE FU15
FROM
/1.C5
7219/0018
LIVELINK
-LH_C004
1.00 mm² 611A 10/12
10/12
1.00 mm² 305A 4/12
4/12
1.00 mm² 612 -IP_C005 -LH_C005 1.00 mm² 612 5/12
7/10 7/10
5/12
1.00 mm² 403B -IP_C005 -LH_C005 1.00 mm² 403B 1/12
5/10 5/10
1/12
1.00 mm² 404B -IP_C005 -LH_C005 1.00 mm² 404B 12/12
9/10 9/10
12/12
1.00 mm² 406B -IP_C005 -LH_C005 1.00 mm² 406B 3/12
4/10 4/10
3/12
1.00 mm² 408B -IP_C005 -LH_C005 1.00 mm² 408B 9/12
10/10 10/10
9/12
1.00 mm² 413 -IP_C005 -LH_C005 1.00 mm² 413 7/12
6/10 6/10
7/12
1.00 mm² 170B -IP_C005 -LH_C005 1.00 mm² 107B 8/12
2/10 2/10
8/12
11/12
11/12
2/12 -B2
2/12
NO CONNECTOR
LEAD CUT -C11
1/1 CUT END
GND
-MC4:SH1
0.50 mm² CANHC
0.50 mm² CANSC

0.50 mm² CANLC
7213/0031 -LH_C003
-LH_SP030 0.50 mm² CANHD A/3 -CAN2
C B A
-LH_SP040 727/00002
0.50 mm² CANLD B/3
CAN TERM
GND
RESISTOR 2
-LH_SP050 0.50 mm² CAN SD GND
-MC5:SH1
Page 33-30
-MC3:SH1
NO CONNECTOR
LEAD CUT
-C10
1/1
CUT END
7219/0002 7212/0081
4WD
-CH_C20 -CH_C31
1.00 mm² 878 1/2 1/2 2/2 2/2 1.00 mm² 600W GND TO SPLICE CH_SP020
-B3 TO
/6.A4
7219/0006 7212/0081 AUX SOL CONN

-CH_C19 -CH_C32
1.00 mm² 103 1/2 1/2 2/2 2/2 1.00 mm² 600D GND TO SPLICE CH_SP020
-B4 TO
/6.A4
7212/0128
-IP_C41 AUX CIRCUIT SW.
1.00 mm² 700 1/2 2/2 1.00 mm² 600F GND TO SPLICE IP_SP251
-B7 TO
/6.E6
1/2 2/2
33 - 31 9813/8500-2 33 - 31
33 - 32 9813/8500-2 33 - 32

7213/0058 7213/0066 7212/0060 332/E9928
-CB_C13 -IP_C18 -IP_C21 -CH_C21
FROM HEAD LAMP LH:4 GND -CB_SP040
1.50 mm² 600A 8.00 mm² 600Q 8.00 mm² 600 8.00 mm² 600A 8.00 mm² 600 8.00 mm² 600U
/3.B8 FROM
3/3 3/3 1/2 1/2

FROM HEAD LAMP RH:4 GND -IP_SP380
1.50 mm² 600E
/3.C8 FROM
6.00 mm² 600TT

FROM FR WORK LT LH:1 GND
1.00 mm² 600B
/4.B7 FROM
FROM FR WORK LT RH:1 GND

1.00 mm² 600D
/4.B7 FROM
FROM MOBILE CHARGER:1 FROM LH COLUMN SW:11

GND 2.00 mm² 600P 6.00 mm² 600ZZ1 0.50 mm² 600AB GND
FROM NO PLATE LT RH:2 /1.C7 FROM FROM
/4.E1
GND -IP_SP251
/3.D8 1.00 mm² 600F -IP_SP252
FROM RADIO:2 FROM BRAKE SW:2
FROM
GND 1.50 mm² 600R 0.50 mm² 600AC GND

FROM NO PLATE LH:2 /1.B7 FROM FROM
/4.E7
GND
1.00 mm² 600G
/3.C8 FROM
FROM FR WORK LT SW VC-1:7 FROM HEAD LAMP SW:7

GND 0.50 mm² 600T 0.50 mm² 600X GND
LH RR WL LT:1 /4.B2 FROM FROM
/3.E1
GND
1.00 mm² 600J
/4.B7 FROM
FROM RR WORK LT SW VC-1:7 FROM HAZARD SW:10

GND 0.50 mm² 600U 1.00 mm² 600Y GND
7207/2008 /4.B2 /3.D5
M6
FROM RH RR WL LT:1
FROM FROM
GND
/4.A7 1.00 mm² 600P -CB_C14
FROM WIPER MOTOR:4
FROM
1
FROM PARK BRAKE SW:4 GND 1.00 mm² 600V 1.50 mm² 600N GND
/4.D2 /3.F4
6.00 mm² 600ZZ

FROM FROM
FROM FACE FAN:1 GND 1.00 mm² 600H

/1.C6 FROM
-G5 FROM PARK BRAKE SW:7 GND 0.50 mm² 600AF 1.00 mm² 600F GND FROM AUX CIRCUIT SW IP_C41 :2
/4.D2 FROM FROM
/5.B7
FROM INTERIOR LT:2 GND 1.50 mm² 600C
/1.B7 FROM
FROM SIDE SHIFT SW:7 GND 0.50 mm² 600AE

/4.C2 FROM
FROM FLASHER :6 GND 2.50 mm² 600D -IP_SP250 1.00 mm² 600AG GND FROM PARK BRAKE SW - 2 :2
/3.C3 FROM FROM
/4.C7
FROM SPEEDOMETER:3 GND 1.00 mm² 600AH
/2.E2 FROM
FROM NEUTRAL RLY GND 0.50 mm² 600E

/1.D5 FROM
FROM FWD/REV RLY:3 GND 0.50 mm² 600G

/4.F4 FROM
FROM FWD/REV RLY:6 GND 0.50 mm² 600H

/4.E2 FROM
FROM HEAD LAMP HI/LO RLY:3 GND 0.75 mm² 600J

/3.B3 FROM
FR&RR WORK LAMP RLY:6 GND 0.75 mm² 600K

/4.B3 FROM
FROM DUMP & PARK RLY:6 GND 0.50 mm² 600L

/1.C6 FROM
FR&RR WORK LAMP RLY:3 GND 0.75 mm² 600M

/4.A4 FROM
FROM HEAD LAMP HI/LO RLY:6 GND 0.75 mm² 600Z

/3.A2 FROM
FROM WARNING CLUSTER:3 GND 0.50 mm² 600AA

/2.B7 FROM
FROM 4WD SW:7 GND 0.50 mm² 600BB

/5.C3 FROM
FROM FRONT HORN:1 GND -CH_SP020

1.50 mm² 600A 8.00 mm² 600
/4.E7 FROM
FROM TRANS OIL TEMP SW:2 GND 1.00 mm² 600B

/2.F7 FROM
FROM ENG OIL PR. SW:2 GND 1.00 mm² 600C

/2.D7 FROM
FROM WATER TEMP SW:2 GND 1.00 mm² 600E

/2.E7 FROM
FROM WATER TEMP SENSOR:2 GND 1.00 mm² 600F

/2.C7 FROM
FROM TRANS DUMP SW:2 GND 1.00 mm² 600H

/2.A7 FROM
FROM PARK BRAKE SOLENOID:2 GND 1.00 mm² 600K

/4.D7 FROM
FROM TRANS OIL PRE. SW:2 GND 1.00 mm² 600J

/2.F7 FROM
FROM REAR COMBI LT RH:3 GND 1.00 mm² 600L

/3.F8 FROM
FROM RR COMBI LT LH:3 GND 1.00 mm² 600Z

/3.E8 FROM
FROM REVERSE SOL:2 GND 1.50 mm² 600M

/3.D8 FROM
FROM FWD SOL:2 GND 1.50 mm² 600N

/4.F7 FROM
FROM REAR HORN:2 GND 1.00 mm² 600V

/3.D8 FROM
FROM REAR HORN SW:1 GND 1.00 mm² 600R

/4.D7 FROM
FROM HYDRA CLAMP:2 GND 1.00 mm² 600X

/4.C7 FROM
FROM SPEED SENSOR:1 GND 1.00 mm² 600P

/2.D2 FROM
7207/1514
FROM 4WD GND
/5.C7 FROM 1.00 mm² 600W -CH_C25 M10
1
FROM AUX SOL CONN GND 1.00 mm² 600D
/5.B7 FROM
-G6
FROM DUMP SW:2 GND 1.00 mm² 600T
/2.B7 FROM
33 - 33 9813/8500-2 33 - 33
33-34 33-35
7213/0058 7213/0066
-CB_C13 -IP_C18
FROM HEAD LAMP LH:4 GND -CB_SP040
1.50 mm² 600A 8.00 mm² 600Q 8.00 mm² 600
/3.B8 FROM
3/3 3/3
FROM HEAD LAMP RH:4 GND
1.50 mm² 600E
/3.C8 FROM
FROM FR WORK LT LH:1 GND

1.00 mm² 600B
/4.B7 FROM
FROM FR WORK LT RH:1 GND

1.00 mm² 600D
/4.B7 FROM
FROM MOBILE CHARGER:1 GND

FROM NO PLATE LT RH:2 /1.C7 FROM
GND
1.00 mm² 600F
/3.D8 FROM
FROM RADIO:2 GND

FROM NO PLATE LH:2 /1.B7 FROM
GND
1.00 mm² 600G
/3.C8 FROM
FROM FR WORK LT SW VC-1:7 GND

LH RR WL LT:1 /4.B2 FROM
GND
1.00 mm² 600J
/4.B7 FROM
FROM RR WORK LT SW VC-1:7 GND

7207/2008 /4.B2
M6
FROM RH RR WL LT:1
FROM
GND
/4.A7 FROM 1.00 mm² 600P -CB_C14
FROM PARK BRAKE SW:4 GND
1
/4.D2 FROM
FROM FACE FAN:1 GND 1.00 mm² 600H

/1.C6 FROM
-G5 FROM PARK BRAKE SW:7 GND

/4.D2 FROM
FROM INTERIOR LT:2 GND 1.50 mm² 600C

/1.B7 FROM
FROM SIDE SHIFT SW:7 GND

/4.C2 FROM
FROM FLASHER :6 GND

/3.C3 FROM
FROM SPEEDOMETER:3 GND

/2.E2 FROM
FROM NEUTRAL RLY GND

/1.D5 FROM
FROM FWD/REV RLY:3 GND

/4.F4 FROM
FROM FWD/REV RLY:6 GND

/4.E2 FROM
FROM HEAD LAMP HI/LO RLY:3 GND

/3.B3 FROM
FR&RR WORK LAMP RLY:6 GND

/4.B3 FROM
FROM DUMP & PARK RLY:6 GND

/1.C6 FROM
FR&RR WORK LAMP RLY:3 GND

/4.A4 FROM
FROM HEAD LAMP HI/LO RLY:6 GND

/3.A2
Page 33-35
FROM
FROM WARNING CLUSTER:3 GND

/2.B7 FROM
FROM 4WD SW:7 GND

/5.C3 FROM
FROM FRONT HORN:1 GND

/4.E7 FROM
FROM TRANS OIL TEMP SW:2 GND

/2.F7 FROM
FROM ENG OIL PR. SW:2 GND

/2.D7 FROM
FROM WATER TEMP SW:2 GND

/2.E7 FROM
FROM WATER TEMP SENSOR:2 GND

/2.C7 FROM
FROM TRANS DUMP SW:2 GND

/2.A7 FROM
FROM PARK BRAKE SOLENOID:2 GND

/4.D7 FROM
FROM TRANS OIL PRE. SW:2 GND

/2.F7 FROM
FROM REAR COMBI LT RH:3 GND

/3.F8 FROM
FROM RR COMBI LT LH:3 GND

/3.E8 FROM
FROM REVERSE SOL:2 GND

/3.D8 FROM
FROM FWD SOL:2 GND

/4.F7 FROM
FROM REAR HORN:2 GND

/3.D8 FROM
FROM REAR HORN SW:1 GND

/4.D7 FROM
FROM HYDRA CLAMP:2 GND

/4.C7 FROM
FROM SPEED SENSOR:1 GND

/2.D2 FROM
FROM 4WD GND

/5.C7 FROM
FROM AUX SOL CONN GND

/5.B7 FROM
FROM DUMP SW:2 GND

/2.B7 FROM
33 - 34 9813/8500-2 33 - 34
33-34 33-35
7212/0060 332/E9928
-IP_C21 -CH_C21
8.00 mm² 600A 8.00 mm² 600 8.00 mm² 600U
1/2 1/2
-IP_SP380
6.00 mm² 600TT

FROM MOBILE CHARGER:1 GND GND FROM LH COLUMN SW:11
2.00 mm² 600P 6.00 mm² 600ZZ1 0.50 mm² 600AB
/1.C7 FROM FROM
/4.E1
-IP_SP252 -IP_SP251
FROM RADIO:2 GND GND FROM BRAKE SW:2
1.50 mm² 600R 0.50 mm² 600AC
/1.B7 FROM FROM
/4.E7
FROM FR WORK LT SW VC-1:7 GND GND FROM HEAD LAMP SW:7
0.50 mm² 600T 0.50 mm² 600X
/4.B2 FROM FROM
/3.E1
FROM RR WORK LT SW VC-1:7 GND GND FROM HAZARD SW:10
0.50 mm² 600U 1.00 mm² 600Y
/4.B2 FROM FROM
/3.D5
FROM PARK BRAKE SW:4 GND GND FROM WIPER MOTOR:4
1.00 mm² 600V 1.50 mm² 600N
/4.D2 /3.F4
6.00 mm² 600ZZ
FROM FROM
FROM PARK BRAKE SW:7 GND 0.50 mm² 600AF 1.00 mm² 600F GND FROM AUX CIRCUIT SW IP_C41 :2
/4.D2 FROM FROM
/5.B7
FROM SIDE SHIFT SW:7 GND 0.50 mm² 600AE
/4.C2 FROM
FROM FLASHER :6 GND 2.50 mm² 600D -IP_SP250 1.00 mm² 600AG GND FROM PARK BRAKE SW - 2 :2
/3.C3 FROM FROM
/4.C7
FROM SPEEDOMETER:3 GND 1.00 mm² 600AH
/2.E2 FROM
FROM NEUTRAL RLY GND 0.50 mm² 600E

/1.D5 FROM
FROM FWD/REV RLY:3 GND 0.50 mm² 600G

/4.F4 FROM
FROM FWD/REV RLY:6 GND 0.50 mm² 600H

/4.E2 FROM
FROM HEAD LAMP HI/LO RLY:3 GND 0.75 mm² 600J

/3.B3 FROM
FR&RR WORK LAMP RLY:6 GND 0.75 mm² 600K

/4.B3 FROM
FROM DUMP & PARK RLY:6 GND 0.50 mm² 600L

/1.C6 FROM
FR&RR WORK LAMP RLY:3 GND 0.75 mm² 600M

/4.A4 FROM
FROM HEAD LAMP HI/LO RLY:6 GND 0.75 mm² 600Z

/3.A2
Page 33-34
FROM
FROM WARNING CLUSTER:3 GND 0.50 mm² 600AA

/2.B7 FROM
FROM 4WD SW:7 GND 0.50 mm² 600BB

/5.C3 FROM
FROM FRONT HORN:1 GND -CH_SP020

1.50 mm² 600A 8.00 mm² 600
/4.E7 FROM
FROM TRANS OIL TEMP SW:2 GND 1.00 mm² 600B

/2.F7 FROM
FROM ENG OIL PR. SW:2 GND 1.00 mm² 600C

/2.D7 FROM
FROM WATER TEMP SW:2 GND 1.00 mm² 600E

/2.E7 FROM
FROM WATER TEMP SENSOR:2 GND 1.00 mm² 600F

/2.C7 FROM
FROM TRANS DUMP SW:2 GND 1.00 mm² 600H

/2.A7 FROM
FROM PARK BRAKE SOLENOID:2 GND 1.00 mm² 600K

/4.D7 FROM
FROM TRANS OIL PRE. SW:2 GND 1.00 mm² 600J

/2.F7 FROM
FROM REAR COMBI LT RH:3 GND 1.00 mm² 600L

/3.F8 FROM
FROM RR COMBI LT LH:3 GND 1.00 mm² 600Z

/3.E8 FROM
FROM REVERSE SOL:2 GND 1.50 mm² 600M

/3.D8 FROM
FROM FWD SOL:2 GND 1.50 mm² 600N

/4.F7 FROM
FROM REAR HORN:2 GND 1.00 mm² 600V

/3.D8 FROM
FROM REAR HORN SW:1 GND 1.00 mm² 600R

/4.D7 FROM
FROM HYDRA CLAMP:2 GND 1.00 mm² 600X

/4.C7 FROM
FROM SPEED SENSOR:1 GND 1.00 mm² 600P

/2.D2 FROM
7207/1514
FROM 4WD GND
/5.C7 FROM 1.00 mm² 600W -CH_C25 M10
1
FROM AUX SOL CONN GND 1.00 mm² 600D

/5.B7 FROM
-G6
FROM DUMP SW:2 GND 1.00 mm² 600T
/2.B7 FROM
33 - 35 9813/8500-2 33 - 35
90 - Earth Point
90 - Earth Point
Introduction
The ground or earth refers to the reference point in an

electrical circuit from which voltages are measured,
a common return path for electrical current, or a
direct physical connection to earth. Electrical circuits
may be connected to ground or earth to prevent
user contact with dangerous voltage if the electrical
insulation fails.
Earth points can be useful when tracing electrical

faults typically when several electrical devices are
malfunctioning.
33 - 36 9813/8500-2 33 - 36
03 - Battery
03 - Battery
Contents Page No.
33-03-00 General ........................................................................................................................... 33-39

33-03-03 Isolator Switch ................................................................................................................ 33-48
33 - 37 9813/8500-2 33 - 37
Notes:
33 - 38 9813/8500-2 33 - 38
03 - Battery
00 - General
Introduction .................................................... 33-39 Batteries used in normal temperate climate
Health and Safety .......................................... 33-40 applications should not need topping up. However,
Technical Data ............................................... 33-41 in certain conditions (such as prolonged operation
Fault-Finding .................................................. 33-42 in high ambient temperatures or if the alternator
overcharges) the electrolyte level should be checked
Disconnect and Connect ............................... 33-43 frequently and topped up as necessary.
Check (Condition) .......................................... 33-46
Charge ........................................................... 33-47 The electrolyte level should be checked in
accordance with the routine maintenance schedule.
Shorter maintenance intervals are required if the
machine is operating at high ambient temperatures
or continuously for long periods.
Later Machines may have the new type batteries

installed which include a sight glass to check the
condition of the battery. New batteries should be
used as replacements if replacing the battery on
earlier machines.
Figure 462.
A Maintenance free battery
Maintenance
To make sure that the battery provides optimum
performance the following steps should be observed:
• Make sure that the electrical connections are

clean and tight. Smear petroleum jelly on
connectors to prevent corrosion.
• When applicable - never allow the electrolyte
level to fall below the recommended level of
6mm above the plates. Use only distilled water
for topping up.
• Keep the battery at least three quarters
charged, otherwise the plates may become
sulphated (hardened) - this condition makes
recharging the battery very difficult.
Extra precautions must be taken when bench

charging maintenance free batteries, they are more
prone to damage by overcharging than the standard
type of battery:
• Never boost charge a maintenance free battery

(if installed).
33 - 39 9813/8500-2 33 - 39
03 - Battery
00 - General
• Never charge a battery at a voltage in excess Health and Safety

of 15.8V.
• Never continue to charge a battery after it DANGER Batteries give off an explosive gas.
begins to gas. Do not smoke when handling or working on the
battery. Keep the battery away from sparks and
Quiescent Current Drain flames.
Battery electrolyte contains sulphuric acid. It can
If the machine has no permanently live circuits there burn you if it touches your skin or eyes. Wear
should be zero quiescent current drain, when the goggles. Handle the battery carefully to prevent
key-switch is off and all the lights are switched off. spillage. Keep metallic items (watches, rings, zips
etc) away from the battery terminals. Such items
It should be noted that some permanently live circuits could short the terminals and burn you.
will place a quiescent drain on the battery. Typically
the quiescent drain will be in the range of 10–20 Set all switches to off before disconnecting and
mA. If the quiescent drain measures 40 mA or more, connecting the battery. When disconnecting the
there is a problem with the wiring insulation or the battery, take off the earth (-) lead first.
accessories, if the fault is not rectified it will continue Re-charge the battery away from the machine,
to drain the battery. in a well ventilated area. Switch the charging
circuit off before connecting or disconnecting the
battery. When you have installed the battery in the
machine, wait 5min before connecting it up.
When reconnecting, attach the positive (+) lead
first.
WARNING Keep metal watch straps and any
metal fasteners on your clothes, clear of the
positive (+) battery terminal. Such items can short
between the terminal and nearby metal work. If it
happens you can get burned.
WARNING Battery electrolyte is toxic and
corrosive. Do not breathe the gases given off
by the battery. Keep the electrolyte away from
your clothes, skin, mouth and eyes. Wear safety
glasses.
WARNING Do not top the battery up with acid.
The electrolyte could boil out and burn you.
CAUTION Understand the electrical circuit
before connecting or disconnecting an electrical
component. A wrong connection can cause injury
and/or damage.
Notice: Do not disconnect the battery while the
engine is running, otherwise the electrical circuits
may be damaged.
CAUTION The machine is negatively earthed.
Always connect the negative pole of the battery
to earth.
When connecting the battery, connect the earth
(-) lead last.
When disconnecting the battery, disconnect the
earth (-) lead first.
DANGER If you try to charge a frozen battery, or
jump start and run the engine, the battery could
explode. Do not use a battery if its electrolyte
is frozen. To prevent the battery electrolyte from
freezing, keep the battery at full charge.
CAUTION Damaged or spent batteries and
any residue from fires or spillage must be
33 - 40 9813/8500-2 33 - 40
03 - Battery
00 - General
put in a closed acid proof receptacle and Technical Data

must be disposed of in accordance with local
environmental waste regulations.
Table 99.
Notice: Before carrying out arc welding on the
machine, disconnect the battery and alternator to Item Specification
protect the circuits and components. The battery Battery 12V, 100ah, 20h rate
must still be disconnected even if a battery
isolator is installed.
33 - 41 9813/8500-2 33 - 41
03 - Battery
00 - General
Fault-Finding
The most obvious sign of a battery problem is a
machine not being able to start. However, because
the battery is part of a larger electrical system
connected to other parts of the machine, a flat battery
may indicate another problem.
If something else is going wrong in the electrical
system, for example, a weak alternator, corrosion or
loose connections, cold weather starting, electrical
equipment being left on without the engine running,
interrogate the cause of the problem.
The best way to test the condition of the battery is
with an electronic battery tester. Refer to Battery-
Check Condition.
33 - 42 9813/8500-2 33 - 42
03 - Battery
00 - General
Notice: Before you install a pair of batteries to Figure 463. Parallel and
a machine, make sure you know the machines Series Connection (Example)
voltage. Some machines require two batteries but
have a 12 V electrical system. This means the
batteries need to be connected in parallel.
For 24 V machines, the batteries must be
_ _
connected in series. Incorrect voltage may result
in serious damage to the electrical system. + +
A
C
C
The illustrations show typical battery connections.
The actual battery connections installed on your
machine may look different. _ + _ +
Make sure you connect the batteries correctly for
your machine.
Disconnect 12 V 24 V
1. Make the machine safe. D B D B
Refer to: PIL 01-03-27. Figure 464. Twin Battery 12V Ma-
chines- Parallel Connection (Example)
2. Get access to the battery or batteries (depending
on the specification of your machine). The actual B
installation on your machine may vary from those
shown below.
3. If the machine has a battery isolator, move the
switch to the OFF position, then remove the key. C
4. Disconnect the battery negative lead first.
5. Disconnect the battery positive lead and store
away from the batteries.
A
A D
6. Disconnect and remove the battery link lead or
leads.
A Battery
B Positive lead
C Battery link lead
D Negative lead
33 - 43 9813/8500-2 33 - 43
03 - Battery
00 - General
Figure 465. 24 Volt Machines- Series Connection (Example)

C
_ _ + +
A Battery B Positive lead

C Battery link lead D Negative lead
33 - 44 9813/8500-2 33 - 44
03 - Battery
00 - General
Connect
1. Check the battery as follows:
1.1. If any terminals are dirty, clean them.
1.2. If the terminal is corroded and has white
powder, wash the terminal with hot water.
Make sure the water does not enter the
battery cells.
1.3. If considerable corrosion is found, then
clean with a wire brush or abrasive
paper. Make sure you use eye and hand
protection. Refer to Figure 466.
Figure 466.
1.4. After cleaning, apply a thin coat of

petroleum jelly to the terminals.
2. Connect the leads.
2.1. For single battery machines, connect the
positive lead then the negative lead.
2.2. For twin battery machines, first connect the
link lead or leads, then the positive terminal,
and finally the negative terminal.
3. If the machine has a battery isolator, move the
switch to the ON position.
4. Close and lock the access panels.
33 - 45 9813/8500-2 33 - 45
03 - Battery
00 - General
Check (Condition) Table 100. Fault Diagnosis

Battery Tester Read- Remedy
ings
Battery Test CHECK: 0 -12.6 Volts: Renew battery
LOAD: less than 6 Volts
This test is to determine the electrical condition of
the battery and to give an indication of the remaining CHECK: 6 -12.4 Volts: Recharge and re-test. If
useful life. LOAD: less than 9 Volts tests are still unsatisfac-
and falls steadily but re- tory renew battery
Before you test the battery, make sure that the mains in yellow zone
battery is at least 75% charged (Specific Gravity of CHECK: less than 10 Indicates battery has
1.23 to 1.25 for ambient temperature up to 27°C). Volts: LOAD: less than 3 been over-discharged
Volts and unlikely to recover.
Make sure that the battery is completely Renew battery
disconnected from the vehicle. CHECK: more than 11 Charge battery which
Volts: LOAD: 6 - 10 Volts will probably recover
Figure 467. steady
Specific Gravity Test

The specific gravity of the electrolyte gives an idea
of the state of charge of the battery. Readings
should be taken using a hydrometer, when the
electrolyte temperature is 15°C (60°F). If the battery
has recently been on charge, wait approximately one
hour (or slightly discharge the battery) to dissipate
the surface charge before testing.
Readings should be as tabulated and should not vary

between cells by more than 0.04. A greater variation
indicates an internal fault on that particular cell.
If the electrolyte temperature is other than 15°C

(60°F) a 'correction factor' must be applied to the
reading obtained. Add 0.07 per 10°C (18°F) if the
A Battery voltage switch temperature is higher than 15°C (60°F) and subtract
B Check load switch the same if the temperature is lower.
Connect up the battery tester as follows: Table 101. Specific Gravity at 15°C (60°F))
1. Set the Check Load switch to OFF. Ambient Fully Half Dis- Fully Dis-
Temper- Charged charged charged
2. Set the battery voltage switch to 12V. ature de-
grees C
3. Connect the red flying lead to the battery positive (degrees
(+) terminal and the black flying lead to the F)
battery negative (-) terminal.
Below 27 1.270-1.290 1.190-1.210 1.110-1.130
4. Set the Check/Load switch to CHECK to read the (80)
battery no-load voltage which should be at least Above 27 1.240-1.260 1.170-1.190 1.090-1.110
12.4 volts. (80)
5. Set the Check/Load switch to LOAD and hold

down for 5-10 seconds until the meter reading
stabilises. The reading should be at least 9 volts.
6. If the tests are unsatisfactory, refer to the fault
diagnosis table.
33 - 46 9813/8500-2 33 - 46
03 - Battery
00 - General
Charge
Precautions before Charging

Follow all the precautions described below, to
prevent damage to the alternator and battery.

2. Make sure that the battery negative terminal is
connected to the earth cable.
3. Do not connect or disconnect the battery
or alternator connections, or any part of the
charging circuit while the engine is in operation.
If you disregard this instruction, the regulator or
rectifying diodes will be damaged.
4. Main output cables are always in active state
of current flow even when the engine is not in
operation. If the alternator connector is removed,
do not earth the moulded plug.
5. When you do arc welding on the machine,
remove the moulded plug (or if the separate
output cables are installed, remove the cables)
to protect the alternator.
6. If it is necessary to jump start the battery then
follow the steps below.
6.1. Connect the second battery in parallel
without disconnecting the vehicle battery
from the charging circuit.
6.2. After the jump start, safely disconnect and
remove the secondary battery.
6.3. Make sure you connect the positive terminal
to the positive terminal and the negative
terminal to the negative terminal of both
batteries.
33 - 47 9813/8500-2 33 - 47
03 - Battery
03 - Isolator Switch
03 - Isolator Switch Introduction

Introduction .................................................... 33-48 The battery isolator switch is used to disconnect the
Disconnect and Connect ............................... 33-49 battery from the machine electrics. The switch must
be turned to the OFF position if any maintenance
work is to be performed on the machine.
Some machine systems perform shut down cycles

after the engine stops. Wait until shut down cycles
are complete before setting the battery isolator
switch to the OFF position. For more information
refer to Disconnect and Connect. Refer to: PIL
33-03-00.
33 - 48 9813/8500-2 33 - 48
03 - Battery
03 - Isolator Switch

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.
To disconnect the battery from the machine electrics

a battery isolator has been fitted.
At the end of a working cycle or if the machine

is being left unattended, provided the lights are
not required, the battery must be isolated. Before
attempting to start the engine or use the machine
electrics the battery isolator key must be fitted and
switched on.
Figure 468.
A Battery isolator
Disconnect the Machine Electrics:

1. Turn the ignition key to the off position.
2. Get access to the battery isolator.
3. Turn the battery isolator key in a counter-
clockwise direction and remove.
Connect the Machine Electrics:

1. Make sure the ignition is switched off.
2. Insert the battery isolator key and turn in a
clockwise direction.
33 - 49 9813/8500-2 33 - 49
09 - Power Distribution
Contents Page No.
33-09-00 General ........................................................................................................................... 33-51

33-09-03 Fuse ............................................................................................................................... 33-53
33 - 50 9813/8500-2 33 - 50
00 - General
Introduction .................................................... 33-51 The electrical circuits are protected by fuses. If a
Health and Safety .......................................... 33-52 fuse blows, find out why and rectify the fault before
installing a new one.
A full up to date list of fuses and relays and their

locations can be found in the relevant operator
manual, maintenance section.
33 - 51 9813/8500-2 33 - 51
00 - General
Health and Safety

Notice: Always replace fuses with ones of correct
ampere rating to avoid electrical system damage.
Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
33 - 52 9813/8500-2 33 - 52
03 - Fuse
03 - Fuse
Introduction
Notice: Always replace fuses with ones of correct

ampere rating to avoid electrical system damage. The electrical circuits are protected by fuses.
Figure 469.
1 2 3 4 5 6
7 8 9 10 11 12
13 14 15 16 17 18
19 20 21 22 23 24
Table 102.
Fuse No. Circuit Fuse rating
1 Dump Relay 20
2 Head lights 20
3 Wiper 10
4 Main 20
5 LL battery 3
6 Radio 15
7 2/4 wheel drive 10
8 Horn 10
9 Main beam, Low beam 10
10 Low beam 15
11 LL Engine Run 3
12 Face Fan 10
13 Indicators 5
14 Cluster 5
15 Hazard 15
16 Park RH 7.5
17 Rear W/L 15
18 2WD/4WD 10
19 Speedometer + LL ignition 5
20 Relay Coils 5
21 LL GND 3
22 Park LH 7.5
23 Front W/L 15
24 Hydra Clamp 15
33 - 53 9813/8500-2 33 - 53
03 - Fuse
Table 103. Fuses (2DX)

Item Part number Description Quantity
1 335/Y4808 Harness panel 1
1A 02/920355 Fuse 15A 0
1B 02/920356 Fuse 5A 0
1C 321/10646 Fuse 10amp 0
1D 321/10644 Fuse 1amp 0
1E 331/69260 Fuse 7.5a 0
1F 332/D8958 Fuse 25amp 0
2 40/302666 Clip locking 1
3 826/01144 Tie cable 200mm 20
4 1420/0005Z Washer M5 6
5 826/01528 Screw 6
33 - 54 9813/8500-2 33 - 54
12 - Harness
12 - Harness
Contents Page No.
33-12-00 General ........................................................................................................................... 33-57

33-12-03 Main Frame .................................................................................................................... 33-67
33-12-18 Side Console .................................................................................................................. 33-76
33-12-28 Exterior Roof .................................................................................................................. 33-93
33 - 55 9813/8500-2 33 - 55
Notes:
33 - 56 9813/8500-2 33 - 56
12 - Harness
00 - General
Introduction .................................................... 33-57
Health and Safety .......................................... 33-58
Harness Drawings
Component Identification ............................... 33-59 Drawings are reproduced from production electrical
Repair ............................................................ 33-61 harness drawings. Each harness drawing includes
Check (Condition) .......................................... 33-63 tables showing wire connections and destinations
for all the connectors on the harness. To identify
the correct harness drawing for a particular machine
refer to the relevant Harness Interconnection page
for the machine serial number range.
33 - 57 9813/8500-2 33 - 57
12 - Harness
00 - General
Health and Safety

WARNING In addition to the warnings
incorporated into this procedure, extreme care
should be taken when handling the gas heating
tool to ensure that the flame does not damage or
set fire to any items in the vicinity of the repair,
i.e. other wires, floor panels, floor mats, sound
proofing, paintwork, etc. This tool should not be
used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas
or similar safety parameters apply. No other heat
source should be used to attempt a sealed joint.
Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.
CAUTION When the heater is in use, the reflector
and the air coming out are extremely hot. Keep
away to avoid accidental burns. Do not touch the
reflector until it has had time to cool down after
switching off. If flame reappears at the reflector
when the heater is in use, the catalytic element is
damaged or used up. Stop work immediately and
replace the heater.
33 - 58 9813/8500-2 33 - 58
12 - Harness
00 - General
Wire and Harness Number Identification

This section details the allocation of wire numbers
and the identification of wires in the wiring harness.
Figure 470.
The illustration shows a typical connector and wires. Identifica- Description

Each wire has an individual identification number tion Num-
permanently marked on it, at regular intervals along ber
it's length. The number stamped on the wire identifies 819 The wire's unique identification num-
the following: ber. The wire functions and num-
bers allocated to them are consis-
Table 104. Wire and Harness tent through out the JCB range of
Number Identification products. Refer to Wire Numbers and
Identifica- Description Functions.
tion Num- 9/371 If applicable - The part number of
ber the harness that the wire originates
# The # indicates the start of the identi- from. If the harness part number is
fication number. It is always printed to 719/37100, the number printed on the
the left of the identification number. harness wires will be 9/371 (71 and
B If applicable - The colour of the fly- 00 are common numbers and there-
ing lead that the harness wire should fore deleted).
mate with. For instance, if wire 819
from harness 719/37100 mated with Wire Numbers and Functions
a flying lead coloured black (colour
code B) then the number printed on
the wire would be B-819 9/371. Table 105. Wires 000-199, 1000-1999 (These
numbers are reserved for ignition feeds,
heater start circuits and start circuits)
Wire Number Description
Wires 000 - 099 Unfused ignition feeds
Wires 100 - 199 Fused ignition feeds (feeds via
and 1000 -1999 ignition relays are also classed
as ignition feeds). Power sup-
plies output by a control module.
33 - 59 9813/8500-2 33 - 59
12 - Harness
00 - General
Table 106. Wires 200-399, 2000-3999 (These Table 110. Wires In Splices
numbers are reserved for battery feeds)
Wire Number Description Various The main input wire is allocated
Wires 200-299 Unfused battery feeds. Pow- with a wire number and a suit-
and 2000-2999 er supplies output by a control able description, i.e. Wire 640
module. earth splice to earth. The addi-
Wires 300-399 Fused battery feeds. Power sup- tional wires in the splice are al-
and 3000-3999 plies output by a control module. located the same wire number
and a postfix, i.e. 640A, 640B,
etc.
Table 107. Wires 400-599, 4000-5999
Figure 472.
Wires 400-599 These numbers are reserved for
and 1000-5999 instruments, sensors and vari-
able input/output signal wires
used in electronic systems. CAN
wires also use numbers in this
series.
Table 108. Wires 600-799, 6000-7999

Wires 600-799 These numbers are used for
and 6000-7999 earth wires. When the number
is printed on to a wire it is pre-
fixed by the Earth symbol. This
symbol is printed onto the wire,
it may however be omitted from General Points
harness drawings. Where a load 1. Wires continue to have the same number even
is switched negative, the wire after passing through a connector block to
number from the load to the another harness.
switch shall be different to that
of the wire from the switch to the 2. The descriptions are applicable to JCB
earth. specification wiring harnesses. The machine
may be installed with some wiring that does
not conform to the JCB specifications, typically
Figure 471. when it is part of equipment supplied by other
manufacturers.
600
Table 109. Wires 800-999, 8000-9999
Wires 800-999 These numbers are reserved
and 8000-9999 for switched supplies to electri-
cal loads, i.e. to lights, etc. Pow-
er supplies output by a control
module.
33 - 60 9813/8500-2 33 - 60
12 - Harness
00 - General
Repair 2. Using the correct sized splice, attach the new

section of wire required or auxiliary flying
Special Tools lead to the existing harness and secure using
Description Part No. Qty. the crimp tool. Note that each of the splices
Wiring Crimp Tool 892/00349 1 detailed is colour-coded to make size and range
readily visible. They are secured using the
Butane Heater 892/00350 1 corresponding size and matching colour-coded
jaws of the crimp tool to ensure joint security.
Consumables This tool also incorporates a ratchet closing
Description Part No. Size mechanism which will not release until the splice
Wiring Splice 892/00351 - is fully closed to the correct compression size.
(0.5-1.5mm Red,
Consumable: Wiring Splice (0.5-1.5mm Red,
contains 50 off)
contains 50 off)
Wiring Splice 892/00352 - Consumable: Wiring Splice (1.5-2.5mm Blue,
(1.5-2.5mm Blue, contains 50 off)
contains 50 off) Consumable: Wiring Splice (3-6mm Yellow,
Wiring Splice (3-6mm 892/00353 - contains 50 off)
Yellow, contains 50 off)
3. With the Butane heater assembly, seal the
Instances occur where it is necessary to incorporate connection.
auxiliary electrical components into existing electrical Special Tool: Butane Heater (Qty.: 1)
circuits and although unlikely with present wiring
harnesses, repair or replace specific individual wires 3.1. Remove the cap from the end of the
within a harness. This will also apply to other disposable gas cartridge.
machines in addition to those of manufacture.
Figure 474.
To make sure that either the inclusion of an auxiliary
electrical component or a repair within a harness is
completed to an acceptable standard it is strongly A
recommended that the following tools, equipment
and procedures are always used. Note that JCB
harnesses have an Ingress Protection rating of 67
(I.P.67). B
The sheath covering of the recommended splice is A Cap

heat shrunk onto the original wire insulation. This B Gas cartridge
results in a seal and corresponding joint to IP 67
specifications. 3.2. Before assembling the gas cartridge to the
reflector element, turn the red ring to the left,
Procedure (in the direction of the minus sign marked
on the ring).
1. Cut the wire and remove the protective insulation
for a suitable distance dependent upon the size Figure 475.
of wire and splice to be used.
Special Tool: Wiring Crimp Tool (Qty.: 1)
Figure 473.
A
C Reflector element
D Red ring
3.3. Position the tube hanging down from inside
the reflector assembly into the hole at the
top of the gas cartridge. Then press the gas
A Distance for splice (check size)
33 - 61 9813/8500-2 33 - 61
12 - Harness
00 - General
cartridge up into the reflector assembly as Figure 478.

far as possible until the two elements are
clasped firmly together. An audible click will
be heard.
Figure 476.
D Red ring
3.6. Hold the heater vertically and, using a
match or cigarette lighter, light the gas as
shown. Hold the heater vertically for 1 to 2
minutes until the catalytic reaction occurs.
This is indicated when the blue flame fades
3.4. Turn the small ring so that the air holes are and the ceramic element glows red. Then
completely closed. turn the small ring until the air holes at
are completely open. The tool is ready
Figure 477. for use. Note: The fact that the sound of
liquid cannot be heard when the cartridge is
shaken does not mean it is empty. No sound
will be heard even when the cartridge is full.
Figure 479.
E Small ring
F Air holes
3.5. Turn the red ring to the right (in the direction
of the plus sign) in order to turn on the E Small ring
gas. Important: Before turning the heater F Air holes
on, make sure that the cartridge is not hotter
than the reflector element. This may occur 3.7. The heater can be used in two modes:
if the cartridge is held in the hand for a long
time. The temperature difference between 3.8. Side wings down, reflector head completely
the cartridge and the reflector element may open. In this mode the infra-red heat waves
cause long yellow flames to appear on are dominant (recommended for the light
ignition. coloured plastic splices).
33 - 62 9813/8500-2 33 - 62
12 - Harness
00 - General
Figure 480. Check (Condition)
This section describes how to use electrical

measuring devices that are used in electrical fault
finding.
Use of Multimeters
In order to obtain the maximum benefit from the
fault finding information contained in the Electrical
Section, it is important that the technician fully
understands the approach to fault finding and the
use of the recommended test equipment, in this case
a FLUKE 85 or AVO 2003 digital multimeter, or a
moving pointer analogue multimeter. The approach
is based on a fault finding check list. In tracing
G Side wings the fault from the symptoms displayed you will be
directed to make measurements using a multimeter.
3.9. Side wings up, reflector head opening These instructions are intended to cover the use of
reduced. In this mode the heating is done the recommended meters.
only by the hot gas (use for dark coloured
plastic splices). 1. Make sure that the test leads are plugged into
the correct sockets. The black test lead should
Figure 481.
be plugged into the black socket (sometimes, this
socket is also marked by a -, or E or marked as
COMMON or COM). The red test lead should be
plugged into the red socket marked with +, V or
Ω.
2. When you make a measurement, make sure that
the test probes have a good clean contact with
bare metal, free from grease, dirt, and corrosion
as these can cause a false reading.
3. When you measure a voltage, make sure that
the correct range is selected, that it is set to the
selector value equal to or greater than that you
are about to measure. e.g. If asked to measure
12 Volts, set the selector to the 12V range. If
D Red ring there is no 12V range, set the selector to the next
G Side wings range higher, 20V for instance. If the meter is set
to a range that is too low, it may be damaged.
e.g. setting to the 2V range to measure 12V.
Measuring DC Voltage
1. Select the correct range on the multimeter.
1.1. On the digital multimeter, turn the switch to
position B.
33 - 63 9813/8500-2 33 - 63
12 - Harness
00 - General
Figure 482. Fluke 85 Multimeter Figure 483. AVO 2003 Multimeter
1.2. On the AV0 meter, move the right slider

switch to position A, and the left hand slider 1.3. On an analogue meter, turn the dial to the
switch to the appropriate range. appropriate DC Volts range.
Figure 484. Typical Analogue Multimeter
2. Connect the black probe to the nearest available

suitable earth point, usually this will be the starter
motor earth, the battery negative, or the chassis.
Connect the red probe to the wire or contact from
which you are measuring the voltage.
33 - 64 9813/8500-2 33 - 64
12 - Harness
00 - General
Measuring Resistance Measuring Frequency

1. Make sure that there is no power to the part of The AVO meter and the analogue meter are not
the circuit you are about to measure. capable of measuring frequency, therefore a digital
multimeter must be used.
2. Connect one probe at one end of the component
or wire to be checked and the other probe at the 1. Insert the black plug into the COM socket on
other end. It does not matter which way round the the meter and attach the probe to the nearest
two probes are placed. suitable earth point on the chassis, for example,
the battery negative terminal.
3. Select the correct range on the multimeter.
2. Insert the red probe into socket J.
3.1. On the digital multimeter. Turn the switch to
position C and check that the W sign at the 3. Turn the selector switch to position A and
right hand side of the display window is on. depress G repeatedly until F is highlighted on the
If the F sign is on instead, press the blue top row of the display.
button G to change the reading to Ω. Touch
the meter lead probes together and press 4. Press button H once.
the REL3 key on the meter to eliminate the
lead resistance from the meter reading. 5. Touch or connect the red probe to the frequency
source to be measured. Press and hold the
3.2. On the AV0 meter, move the right hand button if an average reading is required.
slider switch to position B, and the left hand
slider switch to the appropriate Ohms (Ω) Testing a Diode or a Diode Wire
range.
3.3. On an analogue meter, move the dial to the A diode wire is a diode with male connector installed
appropriate Ohms (Ω) range. on one end and a female connector installed on the
other end. The diode is sealed in heatshrink sleeving.
Measuring Continuity To test a Diode or a Diode Wire.
1. Make sure that there is no power to the part of 1. On the digital multimeter:
the circuit you are checking for continuity.
1.1. Turn the switch to position D.
2. Connect one probe to one end of the component 1.2. Press the HOLD button and check that the
or wire to be checked and the other probe to the H sign appears at the top right hand side of
other end. It does not matter which way round the the display window.
two probes are placed.
1.3. Connect the black probe to the end of the
3. Select the correct range on the multimeter. diode with a band or to the male connector
of the diode wire. Connect the red probe
3.1. On the digital multimeter, turn the switch to the other end of the diode or diode wire.
to position C and check that the beeper If the beeper does not sound the diode or
symbol appears at the left hand side of diode wire is faulty.
the display window. If the F sign is on
instead, press the button labelled F. If there 1.4. Connect the red probe to the end of the
is continuity in the circuit, the beeper will diode marked with a band, or to the male
sound. If there is no continuity (open circuit), connector of the diode wire, the black probe
the beeper will not sound. should be connected to the other end of the
diode or diode wire. If the beeper sounds or
3.2. On the AV0 meter, move the right hand the meter does not read O.L., the diode or
slider switch to position B, and the left diode wire is faulty.
hand slider switch to position C. If there is
continuity (i.e. very low resistance) between 1.5. Press the HOLD button and check that the
two points the buzzer will sound. H sign disappears from the right hand side
of the display window.
3.3. On an analogue meter, turn the dial to
the lowest Ohms (Ω) range. If there is 2. On the AV0 meter:
continuity (i.e. very low resistance) between
two points the needle will move across fully 2.1. Move the right hand slider to position A, and
(or almost fully) to the right hand side of the the left hand slider switch to position C.
scale. 2.2. Connect the black probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the red probe
should be connected to the other end of the
33 - 65 9813/8500-2 33 - 65
12 - Harness
00 - General
diode or diode wire. If the Avo meter does

not buzz the diode is faulty.
2.3. Connect the red probe to the end of the
diode marked with a band, or to the male
connector of the diode wire, the black probe
diode or diode wire. If the Avo meter does
not read 1 the diode is faulty.
3. On an analogue meter:
3.1. Select the Ohms 1000s (1k) range, connect
the black probe to the end of the diode
marked with a band, or to the male
connector of the diode wire, the red probe
diode or diode wire. The meter should read
20-400 kΩ, if it reads more than this the
diode is faulty.
3.2. Select the Ohms 100s range, connect the
red probe to the end of the diode marked
with a band, or to the male connector of
the diode wire, the black probe should
be connected to the other end of the
diode or diode wire. The meter should read
300-400Ω, if it reads less than this the diode
is faulty.
33 - 66 9813/8500-2 33 - 66
12 - Harness
03 - Main Frame
03 - Main Frame
Diagram

33 - 67 9813/8500-2 33 - 67
Notes:
33 - 68 9813/8500-2 33 - 68
12 - Harness
03 - Main Frame

1 2 3
4 5 6 7
8 9 10
-CH_C20#1
-CH_C20 7219/0002
TO PANELW/H CONN 2
-CH_C21
1 2
-CH_C19 1 2 3
PLEASE PROVIDE
4 5 6 7
7219/0006
8 9 10 11
SIDE VIEW
-CH_C21#1 12 13 14
332/E9928
TO PANELW/H CONN 3 -CH_C19#1
7219/0006
TO PANELW/H CONN 1
100 mm
50 mm
50 mm
50 mm
-CH_C4 50 mm
1 2
-CH_C13
-CH_C32
-CH_C4#1
7212/0044
PLEASE PROVIDE
TO FUELSENDER
SIDE-VIEW
NO END CAP
1 2
2 1
500 mm
-CH_C32#1
7000/3207
7212/0081
TO AUX SOLCONN
-P32 BLACK
-CH_C13#1
(SEE NOTES)
7212/0127
TO REAR HORN
50 mm
80 mm
100 mm
-CH
4 _C2
2
-CH_C17 _C2
02
TO
STA 7207/151
-CH RTE
7/13 R MOT4
720 ID
ENO OR
B+
R SOL -CH_SP010
RTE
STA FIT AFTER TEST
TO
-CH_C8
M6 50 mm 50 mm -CH_C8_CAP
M1
100 mm
-CH_C17#1 0
7201/0403
TO FRONTHORN +VE 7000/3207
-P33
OR
(MSSLp/n : 6260-3700 can be used)
200 mm
1 2
21
mm
400 mm
350 mm
270
7000/3207
FIX TO MAIN BUNDLE
0m
-P18 -CH_C8_CAP#1
100 mm
NATURAL
/3207
220
10
7000/3207 7212/0156 7000/3207
-P11
mm
-CH_C8#1
7000
7000
-P20 -P40
MATING PLUG DUMPSW
-P1 2
7212/0128
/320
HNC (WITHOUTDUMM YPLUG)

TO DUMPSW
FIT AFTER TEST

-CH_C15
-CH_C18 100 mm 750 mm 150 mm 100 mm 250 mm 300 mm 100 mm 100 mm 90 mm 90 mm 50 mm 50 mm 850 mm 250 mm 350 mm 50 mm -CH_C15_CAP
100 mm
7000/3215 7000/3207
7000/3207 7000/3207 7000/3207 7000/3207 7000/3207
-P5 HNC
-P6
HNC -P10
HNC -ID1 -P12
7000/3207
-P17 -P19 -CH_SP050 -P31 -CH_SP020 -CH_SP040 -CH_SP030 -P34
7000/3207
-P38
7000/3207
-P41
ID Label HNC
-CH_C18#1 HNC HNC
21
15
1 2
7201/0403
0m
NATURAL
TO FRONTHORN GND
-CH_C15#1 -CH_C15_CAP#1
m
OR
200 mm
7212/0128 7212/0156
m

500 mm
0m
TO REAR HORN SW MATING PLUG REAR HORN

7000/3207
50 mm 50 mm (WITHOUTDUMM YPLUG)
50
170 mm
-P21
330
-P7
M10
-P1 207
-CH_C25
7000/3215
0/3
3
7000/3207 7207/1514
700
m
HNC
700 mm
-P8 TO CHASSIS EARTH
HNC
700
m
-P9 07
HNC
0/32
7000/3202
-P2 7000/3207
-P39
HNC
FIT AFTER TEST
-CH_C9
-CH_C9_CAP 50 mm 200 mm
400 mm
mm
1 1 2
21 7000/3207
50
-P35
C1
M8 H_ 2 -CH_C9_CAP#1 NATURAL
7000/3207
-P22
-C
3
7212/0156 -CH_C9#1
_C
250 mm
MATING PLUG TRANS DUMP 7212/0128
H
-CH_C1#1
-C
(WITHOUTDUMM YPLUG) TO TRANS DUMP

7232/0023 7000/3207
-P24
-CH_C23 TO ALTERNATOR
7207/1419
-CH_C16
NO END CAP
TO ALTERNATOR B+ -CH_C7
750 mm
ADD CAP(MSS LP/N) :- 7102-0712 2 1 50 mm 250 mm 80 mm 80 mm 50 mm

-CH_C3#1 7000/3207 NO END CAP NO END CAP
-P14
7212/0081
2 1 2 1
HNC
100 mm
TO ENG OILPR SW
-CH_C7#1 7000/3207 7000/3207 7000/3203 -CH_C16#1
(SEE NOTES) -P23 -P25 -P3
7212/0081 7212/0081
TRANS OILPR SW TO FWD SOLENOID
(SEE NOTES)
50 mm
(SEE NOTES)
80 mm
7000/3203
-P4
M8
400
mm mm
1100
07 700 -P3
-CH_T1 0/326 0/327
7207/1417 700 -P3 07
50 mm
TO BATTERYGROUND
100 mm
-CH_C29
7000/3207
-P26
NO END CAP
-CH_C5
50 mm
50 mm
250 mm 2 1
50 mm NO END CAP
-CH_C29#1
2 1 NO END CAP
7212/0081
7000/3207 -CH_C5#1 TO HYDRACLAMP
-P15 2 1 (SEE NOTES)
7212/0081
HNC -CH_C14#1
TO WATER TEMPSENSOR -CH_C14
(SEE NOTES) 7212/0081
TO REVERSE SOL
PLEASE PROVIDE
PLEASE PROVIDE
(SEE NOTES)
1 2 3 1 2 3
250 mm
SIDE VIEW
SIDE VIEW
7000/3207
-P16
HNC 4 5 6 4 5 6
-CH_C31 -CH_C12#1 -CH_C11#1
300 mm -CH_C12 -CH_C11
60 mm NO END CAP
7216/0051
TO LH REAR COMBI
7216/0051
TO RH REAR COMBI
2 1
mm 250
200
7000/3207 -CH_C31#1
mm -P30
7212/0081
TO 4WD
07 (SEE NOTES)
0/32 700 -P29
700 -P27 0/32
07 GREEN POINT TAPE
50 mm
SUPPLIER P/N:- 40000302
600 mm
60 mm
50 mm
7000/3207
-P28
1 2
NATURAL
-CH_C2 -CH_C30#1
7212/0128 -CH_C10
NO END CAP
TO SPEED SENSOR -CH_C30
2 1
60 mm NO END CAP
-CH_C2#1
2 1
7212/0081
TO WATER TEMPSW -CH_C10#1
(SEE NOTES) 7212/0081
TO TRANS OIL TEMPSW
(SEE NOTES)
-CH_C33
NO END CAP
2 1
-CH_C33#1
7212/0081
TO PARK BRAKE SOLENOID
(SEE NOTES)
33 - 69 9813/8500-2 33 - 69
12 - Harness
03 - Main Frame
33-70 33-71
-CH_C4
-CH_C32
NO END CAP
2 1
-CH_C32#1
7212/0081
TO AUX SOLCONN
(SEE NOTES)
50 mm
80 mm
-CH_
4 C22
-CH_C17 C2
2
TO
STAR7207/15
-CH_ /130 14
07 TE
72 ID R MO
NO TO
LE R B+
R SO
TE
AR
ST
TO
M6
M1
-CH_C17#1 0
7201/0403
TO FRONTHORN +VE
OR
200 mm
mm
350 mm
270
7000/3207
FIX TO MAIN BUNDLE -P18
100 mm
-P1 07
220
/32
7000/3207
1
mm
70
7000
-P20
00
-P1 02
/32
HNC
-CH_C18 100 mm 750 mm 150 mm 100 mm 250 mm 300 mm 100 mm 100 mm

100 mm
7000/3215
7000/3207 7000/3207 7000/3207 7000/3207
-P5 HNC
-P6
HNC -P10
HNC -ID1 -P12
7000/3207
-P17 -P19 -CH_SP050
ID Label HNC
-CH_C18#1 HNC HNC
7201/0403
TO FRONTHORN GND
OR
200 mm
mm
500 mm
0
7000/3207
50
170 mm
-P21
330
-P7
7
-P /320
7000/3215
13
00
7000/3207
mm
HNC
70
-P8
HNC
70
-P 20
00
HNC
9 7
/3
HNC
FIT AFTER TEST
-CH_C9
-CH_C9_CAP 50 mm 200 mm
mm
1 1 2
21
50
C1
H_ 2 7000/3207
M8 -C
-CH_C9_CAP#1 NATURAL -P22
3
7212/0156 -CH_C9#1
_C
250 mm
MATING PLUG TRANS DUMP 7212/0128
H
-CH_C1#1 -C TO TRANS DUMP
(WITHOUTDUMM YPLUG)
7232/0023 7000/3207
-P24
-CH_C23 TO ALTERNATOR
7207/1419
NO END CAP
TO ALTERNATOR B+ -CH_C7
750 mm
ADD CAP(MSS LP/N) :- 7102-0712 2 1 50 mm 250 mm
-CH_C3#1 7000/3207 NO END CAP
-P14
7212/0081
2 1
HNC
100 mm
TO ENG OILPR SW
-CH_C7#1 7000/3207
(SEE NOTES) -P23
7212/0081
TRANS OILPR SW
(SEE NOTES)
M8
-CH_T1
7207/1417
TO BATTERYGROUND
100 mm
7000/3207
-P26
-CH_C5
250 mm
50 mm NO END CAP
2 1
7000/3207 -CH_C5#1
-P15
7212/0081
HNC TO WATER TEMPSENSOR
(SEE NOTES)
250 mm
7000/3207
-P16
HNC
m m 250
200 m m
7
/320 70 -P29
00 00
70 -P27 /320
7
50 mm
Page 33-71
600 mm
50 mm
7000/3207
-P28
1 2
NATURAL
-CH_C2 -CH_C30#1
7212/0128
NO END CAP
TO SPEED SENSOR -CH_C30
60 mm
2 1
-CH_C2#1
7212/0081
TO WATER TEMPSW
(SEE NOTES)
-CH_C33
NO END CAP
2 1
-CH_C33#1
7212/0081
(SEE NOTES)
33 - 70 9813/8500-2 33 - 70
12 - Harness
03 - Main Frame
33-70 33-71
1 2 3
4 5 6 7
8 9 10
-CH_C20#1
-CH_C20 7219/0002
TO PANELW/H CONN 2
-CH_C21
1 2
-CH_C19 1 2 3
PLEASE PROVIDE
4 5 6 7
7219/0006
8 9 10 11
SIDE VIEW
-CH_C21#1 12 13 14
332/E9928
TO PANELW/H CONN 3 -CH_C19#1
7219/0006
TO PANELW/H CONN 1
100 mm
50 mm
50 mm
50 m m
-CH_C4
m 50 m
1 2
-CH_C13
-CH_C4#1
7212/0044
PLEASE PROVIDE
TO FUELSENDER
SIDE-VIEW
1 2
500 mm
7000/3207
-P32 BLACK
-CH_C13#1
7212/0127
TO REAR HORN
80 mm
100 mm
-CH_SP010
FIT AFTER TEST
-CH_C8
50 mm 50 mm -CH_C8_CAP
100 mm
7000/3207
-P33
1 2
21
m
400 mm
350 mm
0m
NATURAL -CH_C8_CAP#1
10
7000/3207 7212/0156 7000/3207

-P20 -CH_C8#1 -P40
MATING PLUG DUMPSW
7212/0128
(WITHOUTDUMM YPLUG)
TO DUMPSW
FIT AFTER TEST

-CH_C15
100 mm 90 mm 90 mm 50 mm 50 mm 850 mm 250 mm 350 mm 50 mm -CH_C15_CAP
7000/3207 7000/3207 7000/3207

-P31 -CH_SP020 -CH_SP040 -CH_SP030 -P34 -P38
7000/3207
-P41
21
15
1 2
0m
NATURAL
-CH_C15#1 -CH_C15_CAP#1
m
200 mm
7212/0128 7212/0156
TO REAR HORN SW MATING PLUG REAR HORN
7000/3207
-P21 50 mm 50 mm (WITHOUTDUMM YPLUG)
M10 -CH_C25
7207/1514
700 mm
TO CHASSIS EARTH
7000/3202
-P2 7000/3207
-P39
50 mm 200 mm
400 mm
7000/3207
-P35
7000/3207
-P22
250 mm
7000/3207
-P24
-CH_C16
50 mm 250 mm 80 mm 80 mm 50 mm
NO END CAP
2 1
7000/3207 7000/3207 7000/3203 -CH_C16#1
-P23 -P25 -P3
7212/0081
TO FWD SOLENOID
50 mm
(SEE NOTES)
80 mm
7000/3203
-P4
400
0 mm mm
110
7 70 -P37
/320 00
00 /320
70 -P36
7
50 mm
100 mm
-CH_C29
7000/3207
-P26
NO END CAP
50 mm
50 mm
2 1
-CH_C29#1
NO END CAP
7212/0081
TO HYDRACLAMP
2 1 (SEE NOTES)
-CH_C14 -CH_C14#1
7212/0081
TO REVERSE SOL
PLEASE PROVIDE
PLEASE PROVIDE
(SEE NOTES)
1 2 3 1 2 3
SIDE VIEW
SIDE VIEW
4 5 6 4 5 6
-CH_C31 -CH_C12#1 -CH_C11#1
300 mm -CH_C12 -CH_C11
60 mm NO END CAP
7216/0051
TO LH REAR COMBI
7216/0051
TO RH REAR COMBI
2 1
m m 250
200
7000/3207 -CH_C31#1
mm -P30
7212/0081
TO 4WD
7 (SEE NOTES)
/320 70 -P29
00 00
70 -P27 /320
7 GREEN POINT TAPE
SUPPLIER P/N:- 40000302
Page 33-70
600 mm
60 mm
50 mm
7000/3207
-P28
TURAL
-CH_C30#1
7212/0128 -CH_C10
O SPEED SENSOR -CH_C30
60 mm
NO END CAP
2 1
-CH_C10#1
7212/0081
TO TRANS OIL TEMPSW
(SEE NOTES)
-CH_C33
NO END CAP
2 1
-CH_C33#1
7212/0081
(SEE NOTES)
33 - 71 9813/8500-2 33 - 71
12 - Harness
03 - Main Frame
33 - 72 9813/8500-2 33 - 72
12 - Harness
03 - Main Frame

-CH_C1 TO ALTERNATOR -CH_C11 TO RH REAR COMBI -CH_C19 TO PANELW/H CONN 1 -CH_C29 TO HYDRACLAMP
Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal
1 412 1.00 mm² -CH_C19:11 1 7210/0100 1 805 1.00 mm² -CH_C12:6 1 920 1.00 mm² -CH_C19:14
2 407 1.00 mm² -CH_C19:7 2 811C 1.00 mm² -CH_SP030:S 2 103 1.00 mm² -CH_C32:1 2 600X 1.00 mm² -CH_SP020:S
3 600L 1.00 mm² -CH_SP020:S 3 403 1.00 mm² -CH_C3:1
7232/0023 2 WAY250 E TFEM HSG UNSEALED 4 816A 1.00 mm² -CH_SP040:S 4 404 1.00 mm² -CH_C10:1 7212/0081 2 WAYDT06 SOC HSG NO END CAP
Additional Components 5 830 1.00 mm² -CH_C19:10 5 405 1.00 mm² -CH_C7:1 Additional Components
6 806 1.00 mm² -CH_C20:7 6 406 1.00 mm² -CH_C2:1 7243/0361;1 # 2W DT06 Orange wedge (HP's onl y, unsealed)
-CH_C2 TO WATER TEMPSW 7 407 1.00 mm² -CH_C1:2
Cav Id Tag Size Destination Cavity Seal 7216/0051 6 WAYMT090 FEM HSG N ATURAL 8 408 1.00 mm² -CH_C4:B -CH_C30 TO SPEED SENSOR
1 406 1.00 mm² -CH_C19:6 Additional Components 9 409 1.00 mm² -CH_C5:1 Cav Id Tag Size Destination Cavity Seal
2 600E 1.00 mm² -CH_SP020:S 10 830 1.00 mm² -CH_C11:5 1 600P 1.00 mm² -CH_SP020:S
-CH_C12 TO LH REAR COMBI 11 412 1.00 mm² -CH_C1:1 2 974 1.00 mm² -CH_C20:5
7212/0081 2 WAYDT06 SOC HSG NO END CAP Cav Id Tag Size Destination Cavity Seal 12 921A 1.00 mm² -CH_C15:2
Additional Components 1 7210/0100 13 934A 1.00 mm² -CH_SP010:S 7212/0128 2 WAYMT090 FEM HSG N ATURAL
7212/0031;1 # 2 Way DT06 Wedge 2 811B 1.00 mm² -CH_SP030:S 14 920 1.00 mm² -CH_C29:1 Additional Components
3 600Z 1.00 mm² -CH_SP020:S
4 816B 1.00 mm² -CH_SP040:S 7219/0006 14 Way HW090 Pin Housing -CH_C31 TO 4WD
-CH_C3 TO ENG OILPR SW
5 829 1.00 mm² -CH_C20:10 Additional Components Cav Id Tag Size Destination Cavity Seal
Cav Id Tag Size Destination Cavity Seal
6 805 1.00 mm² -CH_C19:1 7219/0008 1 878 1.00 mm² -CH_C20:9
1 403 1.00 mm² -CH_C19:3
2 600W 1.00 mm² -CH_SP020:S
2 600C 1.00 mm² -CH_SP020:S
7216/0051 6 WAYMT090 FEM HSG N ATURAL -CH_C20 TO PANELW/H CONN 2
Additional Components Cav Id Tag Size Destination Cavity Seal 7212/0081 2 WAYDT06 SOC HSG NO END CAP
7212/0081 2 WAYDT06 SOC HSG NO END CAP
1 811 1.50 mm² -CH_SP030:S Additional Components
Additional Components
7212/0031;1 # 2 Way DT06 Wedge -CH_C13 TO REAR HORN 2 812 1.50 mm² -CH_C16:1 7212/0031;1 # 2 Way DT06 Wedge
Cav Id Tag Size Destination Cavity Seal 3 814 1.50 mm² -CH_C17:1
1 811A 1.00 mm² -CH_SP030:S 4 816 1.00 mm² -CH_SP040:S -CH_C32 TO AUX SOLCONN
-CH_C4 TO FUELSENDER 5 974 1.00 mm² -CH_C30:2
2 600V 1.00 mm² -CH_SP020:S Cav Id Tag Size Destination Cavity Seal
6 1936 1.00 mm² -CH_C33:1 1 103 1.00 mm² -CH_C19:2
1 611A 1.00 mm² -CH_SP050:S 7212/0127 2 WAYMT090 FEM HSG BLACK 7 806 1.00 mm² -CH_C11:6 2 600D 1.00 mm² -CH_SP020:S
2 408 1.00 mm² -CH_C19:8 Additional Components 8 611B 2.00 mm² -CH_SP050:S
9 878 1.00 mm² -CH_C31:1 7212/0081 2 WAYDT06 SOC HSG NO END CAP
7212/0044 2 Way Superseal Recept Housing
-CH_C14 TO REVERSE SOL 10 829 1.00 mm² -CH_C12:5 Additional Components
Cav Id Tag Size Destination Cavity Seal 7212/0031;1 # 2 Way DT06 Wedge
7219/0002 10 Way HW090 Pin Housing 332/E0988;1 # Deutsch DT04 2 Way Blanking Cap
1 811D 1.50 mm² -CH_SP030:S
-CH_C5 TO WATER TEMPSENSOR 2 600M 1.50 mm² -CH_SP020:S
Cav Id Tag Size Destination Cavity Seal 7219/0004;1 # 10 Way HW090 Pin Retainer -CH_C33 TO PARK BRAKE SOLENOID
1 409 1.00 mm² -CH_C19:9 7212/0081 2 WAYDT06 SOC HSG NO END CAP Cav Id Tag Size Destination Cavity Seal
2 600F 1.00 mm² -CH_SP020:S Additional Components TO PANELW/H CONN 3 1 1936 1.00 mm² -CH_C20:6
-CH_C21
7212/0031;1 # 2 Way DT06 Wedge Cav Id Tag Size Destination Cavity Seal 2 600K 1.00 mm² -CH_SP020:S
1 600U 8.00 mm² -CH_C25:1
Additional Components 7212/0081 2 WAYDT06 SOC HSG NO END CAP
2 842 6.00 mm² -CH_C24:1
7243/0361;1 # 2W DT06 Orange wedge (HP's onl y, unsealed) -CH_C15 TO REAR HORN SW Additional Components
Cav Id Tag Size Destination Cavity Seal 332/E9928 2 Way DL305 Male Hsg 7212/0031;1 # 2 Way DT06 Wedge
1 600R 1.00 mm² -CH_SP020:S Additional Components
-CH_C7 TRANS OILPR SW 2 921A 1.00 mm² -CH_C19:12
Cav Id Tag Size Destination Cavity Seal -CH_T1 TO BATTERYGROUND
-CH_C22 TO STARTER MOTOR B+ Cav Id Tag Size Destination Cavity Seal
1 405 1.00 mm² -CH_C19:5 7212/0128 2 WAYMT090 FEM HSG N ATURAL Cav Id Tag Size Destination Cavity Seal 1 611 2.00 mm² -CH_SP050:S
2 600J 1.00 mm² -CH_SP020:S Additional Components 1 200 16.00 mm² -CH_C23:1
7207/1417 Ring Terminal M8 1.0-2.5
7212/0081 2 WAYDT06 SOC HSG NO END CAP 7207/1514 Ring Terminal M10 10.0-16.0 Additional Components
Additional Components -CH_C16 TO FWD SOLENOID Additional Components
7000/3212 ; 45
7243/0361;1 # 2W DT06 Orange wedge (HP's onl y, unsealed) Cav Id Tag Size Destination Cavity Seal 7000/3212 ; 45
1 812 1.50 mm² -CH_C20:2 SPLICE CHASIS EARTH
-CH_SP020
-CH_C8 TO DUMPSW 2 600N 1.50 mm² -CH_SP020:S -CH_C23 TO ALTERNATOR B+ Cav Id Tag Size Destination Cavity Seal
Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal S 600B 1.00 mm² -CH_C10:2
7212/0081 2 WAYDT06 SOC HSG NO END CAP 1 200 16.00 mm² -CH_C22:1
1 934C 1.00 mm² -CH_SP010:S S 600C 1.00 mm² -CH_C3:2
2 600T 1.00 mm² -CH_SP020:S S 600E 1.00 mm² -CH_C2:2
7243/0361;1 # 2W DT06 Orange wedge (HP's onl y, unsealed) 7207/1419 Ring Terminal M8 10.0-16.0
S 600F 1.00 mm² -CH_C5:2
7212/0128 2 WAYMT090 FEM HSG N ATURAL Additional Components
S 600H 1.00 mm² -CH_C9:2
Additional Components 7000/3212 ; 45
-CH_C17 TO FRONTHORN +VE S 600J 1.00 mm² -CH_C7:2
Cav Id Tag Size Destination Cavity Seal S 600L 1.00 mm² -CH_C11:3
-CH_C24 TO STARTER SOLENOID
TO TRANS DUMP 1 814 1.50 mm² -CH_C20:3 S 600Z 1.00 mm² -CH_C12:3
-CH_C9 Cav Id Tag Size Destination Cavity Seal
Cav Id Tag Size Destination Cavity Seal S 600V 1.00 mm² -CH_C13:2
7201/0403 1 Way Pos Lock Housing Straight 1 842 6.00 mm² -CH_C21:2
1 934B 1.00 mm² -CH_SP010:S S 600R 1.00 mm² -CH_C15:1
Additional Components S 600X 1.00 mm² -CH_C29:2
2 600H 1.00 mm² -CH_SP020:S 7207/1302 Ring Terminal M6 4.0-6.0
Additional Components S 600P 1.00 mm² -CH_C30:1
7212/0128 2 WAYMT090 FEM HSG N ATURAL -CH_C18 TO FRONTHORN GND 7000/3212;45 # Adhesive Lined Heatshrink S 600M 1.50 mm² -CH_C14:2
Additional Components Cav Id Tag Size Destination Cavity Seal S 600N 1.50 mm² -CH_C16:2
1 600A 1.50 mm² -CH_SP020:S -CH_C25 TO CHASSIS EARTH S 600W 1.00 mm² -CH_C31:2
-CH_C10 TO TRANS OIL TEMPSW Cav Id Tag Size Destination Cavity Seal S 600D 1.00 mm² -CH_C32:2
Cav Id Tag Size Destination Cavity Seal 7201/0403 1 Way Pos Lock Housing Straight 1 600 8.00 mm² -CH_SP020:S S 600K 1.00 mm² -CH_C33:2
1 404 1.00 mm² -CH_C19:4 Additional Components 1 600U 8.00 mm² -CH_C21:1 S 600 8.00 mm² -CH_C25:1
2 600B 1.00 mm² -CH_SP020:S S 600A 1.50 mm² -CH_C18:1
-CH_SP030 SPLICE REVERSE LAMP 7207/1514 Ring Terminal M10 10.0-16.0 S 600T 1.00 mm² -CH_C8:2
7212/0081 2 WAYDT06 SOC HSG NO END CAP Additional Components
Additional Components 7000/3104 In Line Ultrasonic Splice
S 811C 1.00 mm² -CH_C11:2 7000/3212 ; 45
7212/0031;1 # 2 Way DT06 Wedge S 811B 1.00 mm² -CH_C12:2 Additional Components
-CH_SP040 SPLICE BRAKE LAMP 7000/3212 ; 45
S 811A 1.00 mm² -CH_C13:1
-CH_SP050 SPLICE_GND Cav Id Tag Size Destination Cavity Seal
S 811 1.50 mm² -CH_C20:1
Cav Id Tag Size Destination Cavity Seal S 816A 1.00 mm² -CH_C11:4 -CH_SP010 SPLICE DUMP TRANS
S 811D 1.50 mm² -CH_C14:1
S 611A 1.00 mm² -CH_C4:A S 816B 1.00 mm² -CH_C12:4 Cav Id Tag Size Destination Cavity Seal
S 611 2.00 mm² -CH_T1:1 7000/3104 In Line Ultrasonic Splice S 816 1.00 mm² -CH_C20:4 S 934C 1.00 mm² -CH_C8:1
S 611B 2.00 mm² -CH_C20:8 Additional Components S 934B 1.00 mm² -CH_C9:1
7000/3104 In Line Ultrasonic Splice S 934A 1.00 mm² -CH_C19:13
7000/3212 ; 45
7000/3104 In Line Ultrasonic Splice Additional Components
Additional Components 7000/3212 ; 45 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45 Additional Components
7000/3212 ; 45
33 - 73 9813/8500-2 33 - 73
12 - Harness
03 - Main Frame
33-74 33-75
-CH_C1 TO ALTERNATOR -CH_C11 TO RH REAR COMBI

Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal
1 412 1.00 mm² -CH_C19:11 1 7210/0100
2 407 1.00 mm² -CH_C19:7 2 811C 1.00 mm² -CH_SP030:S
3 600L 1.00 mm² -CH_SP020:S
7232/0023 2 WAY250 E TFEM HSG UNSEALED 4 816A 1.00 mm² -CH_SP040:S
Additional Components 5 830 1.00 mm² -CH_C19:10
6 806 1.00 mm² -CH_C20:7
-CH_C2 TO WATER TEMPSW
Cav Id Tag Size Destination Cavity Seal 7216/0051 6 WAYMT090 FEM HSG N ATURAL
1 406 1.00 mm² -CH_C19:6 Additional Components
2 600E 1.00 mm² -CH_SP020:S
-CH_C12 TO LH REAR COMBI
7212/0081 2 WAYDT06 SOC HSG NO END CAP Cav Id Tag Size Destination Cavity Seal
Additional Components 1 7210/0100
7212/0031;1 # 2 Way DT06 Wedge 2 811B 1.00 mm² -CH_SP030:S
3 600Z 1.00 mm² -CH_SP020:S
TO ENG OILPR SW 4 816B 1.00 mm² -CH_SP040:S
-CH_C3
Cav Id Tag Size Destination Cavity Seal 5 829 1.00 mm² -CH_C20:10
1 403 1.00 mm² -CH_C19:3 6 805 1.00 mm² -CH_C19:1
2 600C 1.00 mm² -CH_SP020:S
7216/0051 6 WAYMT090 FEM HSG N ATURAL
7212/0081 2 WAYDT06 SOC HSG NO END CAP Additional Components
7212/0031;1 # 2 Way DT06 Wedge -CH_C13 TO REAR HORN
1 811A 1.00 mm² -CH_SP030:S
-CH_C4 TO FUELSENDER
2 600V 1.00 mm² -CH_SP020:S
1 611A 1.00 mm² -CH_SP050:S 7212/0127 2 WAYMT090 FEM HSG BLACK
7212/0044 2 Way Superseal Recept Housing

Additional Components -CH_C14 TO REVERSE SOL
1 811D 1.50 mm² -CH_SP030:S
-CH_C5 TO WATER TEMPSENSOR 2 600M 1.50 mm² -CH_SP020:S
2 600F 1.00 mm² -CH_SP020:S Additional Components
7212/0031;1 # 2 Way DT06 Wedge
7243/0361;1 # 2W DT06 Orange wedge (HP's onl y, unsealed) -CH_C15 TO REAR HORN SW
Page 33-75
1 600R 1.00 mm² -CH_SP020:S
-CH_C7 TRANS OILPR SW 2 921A 1.00 mm² -CH_C19:12
1 405 1.00 mm² -CH_C19:5 7212/0128 2 WAYMT090 FEM HSG N ATURAL
2 600J 1.00 mm² -CH_SP020:S Additional Components

Additional Components -CH_C16 TO FWD SOLENOID
7243/0361;1 # 2W DT06 Orange wedge (HP's onl y, unsealed) Cav Id Tag Size Destination Cavity Seal
1 812 1.50 mm² -CH_C20:2
TO DUMPSW 2 600N 1.50 mm² -CH_SP020:S
-CH_C8
1 934C 1.00 mm² -CH_SP010:S
2 600T 1.00 mm² -CH_SP020:S
7243/0361;1 # 2W DT06 Orange wedge (HP's onl y, unsealed)
7212/0128 2 WAYMT090 FEM HSG N ATURAL
Additional Components TO FRONTHORN +VE
-CH_C17
TO TRANS DUMP 1 814 1.50 mm² -CH_C20:3
-CH_C9
7201/0403 1 Way Pos Lock Housing Straight
1 934B 1.00 mm² -CH_SP010:S
2 600H 1.00 mm² -CH_SP020:S
7212/0128 2 WAYMT090 FEM HSG N ATURAL -CH_C18 TO FRONTHORN GND

Additional Components Cav Id Tag Size Destination Cavity Seal
1 600A 1.50 mm² -CH_SP020:S
-CH_C10 TO TRANS OIL TEMPSW
Cav Id Tag Size Destination Cavity Seal 7201/0403 1 Way Pos Lock Housing Straight
2 600B 1.00 mm² -CH_SP020:S
-CH_SP030 SPLICE REVERSE LAMP
S 811C 1.00 mm² -CH_C11:2
7212/0031;1 # 2 Way DT06 Wedge S 811B 1.00 mm² -CH_C12:2
S 811A 1.00 mm² -CH_C13:1
-CH_SP050 SPLICE_GND
S 811 1.50 mm² -CH_C20:1
S 811D 1.50 mm² -CH_C14:1
S 611A 1.00 mm² -CH_C4:A
S 611 2.00 mm² -CH_T1:1 7000/3104 In Line Ultrasonic Splice
S 611B 2.00 mm² -CH_C20:8 Additional Components
7000/3212 ; 45
7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
33 - 74 9813/8500-2 33 - 74
12 - Harness
03 - Main Frame
33-74 33-75
-CH_C19 TO PANELW/H CONN 1 -CH_C29 TO HYDRACLAMP

1 805 1.00 mm² -CH_C12:6 1 920 1.00 mm² -CH_C19:14
2 103 1.00 mm² -CH_C32:1 2 600X 1.00 mm² -CH_SP020:S
3 403 1.00 mm² -CH_C3:1
6 406 1.00 mm² -CH_C2:1 7243/0361;1 # 2W DT06 Orange wedge (HP's onl y, unsealed)
7 407 1.00 mm² -CH_C1:2
8 408 1.00 mm² -CH_C4:B -CH_C30 TO SPEED SENSOR
9 409 1.00 mm² -CH_C5:1 Cav Id Tag Size Destination Cavity Seal
10 830 1.00 mm² -CH_C11:5 1 600P 1.00 mm² -CH_SP020:S
11 412 1.00 mm² -CH_C1:1 2 974 1.00 mm² -CH_C20:5
12 921A 1.00 mm² -CH_C15:2
13 934A 1.00 mm² -CH_SP010:S 7212/0128 2 WAYMT090 FEM HSG N ATURAL
7219/0006 14 Way HW090 Pin Housing -CH_C31 TO 4WD

7219/0008 1 878 1.00 mm² -CH_C20:9
2 600W 1.00 mm² -CH_SP020:S
-CH_C20 TO PANELW/H CONN 2
Cav Id Tag Size Destination Cavity Seal 7212/0081 2 WAYDT06 SOC HSG NO END CAP
1 811 1.50 mm² -CH_SP030:S Additional Components
2 812 1.50 mm² -CH_C16:1 7212/0031;1 # 2 Way DT06 Wedge
3 814 1.50 mm² -CH_C17:1
4 816 1.00 mm² -CH_SP040:S -CH_C32 TO AUX SOLCONN
5 974 1.00 mm² -CH_C30:2 Cav Id Tag Size Destination Cavity Seal
6 1936 1.00 mm² -CH_C33:1 1 103 1.00 mm² -CH_C19:2
7 806 1.00 mm² -CH_C11:6 2 600D 1.00 mm² -CH_SP020:S
8 611B 2.00 mm² -CH_SP050:S
7212/0031;1 # 2 Way DT06 Wedge
7219/0002 10 Way HW090 Pin Housing 332/E0988;1 # Deutsch DT04 2 Way Blanking Cap
7219/0004;1 # 10 Way HW090 Pin Retainer -CH_C33 TO PARK BRAKE SOLENOID
-CH_C21 TO PANELW/H CONN 3 1 1936 1.00 mm² -CH_C20:6
Cav Id Tag Size Destination Cavity Seal 2 600K 1.00 mm² -CH_SP020:S
1 600U 8.00 mm² -CH_C25:1
332/E9928 2 Way DL305 Male Hsg 7212/0031;1 # 2 Way DT06 Wedge
Page 33-74
-CH_T1 TO BATTERYGROUND
-CH_C22 TO STARTER MOTOR B+ Cav Id Tag Size Destination Cavity Seal
Cav Id Tag Size Destination Cavity Seal 1 611 2.00 mm² -CH_SP050:S
1 200 16.00 mm² -CH_C23:1
7207/1417 Ring Terminal M8 1.0-2.5
7207/1514 Ring Terminal M10 10.0-16.0 Additional Components
7000/3212 ; 45
7000/3212 ; 45
-CH_SP020 SPLICE CHASIS EARTH
-CH_C23 TO ALTERNATOR B+ Cav Id Tag Size Destination Cavity Seal
Cav Id Tag Size Destination Cavity Seal S 600B 1.00 mm² -CH_C10:2
1 200 16.00 mm² -CH_C22:1 S 600C 1.00 mm² -CH_C3:2
S 600E 1.00 mm² -CH_C2:2
7207/1419 Ring Terminal M8 10.0-16.0
S 600F 1.00 mm² -CH_C5:2
S 600H 1.00 mm² -CH_C9:2
7000/3212 ; 45
S 600J 1.00 mm² -CH_C7:2
S 600L 1.00 mm² -CH_C11:3
-CH_C24 TO STARTER SOLENOID
S 600Z 1.00 mm² -CH_C12:3
S 600V 1.00 mm² -CH_C13:2
1 842 6.00 mm² -CH_C21:2
S 600R 1.00 mm² -CH_C15:1
7207/1302 Ring Terminal M6 4.0-6.0 S 600X 1.00 mm² -CH_C29:2
Additional Components S 600P 1.00 mm² -CH_C30:1
7000/3212;45 # Adhesive Lined Heatshrink S 600M 1.50 mm² -CH_C14:2
S 600N 1.50 mm² -CH_C16:2
-CH_C25 TO CHASSIS EARTH S 600W 1.00 mm² -CH_C31:2
Cav Id Tag Size Destination Cavity Seal S 600D 1.00 mm² -CH_C32:2
1 600 8.00 mm² -CH_SP020:S S 600K 1.00 mm² -CH_C33:2
1 600U 8.00 mm² -CH_C21:1 S 600 8.00 mm² -CH_C25:1
S 600A 1.50 mm² -CH_C18:1
7207/1514 Ring Terminal M10 10.0-16.0 S 600T 1.00 mm² -CH_C8:2
7000/3212 ; 45 7000/3104 In Line Ultrasonic Splice
-CH_SP040 SPLICE BRAKE LAMP 7000/3212 ; 45
S 816A 1.00 mm² -CH_C11:4 -CH_SP010 SPLICE DUMP TRANS
S 816B 1.00 mm² -CH_C12:4 Cav Id Tag Size Destination Cavity Seal
S 816 1.00 mm² -CH_C20:4 S 934C 1.00 mm² -CH_C8:1
S 934B 1.00 mm² -CH_C9:1
7000/3104 In Line Ultrasonic Splice S 934A 1.00 mm² -CH_C19:13
7000/3212 ; 45 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
33 - 75 9813/8500-2 33 - 75
12 - Harness
18 - Side Console
18 - Side Console
Diagram

33 - 76 9813/8500-2 33 - 76
12 - Harness
18 - Side Console

RELAY A,B & C TO BE GROUPED TOGETHER. RELAY D & E TO BE GROUPED TOGETHER.
A B C D E
F C G F C G F C G -IP_C23#2 F C G F C G
-IP_C22#2 7241/0058
D D D D D -IP_C15#1
7241/0058 TO IGN RELAY - 2 E B E B -IP_C35#1
E B E B E B
7219/0013 7219/0013
TO IGN RELAY -1
A A A A A TO REAR WL SW TO PARK BRAKE SW
H J H J H J H J H J
-IP_C33#2 -IP_C24#2 -IP_C26#2 10 9 10 9

7241/0058 NOTE: USE SUITABLE TERMINALS FOR MINI REA LY BASE 7241/0058 1 2 3 4 3 6 3 6
7241/0058
TO NEUTRAL START RELAY TO BUZZER 2 5 2 5
TO FLASHER 5 6 7 8
10 9 10 9
1 4 1 4
-IP_C23 9 10 11 12
-IP_C2 3 6
8 7 8 7
3 6
2 5 2 5
C
13 14 15 16
1 4
-IP_C14 -IP_C15 -IP_C35 -IP_C40 1 4
17 18 19 20
8 7 8 7
21 22 23 24
-IP_C33 -IP_C14#1 -IP_C40#1
25 26 27 28
7219/0013 7219/0013
B -IP_C24
29 30 31 32
TO FRONT WL SW TO 4WD SWITCH
33 34 35 36
GROMMET DIA 56 BLACK
D 7100-0567(MSSL NUMBER)
INSTRUMEN T CLUSTER
-IP_C2#1
75 mm
70 mm
70 mm
70 mm
70 mm
7239/0031
115 mm
10 TO INSTRUMENT CLUSTER -IP_C005

0m
m
m
0m
3 2 1
7 6 5 4
10
10 9 8
-IP_C1#1 -IP_C3#1
-IP_C005#1 7234/0003 8 7236/0003
2 1
10
7219/0001 TO IGN SW
9 TO IGN SW 1
TO LIVELINK HARNESS
7
4 -IP_C1
5 6 -IP_C7 3 2 1
-IP_C26
115 mm 100 mm
100 mm
3 -IP_ 4
7219/0005
7 6 5
SPOT TAPE SPOT TAPE SPOT TAPE SPOT TAPE C3
A
11 10 9 8
50 mm
7000/3207
50 14 13 12
mm
-P71
mm
50
-IP_C22 -IP_C10 10 18
-IP_C11
mm
50
10 9
3 17
mm
-IP_C17 3 6
2 5
50
2 5
4 3 2 1 1 4 -IP_C7#1
75 mm
1 4
8 7 7219/0005
8 7
8 7 6 5 TO RH COLUMN SW
70 mm -IP_C36 -IP_C11#1
-IP_C10#1
-IP_SP080 50 mm 10 9
7219/0013 7219/0014
75 mm
75 mm
75 mm
3 6 TO HEAD LAMP SW TO HAZARD SW
-IP_C17#1
50 mm
75 mm
2 5
7218/0001
75 mm
1 4
100 mm
7000/3207 7000/3207
50 mm
-P51 SPOT TAPE 8 7
TO W/H CAB CONN 1 BLUE POINT TAPE
-P43
7000/3207 -IP_C36#1
-P42
7219/0013
75
mm
100 mm
TO SIDE SHIFT SW
mm
75
150 mm
-P6 09
0/32
-IP_SP260
3
700
-P60/3
700
-IP_C18
4
50 mm
209
-IP_SP330 PLEASE PROVIDE 1 2
SIDE VIEW
3
50 mm
-IP_C18#1
-IP_C6 -IP_SP160 -IP_C5
50 mm
7213/0066
100 mm TO W/H CAB CONN 2
100 mm
1 -IP_SP140 50 mm
-IP_SP270 7000/3209
-P67
-IP_SP280
2 7000/3203
-P1
25 mm
100 mm
-IP_C6#1
100 mm
50 mm
7232/0023
mm 1
175
100 mm
TO RADIO
07
200 mm
0/320
700 -P6 2 7000/3209
-P61
-IP_C37
75 mm
-IP_SP340
7000/3207
-P62 50 mm 50 mm 7
3
6
2
5
1
-IP_C5#1
11 10 9 8
-IP_FB1#1 -IP_SP210
7219/0005
50
14 13 12
7241/0054 -IP_SP030 7232/0023

WHITE POINT TAPE
mm
FUSEBOX TO MOBILE CHARGER
4 3 2 1 10 -IP_C37#1
100 mm
0m
FUSE PULER
7219/0005
-IP_SP070
75 mm
5A-FU3
15A-FU1
m
5A-FU4
10A-FU2
7000/3207 TO WARNING CLUSTER
50 mm
100 mm
-P44
8 7 6 5 FIX TO MAIN BRANCH
700 -P5
mm
7000/3209
100
-P66
12 11 10 9 -IP_FB1 0/3 2
207
5A-FU8
10A-FU6
15A-FU5
10A-FU7
SPARE FUSE
16 15 14 13
5A-FS1
-IP_C12
20 19 18 17 80 mm 40 mm 30 mm 30 mm 40 mm 25 mm 25 mm 25 mm 50 mm 50 mm 25 mm 25 mm 25 mm 50 mm 80 mm 50 mm 50 mm 45 mm 75 mm 100 mm 50 mm 50 mm 1050 mm 100 mm 100 mm 100 mm 450 mm 50 mm 110 mm 80 mm 3 2 1
30 mm
3A-FU11
3A-FU12
5A-FU10
4
10A-FU9
7 6 5
11 10 9 8
24 23 22 21 14 13 12
SPARE FUSE
7219/0005
28 27 26 25 -IP_SP240 -IP_SP060
7000/3203
-IP_SP150 7000/3207
10A-FS2
-IP_SP350 -IP_SP010 7000/3202

-P4
7000/3207
-P59 -IP_SP300 -IP_SP252 -IP_SP100 -IP_SP290 7000/3207
-P56 -IP_SP380 -P57 7000/3203
-P48 -IP_SP220 -IP_SP230 -IP_SP170 -IP_SP020 7000/3207 -IP_SP120 -P5 -IP_SP251 -IP_SP110 -IP_SP090 7000/3207
-P3 -IP_SP050 7000/3203
-P68
15A-FU16
3A-FU15
7.5A-FU14
7.5A-FU13
30 mm
50
SLIT PVC TUBE WITH OVERLAP TAPE -P6 ID Label

-ID1
32 31 30 29 25
mm
7000/3207 -IP_C12#1
-P53
mm
40 mm
25 mm
7219/0005
36 35 34 33
70 mm
SPARE FUSE
TO LH COLUMN SW
1300 mm 50 mm
FIX TO MAIN BRANCH
15A-FU20
-IP_C38
15A-FU18
15A-FS3
15A-FU19
15A-FU17
PLEASE PROVIDE -IP_SP200 FIX TO MAIN BRANCH

40 39 38 37 SIDE VIEW
44 43 42 41 7000/3207
SPARE FUSE
30 mm
-P58 -IP_C39
10A-FU23
10A-FU22
20A-FU24
15A-FU21
30 mm 300 mm
300 mm
20A -FS4
100 mm
-IP_SP130
SPOT TAPE SPOT TAPE
48 47 46 45 2 1
50 mm 1 2 3 7000/3207
-P69
7000/3207
-P70
40 mm
-IP_C38#1 4 5 6
-IP_SP320 7000/3207
7212/0141 -IP_SP360 -P55
TO PARK BRAKE SW - 2
30 mm
50 mm
-IP_C39#1
7216/0052
50 mm
TO SPEEDOMETER
-IP_SP180
-IP_C21
-IP_SP310
50 mm
FUSE PULER
5A 5A 10A 15A
30 mm
40 mm
7000/3202
LIVELINK, IHAZARD SW BRK LAMP PRK BRK, -P2
SPEEDOMETER IGN HYDRACLAMP SLIT PVC TUBE WITH OVERLAP TAPE
SPOT TAPE
50 mm
SPARE FUSE
5A 10A 10A 15A -IP_SP190

5A
HORN -IP_SP040
50 mm
50 mm
CLUSTERS 4WD, AUX SOL WIPER, 2
1
30 mm
(IGN) WASHER -IP_C20 1 2

(IGN) INSERT AFTER TEST FIX TO MAIN BRANCH
3 4
3 4
-IP_C41 -IP_C9#1
40 mm
-IP_C41_CAP
200 mm 50 mm 7214/0068 -IP_C4#1
SPARE FUSE
3A 3A 5A 10A 50 mm 3 2 1
TO DIODE - I
-IP_C4
7214/0068
LL GND ALT W IGN RELAYS FACE FAN -IP_C42 7 6 5 4 -IP_C9 TO DIODE -II
10A
10 9 8
1 -IP_SP250
7000/3202 SPOT TAPE
PLEASE PROVIDE
-P45
SIDE VIEW
21 1 2
1 2
SPARE FUSE
50 A C A C
mm
NATURAL 2 1
15A 3A 7.5A 7.5A
135 -IP_C41_CAP#1
7212/0156
-IP_C41#1
-IP_C20#1
15A CHARGER,
RADIO, INT
CLUSTER,
LL (BATT)
ILLUMINATION ILLUMINATION
mm MATING AUX CIRCUIT SW 7212/0128
TO AUX CIRCUIT SW
7219/0001
TO CHASSIS W/H CONN 2
3 4 -IP_C13#1
7212/0141
40 mm
LAMP WITHOUT DUMMY PLUG B D B D

-IP_C8 -IP_C8#1 -IP_C13 TO BRAKE SW
-D1 -D2 7214/0068
-IP_C19
SPARE FUSE
15A 15A 15A 15A 50 mm 3 2 1

7514/0010
DIODE 1
7514/0010
DIODE -II
TO WIPER MOTOR
20A FRONT WORK RR WORK LOW BEAM HIGH BEAM -IP_C27 4 -IP_C19#1
-IP_C28
7 6 5
INSERT AFTER TEST INSERT AFTER TEST
LIGHT LIGHT-I 11 10 9 8
7219/0005
75 mm
110 mm 110 mm
7219/0005
14 13 12
2 6
7000/3203
-P50 SPOT TAPE
20A 10A 10A 15A
FWD / REV HEAD LAMP WIPER,

WASHER HAZARD
SW
(BATT) (BATT)
mm 90
90 mm
80 mm -IP_C31
1
-IP_C29 -IP_C34
75 mm
3 5
100 mm
-IP_C31#1
7211/0025
TO W/H MAXI FUSE CONN 2
4
-IP_C25 POINT / SPOT TAPE
TO FR & RR WORK LAMP RLY
50 mm
TO BRAKE & HORN RELAY
TO DUMP & PARK RELAY
TO HEAD LAMP HI/LO RLY

TO AUX CIRCUIT RELAY
TO FWD / REV REL AY
7241/0060
-IP_C27#1
7241/0060
7241/0060
-IP_C34#1
-IP_C25#1
-IP_C29#1
-IP_C42#1
7241/0060
7241/0060
7241/0060
PLEASE PROVIDE
-IP_C28#1
1 2
SIDE VIEW
3
3
3
3
2
4
5
5
2
-IP_C32#1
1
-IP_C32
1
1
1
332/E9928
8
8
8
8
10
10
9

10
10
9
7
10
10
7
9
9
7
7
6
6
6
1 2 3 4 5 6
ALL RELAYS TO BE ASSEMBLED THE GROUP OF 6 AS SEQUENCE SHOWN ABOVE.
33 - 77 9813/8500-2 33 - 77
12 - Harness
18 - Side Console
33-78 33-79
RELAY A,B & C TO BE GROUPED TOGETHER. RELAY D & E TO BE GROUPED TOGETHER.

A B C D E
F C G F C G F C G -IP_C23#2 F C G F C G
-IP_C22#2 7241/0058
D D D D D -IP_C15#1 -IP_C35#1
7241/0058 E B E B E B TO IGN RELAY - 2 E B E B
7219/0013 7219/0013
TO IGN RELAY -1
A A A A A TO REAR WL SW TO PARK BRAKE SW
H J H J H J H J H J
-IP_C33#2 -IP_C24#2 -IP_C26#2 10 9 10 9

7241/0058 NOTE: USE SUITABLE TERMINALS FOR MINI REA LY BASE 7241/0058 1 2 3 4 3 6 3 6
7241/0058
TO NEUTRAL START RELAY TO BUZZER 2 5 2 5
TO FLASHER 5 6 7 8
10 9
1 4 1 4
-IP_C23 9 10 11 12
-IP_C2 3 6
8 7 8 7
2 5
C
13 14 15 16
1 4
-IP_C14 -IP_C15 -IP_C35
17 18 19 20
8 7
21 22 23 24
-IP_C33 -IP_C14#1
25 26 27 28
7219/0013
B -IP_C24
29 30 31 32
TO FRONT WL SW
33 34 35 36
GROMMET DIA 56 BLACK
D 7100-0567(MSSL NUMBER)
INSTRUMEN T CLUSTER
-IP_C2#1
75 mm
70 mm
70 mm
70 mm
7239/0031
115 mm
10 TO INSTRUMENT CLUSTER -IP_C005
0m
m
m
0m
3 2 1
7 6 5 4
10
10 9 8
-IP_C005#1
7219/0001
TO LIVELINK HARNESS
-IP_C26
115 mm 100 mm
100 mm
SPOT TAPE SPOT TAPE SPOT TAPE
A E
50 mm
7000/3207
50
mm
-P71
mm
50
-IP_C22
50
mm
mm
50
-IP_SP080 50 mm
50 mm
75 mm
100 mm
7000/3207 7000/3207
-P43 -P51 SPOT TAPE
7000/3207
-P42
100 mm
150 mm
-IP_SP260
50 mm -IP_SP330
-IP_C6 -IP_SP160
50 mm
1 -IP_SP140
-IP_SP270
-IP_SP280
2
25 mm
100 mm
-IP_C6#1
100 mm
mm
50 mm
7232/0023
175
TO RADIO
70
75 mm
-IP_SP340
-IP_FB1#1 -IP_SP210
50
7241/0054 -IP_SP030
mm
FUSEBOX
4 3 2 1 10
100 mm
0m
FUSE PULER
75 mm
5A-FU3
15A-FU1
m
5A-FU4
10A-FU2
7000/3207
100 mm
-P44
8 7 6 5 FIX TO MAIN BRANCH
70 -P
mm
12 11 10 9 100
-IP_FB1 00 52
/3
20
7
5A-FU8
10A-FU6
15A-FU5
10A-FU7
SPARE FUSE
16 15 14 13
5A-FS1
20 19 18 17 80 mm 40 mm 30 mm 30 mm 40 mm 25 mm 25 mm 25 mm 50 mm 50 mm 25 mm 25 mm 25 mm 50 mm
30 mm
3A-FU11
3A-FU12
5A-FU10
10A-FU9
24 23 22 21
SPARE FUSE
28 27 26 25 -IP_SP240 -IP_SP060
7000/3203
10A-FS2
-IP_SP350 -IP_SP010 7000/3202

-P4
7000/3207
-P59 -IP_SP300 -IP_SP252 -IP_SP100 -IP_SP290 7000/3207
-P56 -IP_SP380 -P57 7000/3203
-P48
15A-FU16
3A-FU15
7.5A-FU14
7.5A-FU13
30 mm
50
SLIT PVC TUBE WITH OVERLAP TAPE
32 31 30 29 25
mm
7000/3207
-P53
mm
40 mm
25 mm
36 35 34 33
70 mm
SPARE FUSE
1300 mm 50 mm
FIX TO MAIN BRANCH
15A-FU20
-IP_C38
15A-FU18
15A-FS3
15A-FU19
15A-FU17
PLEASE PROVIDE -IP_SP200

40 39 38 37 SIDE VIEW
44 43 42 41 7000/3207
SPARE FUSE
30 mm
-P58 -IP_C39
10A-FU23
10A-FU22
20A-FU24
15A-FU21
30 mm 300 mm
20A -FS4
-IP_SP130
SPOT TAPE
48 47 46 45 2 1
50 mm 1 2 3
40 mm
-IP_C38#1 4 5 6
-IP_SP320 7000/3207
7212/0141 -IP_SP360 -P55
TO PARK BRAKE SW - 2
30 mm
50 mm
-IP_C39#1
7216/0052
TO SPEEDOMETER
-IP_SP180
-IP_C21
-IP_SP310
50 mm
FUSE PULER
5A 5A 10A 15A
30 mm
40 mm
7000/3202
LIVELINK, IHAZARD SW BRK LAMP PRK BRK, -P2
SPEEDOMETER IGN HYDRACLAMP SLIT PVC TUBE WITH OVERLAP TAPE
SPOT TAPE
50 mm
SPARE FUSE
5A 10A 10A 15A -IP_SP190

5A
4WD, AUX SOL HORN -IP_SP040
CLUSTERS WIPER, 1 2
30 mm
(IGN) WASHER -IP_C20
(IGN) INSERT AFTER TEST FIX TO MAIN BRANCH
3 4
-IP_C41 -IP_C9#1
40 mm
-IP_C41_CAP
200 mm 50 mm 7214/0068
SPARE FUSE
3A 3A 5A 10A 50 mm 3 2 1
TO DIODE - I
LL GND ALT W IGN RELAYS FACE FAN -IP_C42 7 6 5 4 -IP_C9

10A
10 9 8
1 -IP_SP250
7000/3202
-P45
SPOT TAPE
21 1 2
SPARE FUSE
50 A C
mm
NATURAL
15A 3A 7.5A 7.5A
135 -IP_C41_CAP#1
7212/0156
-IP_C41#1
-IP_C20#1
15A CHARGER,
RADIO, INT
CLUSTER,
LL (BATT)
ILLUMINATION ILLUMINATION
mm MATING AUX CIRCUIT SW 7212/0128
TO AUX CIRCUIT SW
7219/0001
40 mm
LAMP WITHOUT DUMMY PLUG B D
-IP_C19 -D1
SPARE FUSE
15A 15A 15A 15A 50 mm 3 2 1

7514/0010
DIODE 1
20A FRONT WORK RR WORK LOW BEAM HIGH BEAM -IP_C27 4 -IP_C19#1
-IP_C28
7 6 5
INSERT AFTER TEST
LIGHT LIGHT-I 11 10 9 8
7219/0005
75 mm
110 mm 110 mm
7219/0005
14 13 12
2 6
7000/3203
-P50 SPOT TAPE
20A 10A 10A 15A
FWD / REV HEAD LAMP WIPER,

WASHER HAZARD
SW
(BATT) (BATT)
mm 90
90 mm
80 mm -IP_C31
1
-IP_C29 -IP_C34
75 mm
3 5
100 mm
Page 33-79
-IP_C31#1
7211/0025
4
-IP_C25 POINT / SPOT TAPE
TO FR & RR WORK LAMP RLY
50 mm
TO BRAKE & HORN RELAY
TO DUMP & PARK RELAY
TO HEAD LAMP HI/LO RLY

TO AUX CIRCUIT RELAY
TO FWD / REV REL AY
7241/0060
-IP_C27#1
7241/0060
7241/0060
-IP_C34#1
-IP_C25#1
-IP_C29#1
-IP_C42#1
7241/0060
7241/0060
7241/0060
PLEASE PROVIDE
-IP_C28#1
1 2
SIDE VIEW
3
3
3
3
2
4
5
5
2
-IP_C32#1
1
-IP_C32
1
1
1
332/E9928
8
8
8
8
10
10
9

10
10
9
7
10
10
7
9
9
7
7
7
7
6
6
6
1 2 3 4 5 6
ALL RELAYS TO BE ASSEMBLED THE GROUP OF 6 AS SEQUENCE SHOWN ABOVE.
33 - 78 9813/8500-2 33 - 78
12 - Harness
18 - Side Console
33-78 33-79
-IP_C15#1 -IP_C35#1
7219/0013 7219/0013
TO REAR WL SW TO PARK BRAKE SW
10 9 10 9
3 6 3 6
2 5 2 5
10 9
1 4 1 4
3 6
8 7 8 7
2 5
-IP_C15 -IP_C35 -IP_C40 1 4

8 7
-IP_C40#1
7219/0013
TO 4WD SWITCH
70 mm
70 mm
70 mm
-IP_C1#1 -IP_C3#1
7234/0003 8 7236/0003
2 1
10
TO IGN SW
9 TO IGN SW 1
7
4 -IP_C1
5 6 -IP_C7 3 2 1
3 -IP_C 4
7219/0005
7 6 5
SPOT TAPE SPOT TAPE SPOT TAPE SPOT TAPE
3
11 10 9 8
50 14 13 12
mm
mm
50
50
10 18
-IP_C11 -IP_C10
mm
10 9
3 17
mm
-IP_C17 3 6
2 5
50
2 5
4 3 2 1 1 4 -IP_C7#1
75 mm
1 4
8 7 7219/0005
8 7
8 7 6 5 TO RH COLUMN SW
70 mm -IP_C36 -IP_C11#1
-IP_C10#1
50 mm 10 9
7219/0013 7219/0014
75 mm
75 mm
75 mm
3 6 TO HEAD LAMP SW TO HAZARD SW

2 5 -IP_C17#1
7218/0001
m
1 4
TO W/H CAB CONN 1
50 mm
SPOT TAPE BLUE POINT TAPE
75 m
8 7
-IP_C36#1
7219/0013
TO SIDE SHIFT SW
mm
75
mm
75
150 mm
63 9
-P /320
70
-P /3
00
00
64 20
-IP_C18
70
50 mm
9
PLEASE PROVIDE 1 2
SIDE VIEW
3
-IP_C18#1
-IP_C5 7213/0066
100 mm TO W/H CAB CONN 2
100 mm
-IP_SP140 50 mm
7000/3209
-P67
7000/3203
-P1
100 mm
mm 1
175
100 mm
7
/320
200 mm
00
70 -P60 2 7000/3209
-P61
-IP_C37
7000/3207
-P62 50 mm 50 mm 7
3
6
2
5
1
-IP_C5#1
11 10 9 8
-IP_SP210
7219/0005
14 13 12
7232/0023
TO MOBILE CHARGER WHITE POINT TAPE
-IP_C37#1
100 mm
7219/0005
-IP_SP070 TO WARNING CLUSTER
7000/3207
50 mm
-P44
mm
7000/3209
100
-P66
-IP_C12
50 mm 80 mm 50 mm 50 mm 45 mm 75 mm 100 mm 50 mm 50 mm 1050 mm 100 mm 100 mm 100 mm 450 mm 50 mm 110 mm 80 mm 7
3
6
2
5
1
11 10 9 8
14 13 12
7219/0005
7000/3207
7000/3203
-IP_SP220 -IP_SP230 -IP_SP170 -IP_SP020 7000/3207 -IP_SP120 -IP_SP150 -P5 -IP_SP251 -IP_SP110 -IP_SP090 7000/3207
-IP_SP050 7000/3203
-P48 -P3 -P68
-P6 ID Label
-ID1
25 -IP_C12#1
mm
25 mm
7219/0005
FIX TO MAIN BRANCH TO LH COLUMN SW
FIX TO MAIN BRANCH
300 mm
100 mm
SPOT TAPE SPOT TAPE
1 2 7000/3207 7000/3207
3 -P69 -P70
4 5 6
50 mm
-IP_C39#1
7216/0052
50 mm
TO SPEEDOMETER
50 mm
50 mm
1 2
1 2
3 4
3 4
-IP_C9#1
7214/0068 -IP_C4#1
TO DIODE - I 7214/0068
-IP_C9 -IP_C4 TO DIODE -II
PLEASE PROVIDE
SIDE VIEW
1 2
A C A C 2 1
3 4 -IP_C13#1
7212/0141
B D B D
-IP_C8 -IP_C8#1 -IP_C13 TO BRAKE SW
-D1 -D2 7214/0068
7514/0010 7514/0010 TO WIPER MOTOR
DIODE 1 DIODE -II
INSERT AFTER TEST INSERT AFTER TEST
Page 33-78
33 - 79 9813/8500-2 33 - 79
12 - Harness
18 - Side Console
33 - 80 9813/8500-2 33 - 80
12 - Harness
18 - Side Console

-IP_C1 TO IGN SW -IP_C005 TO LIVELINK HARNESS -IP_C12 TO LH COLUMN SW -IP_C17 TO W/H CAB CONN 1
1 302A 6.00 mm² -IP_SP260:S 1 611 2.00 mm² -IP_SP290:S 1 7210/0001 1 837B 2.00 mm² -IP_SP160:S
2 2 170B 1.00 mm² -IP_SP360:S 2 7210/0001 2 806 1.00 mm² -IP_SP120:S
3 3 305 1.00 mm² -FB1:31 3 7210/0001 3 829A 1.00 mm² -IP_SP220:S
4 4 406B 1.00 mm² -IP_SP320:S 4 809 1.50 mm² -IP_C27:1 4 805C 1.00 mm² -IP_SP110:S
5 403B 1.00 mm² -IP_SP310:S 5 7210/0001 5 304C 1.50 mm² -IP_SP070:S
7234/0003 4 WAY IGN SWT FEM HSG 6 413 1.00 mm² -FB1:23 6 810 1.50 mm² -IP_SP130:S 6 114 1.00 mm² -FB1:21
Additional Components 7 612 1.00 mm² -FB1:24 7 107B 2.00 mm² -IP_SP040:S 7 830B 1.00 mm² -IP_SP230:S
8 7210/0001 8 600AB 0.50 mm² -IP_SP251:S 8 834B 2.00 mm² -IP_SP080:S
9 404B 1.00 mm² -IP_SP340:S 9 7210/0001
-IP_C2 TO INSTRUMENT CLUSTER 7218/0001 8 Way HW090 Socket Housing
10 408B 1.00 mm² -IP_SP330:S 10 808 1.50 mm² -IP_C27:8
Cav Id Tag Size Destination Cavity Seal Additional Components
11 921 1.00 mm² -IP_SP190:S
1 805D 0.75 mm² -IP_SP110:S 7219/0001 10 Way HW090 Socket Housing 12 7210/0001 7218/0003
2 405 0.50 mm² -IP_C19:5 Additional Components 13 7210/0001
3 861B 0.75 mm² -IP_SP100:S
7219/0003;1 # 10 Way HW090 Socket Retainer 14 7210/0001
4 401 0.75 mm² -IP_C25:10
5 804A 0.50 mm² -IP_SP020:S 7219/0005 14 Way HW090 Socket Housing
-IP_C18 TO W/H CAB CONN 2
6 806B 0.75 mm² -IP_SP120:S Additional Components Cav Id Tag Size Destination Cavity Seal
7 830C 0.50 mm² -IP_SP230:S -IP_C7 TO RH COLUMN SW 7219/0007 1 855 2.00 mm² -IP_SP170:S
8 Cav Id Tag Size Destination Cavity Seal
2 861 2.00 mm² -IP_SP100:S
9 106 0.75 mm² -IP_SP030:S 1 110C 1.50 mm² -IP_SP050:S
3 600A 8.00 mm² -IP_SP380:S
10 403A 0.50 mm² -IP_SP310:S 2 7210/0001
11 411 0.75 mm² -IP_SP270:S 3 7210/0001 -IP_C13 TO BRAKE SW 7213/0066 3 WAY FEM SEALED GREY HSG 11045WYA03F-GREY
12 305A 0.75 mm² -FB1:31 4 110B 1.50 mm² -IP_SP050:S Cav Id Tag Size Destination Cavity Seal Additional Components
13 409 0.50 mm² -IP_C19:9 5 7210/0001 1 600AC 0.50 mm² -IP_SP251:S
14 855D 0.75 mm² -IP_SP170:S 6 7210/0001 2 877 0.50 mm² -IP_C28:3
15 412A 0.50 mm² -IP_SP300:S 7 982 1.50 mm² -IP_C8:2
16 611A 0.75 mm² -IP_SP290:S 8 127 0.75 mm² -IP_C11:6 7212/0141 2WAY SEALED FEM HSG WP 2P-B
17 828C 0.75 mm² -IP_SP150:S 9 833 0.75 mm² -IP_C34:8 Additional Components
18 406A 0.50 mm² -IP_SP320:S 10 805 1.00 mm² -IP_SP110:S -IP_C19 TO CHASSIS W/H CONN 1
19 834A 0.75 mm² -IP_SP080:S 11 806A 1.00 mm² -IP_SP120:S Cav Id Tag Size Destination Cavity Seal
20 408A 0.50 mm² -IP_SP330:S 12 840 1.50 mm² -IP_C8:3 1 805B 1.00 mm² -IP_SP110:S
21 13 836 0.75 mm² -IP_C34:1 2 103 1.00 mm² -IP_C42:4
22 404A 0.50 mm² -IP_SP340:S 14 803 1.00 mm² -IP_SP090:S -IP_C14 TO FRONT WL SW 3 403 1.00 mm² -IP_SP310:S
23 Cav Id Tag Size Destination Cavity Seal 4 404 1.00 mm² -IP_SP340:S
24 7219/0005 14 Way HW090 Socket Housing 1 5 405 0.50 mm² -IP_C2:2
25 Additional Components 2 133C 0.75 mm² -IP_SP060:S 6 406 1.00 mm² -IP_SP320:S
26 7219/0007 3 116 0.75 mm² -IP_C29:8 7 407 0.50 mm² -IP_C2:28
27 4 8 408 1.00 mm² -IP_SP330:S
28 407 0.50 mm² -IP_C19:7 5 9 409 0.50 mm² -IP_C2:13
29 837A 0.75 mm² -IP_SP160:S -IP_C8 TO WIPER MOTOR 6 10 830E 1.00 mm² -IP_SP230:S
30 Cav Id Tag Size Destination Cavity Seal 7 600T 0.50 mm² -IP_SP252:S 11 412 1.00 mm² -IP_SP300:S
31 1 306 1.50 mm² -FB1:46 8 829B 0.50 mm² -IP_SP220:S 12 921A 1.00 mm² -IP_SP190:S
32 2 982 1.50 mm² -IP_C7:7 9 13 934A 1.00 mm² -IP_SP200:S
33 3 840 1.50 mm² -IP_C7:12 10 14 920 1.00 mm² -IP_C36:3
34 4 600N 1.50 mm² -IP_SP251:S
35 7219/0013 10 Way 6.3 Fastin Switch Hsg 7219/0005 14 Way HW090 Socket Housing
36 7214/0068 4 WAY ET250 FEM HSG UNSEALED Additional Components Additional Components
Additional Components 7219/0007
7239/0031 36 Way Fem Mini Recpt Hsg
-IP_C15 TO REAR WL SW -IP_C20 TO CHASSIS W/H CONN 2
-IP_C9 TO DIODE - I
-IP_C3 TO IGN SW 1 1 1 811 1.50 mm² -IP_C27:9
1 804B 1.00 mm² -IP_SP020:S
Cav Id Tag Size Destination Cavity Seal 2 133D 0.75 mm² -IP_SP060:S 2 812 1.50 mm² -IP_C27:4
2 806C 1.00 mm² -IP_SP120:S
5 001 4.00 mm² -FB1:18 3 117 0.75 mm² -IP_C29:1 3 814 1.50 mm² -IP_C28:9
3 855A 2.00 mm² -IP_SP170:S
6 4 4 816 1.00 mm² -IP_C28:4
4 828A 1.50 mm² -IP_SP150:S
7 004 6.00 mm² -IP_C33:A 5 5 974 1.00 mm² -IP_C39:1
8 7214/0068 4 WAY ET250 FEM HSG UNSEALED 6 6 1936 1.00 mm² -IP_C35:3
9 Additional Components 7 600U 0.50 mm² -IP_SP252:S 7 806D 1.00 mm² -IP_SP120:S
10 8 829C 0.50 mm² -IP_SP220:S 8 611B 2.00 mm² -IP_SP290:S
9 9 878 1.00 mm² -IP_C40:3
7236/0003 6 WAY IGN SWT FEM HSG -IP_C10 TO HAZARD SW
10 10 829D 1.00 mm² -IP_SP220:S
1 104 1.00 mm² -FB1:7 7219/0013 10 Way 6.3 Fastin Switch Hsg 7219/0001 10 Way HW090 Socket Housing
2 802 2.00 mm² -IP_C24:E Additional Components Additional Components
3 300 2.00 mm² -FB1:45
7219/0003;1 # 10 Way HW090 Socket Retainer
-IP_C4 TO DIODE -II 4
Cav Id Tag Size Destination Cavity Seal 5 805A 1.00 mm² -IP_SP110:S
1 934 1.00 mm² -IP_SP200:S 7
2 936A 1.00 mm² -IP_SP210:S 8 830A 0.50 mm² -IP_SP230:S
3 10 600Y 1.00 mm² -IP_SP251:S
4 17 804 1.00 mm² -IP_SP020:S
18 803A 2.00 mm² -IP_SP090:S
7214/0068 4 WAY ET250 FEM HSG UNSEALED
Additional Components 7219/0014 10 Way 6.3 Fastin Switch Hsg Red
-IP_C5 TO MOBILE CHARGER

-IP_C11 TO HEAD LAMP SW
1 600P 2.00 mm² -IP_SP252:S
2 304A 2.00 mm² -IP_SP070:S
1
7232/0023 2 WAY 250 ET FEM HSG UNSEALED 2 311 1.50 mm² -FB1:47
Additional Components 3 828 1.50 mm² -IP_SP150:S
4
5 133 0.75 mm² -IP_SP060:S
6 127 0.75 mm² -IP_C7:8
-IP_C6 TO RADIO
7 600X 0.50 mm² -IP_SP251:S
8 830D 0.50 mm² -IP_SP230:S
1 304E 1.50 mm² -IP_SP070:S
9
2 600R 1.50 mm² -IP_SP252:S
10
7232/0023 2 WAY 250 ET FEM HSG UNSEALED
7219/0013 10 Way 6.3 Fastin Switch Hsg
33 - 81 9813/8500-2 33 - 81
12 - Harness
18 - Side Console
33-82 33-83
-IP_C1 TO IGN SW -IP_C005 TO LIVELINK HARNESS

1 302A 6.00 mm² -IP_SP260:S 1 611 2.00 mm² -IP_SP290:S
2 2 170B 1.00 mm² -IP_SP360:S
3 3 305 1.00 mm² -FB1:31
4 4 406B 1.00 mm² -IP_SP320:S
5 403B 1.00 mm² -IP_SP310:S
7234/0003 4 WAY IGN SWT FEM HSG 6 413 1.00 mm² -FB1:23
Additional Components 7 612 1.00 mm² -FB1:24
8 7210/0001
9 404B 1.00 mm² -IP_SP340:S
-IP_C2 TO INSTRUMENT CLUSTER
10 408B 1.00 mm² -IP_SP330:S
1 805D 0.75 mm² -IP_SP110:S 7219/0001 10 Way HW090 Socket Housing
2 405 0.50 mm² -IP_C19:5 Additional Components
3 861B 0.75 mm² -IP_SP100:S
4 401 0.75 mm² -IP_C25:10
5 804A 0.50 mm² -IP_SP020:S
6 806B 0.75 mm² -IP_SP120:S
7 830C 0.50 mm² -IP_SP230:S -IP_C7 TO RH COLUMN SW
9 106 0.75 mm² -IP_SP030:S 1 110C 1.50 mm² -IP_SP050:S
10 403A 0.50 mm² -IP_SP310:S 2 7210/0001
11 411 0.75 mm² -IP_SP270:S 3 7210/0001
12 305A 0.75 mm² -FB1:31 4 110B 1.50 mm² -IP_SP050:S
13 409 0.50 mm² -IP_C19:9 5 7210/0001
14 855D 0.75 mm² -IP_SP170:S 6 7210/0001
15 412A 0.50 mm² -IP_SP300:S 7 982 1.50 mm² -IP_C8:2
16 611A 0.75 mm² -IP_SP290:S 8 127 0.75 mm² -IP_C11:6
17 828C 0.75 mm² -IP_SP150:S 9 833 0.75 mm² -IP_C34:8
20 408A 0.50 mm² -IP_SP330:S 12 840 1.50 mm² -IP_C8:3
21 13 836 0.75 mm² -IP_C34:1
23
24 7219/0005 14 Way HW090 Socket Housing
25 Additional Components
26 7219/0007
27
28 407 0.50 mm² -IP_C19:7
29 837A 0.75 mm² -IP_SP160:S -IP_C8 TO WIPER MOTOR
31 1 306 1.50 mm² -FB1:46
32 2 982 1.50 mm² -IP_C7:7
33 3 840 1.50 mm² -IP_C7:12
34 4 600N 1.50 mm² -IP_SP251:S
35
Page 33-83
36 7214/0068 4 WAY ET250 FEM HSG UNSEALED
7239/0031 36 Way Fem Mini Recpt Hsg
-IP_C9 TO DIODE - I
-IP_C3 TO IGN SW 1
1 804B 1.00 mm² -IP_SP020:S
2 806C 1.00 mm² -IP_SP120:S
5 001 4.00 mm² -FB1:18
3 855A 2.00 mm² -IP_SP170:S
6
4 828A 1.50 mm² -IP_SP150:S
7 004 6.00 mm² -IP_C33:A
8 7214/0068 4 WAY ET250 FEM HSG UNSEALED
10
7236/0003 6 WAY IGN SWT FEM HSG -IP_C10 TO HAZARD SW

1 104 1.00 mm² -FB1:7
2 802 2.00 mm² -IP_C24:E
3 300 2.00 mm² -FB1:45
-IP_C4 TO DIODE -II 4
1 934 1.00 mm² -IP_SP200:S 7
3 10 600Y 1.00 mm² -IP_SP251:S
4 17 804 1.00 mm² -IP_SP020:S
18 803A 2.00 mm² -IP_SP090:S
7214/0068 4 WAY ET250 FEM HSG UNSEALED
Additional Components 7219/0014 10 Way 6.3 Fastin Switch Hsg Red
-IP_C5 TO MOBILE CHARGER

-IP_C11 TO HEAD LAMP SW
1 600P 2.00 mm² -IP_SP252:S
2 304A 2.00 mm² -IP_SP070:S
1
7232/0023 2 WAY 250 ET FEM HSG UNSEALED 2 311 1.50 mm² -FB1:47
Additional Components 3 828 1.50 mm² -IP_SP150:S
4
5 133 0.75 mm² -IP_SP060:S
6 127 0.75 mm² -IP_C7:8
-IP_C6 TO RADIO
7 600X 0.50 mm² -IP_SP251:S
8 830D 0.50 mm² -IP_SP230:S
1 304E 1.50 mm² -IP_SP070:S
9
2 600R 1.50 mm² -IP_SP252:S
10
7232/0023 2 WAY 250 ET FEM HSG UNSEALED
7219/0013 10 Way 6.3 Fastin Switch Hsg
33 - 82 9813/8500-2 33 - 82
12 - Harness
18 - Side Console
33-82 33-83
-IP_C12 TO LH COLUMN SW -IP_C17 TO W/H CAB CONN 1

1 7210/0001 1 837B 2.00 mm² -IP_SP160:S
2 7210/0001 2 806 1.00 mm² -IP_SP120:S
3 7210/0001 3 829A 1.00 mm² -IP_SP220:S
4 809 1.50 mm² -IP_C27:1 4 805C 1.00 mm² -IP_SP110:S
5 7210/0001 5 304C 1.50 mm² -IP_SP070:S
6 810 1.50 mm² -IP_SP130:S 6 114 1.00 mm² -FB1:21
7 107B 2.00 mm² -IP_SP040:S 7 830B 1.00 mm² -IP_SP230:S
8 600AB 0.50 mm² -IP_SP251:S 8 834B 2.00 mm² -IP_SP080:S
9 7210/0001
10 808 1.50 mm² -IP_C27:8 7218/0001 8 Way HW090 Socket Housing
11 921 1.00 mm² -IP_SP190:S Additional Components
12 7210/0001 7218/0003
13 7210/0001
14 7210/0001
7219/0005 14 Way HW090 Socket Housing TO W/H CAB CONN 2

-IP_C18
7219/0007 1 855 2.00 mm² -IP_SP170:S
2 861 2.00 mm² -IP_SP100:S
3 600A 8.00 mm² -IP_SP380:S
-IP_C13 TO BRAKE SW 7213/0066 3 WAY FEM SEALED GREY HSG 11045WYA03F-GREY

1 600AC 0.50 mm² -IP_SP251:S
2 877 0.50 mm² -IP_C28:3
7212/0141 2WAY SEALED FEM HSG WP 2P-B

-IP_C19 TO CHASSIS W/H CONN 1
1 805B 1.00 mm² -IP_SP110:S
2 103 1.00 mm² -IP_C42:4
-IP_C14 TO FRONT WL SW 3 403 1.00 mm² -IP_SP310:S
Cav Id Tag Size Destination Cavity Seal 4 404 1.00 mm² -IP_SP340:S
1 5 405 0.50 mm² -IP_C2:2
2 133C 0.75 mm² -IP_SP060:S 6 406 1.00 mm² -IP_SP320:S
3 116 0.75 mm² -IP_C29:8 7 407 0.50 mm² -IP_C2:28
4 8 408 1.00 mm² -IP_SP330:S
5 9 409 0.50 mm² -IP_C2:13
6 10 830E 1.00 mm² -IP_SP230:S
7 600T 0.50 mm² -IP_SP252:S 11 412 1.00 mm² -IP_SP300:S
8 829B 0.50 mm² -IP_SP220:S 12 921A 1.00 mm² -IP_SP190:S
9 13 934A 1.00 mm² -IP_SP200:S
10 14 920 1.00 mm² -IP_C36:3
7219/0013 10 Way 6.3 Fastin Switch Hsg 7219/0005 14 Way HW090 Socket Housing
Page 33-82
Additional Components Additional Components

7219/0007
-IP_C15 TO REAR WL SW -IP_C20 TO CHASSIS W/H CONN 2

1 1 811 1.50 mm² -IP_C27:9
2 133D 0.75 mm² -IP_SP060:S 2 812 1.50 mm² -IP_C27:4
3 117 0.75 mm² -IP_C29:1 3 814 1.50 mm² -IP_C28:9
4 4 816 1.00 mm² -IP_C28:4
5 5 974 1.00 mm² -IP_C39:1
6 6 1936 1.00 mm² -IP_C35:3
7 600U 0.50 mm² -IP_SP252:S 7 806D 1.00 mm² -IP_SP120:S
8 829C 0.50 mm² -IP_SP220:S 8 611B 2.00 mm² -IP_SP290:S
9 9 878 1.00 mm² -IP_C40:3
10 10 829D 1.00 mm² -IP_SP220:S
7219/0013 10 Way 6.3 Fastin Switch Hsg 7219/0001 10 Way HW090 Socket Housing
33 - 83 9813/8500-2 33 - 83
12 - Harness
18 - Side Console
33 - 84 9813/8500-2 33 - 84
12 - Harness
18 - Side Console

-IP_C21 TO CHASSIS W/H CONN 3 -IP_C27 TO FWD / REV REL AY -IP_C31 TO W/H MAXI FUSE CONN 2
-IP_FB1 FUSEBOX
Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal
1 600 8.00 mm² -IP_SP380:S 1 809 1.50 mm² -IP_C12:4 1 303 8.00 mm² -IP_SP240:S
1 002H 4.00 mm² -IP_SP010:S
2 842 6.00 mm² -IP_C33:C 2
5 101 1.50 mm² -IP_SP140:S 7211/0025 1 WAY TS312 MALE HSG
3 600G 0.50 mm² -IP_SP250:S
7212/0060 2 Way DL305 Fem Hsg 2 002J 4.00 mm² -IP_SP010:S Additional Components
4 812 1.50 mm² -IP_C20:2
Additional Components 6 126 1.00 mm² -IP_C28:5
5 852A 1.50 mm² -IP_C27:10
3
6 600H 0.50 mm² -IP_SP250:S
7 104 1.00 mm² -IP_C10:1
7 -IP_C32 TO W/H MAXI FUSE CONN 1
4
8 808 1.50 mm² -IP_C12:10 Cav Id Tag Size Destination Cavity Seal
-IP_C22 TO IGN RELAY -1 8 170 1.00 mm² -IP_SP360:S
9 811 1.50 mm² -IP_C20:1 1 301 8.00 mm² -IP_SP180:S
10 852 1.50 mm² -IP_C25:2 2 302 8.00 mm² -IP_SP260:S
A 301A 4.00 mm² -IP_SP180:S 13 110 2.00 mm² -IP_SP050:S
10 852A 1.50 mm² -IP_C27:5
B 600C 0.75 mm² -IP_C23:B 10 007C 4.00 mm² -IP_SP280:S 332/E9928 2 Way DL305 Male Hsg
C 002 4.00 mm² -IP_SP010:S 7241/0060 10 WAY W/H RELAY PLATE MRB MISO 2P-NY 66B 14 118 1.50 mm² -IP_C28:10 Additional Components
D Additional Components 11
E 133A 0.75 mm² -IP_SP060:S 15 102 1.50 mm² -IP_SP350:S
F 12
-IP_C35 TO PARK BRAKE SW
G 16 106C 1.00 mm² -IP_SP030:S
-IP_C28 TO BRAKE & HORN RELAY Cav Id Tag Size Destination Cavity Seal
H 17 007B 4.00 mm² -IP_SP280:S
Cav Id Tag Size Destination Cavity Seal 1
J 21 114 1.00 mm² -IP_C17:6
1 126A 0.50 mm² -IP_C28:5 2 101A 1.00 mm² -IP_SP140:S
18 001 4.00 mm² -IP_C3:5
7241/0058 40A Relay Base Black 2 3 1936 1.00 mm² -IP_C20:6
22 133F 1.00 mm² -IP_SP060:S
Additional Components 3 877 0.50 mm² -IP_C13:2 4 600V 1.00 mm² -IP_SP252:S
19 412B 1.00 mm² -IP_SP300:S
4 816 1.00 mm² -IP_C20:4 5 936 1.00 mm² -IP_SP210:S
23 413 1.00 mm² -IP_C005:6
5 126A 0.50 mm² -IP_C28:1 6
20 611C 1.00 mm² -IP_SP290:S
-IP_C23 TO IGN RELAY - 2 5 126 1.00 mm² -FB1:6 7 600AF 0.50 mm² -IP_SP252:S
24 612 1.00 mm² -IP_C005:7
Cav Id Tag Size Destination Cavity Seal 6 921B 1.00 mm² -IP_SP190:S 8 829E 0.50 mm² -IP_SP220:S
25 828B 1.50 mm² -IP_SP150:S
A 302C 4.00 mm² -IP_SP260:S 7 9
29 830 1.00 mm² -IP_SP230:S
B 600C 0.75 mm² -IP_C22:B 8 118A 1.00 mm² -IP_C28:10 10
26
B 600B 0.75 mm² -IP_C24:B 9 814 1.50 mm² -IP_C20:3
30 829 1.00 mm² -IP_SP220:S 7219/0013 10 Way 6.3 Fastin Switch Hsg
C 007 4.00 mm² -IP_SP280:S 10 118A 1.00 mm² -IP_C28:8
D 10 118 1.50 mm² -FB1:14
31 305 1.00 mm² -IP_C005:3
E 133B 0.75 mm² -IP_SP060:S
7241/0060 10 WAY W/H RELAY PLATE MRB MISO 2P-NY 66B 31 305A 0.75 mm² -IP_C2:12
F
Additional Components 28 302E 4.00 mm² -IP_SP260:S -IP_C36 TO SIDE SHIFT SW
G
32 304 2.00 mm² -IP_SP070:S Cav Id Tag Size Destination Cavity Seal
H
33 301C 4.00 mm² -IP_SP180:S 1
J
37 312 2.50 mm² -IP_C34:5 2 101B 1.00 mm² -IP_SP140:S
7241/0058 40A Relay Base Black -IP_C29 TO FR & RR WORK LAMP RLY 34 3 920 1.00 mm² -IP_C19:14
Additional Components Cav Id Tag Size Destination Cavity Seal 38 313 2.00 mm² -IP_C34:10 4
1 117 0.75 mm² -IP_C15:3 35 5
2 39 309 2.00 mm² -IP_C29:5 6
3 600M 0.75 mm² -IP_SP250:S 36 303A 4.00 mm² -IP_SP240:S 7 600AE 0.50 mm² -IP_SP252:S
-IP_C24 TO FLASHER
4 861A 2.00 mm² -IP_SP100:S 40 310 2.00 mm² -IP_C29:10 8 829F 0.50 mm² -IP_SP220:S
5 309 2.00 mm² -FB1:39 41 303C 4.00 mm² -IP_SP240:S 9
A
6 600K 0.75 mm² -IP_SP250:S 45 300 2.00 mm² -IP_C10:3 10
B 600D 2.50 mm² -IP_SP250:S
7 42
B 600B 0.75 mm² -IP_C23:B 7219/0013 10 Way 6.3 Fastin Switch Hsg
8 116 0.75 mm² -IP_C14:3 46 306 1.50 mm² -IP_C8:1
C 803B 2.00 mm² -IP_SP090:S Additional Components
9 855C 2.00 mm² -IP_SP170:S 43
D
10 310 2.00 mm² -FB1:40 47 311 1.50 mm² -IP_C11:2
E 802 2.00 mm² -IP_C10:2
44 002G 4.00 mm² -IP_SP010:S
F 7241/0060 10 WAY W/H RELAY PLATE MRB MISO 2P-NY 66B 48 107D 2.00 mm² -IP_SP040:S
G Additional Components
-IP_C37 TO WARNING CLUSTER
H 7241/0054 24 FUSE CASSETTE FUSE HOLDER ASSY Cav Id Tag Size Destination Cavity Seal
J Additional Components 1 600AA 0.50 mm² -IP_SP250:S
7241/0058 40A Relay Base Black 2 837C 0.75 mm² -IP_SP160:S
Additional Components -IP_C33 TO NEUTRAL START RELAY 3 829G 0.50 mm² -IP_SP220:S
Cav Id Tag Size Destination Cavity Seal 4 805E 0.75 mm² -IP_SP110:S
A 004 6.00 mm² -IP_C3:7 5 806E 0.75 mm² -IP_SP120:S
B 600E 0.50 mm² -IP_SP250:S 6 804C 0.50 mm² -IP_SP020:S
C 842 6.00 mm² -IP_C21:2 7 855B 0.75 mm² -IP_SP170:S
D 8 861C 0.75 mm² -IP_SP100:S
-IP_C25 TO DUMP & PARK RELAY E 810B 1.50 mm² -IP_SP130:S 9 7210/0001
Cav Id Tag Size Destination Cavity Seal F 10 7210/0001
1 107A 1.50 mm² -IP_SP040:S G 11 411A 0.50 mm² -IP_SP270:S
2 852 1.50 mm² -IP_C27:10 H 12 106B 0.50 mm² -IP_SP030:S
3 934B 1.00 mm² -IP_SP200:S J 13 7210/0001
4 14 7210/0001
5 107 2.00 mm² -IP_SP040:S 7241/0058 40A Relay Base Black
6 600L 0.50 mm² -IP_SP250:S Additional Components 7219/0005 14 Way HW090 Socket Housing
7 936B 1.00 mm² -IP_SP210:S Additional Components
8 810A 1.50 mm² -IP_SP130:S 7219/0007
9
10 401 0.75 mm² -IP_C2:4
-IP_C34 TO HEAD LAMP HI/LO RLY
7241/0060 10 WAY W/H RELAY PLATE MRB MISO 2P-NY 66B Cav Id Tag Size Destination Cavity Seal
2
3 600J 0.75 mm² -IP_SP250:S
4 837 2.50 mm² -IP_SP160:S
-IP_C26 TO BUZZER 5 312 2.50 mm² -FB1:37
Cav Id Tag Size Destination Cavity Seal 6 600Z 0.75 mm² -IP_SP250:S
A 7
B 411B 0.50 mm² -IP_SP270:S 8 833 0.75 mm² -IP_C7:9
C 106A 0.50 mm² -IP_SP030:S 9 834 2.00 mm² -IP_SP080:S
D 10 313 2.00 mm² -FB1:38
E
F 7241/0060 10 WAY W/H RELAY PLATE MRB MISO 2P-NY 66B
H
J
7241/0058 40A Relay Base Black

33 - 85 9813/8500-2 33 - 85
12 - Harness
18 - Side Console
33-86 33-87
-IP_C21 TO CHASSIS W/H CONN 3 -IP_C27 TO FWD / REV REL AY

1 600 8.00 mm² -IP_SP380:S 1 809 1.50 mm² -IP_C12:4
2 842 6.00 mm² -IP_C33:C 2
3 600G 0.50 mm² -IP_SP250:S
7212/0060 2 Way DL305 Fem Hsg 4 812 1.50 mm² -IP_C20:2
Additional Components 5 852A 1.50 mm² -IP_C27:10
6 600H 0.50 mm² -IP_SP250:S
7
8 808 1.50 mm² -IP_C12:10
-IP_C22 TO IGN RELAY -1
9 811 1.50 mm² -IP_C20:1
10 852 1.50 mm² -IP_C25:2
A 301A 4.00 mm² -IP_SP180:S
10 852A 1.50 mm² -IP_C27:5
B 600C 0.75 mm² -IP_C23:B
C 002 4.00 mm² -IP_SP010:S 7241/0060 10 WAY W/H RELAY PLATE MRB MISO 2P-NY 66B
D Additional Components
E 133A 0.75 mm² -IP_SP060:S
F
G
-IP_C28 TO BRAKE & HORN RELAY
H
J
1 126A 0.50 mm² -IP_C28:5
7241/0058 40A Relay Base Black 2
4 816 1.00 mm² -IP_C20:4
5 126A 0.50 mm² -IP_C28:1
-IP_C23 TO IGN RELAY - 2 5 126 1.00 mm² -FB1:6
Cav Id Tag Size Destination Cavity Seal 6 921B 1.00 mm² -IP_SP190:S
A 302C 4.00 mm² -IP_SP260:S 7
B 600C 0.75 mm² -IP_C22:B 8 118A 1.00 mm² -IP_C28:10
B 600B 0.75 mm² -IP_C24:B 9 814 1.50 mm² -IP_C20:3
C 007 4.00 mm² -IP_SP280:S 10 118A 1.00 mm² -IP_C28:8
D 10 118 1.50 mm² -FB1:14
E 133B 0.75 mm² -IP_SP060:S
H
J
7241/0058 40A Relay Base Black -IP_C29 TO FR & RR WORK LAMP RLY
1 117 0.75 mm² -IP_C15:3
2
3 600M 0.75 mm² -IP_SP250:S
-IP_C24 TO FLASHER
4 861A 2.00 mm² -IP_SP100:S
5 309 2.00 mm² -FB1:39
A
6 600K 0.75 mm² -IP_SP250:S
B 600D 2.50 mm² -IP_SP250:S
7
B 600B 0.75 mm² -IP_C23:B
Page 33-87
8 116 0.75 mm² -IP_C14:3
C 803B 2.00 mm² -IP_SP090:S
9 855C 2.00 mm² -IP_SP170:S
D
10 310 2.00 mm² -FB1:40
E 802 2.00 mm² -IP_C10:2
H
J

Additional Components -IP_C33 TO NEUTRAL START RELAY
A 004 6.00 mm² -IP_C3:7
B 600E 0.50 mm² -IP_SP250:S
C 842 6.00 mm² -IP_C21:2
D
-IP_C25 TO DUMP & PARK RELAY E 810B 1.50 mm² -IP_SP130:S
Cav Id Tag Size Destination Cavity Seal F
1 107A 1.50 mm² -IP_SP040:S G
2 852 1.50 mm² -IP_C27:10 H
3 934B 1.00 mm² -IP_SP200:S J
4
5 107 2.00 mm² -IP_SP040:S 7241/0058 40A Relay Base Black
6 600L 0.50 mm² -IP_SP250:S Additional Components
7 936B 1.00 mm² -IP_SP210:S
8 810A 1.50 mm² -IP_SP130:S
9
10 401 0.75 mm² -IP_C2:4
-IP_C34 TO HEAD LAMP HI/LO RLY
7241/0060 10 WAY W/H RELAY PLATE MRB MISO 2P-NY 66B Cav Id Tag Size Destination Cavity Seal
2
3 600J 0.75 mm² -IP_SP250:S
4 837 2.50 mm² -IP_SP160:S
-IP_C26 TO BUZZER 5 312 2.50 mm² -FB1:37
Cav Id Tag Size Destination Cavity Seal 6 600Z 0.75 mm² -IP_SP250:S
A 7
B 411B 0.50 mm² -IP_SP270:S 8 833 0.75 mm² -IP_C7:9
C 106A 0.50 mm² -IP_SP030:S 9 834 2.00 mm² -IP_SP080:S
D 10 313 2.00 mm² -FB1:38
E
H
J

33 - 86 9813/8500-2 33 - 86
12 - Harness
18 - Side Console
33-86 33-87
-IP_C31 TO W/H MAXI FUSE CONN 2

-IP_FB1 FUSEBOX
1 303 8.00 mm² -IP_SP240:S
1 002H 4.00 mm² -IP_SP010:S
5 101 1.50 mm² -IP_SP140:S 7211/0025 1 WAY TS312 MALE HSG
2 002J 4.00 mm² -IP_SP010:S Additional Components
6 126 1.00 mm² -IP_C28:5
3
7 104 1.00 mm² -IP_C10:1
-IP_C32 TO W/H MAXI FUSE CONN 1
4
8 170 1.00 mm² -IP_SP360:S
1 301 8.00 mm² -IP_SP180:S
9 007A 4.00 mm² -IP_SP280:S
2 302 8.00 mm² -IP_SP260:S
13 110 2.00 mm² -IP_SP050:S
10 007C 4.00 mm² -IP_SP280:S 332/E9928 2 Way DL305 Male Hsg
14 118 1.50 mm² -IP_C28:10 Additional Components
11
15 102 1.50 mm² -IP_SP350:S
12
-IP_C35 TO PARK BRAKE SW
16 106C 1.00 mm² -IP_SP030:S
17 007B 4.00 mm² -IP_SP280:S
1
21 114 1.00 mm² -IP_C17:6
2 101A 1.00 mm² -IP_SP140:S
18 001 4.00 mm² -IP_C3:5
3 1936 1.00 mm² -IP_C20:6
22 133F 1.00 mm² -IP_SP060:S
4 600V 1.00 mm² -IP_SP252:S
19 412B 1.00 mm² -IP_SP300:S
5 936 1.00 mm² -IP_SP210:S
23 413 1.00 mm² -IP_C005:6
6
20 611C 1.00 mm² -IP_SP290:S
7 600AF 0.50 mm² -IP_SP252:S
24 612 1.00 mm² -IP_C005:7
8 829E 0.50 mm² -IP_SP220:S
25 828B 1.50 mm² -IP_SP150:S
9
29 830 1.00 mm² -IP_SP230:S
10
26
30 829 1.00 mm² -IP_SP220:S 7219/0013 10 Way 6.3 Fastin Switch Hsg
31 305 1.00 mm² -IP_C005:3
31 305A 0.75 mm² -IP_C2:12
28 302E 4.00 mm² -IP_SP260:S -IP_C36 TO SIDE SHIFT SW
32 304 2.00 mm² -IP_SP070:S Cav Id Tag Size Destination Cavity Seal
33 301C 4.00 mm² -IP_SP180:S 1
37 312 2.50 mm² -IP_C34:5 2 101B 1.00 mm² -IP_SP140:S
34 3 920 1.00 mm² -IP_C19:14
38 313 2.00 mm² -IP_C34:10 4
35 5
39 309 2.00 mm² -IP_C29:5 6
36 303A 4.00 mm² -IP_SP240:S 7 600AE 0.50 mm² -IP_SP252:S
40 310 2.00 mm² -IP_C29:10 8 829F 0.50 mm² -IP_SP220:S
41 303C 4.00 mm² -IP_SP240:S 9
45 300 2.00 mm² -IP_C10:3 10
42
Page 33-86
46 306 1.50 mm² -IP_C8:1 7219/0013 10 Way 6.3 Fastin Switch Hsg
47 311 1.50 mm² -IP_C11:2
44 002G 4.00 mm² -IP_SP010:S
48 107D 2.00 mm² -IP_SP040:S
-IP_C37 TO WARNING CLUSTER
7241/0054 24 FUSE CASSETTE FUSE HOLDER ASSY Cav Id Tag Size Destination Cavity Seal
Additional Components 1 600AA 0.50 mm² -IP_SP250:S
2 837C 0.75 mm² -IP_SP160:S
3 829G 0.50 mm² -IP_SP220:S
4 805E 0.75 mm² -IP_SP110:S
5 806E 0.75 mm² -IP_SP120:S
6 804C 0.50 mm² -IP_SP020:S
7 855B 0.75 mm² -IP_SP170:S
8 861C 0.75 mm² -IP_SP100:S
9 7210/0001
10 7210/0001
11 411A 0.50 mm² -IP_SP270:S
12 106B 0.50 mm² -IP_SP030:S
13 7210/0001
14 7210/0001
7219/0005 14 Way HW090 Socket Housing

7219/0007
33 - 87 9813/8500-2 33 - 87
12 - Harness
18 - Side Console
33 - 88 9813/8500-2 33 - 88
12 - Harness
18 - Side Console

-IP_C38 TO PARK BRAKE SW - 2 -IP_SP130 SPLICE NEUTRAL -IP_SP090 SPLICE FLASHER -IP_SP190 SPLICE REAR HORN
1 600AG 1.00 mm² -IP_SP250:S S 810 1.50 mm² -IP_C12:6 S 803 1.00 mm² -IP_C7:14 S 921 1.00 mm² -IP_C12:11
2 936C 1.00 mm² -IP_SP210:S S 810A 1.50 mm² -IP_C25:8 S 803B 2.00 mm² -IP_C24:C S 921A 1.00 mm² -IP_C19:12
S 810B 1.50 mm² -IP_C33:E S 803A 2.00 mm² -IP_C10:18 S 921B 1.00 mm² -IP_C28:6
Additional Components 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
Additional Components Additional Components Additional Components
7000/3212 ; 45 7000/3212 ; 45 7000/3212 ; 45
-IP_C39 TO SPEEDOMETER
SPLICE FR & RR WORKLAMP -IP_SP200 SPLICE TRANS DUMP
SPLICE_IGN -IP_SP100
1 974 1.00 mm² -IP_C20:5 -IP_SP140 Cav Id Tag Size Destination Cavity Seal
2 600AH 1.00 mm² -IP_SP250:S Cav Id Tag Size Destination Cavity Seal S 934B 1.00 mm² -IP_C25:3
S 861A 2.00 mm² -IP_C29:4
3 170A 1.00 mm² -IP_SP360:S S 101B 1.00 mm² -IP_C36:2 S 934A 1.00 mm² -IP_C19:13
S 861 2.00 mm² -IP_C18:2
4 830F 0.50 mm² -IP_SP230:S S 101A 1.00 mm² -IP_C35:2 S 934 1.00 mm² -IP_C4:1
S 861B 0.75 mm² -IP_C2:3
5 S 101 1.50 mm² -FB1:5
S 861C 0.75 mm² -IP_C37:8 7000/3104 In Line Ultrasonic Splice
6
7216/0052 6 WAY MATENLOK FEM HSG UNSEALED Additional Components 7000/3212 ; 45
7000/3212 ; 45
-IP_SP210 SPLICE PARK BRAK
-IP_C40 TO 4WD SWITCH -IP_SP150 SPLICE DIODE -I Cav Id Tag Size Destination Cavity Seal
Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal -IP_SP110 SPLICE LH IND S 936B 1.00 mm² -IP_C25:7
1 S 828A 1.50 mm² -IP_C9:4 Cav Id Tag Size Destination Cavity Seal S 936 1.00 mm² -IP_C35:5
2 102A 1.00 mm² -IP_SP350:S S 828C 0.75 mm² -IP_C2:17 S 805 1.00 mm² -IP_C7:10 S 936A 1.00 mm² -IP_C4:2
3 878 1.00 mm² -IP_C20:9 S 828B 1.50 mm² -FB1:25 S 805B 1.00 mm² -IP_C19:1 S 936C 1.00 mm² -IP_C38:2
4 S 828 1.50 mm² -IP_C11:3 S 805A 1.00 mm² -IP_C10:5
5 S 805D 0.75 mm² -IP_C2:1 7000/3104 In Line Ultrasonic Splice
6 7000/3104 In Line Ultrasonic Splice S 805E 0.75 mm² -IP_C37:4 Additional Components
7 600BB 0.50 mm² -IP_SP250:S Additional Components S 805C 1.00 mm² -IP_C17:4 7000/3212 ; 45
8 829H 0.50 mm² -IP_SP220:S 7000/3212 ; 45
9 7000/3104 In Line Ultrasonic Splice SPLICE ILLUMINATION
-IP_SP220
10 Additional Components Cav Id Tag Size Destination Cavity Seal
7000/3212 ; 45 S 829A 1.00 mm² -IP_C17:3
7219/0013 10 Way 6.3 Fastin Switch Hsg SPLICE DUMP & PARK
-IP_SP040 S 829D 1.00 mm² -IP_C20:10
Additional Components Cav Id Tag Size Destination Cavity Seal S 829B 0.50 mm² -IP_C14:8
S 107 2.00 mm² -IP_C25:5 -IP_SP120 SPLICE RH IND S 829C 0.50 mm² -IP_C15:8
S 107B 2.00 mm² -IP_C12:7 Cav Id Tag Size Destination Cavity Seal S 829E 0.50 mm² -IP_C35:8
-IP_C41 TO AUX CIRCUIT SW S 107A 1.50 mm² -IP_C25:1 S 806A 1.00 mm² -IP_C7:11 S 829F 0.50 mm² -IP_C36:8
Cav Id Tag Size Destination Cavity Seal S 107D 2.00 mm² -FB1:48 S 806 1.00 mm² -IP_C17:2 S 829G 0.50 mm² -IP_C37:3
1 700 1.00 mm² -IP_C42:3 S 806B 0.75 mm² -IP_C2:6 S 829H 0.50 mm² -IP_C40:8
2 600F 1.00 mm² -IP_SP251:S 7000/3104 In Line Ultrasonic Splice S 806D 1.00 mm² -IP_C20:7 S 829 1.00 mm² -FB1:30
Additional Components S 806E 0.75 mm² -IP_C37:5
7212/0128 2 WAY MT090 FEM HSG NATURAL 7000/3212 ; 45 S 806C 1.00 mm² -IP_C9:2 7000/3104 In Line Ultrasonic Splice
7000/3104 In Line Ultrasonic Splice 7000/3212 ; 45
-IP_SP050 SPLICE RH COLUMN Additional Components
TO AUX CIRCUIT RELAY Cav Id Tag Size Destination Cavity Seal
-IP_C42 7000/3212 ; 45
Cav Id Tag Size Destination Cavity Seal S 110C 1.50 mm² -IP_C7:1 -IP_SP230 SPLICE IGN
1 102B 1.00 mm² -IP_SP350:S S 110B 1.50 mm² -IP_C7:4 Cav Id Tag Size Destination Cavity Seal
2 S 110 2.00 mm² -FB1:13 S 830A 0.50 mm² -IP_C10:8
3 700 1.00 mm² -IP_C41:1 -IP_SP160 SPLICE HIGH BEAM S 830D 0.50 mm² -IP_C11:8
4 103 1.00 mm² -IP_C19:2 Cav Id Tag Size Destination Cavity Seal S 830B 1.00 mm² -IP_C17:7
5 102C 1.00 mm² -IP_SP350:S S 837B 2.00 mm² -IP_C17:1 S 830C 0.50 mm² -IP_C2:7
7000/3212 ; 45 S 837 2.50 mm² -IP_C34:4 S 830E 1.00 mm² -IP_C19:10
6
7 S 837C 0.75 mm² -IP_C37:2 S 830F 0.50 mm² -IP_C39:4
8 -IP_SP060 SPLICE IGN S 837A 0.75 mm² -IP_C2:29 S 830 1.00 mm² -FB1:29
10 S 133C 0.75 mm² -IP_C14:2 7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice
S 133A 0.75 mm² -IP_C22:E Additional Components Additional Components
7241/0060 10 WAY W/H RELAY PLATE MRB MISO 2P-NY 66B S 133D 0.75 mm² -IP_C15:2 7000/3212 ; 45 7000/3212 ; 45
Additional Components S 133 0.75 mm² -IP_C11:5
S 133F 1.00 mm² -FB1:22
S 133B 0.75 mm² -IP_C23:E -IP_SP170 SPLICE FRONT WL
-IP_SP010 SPLICE_IGN -IP_SP240 SPLICE WORK LAMP
7000/3104 In Line Ultrasonic Splice S 855C 2.00 mm² -IP_C29:9
S 002 4.00 mm² -IP_C22:C S 303A 4.00 mm² -FB1:36
Additional Components S 855D 0.75 mm² -IP_C2:14
S 002H 4.00 mm² -IP_FB1:1 S 303 8.00 mm² -IP_C31:1
7000/3212 ; 45 S 855 2.00 mm² -IP_C18:1
S 002G 4.00 mm² -IP_FB1:44 S 303C 4.00 mm² -FB1:41
S 855B 0.75 mm² -IP_C37:7
S 002J 4.00 mm² -IP_FB1:2 S 855A 2.00 mm² -IP_C9:3
-IP_SP070 SPLICE IGN 7000/3104 In Line Ultrasonic Splice
7000/3104 In Line Ultrasonic Splice Cav Id Tag Size Destination Cavity Seal Additional Components
Additional Components S 304E 1.50 mm² -IP_C6:1 7000/3212 ; 45
7000/3212 ; 45 S 304 2.00 mm² -FB1:32
7000/3212 ; 45
S 304A 2.00 mm² -IP_C5:2
S 304C 1.50 mm² -IP_C17:5
-IP_SP180 SPLICE MAXI FUSE -IP_SP030 SPLICE BUZZER
-IP_SP020 SPLICE HAZARD ASSEMBLY 7000/3104 In Line Ultrasonic Splice Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal
Cav Id Tag Size Destination Cavity Seal Additional Components S 301 8.00 mm² -IP_C32:1 S 106 0.75 mm² -IP_C2:9
S 804A 0.50 mm² -IP_C2:5 S 301A 4.00 mm² -IP_C22:A S 106B 0.50 mm² -IP_C37:12
7000/3212 ; 45
S 804 1.00 mm² -IP_C10:17 S 301C 4.00 mm² -FB1:33 S 106A 0.50 mm² -IP_C26:C
S 804C 0.50 mm² -IP_C37:6 S 106C 1.00 mm² -FB1:16
S 804B 1.00 mm² -IP_C9:1 -IP_SP080 SPLICE LOW BEAM 7000/3104 In Line Ultrasonic Splice
Cav Id Tag Size Destination Cavity Seal Additional Components 7000/3104 In Line Ultrasonic Splice
7000/3104 In Line Ultrasonic Splice S 834 2.00 mm² -IP_C34:9 Additional Components
7000/3212 ; 45
Additional Components S 834B 2.00 mm² -IP_C17:8 7000/3212 ; 45
7000/3212 ; 45 S 834A 0.75 mm² -IP_C2:19

7000/3212 ; 45
33 - 89 9813/8500-2 33 - 89
12 - Harness
18 - Side Console
33-90 33-91
-IP_C38 TO PARK BRAKE SW - 2 -IP_SP130 SPLICE NEUTRAL

1 600AG 1.00 mm² -IP_SP250:S S 810 1.50 mm² -IP_C12:6
2 936C 1.00 mm² -IP_SP210:S S 810A 1.50 mm² -IP_C25:8
S 810B 1.50 mm² -IP_C33:E
7000/3212 ; 45
-IP_C39 TO SPEEDOMETER
1 974 1.00 mm² -IP_C20:5 -IP_SP140 SPLICE_IGN
2 600AH 1.00 mm² -IP_SP250:S Cav Id Tag Size Destination Cavity Seal
3 170A 1.00 mm² -IP_SP360:S S 101B 1.00 mm² -IP_C36:2
4 830F 0.50 mm² -IP_SP230:S S 101A 1.00 mm² -IP_C35:2
5 S 101 1.50 mm² -FB1:5
6
7216/0052 6 WAY MATENLOK FEM HSG UNSEALED Additional Components
-IP_C40 TO 4WD SWITCH -IP_SP150 SPLICE DIODE -I

1 S 828A 1.50 mm² -IP_C9:4
2 102A 1.00 mm² -IP_SP350:S S 828C 0.75 mm² -IP_C2:17
3 878 1.00 mm² -IP_C20:9 S 828B 1.50 mm² -FB1:25
4 S 828 1.50 mm² -IP_C11:3
5
6 7000/3104 In Line Ultrasonic Splice
7 600BB 0.50 mm² -IP_SP250:S Additional Components
8 829H 0.50 mm² -IP_SP220:S 7000/3212 ; 45
9
10
7219/0013 10 Way 6.3 Fastin Switch Hsg SPLICE DUMP & PARK
-IP_SP040
S 107 2.00 mm² -IP_C25:5
S 107B 2.00 mm² -IP_C12:7
-IP_C41 TO AUX CIRCUIT SW S 107A 1.50 mm² -IP_C25:1
Cav Id Tag Size Destination Cavity Seal S 107D 2.00 mm² -FB1:48
1 700 1.00 mm² -IP_C42:3
2 600F 1.00 mm² -IP_SP251:S 7000/3104 In Line Ultrasonic Splice
7212/0128 2 WAY MT090 FEM HSG NATURAL 7000/3212 ; 45
-IP_SP050 SPLICE RH COLUMN

TO AUX CIRCUIT RELAY Cav Id Tag Size Destination Cavity Seal
-IP_C42
Cav Id Tag Size Destination Cavity Seal S 110C 1.50 mm² -IP_C7:1
Page 33-91
1 102B 1.00 mm² -IP_SP350:S S 110B 1.50 mm² -IP_C7:4
2 S 110 2.00 mm² -FB1:13
3 700 1.00 mm² -IP_C41:1
4 103 1.00 mm² -IP_C19:2
5 102C 1.00 mm² -IP_SP350:S
7000/3212 ; 45
6
7
8 -IP_SP060 SPLICE IGN
10 S 133C 0.75 mm² -IP_C14:2
S 133A 0.75 mm² -IP_C22:E
7241/0060 10 WAY W/H RELAY PLATE MRB MISO 2P-NY 66B S 133D 0.75 mm² -IP_C15:2
S 133F 1.00 mm² -FB1:22
S 133B 0.75 mm² -IP_C23:E
-IP_SP010 SPLICE_IGN
Cav Id Tag Size Destination Cavity Seal 7000/3104 In Line Ultrasonic Splice
S 002 4.00 mm² -IP_C22:C Additional Components
S 002H 4.00 mm² -IP_FB1:1
7000/3212 ; 45
S 002G 4.00 mm² -IP_FB1:44
S 002J 4.00 mm² -IP_FB1:2
-IP_SP070 SPLICE IGN
7000/3104 In Line Ultrasonic Splice Cav Id Tag Size Destination Cavity Seal
Additional Components S 304E 1.50 mm² -IP_C6:1
7000/3212 ; 45 S 304 2.00 mm² -FB1:32
S 304A 2.00 mm² -IP_C5:2
S 304C 1.50 mm² -IP_C17:5
-IP_SP020 SPLICE HAZARD ASSEMBLY 7000/3104 In Line Ultrasonic Splice

S 804A 0.50 mm² -IP_C2:5
7000/3212 ; 45
S 804 1.00 mm² -IP_C10:17
S 804C 0.50 mm² -IP_C37:6
S 804B 1.00 mm² -IP_C9:1 -IP_SP080 SPLICE LOW BEAM
7000/3104 In Line Ultrasonic Splice S 834 2.00 mm² -IP_C34:9
Additional Components S 834B 2.00 mm² -IP_C17:8
7000/3212 ; 45 S 834A 0.75 mm² -IP_C2:19

7000/3212 ; 45
33 - 90 9813/8500-2 33 - 90
12 - Harness
18 - Side Console
33-90 33-91
-IP_SP090 SPLICE FLASHER -IP_SP190 SPLICE REAR HORN

S 803 1.00 mm² -IP_C7:14 S 921 1.00 mm² -IP_C12:11
S 803B 2.00 mm² -IP_C24:C S 921A 1.00 mm² -IP_C19:12
S 803A 2.00 mm² -IP_C10:18 S 921B 1.00 mm² -IP_C28:6
7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice

7000/3212 ; 45 7000/3212 ; 45
SPLICE FR & RR WORKLAMP -IP_SP200 SPLICE TRANS DUMP

-IP_SP100 Cav Id Tag Size Destination Cavity Seal
S 934B 1.00 mm² -IP_C25:3
S 861A 2.00 mm² -IP_C29:4
S 934A 1.00 mm² -IP_C19:13
S 861 2.00 mm² -IP_C18:2
S 934 1.00 mm² -IP_C4:1
S 861B 0.75 mm² -IP_C2:3
7000/3212 ; 45
-IP_SP210 SPLICE PARK BRAK
-IP_SP110 SPLICE LH IND S 936B 1.00 mm² -IP_C25:7
Cav Id Tag Size Destination Cavity Seal S 936 1.00 mm² -IP_C35:5
S 805 1.00 mm² -IP_C7:10 S 936A 1.00 mm² -IP_C4:2
S 805B 1.00 mm² -IP_C19:1 S 936C 1.00 mm² -IP_C38:2
S 805A 1.00 mm² -IP_C10:5
S 805D 0.75 mm² -IP_C2:1 7000/3104 In Line Ultrasonic Splice
S 805E 0.75 mm² -IP_C37:4 Additional Components
S 805C 1.00 mm² -IP_C17:4 7000/3212 ; 45
7000/3104 In Line Ultrasonic Splice SPLICE ILLUMINATION

-IP_SP220
7000/3212 ; 45 S 829A 1.00 mm² -IP_C17:3
S 829D 1.00 mm² -IP_C20:10
S 829B 0.50 mm² -IP_C14:8
-IP_SP120 SPLICE RH IND S 829C 0.50 mm² -IP_C15:8
Cav Id Tag Size Destination Cavity Seal S 829E 0.50 mm² -IP_C35:8
S 806A 1.00 mm² -IP_C7:11 S 829F 0.50 mm² -IP_C36:8
S 806 1.00 mm² -IP_C17:2 S 829G 0.50 mm² -IP_C37:3
S 806B 0.75 mm² -IP_C2:6 S 829H 0.50 mm² -IP_C40:8
S 806D 1.00 mm² -IP_C20:7 S 829 1.00 mm² -FB1:30
S 806E 0.75 mm² -IP_C37:5
7000/3104 In Line Ultrasonic Splice 7000/3212 ; 45
7000/3212 ; 45
-IP_SP230 SPLICE IGN
Page 33-90

S 830A 0.50 mm² -IP_C10:8
-IP_SP160 SPLICE HIGH BEAM S 830D 0.50 mm² -IP_C11:8
Cav Id Tag Size Destination Cavity Seal S 830B 1.00 mm² -IP_C17:7
S 837B 2.00 mm² -IP_C17:1 S 830C 0.50 mm² -IP_C2:7
S 837 2.50 mm² -IP_C34:4 S 830E 1.00 mm² -IP_C19:10
S 837C 0.75 mm² -IP_C37:2 S 830F 0.50 mm² -IP_C39:4
S 837A 0.75 mm² -IP_C2:29 S 830 1.00 mm² -FB1:29
7000/3104 In Line Ultrasonic Splice 7000/3104 In Line Ultrasonic Splice

7000/3212 ; 45 7000/3212 ; 45
-IP_SP170 SPLICE FRONT WL

-IP_SP240 SPLICE WORK LAMP
S 855C 2.00 mm² -IP_C29:9
S 303A 4.00 mm² -FB1:36
S 855D 0.75 mm² -IP_C2:14
S 303 8.00 mm² -IP_C31:1
S 855 2.00 mm² -IP_C18:1
S 303C 4.00 mm² -FB1:41
S 855B 0.75 mm² -IP_C37:7
S 855A 2.00 mm² -IP_C9:3 7000/3104 In Line Ultrasonic Splice
7000/3212 ; 45
-IP_SP180 SPLICE MAXI FUSE -IP_SP030 SPLICE BUZZER

S 301 8.00 mm² -IP_C32:1 S 106 0.75 mm² -IP_C2:9
S 301A 4.00 mm² -IP_C22:A S 106B 0.50 mm² -IP_C37:12
S 301C 4.00 mm² -FB1:33 S 106A 0.50 mm² -IP_C26:C
S 106C 1.00 mm² -FB1:16
7000/3212 ; 45 Additional Components
7000/3212 ; 45
33 - 91 9813/8500-2 33 - 91
12 - Harness
18 - Side Console
Figure 491. 335/Y4808 Issue 2 (Sheet 5 of 5)

-IP_SP250 SPLICE INST PANEL EARTH -IP_SP350
S 600G 0.50 mm² -IP_C27:3 S 102A 1.00 mm² -IP_C40:2
S 600H 0.50 mm² -IP_C27:6 S 102C 1.00 mm² -IP_C42:5
S 600J 0.75 mm² -IP_C34:3 S 102B 1.00 mm² -IP_C42:1
S 600K 0.75 mm² -IP_C29:6 S 102 1.50 mm² -FB1:15
S 600M 0.75 mm² -IP_C29:3
S 600Z 0.75 mm² -IP_C34:6
S 600ZZ 6.00 mm² -IP_SP252:S
7000/3212 ; 45
S 600AA 0.50 mm² -IP_C37:1
S 600L 0.50 mm² -IP_C25:6 -IP_SP360 SPLICE_IGN
S 600BB 0.50 mm² -IP_C40:7 Cav Id Tag Size Destination Cavity Seal
S 600E 0.50 mm² -IP_C33:B S 170B 1.00 mm² -IP_C005:2
S 600AH 1.00 mm² -IP_C39:2 S 170A 1.00 mm² -IP_C39:3
S 600D 2.50 mm² -IP_C24:B S 170 1.00 mm² -FB1:8
S 600AG 1.00 mm² -IP_C38:1
7000/3212 ; 45 -IP_SP380 SPLICE GND 2
-IP_SP251 SPLICE INST PANEL EARTH S 600TT 6.00 mm² -IP_SP252:S
Cav Id Tag Size Destination Cavity Seal S 600 8.00 mm² -IP_C21:1
S 600ZZ1 6.00 mm² -IP_SP252:S S 600A 8.00 mm² -IP_C18:3
S 600AB 0.50 mm² -IP_C12:8
S 600X 0.50 mm² -IP_C11:7 7000/3104 In Line Ultrasonic Splice
S 600Y 1.00 mm² -IP_C10:10 Additional Components
S 600N 1.50 mm² -IP_C8:4 7000/3212 ; 45
S 600F 1.00 mm² -IP_C41:2 -IP_SP300
S 600AC 0.50 mm² -IP_C13:1 Cav Id Tag Size Destination Cavity Seal
S 412 1.00 mm² -IP_C19:11
S 412A 0.50 mm² -IP_C2:15
S 412B 1.00 mm² -FB1:19
7000/3212 ; 45
-IP_SP252 SPLICE INST PANEL EARTH
7000/3212 ; 45
S 600R 1.50 mm² -IP_C6:2
S 600T 0.50 mm² -IP_C14:7 -IP_SP310
S 600U 0.50 mm² -IP_C15:7 Cav Id Tag Size Destination Cavity Seal
S 600ZZ1 6.00 mm² -IP_SP251:S S 403A 0.50 mm² -IP_C2:10
S 600ZZ 6.00 mm² -IP_SP250:S S 403B 1.00 mm² -IP_C005:5
S 600TT 6.00 mm² -IP_SP380:S S 403 1.00 mm² -IP_C19:3
S 600V 1.00 mm² -IP_C35:4
S 600AF 0.50 mm² -IP_C35:7 7000/3104 In Line Ultrasonic Splice
S 600AE 0.50 mm² -IP_C36:7 Additional Components
S 600P 2.00 mm² -IP_C5:1 7000/3212 ; 45
7000/3104 In Line Ultrasonic Splice -IP_SP320

7000/3212 ; 45 S 406 1.00 mm² -IP_C19:6
S 406A 0.50 mm² -IP_C2:18
-IP_SP260 SPLICE MAXI FUSE S 406B 1.00 mm² -IP_C005:4
S 302A 6.00 mm² -IP_C1:1 7000/3104 In Line Ultrasonic Splice
S 302 8.00 mm² -IP_C32:2 Additional Components
S 302E 4.00 mm² -FB1:28 7000/3212 ; 45
S 302C 4.00 mm² -IP_C23:A
-IP_SP330
7000/3212 ; 45 S 408A 0.50 mm² -IP_C2:20
S 408B 1.00 mm² -IP_C005:10
-IP_SP270 SPLICE_BUZZER
Cav Id Tag Size Destination Cavity Seal 7000/3104 In Line Ultrasonic Splice
S 411 0.75 mm² -IP_C2:11 Additional Components
S 411A 0.50 mm² -IP_C37:11 7000/3212 ; 45
S 411B 0.50 mm² -IP_C26:B
-IP_SP340
Additional Components S 404A 0.50 mm² -IP_C2:22
7000/3212 ; 45 S 404 1.00 mm² -IP_C19:4
S 404B 1.00 mm² -IP_C005:9
-IP_SP280 SPLICE IGN 7000/3104 In Line Ultrasonic Splice
S 007 4.00 mm² -IP_C23:C
7000/3212 ; 45
S 007B 4.00 mm² -IP_FB1:17
S 007C 4.00 mm² -IP_FB1:10
-IP_SP290
S 007A 4.00 mm² -IP_FB1:9
S 611A 0.75 mm² -IP_C2:16
S 611C 1.00 mm² -FB1:20
S 611 2.00 mm² -IP_C005:1
7000/3212 ; 45
S 611B 2.00 mm² -IP_C20:8

7000/3212 ; 45
33 - 92 9813/8500-2 33 - 92
12 - Harness
28 - Exterior Roof
28 - Exterior Roof
Diagram
33 - 93 9813/8500-2 33 - 93
Notes:
33 - 94 9813/8500-2 33 - 94
12 - Harness
28 - Exterior Roof

REFERENCE FRONT VIEW 7232/0005 DOME LAMP BOO T
REFERENCE FRONT VIEW 7232/0005
BLACK
DOME LAMP BOO T
BLACK
DOME LAMP BOO T

BLACK
Add: 7243/0301 : Dome Lamp Boot Black

-CB_C10
-CB_C7 -CB_C6
-CB_C5
1 2 REFERENCE FRONT VIEW 7232/0005
1 2 -CB_C10#1
1
2
DOME LAMP BOO T
-CB_C6#1 -CB_C8#1
7201/0403 -CB_C5#1
BLACK REFERENCE FRONT VIEW 7232/0005
-CB_C7#1 7232/0005 7232/0005
TO INTERIOR LIGHT SUPPLY 7232/0023
TO FRONT WL RH OR TO REAR WL RH
7232/0005
TO FACE FAN
TO FRONT WL LH (MSSL p/n : 6260-3700 can be used) -CB_C2 1
50 mm
1 2 2
70 mm
100 mm
70 mm
-CB_C2#1
-CB_C8 7232/0023
TO NO PLATE LAMP RH -CB_C9
50 mm
-CB_C11 -CB_C14
7207/2008
100 mm
1 2
TO CAB EARTH
230 mm
230 mm
7000/3207
-CB_C11#1
-P4 7201/0403 -CB_C9#1
TO INTERIOR LIGHT GND
OR M6 7232/0005
7000/3207 TO REAR WL LH
(MSSL p/n : 6260-3700 can be used)
300 mm
-P5
50 mm
50 mm
100 mm
7000/3207
150
-P20
1 2 3 100 mm 1100 mm 100 mm 650 mm 50 mm 50 mm
7000/3207
0m
-P12
-CB_C4
50 mm
7000
PLEASE PROVIDE
m
-P22 07
SIDE VIEW 7000/3202
4 5 6
/32
-P15
7000/3207 7000/3209 7000/3203
-P3 -ID1 -P21 -P1 -CB_SP050
-CB_C4#1 ID Label
7216/0051
150 mm
7000/3207
TO HEAD LAMP LH
80 mm
-P11
150 mm
7000/3202
-P17
SLIT VTB TUBE
50 m
7000/3207
mm
-P13
m
50
-CB_C1
100 mm 800 mm 100 mm 200 mm 350 mm 100 mm 800 mm 150 mm 50 mm
1
7000/3203 7000/3207 7000/3209 7000/3209 7000/3207
7000/3209 -CB_SP040 -P9 -CB_SP020
2
100 mm
-P2 -P8 -P10 -P23 -P14
-CB_C1#1
7232/0023
-CB_SP060 TO NO PLATE LAMP LH
640 mm
7000/3202
-P18
SLIT VTB TUBE
-CB_SP030
50 mm
-CB_SP010
50 mm
200 mm 100 mm -CB_C3 1 2 3

PLEASE PROVIDE
SIDE VIEW
4 5 6
7000/3207
-P6
-CB_C3#1
620 mm
7216/0051
SLIT VTB TUBE TO HEAD LAMP RH
-P19
7000/3202
950 mm
7000/3207
-P7
50 mm -CB_C13
PLEASE PROVIDE
SIDE VIEW
2 1
3
50 mm
-CB_C13#1
7213/0058
TO W/H INST PANEL CONN 2
NOTE : USE GRAY CONNECTOR (MSSL P/N : 6188-0104)
1 2 3 4
5 6 7 8
-CB_C12
-CB_C12#1
7218/0002
33 - 95 9813/8500-2 33 - 95
12 - Harness
28 - Exterior Roof
33-96 33-97
REFERENCE FRONT VIEW 7232/0005 DOME LAMP BOO T

BLACK
DOME LAMP BOO T
BLACK

-CB_C10
-CB_C7 -CB_C6
-CB_C5
1 2
1 2 -CB_C10#1
1
2
-CB_C6#1
7201/0403 -CB_C5#1
-CB_C7#1 7232/0005
TO INTERIOR LIGHT SUPPLY 7232/0023
7232/0005 TO FRONT WL RH OR
TO FACE FAN
TO FRONT WL LH (MSSL p/n : 6260-3700 can be used)
50 mm
70 mm
100 mm
70 mm
-CB_C11
100 mm
230 mm
230 mm
7000/3207
-CB_C11#1
-P4 7201/0403
TO INTERIOR LIGHT GND
OR
7000/3207
(MSSL p/n : 6260-3700 can be used)
300 mm
-P5
7000/3207
150
-P20
1 2 3 100 mm 1100 mm 100 mm 650 mm 50 mm 50 mm
0
-CB_C4
mm
700
PLEASE PROVIDE
-P2 207
0/3
SIDE VIEW
4 5 6
2
7000/3207 7000/3209 7000/3203
-P3 -ID1 -P21 -P1 -CB_SP050
-CB_C4#1 ID Label
7216/0051
TO HEAD LAMP LH
80 mm
7000/3202
-P17
SLIT VTB TUBE
100 mm 800 mm 100 mm 200 mm
7000/3203 7000/3207
7000/3209 -CB_SP040
100 mm
-P2 -P8 -P10
-CB_SP060
640 mm
7000/3202
-P18
SLIT VTB TUBE
Page 33-97
-CB_SP030
50 mm
-CB_SP010
50 mm
200 mm 100 mm -CB_C3 1 2 3

PLEASE PROVIDE
SIDE VIEW
4 5 6
7000/3207
-P6
-CB_C3#1
620 mm
7216/0051
SLIT VTB TUBE TO HEAD LAMP RH
-P19
7000/3202
950 mm
7000/3207
-P7
50 mm -CB_C13
PLEASE PROVIDE
SIDE VIEW
2 1
3
50 mm
-CB_C13#1
7213/0058
NOTE : USE GRAY CONNECTOR (MSSL P/N : 6188-0104)
1 2 3 4
5 6 7 8
-CB_C12
-CB_C12#1
7218/0002
33 - 96 9813/8500-2 33 - 96
12 - Harness
28 - Exterior Roof
33-96 33-97
DOME LAMP BOO T

BLACK
-CB_C5
1
2
-CB_C8#1 DOME LAMP BOO T
-CB_C5#1
BLACK REFERENCE FRONT VIEW 7232/0005
7232/0005
7232/0023 TO REAR WL RH
TO FACE FAN
-CB_C2 1
50 mm
1 2 2
-CB_C2#1
-CB_C8 7232/0023
TO NO PLATE LAMP RH -CB_C9
50 mm
-CB_C14
7207/2008
1 2
TO CAB EARTH
-CB_C9#1
M6 7232/0005
TO REAR WL LH
300 mm
50 mm
50 mm
100 mm
7000/3207
150
-P20
7000/3207
0m
-P12
50 mm
700
m
-P2 207
7000/3202
0/3
-P15
2
150 mm
7000/3207
-P11
150 mm
50 7000/3207
mm mm
-P13
50
-CB_C1
100 mm 200 mm 350 mm 100 mm 800 mm 150 mm 50 mm
1
7000/3207 7000/3209 7000/3209 7000/3207
-P9 -CB_SP020
-P10 -P23 -P14
2
-CB_C1#1
7232/0023
TO NO PLATE LAMP LH
Page 33-96
2 3
5 6
-CB_C3#1
7216/0051
TO HEAD LAMP RH
33 - 97 9813/8500-2 33 - 97
12 - Harness
28 - Exterior Roof
Figure 493. 334/Y4125 Issue 3 (Sheet 2 of 2)

-CB_C1 TO NO PLATE LAMP LH -CB_C9 TO REAR WL LH -CB_SP040 SPLICE CAB EARTH
Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal Cav Id Tag Size Destination Cavity Seal
1 830 1.00 mm² -CB_SP060:S 1 600J 1.00 mm² -CB_SP040:S S 600B 1.00 mm² -CB_C7:1
2 600G 1.00 mm² -CB_SP040:S 2 861B 1.00 mm² -CB_SP020:S S 600D 1.00 mm² -CB_C6:1
S 600F 1.00 mm² -CB_C2:2
7232/0023 2 WAY 250 ET FEM HSG UNSEALED 7232/0005 2 Way Fastin Fem Hsg Worklight S 600G 1.00 mm² -CB_C1:2
Additional Components Additional Components S 600J 1.00 mm² -CB_C9:1
S 600P 1.00 mm² -CB_C8:1
S 600E 1.50 mm² -CB_C3:4
-CB_C2 TO NO PLATE LAMP RH -CB_C10 TO INTERIOR LIGHT SUPPLY
S 600A 1.50 mm² -CB_C4:4
S 600H 1.00 mm² -CB_C5:1
1 830A 1.00 mm² -CB_SP060:S 1 304C 1.50 mm² -CB_C12:5
S 600Q 8.00 mm² -CB_C14:1
2 600F 1.00 mm² -CB_SP040:S
7201/0403 1 Way Pos Lock Housing Straight S 600C 1.50 mm² -CB_C11:1
7232/0023 2 WAY 250 ET FEM HSG UNSEALED Additional Components
-CB_C11 TO INTERIOR LIGHT GND 7000/3212 ; 45
-CB_C3 TO HEAD LAMP RH 1 600C 1.50 mm² -CB_SP040:S
Cav Id Tag Size Destination Cavity Seal -CB_SP050 SPLICE FRONT WL
7201/0403 1 Way Pos Lock Housing Straight Cav Id Tag Size Destination Cavity Seal
1 830B 1.00 mm² -CB_SP060:S
Additional Components S 855B 1.00 mm² -CB_C6:2
2 837A 1.00 mm² -CB_SP010:S
S 855A 1.00 mm² -CB_C7:2
3 834A 1.00 mm² -CB_SP030:S
S 855 2.00 mm² -CB_C13:1
4 600E 1.50 mm² -CB_SP040:S
-CB_C12 TO W/H INST PANEL CONN 1
5 806 1.00 mm² -CB_C12:2 7000/3104 In Line Ultrasonic Splice
6 7210/0100 Additional Components
1 837 2.00 mm² -CB_SP010:S
7216/0051 6 WAY MT090 FEM HSG NATURAL 2 806 1.00 mm² -CB_C3:5 7000/3212 ; 45
Additional Components 3 829A 1.00 mm² -CB_C4:1
4 805 1.00 mm² -CB_C4:5 -CB_SP060 SPLICE SIDE LAMP
5 304C 1.50 mm² -CB_C10:1 Cav Id Tag Size Destination Cavity Seal
-CB_C4 TO HEAD LAMP LH 6 114 1.00 mm² -CB_C5:2 S 830A 1.00 mm² -CB_C2:1
Cav Id Tag Size Destination Cavity Seal 7 830C 1.00 mm² -CB_SP060:S S 830 1.00 mm² -CB_C1:1
1 829A 1.00 mm² -CB_C12:3 8 834 2.00 mm² -CB_SP030:S S 830B 1.00 mm² -CB_C3:1
2 837B 1.00 mm² -CB_SP010:S S 830C 1.00 mm² -CB_C12:7
3 834B 1.00 mm² -CB_SP030:S 7218/0002 8 Way HW090 Pin Housing
4 600A 1.50 mm² -CB_SP040:S Additional Components 7000/3104 In Line Ultrasonic Splice
5 805 1.00 mm² -CB_C12:4 7218/0004 Additional Components
6 7210/0100 7000/3212 ; 45
-CB_C13 TO W/H INST PANEL CONN 2
7216/0051 6 WAY MT090 FEM HSG NATURAL Cav Id Tag Size Destination Cavity Seal
Additional Components 1 855 2.00 mm² -CB_SP050:S
2 861 2.00 mm² -CB_SP020:S
3 600 8.00 mm² -CB_C14:1
-CB_C5 TO FACE FAN
Cav Id Tag Size Destination Cavity Seal 7213/0058 3 WAY MALE SEALED HSG NOTE : USE GRAY CONNECTOR (MSSL P/N : 6188-0104)
1 600H 1.00 mm² -CB_SP040:S Additional Components
2 114 1.00 mm² -CB_C12:6
7232/0023 2 WAY 250 ET FEM HSG UNSEALED -CB_C14 TO CAB EARTH

1 600 8.00 mm² -CB_C13:3
1 600Q 8.00 mm² -CB_SP040:S
TO FRONT WL RH 7207/2008 Ring Terminal M6 12-16mm2

-CB_C6
1 600D 1.00 mm² -CB_SP040:S 7000/3212;45 # Adhesive Lined Heatshrink
2 855B 1.00 mm² -CB_SP050:S
7232/0005 2 Way Fastin Fem Hsg Worklight -CB_SP010 SPLICE HIGH BEAM
S 837 2.00 mm² -CB_C12:1
S 837A 1.00 mm² -CB_C3:2
S 837B 1.00 mm² -CB_C4:2

TO FRONT WL LH Additional Components
-CB_C7
Cav Id Tag Size Destination Cavity Seal 7000/3212 ; 45
1 600B 1.00 mm² -CB_SP040:S
2 855A 1.00 mm² -CB_SP050:S -CB_SP020 SPLICE REAR WL
7232/0005 2 Way Fastin Fem Hsg Worklight S 861 2.00 mm² -CB_C13:2
Additional Components S 861B 1.00 mm² -CB_C9:2
S 861A 1.00 mm² -CB_C8:2

-CB_C8 TO REAR WL RH 7000/3212 ; 45
1 600P 1.00 mm² -CB_SP040:S
-CB_SP030 SPLICE LOW BEAM
2 861A 1.00 mm² -CB_SP020:S
7232/0005 2 Way Fastin Fem Hsg Worklight S 834 2.00 mm² -CB_C12:8
Additional Components S 834A 1.00 mm² -CB_C3:3
S 834B 1.00 mm² -CB_C4:3

7000/3212 ; 45
33 - 98 9813/8500-2 33 - 98
24 - Instruments
24 - Instruments
Contents Page No.
33-24-03 Instrument Panel .......................................................................................................... 33-101
33 - 99 9813/8500-2 33 - 99
Notes:
33 - 100 9813/8500-2 33 - 100

24 - Instruments
03 - Instrument Panel
03 - Instrument Panel Introduction

Introduction .................................................. 33-101 The instrument panel communicates information to
Remove and Install ..................................... 33-102 the operator about the systems on the machine and
warns of any abnormal conditions that may occur.
The instrument panel houses all the gauges and
warning lights on the machine i.e. fuel gauge, coolant
warning, engine oil pressure warning light. For more
detailed information refer to the operator manual.
33 - 101 9813/8500-2 33 - 101

24 - Instruments
03 - Instrument Panel
Remove and Install
Remove
2. Disconnect the battery.
3. Remove the screws (x5) that attaches the
instrument panel to the side console trim panel.
4. Lift the instrument panel and access the
connectors below it.
5. Disconnect the electrical connections from the
instrument panel from the rear side.
6. Remove the instrument panel from the side
console trim panel.
Figure 494.
A
B
A Screws
B Instrument panel (right side)
C Side console trim panel
Install
step.
2. Make sure that the electrical connections are
connected to the correct connectors.
33 - 102 9813/8500-2 33 - 102

27 - Interior Switch
Contents Page No.
33-27-03 Multi-Purpose ............................................................................................................... 33-105
33 - 103 9813/8500-2 33 - 103

Notes:
33 - 104 9813/8500-2 33 - 104

03 - Multi-Purpose
03 - Multi-Purpose Figure 495.
Remove and Install

B
Remove
C
1. Make the machine safe with the lift arms raised.
2. Remove the front grille and disconnect the
battery.
4 2 1 3
8 7 6 5
3. From inside the cab, remove the front steering

console. A
4. Disconnect the electrical connectors from the
cab harness. 4 2 1 3
8 7 6 5
5. Remove the screw (x2) and remove the multi-

purpose switches.
A Electrical connector (x2)

B Screw (x2)
C Locating pin
Install
1. The installation is the opposite of the removal
procedure. Make sure to do the steps that follow.
2. The left side switch incorporates a locating
pin which engages with a drilled hole in the
steering column and prevents rotation of the
switch mounting.
3. On completion, operate the column switches and
check they all function correctly.
33 - 105 9813/8500-2 33 - 105

Notes:
33 - 106 9813/8500-2 33 - 106

Contents Page No.
72-00 Fasteners and Fixings

72-00-00 General ............................................................................................................................. 72-3
72-03 Screws
72-03-00 General ............................................................................................................................. 72-7
72-06 Bolts
72-06-00 General ........................................................................................................................... 72-11
72-18 Bearings
72-18-00 General ........................................................................................................................... 72-15
72-21 Clips
72-21-03 Worm Drive .................................................................................................................... 72-17
72-36 Threaded Insert
72-36-00 General ........................................................................................................................... 72-23
9813/8500-2
2017-09-25
Notes:
9813/8500-2
2017-09-25
Contents Page No.
72-00-00 General ............................................................................................................................. 72-3
72 - 1 9813/8500-2 72 - 1
Notes:
72 - 2 9813/8500-2 72 - 2
00 - General
00 - General Fastener Type Colour Part Number

Suffix
Zinc Nickel - Black, chalky N (e.g.
Introduction black texture 1315/3712N)
Zinc flake - Black, slight B (e.g.
JCB Fasteners (Before September 2017) black gloss 1315/3712B)
Some external fasteners on JCB machines are Torque and Angle Tightening
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet Insufficient pre-load of a bolted joint can cause
and replaces the original Zinc and Yellow Plating major problems, such as cylinder head warp, leaking
used on earlier machines. The two types of fasteners gasket joints etc. There are several methods of
can be readily identified by colour and part number achieving an accurate pre-load of a bolted joint, the
suffix. Refer to Table 1. Fastener Types. two main methods used on the JCB engine are:
Table 111. • Torque Control Tightening - Using a torque
Fastener Type Colour Part Number meter to control the torque is the most
Suffix popular means of controlling pre-load, and
in the majority of instances this method is
Zinc and Yellow Golden Finish Z (e.g. adequate. It should be noted that with this
1315/3712Z) process, the majority of the torque is used
Dacromet Mottled Silver D (e.g. to overcome friction, therefore slight variations
Finish 1315/3712D) in the frictional conditions can lead to large
changes in the bolt pre-load.
Note: As the Dacromet fasteners have a lower torque • Angle Control Tightening - Where a more
setting than the Zinc and Yellow fasteners, the torque precise pre-load is required, the torque and
figures used must be relevant to the type of fastener. angle tightening method is used. The bolt
is tightened to a predetermined torque (this
A Dacromet bolt should not be used in conjunction may be done in stages), and then as a
with a Zinc or Yellow plated nut, as this could final sequence, the bolt is tightened to a
change the torque characteristics of the torque predetermined angle - this method of tightening
setting further. For the same reason, a Dacromet nut the bolts results in a smaller variation in the
should not be used with a Zinc or Yellow plated bolt. final pre-load. It is critical that the predetermined
tightening angle is accurately achieved, failure
All bolts used on JCB machines are high tensile and to tighten accurately to the specified angle could
must not be replaced by bolts of a lesser tensile result in the bolt pre-load being incorrect - this
specification. will lead to eventual failures. It is good practice
to replace all bolts that have been tightened
Dacromet bolts, due to their high corrosion using the torque + angle procedure.
resistance are used in areas where rust could
occur. Dacromet bolts are only used for external
Tightening Method
applications. They are not used in applications
such as gearbox or engine joint seams or internal The following example explains the recommended
applications. torque and angle procedure. A torque angle gauge
should be used for accuracy, but as a visual check,
JCB Fasteners (After September 2017) the bolts can be match marked as described below.
1. Tighten the bolt to the specified torque (specified

Table 112. torque values will be detailed in the relevant PIL
Fastener Type Colour Part Number sections).
Suffix
2. Mark a line across the centre of the bolt, and a
Zinc flake-silver White alu- D (e.g. second line on the part to be clamped - the two
minium (sil- 1315/3712D) lines should be aligned. Refer to Figure 496.
ver-grey), Dull
Zinc and heavy Silver (Bright iri- V (e.g.
trivalent passi- descent) 1315/3712V)
vated with seal
Zinc Nickel - sil- Dark, dull silver Not assigned
ver/grey grey
72 - 3 9813/8500-2 72 - 3
00 - General
Figure 496.
0°
3. Mark a third line at the specified torque angle - in

this instance the additional torque angle is 90°.
This line must be marked the specified angle in
a clockwise direction (to further tighten the bolt).
Figure 497.
+90°
4. In some instances, angle torque tightening can

be specified in two stages, for instance in this
example, the first angle quoted is 90° and then a
second angle of 180°. The additional 180° angle
is from the LAST tightened position. Refer to
Figure 498.
Figure 498.
+180°
+90°
5. Tighten the bolt so that the line on the bolt

aligns with the angle(s) marked on the item to
be clamped - remember, to ensure complete
accuracy an angle gauge should be used.
72 - 4 9813/8500-2 72 - 4
03 - Screws
03 - Screws
Contents Page No.
72-03-00 General ............................................................................................................................. 72-7
72 - 5 9813/8500-2 72 - 5
Notes:
72 - 6 9813/8500-2 72 - 6
03 - Screws
00 - General
Introduction ...................................................... 72-7 Use the torque setting tables (Technical Data) only
Technical Data ................................................. 72-8 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:
Table 113. Up to September 2017

Type Condition 1 Condition 2
no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.
Table 114. From September 2017

no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black
72 - 7 9813/8500-2 72 - 7
03 - Screws
00 - General
Technical Data
Table 115. Torque Settings - Internal

Hexagon Headed Capscrews (Zinc)
Bolt Size
mm N·m
3 2
4 6
5 11
6 19
8 46
10 91
12 159
16 395
18 550
20 770
24 1,332
72 - 8 9813/8500-2 72 - 8
06 - Bolts
06 - Bolts
Contents Page No.
72-06-00 General ........................................................................................................................... 72-11
72 - 9 9813/8500-2 72 - 9
Notes:
72 - 10 9813/8500-2 72 - 10
06 - Bolts
00 - General
Introduction .................................................... 72-11 Use the torque setting tables (Technical Data) only
Technical Data ............................................... 72-12 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:
Table 116. Up to September 2017

no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.
Table 117. From September 2017

no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black
Verbus-Ripp Bolts
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Figure 499.
72 - 11 9813/8500-2 72 - 11
06 - Bolts
00 - General
Technical Data Table 120. Torque Settings -

Coarse Metric Grade 8.8 Fasteners
Bolt Tread Hexa- Condi- Condi-
From JCB standard STD00019 issue 15.
Size Pitch gon (A/ tion 1 tion 2
1. This information does not apply to:- F)
mm mm mm N·m N·m
1.1. Hydraulic fittings (i.e. BSP, SAE O-ring 4 0.7 7 2.9 2.6
boss, UNF, four bolt split flange and JIC).
5 0.8 8 5.8 5.2
1.2. Locking type fasteners (those with a nylon 6 1 10 9.9 9
insert, or with distorted thread nuts such as
8 1.25 13 24 22
Cleveloc).
10 1.5 17 47 43
2. For information on fastener conditions, refer to 12 1.75 19 83 74
fasteners and fixings, bolts, general, introduction. 14 2 22 132 119
16 2 24 205 184
Table 118. Torque Settings - UNF S Fasteners 20 2.5 30 400 360
Bolt Treads Hexa- Condi- Condi- 24 3 36 690 621
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,372 1,235
F) 36 4 55 2,399 2,159
in in in N·m N·m
(1/4 in) 28 7/16 11.2 10 Table 121. Torque Settings - Coarse
(5/16 in) 24 1/2 22.3 20 Metric Grade 10.9 Fasteners
(3/8 in) 24 9/16 40 36 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 64 57 Size Pitch gon (A/ tion 1 tion 2
F)
(1/2 in) 20 3/4 98 88
mm mm mm N·m N·m
(9/16 in) 18 13/16 140 126
4 0.7 7 4 3.6
(5/8 in) 18 15/16 196 177
5 0.8 8 8.1 7.3
(3/4 in) 16 1 1/8 343 309
6 1 10 13.9 12.5
(7/8 in) 14 1 15/16 547 492
8 1.25 13 34 30
(1 in) 12 1 1/2 814 732
10 1.5 17 67 60
(1 1/8 in) 12 1 7/8 1,181 1,063
12 1.75 19 116 104
(1 1/4 in) 12 2 1/4 1,646 1,481
14 2 22 185 167
16 2 24 288 259
Table 119. Torque Settings - UNF X Fasteners 20 2.5 30 562 506
Bolt Treads Hexa- Condi- Condi- 24 3 36 971 874
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,930 1,737
F)
36 4 55 3,374 3,036
in in in N·m N·m
(1/4 in) 28 7/16 17.6 15.9 Table 122. Torque Settings - Coarse
(5/16 in) 24 1/2 35.2 31.6 Metric Grade 12.9 Fasteners
(3/8 in) 24 9/16 64 57 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 101 91 Size Pitch gon (A/ tion 1 tion 2
(1/2 in) 20 3/4 155 139 F)
(9/16 in) 18 13/16 221 199 mm mm mm N·m N·m
(5/8 in) 18 15/16 310 279 4 0.7 7 4.8 4.4
(3/4 in) 16 1 1/8 542 488 5 0.8 8 9.8 8.8
(7/8 in) 14 1 15/16 864 777 6 1 10 16.6 15
(1 in) 12 1 1/2 1,285 1,156 8 1.25 13 40 36
(1 1/8 in) 12 1 7/8 1,865 1,679 10 1.5 17 80 72
(1 1/4 in) 12 2 1/4 2,598 2,339 12 1.75 19 139 125
14 2 22 223 200
16 2 24 345 311
72 - 12 9813/8500-2 72 - 12
06 - Bolts
00 - General
Bolt Thread Hexa- Condi- Condi-

Size Pitch gon (A/ tion 1 tion 2
F)
mm mm mm N·m N·m
20 2.5 30 674 607
24 3 36 1,165 1,048
30 3.5 46 2,316 2,084
36 4 55 4,049 3,644
Table 123. Torque Settings - Rivet Nuts / Bolts

Bolt Size
mm N·m
3 1.2
4 3
5 6
6 10
8 24
10 48
12 82
72 - 13 9813/8500-2 72 - 13
18 - Bearings
18 - Bearings
Contents Page No.
72-18-00 General ........................................................................................................................... 72-15
72 - 14 9813/8500-2 72 - 14
18 - Bearings
00 - General
00 - General
Check (Condition)
1. Carefully inspect all rollers, cages and cups
for wear, chipping, or nicks to determine the
condition of the bearings for further use.
2. Do not replace a bearing cone or cup individually.
Replace the mating cup and the cone at the same
time.
3. After inspection, lubricate the bearings with a
suitable clean oil.
4. Wrap the bearings in clean lint free cloth or paper
to protect them until you install the bearings
again.
72 - 15 9813/8500-2 72 - 15
21 - Clips
21 - Clips
Contents Page No.
72-21-03 Worm Drive .................................................................................................................... 72-17
72 - 16 9813/8500-2 72 - 16
21 - Clips
03 - Worm Drive
03 - Worm Drive Introduction

Introduction .................................................... 72-17 There are three types of the plain worm drive clips.
Technical Data ............................................... 72-18
Component Identification ............................... 72-20 • Standard worm drive clip
• Heavy duty worm drive clip
• Spring assisted worm drive clip
Spring assisted worm drive clip contains a spring

insert on the inside of the band to provide
compensation against hose compression set.
Use the torque setting tables (Technical Data) only

where no torque setting is specified in the text.
72 - 17 9813/8500-2 72 - 17
21 - Clips
03 - Worm Drive
Technical Data
Dimensions
Figure 500.
C
J
H
Table 124.
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Standard worm drive clips and spring assisted worm drive clips
8–16mm 0.7mm 13mm 9mm 7mm 21mm 11mm
12–22mm 21mm
16–27mm up 0.8mm 14.6mm 12mm 30mm 12.5mm
to 60–80mm
70–90mm 36mm
up to 160–
180mm
72 - 18 9813/8500-2 72 - 18
21 - Clips
03 - Worm Drive
A B C D H J K
Clamping Band thick- Housing Band width Hex size Bolt and Bolt and
range ness width across flats housing housing
length overall
height
Heavy duty worm drive clips
172–206mm 0.7mm 23.1mm 16mm 7mm 37mm 13mm
Torque Values
Table 125. Standard Worm Drive Clip
Clamping Part number Torque values
range
8–16mm 2201/0001 2 -0/+0.5N·m
12–22mm 2201/0003 3 -0/+0.5N·m
16–27mm 2201/0005 5 -0/+0.5N·m
20–32mm 2201/0006 5 -0/+0.5N·m
25–40mm 2201/0007 5 -0/+0.5N·m
35–50mm 2201/0008 5 -0/+0.5N·m
40–60mm 2201/0010 5 -0/+0.5N·m
50–70mm 2201/0012 5 -0/+0.5N·m
60–80mm 2201/0013 5 -0/+0.5N·m
70–90mm 2201/0014 5 -0/+0.5N·m
80–100mm 2201/0015 5 -0/+0.5N·m
90–110mm 2201/0016 5 -0/+0.5N·m
100–120mm 2201/0021 5 -0/+0.5N·m
120–140mm 2201/0017 5 -0/+0.5N·m
130–150mm 2201/0018 5 -0/+0.5N·m
150–170mm 2201/0019 5 -0/+0.5N·m
160–180mm 2201/0020 5 -0/+0.5N·m
Table 126. Heavy Duty Worm Drive Clip

range
172–194mm 2201/0022 10 -0/+0.5N·m
184–206mm 2201/0023 10 -0/+0.5N·m
Table 127. Spring Assisted Worm Drive Clip

range
16–27mm 2206/1627 5 -0/+0.5N·m
20–32mm 2206/2032 5 -0/+0.5N·m
25–40mm 2206/2540 5 -0/+0.5N·m
30–45mm 2206/3045 5 -0/+0.5N·m
35–50mm 2206/3550 5 -0/+0.5N·m
40–60mm 2206/4060 5 -0/+0.5N·m
50–70mm 2206/5070 5 -0/+0.5N·m
60–80mm 2206/6080 5 -0/+0.5N·m
70–90mm 2206/7090 5 -0/+0.5N·m
72 - 19 9813/8500-2 72 - 19
21 - Clips
03 - Worm Drive
Component Identification Figure 503. Spring Assisted Worm Drive Clip

A B
Figure 501. Standard Worm Drive Clip
C
A B
C
D
F
E
A Screw support flange

B Asymmetric housing
C Asymmetric extension
A Screw support flange D Short housing saddle
B Asymmetric housing E Stamped inside
C Asymmetric extension F Spring insert
D Short housing saddle G Identification of material/clamping range
E Stamped inside
F Identification of material/clamping range
Figure 502. Heavy Duty Worm Drive Clip
A Extended bridge
B Band width (16mm)
C Identification of clamping range
72 - 20 9813/8500-2 72 - 20
36 - Threaded Insert
Contents Page No.
72-36-00 General ........................................................................................................................... 72-23
72 - 21 9813/8500-2 72 - 21
Notes:
72 - 22 9813/8500-2 72 - 22
00 - General
Introduction .................................................... 72-23 A threaded insert also known as a rivet nut is a
Technical Data ............................................... 72-24 one piece fastener installed blind from one side of
Remove and Install ....................................... 72-24 the machine body/framework. The threaded insert is
compressed so that a section of its shank forms an
upset against the machine body/framework, leaving
a durable thread.
Figure 504.
A Threaded insert
B Durable thread
Threaded inserts are installed to various parts of

the machine body and framework. They are used in
a number of applications, for instance, hose clamp
and hydraulic valve retention etc. Various sized
threaded inserts are available, refer to technical data
to determine the correct size of threaded insert to be
used for particular applications.
If for any reason a new threaded insert is required,

the correct installation procedure must be followed.
Refer to Remove and Install.
72 - 23 9813/8500-2 72 - 23
00 - General
Technical Data Remove and Install

Consumables
Table 128. Specifications Description Part No. Size
Thread Outside Materi- Total Drill Threaded Insert (M10 x 826/01104 -
Diame- Diame- al Thick- Rivet Hole Di- 23mm)
ter ter ness Length ameter Threaded Insert (M10 x 826/01105A -
mm mm mm mm mm 26mm)
(inch) (inch) (inch) (inch) Threaded Insert (M6 x 826/01099 -
M5 7 0.25–3 14 7.1 16mm)
M5 7 3–5.5 17 7.1 Threaded Insert (M6 x 826/01101 -
M6 9 0.5–3 16 9.1 19mm)
M6 9 3–5.5 19 9.1 Threaded Insert (M8 x 826/01102 -
18mm)
M8 11 0.5–3 18 11.1
Threaded Insert (M8 x 826/01103 -
M8 11 3–5.5 21 11.1
21mm)
M10 13 1–3.5 23 13.1
M10 13 3.5–6 26 13.1 The threaded insert installation tool is available from
Bolhoff Fastenings Ltd. www.bolhoff.com.
Install
1. Drill a hole in the machine body/framework where
the threaded insert is to be installed, refer to
technical data for the correct size.
2. De-burr the hole edges.
3. Screw the threaded insert on to the mandrel of
the installation tool. The bottom of the mandrel
should be in line with the bottom of the threaded
insert.
Consumable: Threaded Insert (M6 x 16mm)
Figure 505.
A Threaded insert
4. Wind the body of the installation tool down the
threaded mandrel until it touches the head of the
threaded insert.
72 - 24 9813/8500-2 72 - 24
00 - General
Figure 506.
B Head of threaded insert

5. Insert the threaded insert (assembled to the tool)
into the hole drilled in step 1.
6. Hold handle and at the same time draw the
mandrel into the installation tool by turning nut.
The threaded insert will contract in length and
form an upset (smooth bulge) seating itself
against the body/ framework. Note: The thread
of the threaded insert must not be stripped, take
care when upsetting the threaded insert.
Figure 507.
C Handle
D Nut
E Body/Framework
7. Remove the installation tool.
72 - 25 9813/8500-2 72 - 25
Notes:
72 - 26 9813/8500-2 72 - 26
75 - Consumable Products
Contents Page No.
75-00 Consumable Products

75-00-00 General ............................................................................................................................. 75-3
75-00-03 Parts List .......................................................................................................................... 75-7
75-03 Oil
75-03-00 General ........................................................................................................................... 75-11
75-03-03 Engine ............................................................................................................................ 75-12
75-06 Grease
75-06-00 General ........................................................................................................................... 75-15
75-09 Fluids
75-09-00 General ........................................................................................................................... 75-19
75-09-03 Antifreeze ....................................................................................................................... 75-20
75-10 Locking Fluids
75-10-00 General ........................................................................................................................... 75-23
75-14 Solvents and Primers
75-14-00 General ........................................................................................................................... 75-27
75-15 Adhesive
75-15-00 General ........................................................................................................................... 75-31
75-16 Sealant
75-16-00 General ........................................................................................................................... 75-37
75-18 Fuel
75-18-00 General ........................................................................................................................... 75-43
9813/8500-2
2017-09-25
Acronyms Glossary
2WD Two Wheel Drive

DEF Diesel Exhaust Fluid
PTFE Polytetrafluoroethylene
9813/8500-2
2017-09-25
Contents Page No.
75-00-00 General ............................................................................................................................. 75-3

75-00-03 Parts List .......................................................................................................................... 75-7
75 - 1 9813/8500-2 75 - 1
Notes:
75 - 2 9813/8500-2 75 - 2
00 - General
Introduction ...................................................... 75-3 JCB recommend that you use the JCB lubricants
Health and Safety ........................................... 75-4 shown as they have been verified by JCB for use
Technical Data ................................................. 75-6 on JCB machines. However, you could use other
lubricants that are equivalent to the JCB standards
and quality or offer the same machine component
protection.
Before you start work, make sure that:
• All safety precautions are observed in

accordance with the information contained
within the relevant support documentation.
• The consumables are used in accordance with
the manufacturer's recommendations.
• The consumables shown are available in the
correct quantity.
Consumables other than those listed may be

required. It is expected that general consumables will
be available in any well equipped workshop or be
available locally.
75 - 3 9813/8500-2 75 - 3
00 - General
Health and Safety
Oil Waste Disposal

Oil is toxic. If you swallow any oil, do not induce CAUTION It is illegal to pollute drains, sewers
vomiting, seek medical advice. Used engine oil or the ground. Clean up all spilt fluids and/or
contains harmful contaminants which can cause skin lubricants.
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves Used fluids and/or lubricants, filters and
to prevent skin contact. Wash skin contaminated with contaminated materials must be disposed of in
oil thoroughly in warm soapy water. Do not use petrol, accordance with local regulations. Use authorised
diesel fuel or paraffin to clean your skin. waste disposal sites.
Fluid Under Pressure CAUTION Damaged or spent batteries and
any residue from fires or spillage must be
Fine jets of fluid at high pressure can penetrate the put in a closed acid proof receptacle and
skin. Keep face and hands well clear of fluid under must be disposed of in accordance with local
pressure and wear personal protective equipment. environmental waste regulations.
fluid. If fluid penetrates your skin, get medical help All waste products must be disposed of in
immediately. accordance with all the relevant regulations.
Fuel The collection and disposal of used oil must be in
Fuel is flammable, keep naked flames away from the accordance with any local regulations. Never pour
fuel system. Stop the engine immediately if a fuel used engine oil into sewers, drains or on the ground.
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the Handling
engine running. Completely wipe off any spilt fuel
CAUTION The temperature of the hydraulic oil
will be high soon after stopping the machine. Wait
injury if you do not follow these precautions.
until it cools before beginning maintenance.
Hygiene
New Oil
JCB lubricants are not a health risk when used
correctly for their intended purposes. There are no special precautions needed for the
handling or use of new oil, beside the normal care
However, excessive or prolonged skin contact can and hygiene practices.
remove the natural fats from your skin, causing
dryness and irritation. Used Oil
Low viscosity oils are more likely to do this, so take Used engine crankcase lubricants contain harmful
special care when handling used oils, which might be contaminants.
diluted with fuel contamination.
Here are precautions to protect your health when
Whenever you are handling oil products you must handling used engine oil:
maintain good standards of care and personal and
plant hygiene. For details of these precautions we • Avoid prolonged, excessive or repeated skin
advise you to read the relevant publications issued contact with used oil
by your local health authority, plus the following. • Apply a barrier cream to the skin before
handling used oil. Note the following when
Storage removing engine oil from skin:
• Wash your skin thoroughly with soap and
Always keep lubricants out of the reach of children. water
• Using a nail brush will help
Never store lubricants in open or unlabelled • Use special hand cleansers to help clean
containers. dirty hands
• Never use petrol, diesel fuel, or paraffin for
washing
• Avoid skin contact with oil soaked clothing
• Don't keep oily rags in pockets
• Wash dirty clothing before re-use
75 - 4 9813/8500-2 75 - 4
00 - General
• Throw away oil-soaked shoes Battery

Warning Symbols
The following warning symbols may be found on the
battery.
Figure 508.
A B C D E F
A Keep away from children B Shield eyes

C No smoking, no naked flames, no sparks D Explosive gas
E Battery acid F Note operating instructions
First Aid - Oil Swallowing
Eyes Do not induce vomiting. Drink large quantities of

water or milk. Then drink milk of magnesia, beaten
In the case of eye contact, flush with water for 15min. egg or vegetable oil. Get medical help.
If irritation persists, get medical attention.
Skin
Swallowing
Flush with water, remove affected clothing. Cover
If oil is swallowed do not induce vomiting. Get burns with a sterile dressing then get medical help.
medical advice.
First Aid - DEF (if applicable)
Skin
Do not drink or inhale DEF (Diesel Exhaust Fluid).
In the case of excessive skin contact, wash with soap If large quantities of DEF have been swallowed
and water. a doctor should be called immediately. Do not
induce vomiting unless directed to do so by medical
Spillage personnel. Never give anything by mouth to an
unconscious person.
Absorb with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a Avoid prolonged or repeated skin contact. After
chemical disposal area. contact with skin wash thoroughly with plenty of soap
and water. If irritation develops seek medical advice.
Fires
Avoid contact with eyes, skin and clothing. Wear
WARNING Do not use water to put out an oil fire. chemical resistant gloves, overalls and safety
This will only spread it because oil floats on water. goggles complying with an approved standard. If
Extinguish oil and lubricant fires with carbon in contact with eyes, rinse immediately with plenty
dioxide, dry chemical or foam. of clean water. If irritation occurs seek medical
attention. Always wash hands and arms thoroughly
after handling before eating, drinking, smoking or
First Aid - Electrolyte using the lavatory.
Eyes
In the case of eye contact, flush with water for 15min.
always get medical attention.
75 - 5 9813/8500-2 75 - 5
00 - General
Technical Data
Table 129.
Item Capacity Fluid/Lubricant International specifica-
tion
Fuel tank 60L Diesel oil ASTM D975-66T Nos.
1D, 2D
Engine (oil)
(2)
8L JCB engine oil max (-10–50°C 15W40CI4+
(14.0–121.9°F))
Engine (coolant)
(1)
13.5L t JCB ready to use coolant ASTM D6210
Synchro shuttle (2WD (Two 16L JCB transmission oil
Wheel Drive))
(2)
-32–40°C (-25.6–103.9°F) 10W, EL4117
-5–46°C (23.0–114.7°F) SAE30, EL4118
Synchro shuttle (4WD 16.6L JCB transmission oil
(Four Wheel Drive))
(2)
-32–40°C (-25.6–103.9°F) 10W, EL4117
-5–46°C (23.0–114.7°F) SAE30, EL4118
Rear axle 10L JCB gear oil API-GL-4
Front axle (4WD) 6.2L JCB gear oil API-GL-4
Brakes 1.4L JCB HVI hydraulic oil HVI 46
Hydraulic system (for 2DX) 84L JCB HVI hydraulic oil HVI 46
Hydraulic system (for 72L Above 38°C (100.3°F)
2DXL)
Grease points - JCB special grease Lithium complex NLGI
No.2 consistency includ-
ing extreme pressure
additives
- JCB special MPL-EP grease
(3)
Lithium based NLGI
No.2 consistency includ-
ing extreme pressure
additives
Electrical connections - As a corrosion and moisture inhibitor all exposed con-
nections should be coated liberally with petroleum jelly
(1) It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate
is any higher than this there is a possibility of air becoming trapped in the system.
(2) The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the
system. Figures quoted within 1.0 litre (0.22 U.K. gal).
(3) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing
must be carried out more frequently.
75 - 6 9813/8500-2 75 - 6
03 - Parts List
03 - Parts List Introduction

Consumables
Antifreeze HP/Coolant ASTM D6210 Concentrate 4006/1101 5L
4006/1120 20L
4006/1103 200L
Black Polyurethane Sealant 4102/2310 0.31L
Black Primer/Activator 4104/2304 0.1L
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
EP Hammer Grease 4003/2107 0.4kg
4003/2106 12.5kg
Extreme Performance Moly Grease 4003/1327 0.4kg
4003/1326 12.5kg
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
JCB Autogrease 4003/2305 0.5kg
JCB Gear Oil HP 4000/0505 20L
4000/0503 200L
JCB Glass Cleaner 4006/3175 0.75L
JCB High Strength Threadlocker 4102/0551 0.05L
JCB Threadlocker and Sealer (High Strength) 4101/0550 0.01L
4101/0552 0.2L
JCB Threadlocker and Sealer (Medium Strength) 4101/0250 0.01L
4101/0251 0.05L
Polyurethane Adhesive 4103/2110 0.31L
Readymix Antifreeze HP/Coolant ASTM D6210 50/50 4006/1110 5L
4006/1115 20L
4006/1125 200L
4003/2006 12.5kg
4003/2005 50kg
Special Hammer Grease 4003/1119 0.4kg
Special MPL-EP Grease 4003/1501 0.4kg
4003/1506 12.5kg
4003/1510 50kg
Special Slew Pinion Grease 4003/1619 0.4kg
Special Slide Grease 4003/1115 0.4kg
Threaded Insert (M10 x 23mm) 826/01104 -
Threaded Insert (M10 x 26mm) 826/01105A -
Wiring Splice (0.5-1.5mm Red, contains 50 off) 892/00351 -
Wiring Splice (1.5-2.5mm Blue, contains 50 off) 892/00352 -
Wiring Splice (3-6mm Yellow, contains 50 off) 892/00353 -
75 - 7 9813/8500-2 75 - 7
03 - Parts List
75 - 8 9813/8500-2 75 - 8
03 - Oil
03 - Oil
Contents Page No.
75-03-00 General ........................................................................................................................... 75-11

75-03-03 Engine ............................................................................................................................ 75-12
75 - 9 9813/8500-2 75 - 9
Notes:
75 - 10 9813/8500-2 75 - 10
03 - Oil
00 - General
00 - General
Introduction
New Oil
There are no special precautions needed for the
handling or use of new oil, besides the normal
health and safety practices mentioned in the relevant
section of this service manual.
Used Oil
Used engine crankcase lubricants contain harmful
contaminants. Here are precautions to protect your
health when handling used engine oil:
1. Avoid prolonged, excessive or repeated skin

contact with used oil.
2. Apply a barrier cream to the skin before handling
used oil.
3. Note the following when removing engine oil from
skin:
3.1. Wash your skin thoroughly with soap and
water.
3.2. Using a nail brush will help.
3.3. Use special hand cleansers to help clean
dirty hands.
3.4. Never use petrol, diesel fuel, or paraffin for
washing.
4. Avoid skin contact with oil soaked clothing.
5. Don't keep oily rags in pockets.
6. Wash dirty clothing before re-use.
7. Throw away oil-soaked shoes.
First Aid
EYES - In the case of eye contact, flush with water for
15 minutes. If irritation persists, get medical attention.
SWALLOWING - If oil is swallowed do not induce

vomiting. Get medical advice.
SKIN - In the case of excessive skin contact, wash

with soap and water.
SPILLAGE - Absorb on sand or a locally approved

brand of absorbent granules. Scrape up and remove
to a chemical disposal area.
FIRES - Extinguish with carbon dioxide, dry chemical

or foam. Firefighters should use self-contained
breathing apparatus.
75 - 11 9813/8500-2 75 - 11
03 - Oil
03 - Engine
03 - Engine
Introduction
New engines DO NOT require a running-in period.

The engine/machine should be used in a normal
work cycle immediately, glazing of the piston cylinder
bores, resulting in excessive oil consumption, could
occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle
for extended periods; (e.g. warming up without load).
The choice of lubricant viscosity should be made

based on the lowest ambient temperature at which
the machine will be started and the maximum
ambient temperature at which it will operate.
The technical data section provides guidance as to

the temperature range that can be accommodated
by standard oil viscosities and can be used to select
an appropriate grade.
When selecting the oil viscosity grade, make

sure that the oil conforms with or exceeds the
recommended specification.
75 - 12 9813/8500-2 75 - 12
06 - Grease
06 - Grease
Contents Page No.
75-06-00 General ........................................................................................................................... 75-15
75 - 13 9813/8500-2 75 - 13
Notes:
75 - 14 9813/8500-2 75 - 14
06 - Grease
00 - General
00 - General Consumable: JCB Autogrease

6. JCB EP Hammer Grease
Introduction Consumable: EP Hammer Grease
Special Tools 7. JCB Special Hammer Grease
Consumable: Special Hammer Grease
Grease Gun 892/00913 1
Attachment 8. JCB Special Slew Pinion Grease
Grease Gun 992/11300 1
Consumable: Special Slew Pinion Grease
Consumables
Description Part No. Size Greasing Procedure
EP Hammer Grease 4003/2107 0.4kg 1. Make the machine safe.
4003/2106 12.5kg
Extreme Performance 4003/1327 0.4kg
Moly Grease 4003/1326 12.5kg 2. If necessary, install any maintenance or
JCB Autogrease 4003/2305 0.5kg articulation struts.
Special HP Grease 4003/2017 0.4kg 3. Make a note of the following:
4003/2006 12.5kg
3.1. The machine must always be greased after
4003/2005 50kg pressure washing or steam cleaning.
Special Hammer 4003/1119 0.4kg
Grease 3.2. Greasing must be done with a grease gun.
Normally, two strokes of the gun should be
Special MPL-EP 4003/1501 0.4kg
sufficient.
Grease 4003/1506 12.5kg
Special Tool: Grease Gun (Qty.: 1)
4003/1510 50kg
Special Tool: Grease Gun Attachment (Qty.:
Special Slew Pinion 4003/1619 0.4kg 1)
Grease
3.3. Stop greasing when fresh grease appears
Special Slide Grease 4003/1115 0.4kg
at the joint.
There are various greasing points on the machine. 3.4. Use only the recommended type of grease.
You must grease the machine regularly to keep
3.5. Do not mix different types of grease, keep
it working efficiently. Regular greasing will also
them separate.
lengthen the machine's working life. You must grease
the machine as stated in the maintenance schedule. 4. Count off the grease points as you grease each
Refer to: PIL 78-24. one.
JCB grease is manufactured to provide significant 5. Install the dust caps after greasing (if installed).
load protection for your machine. It is recommended
to use only JCB grease on your machine because JCB Special HP Grease
they are specifically designed for the particular
application. The list of JCB greases comprises: JCB Special HP grease is a premium quality,
extreme pressure grease. It is recommended
1. JCB Special HP Grease
for use in arduous operating conditions, such
Consumable: Special HP Grease as high temperatures, excessive loading and
extensive exposure to water. The sophisticated
2. JCB Special MPL-EP Grease additive package combines with excellent adhesive
Consumable: Special MPL-EP Grease properties to give high performance protection to
your machine.
3. JCB Extreme Performance Moly Grease
Table 130. JCB Special HP Grease Properties
Consumable: Extreme Performance Moly
Grease Description Data
Colour Blue
4. JCB Special Slide Grease
Soap type Lithium complex
Consumable: Special Slide Grease
5. JCB Autogrease
75 - 15 9813/8500-2 75 - 15
06 - Grease
00 - General
Description Data Table 133. JCB Special Slide Grease Properties

Drop point 245°C (472.7°F) Description Data
Working temperature -20–150°C (-4.0– Colour Dark grey
range 301.8°F) Soap type Lithium
Drop point 180°C (355.7°F)
JCB Special MPL-EP Grease Working temperature -20–120°C (-4.0–
range 247.8°F)
JCB Special MPL-EP grease is a true multipurpose
grease. It is recommended for a wide range of
lubricating applications, such as pivot pins and wheel JCB Autogrease
bearings, where excellent anti wear and anti rust
performance is required. Its EP additive makes it JCB Autogrease is for use with the automatic
particularly suitable for the shock load and vibrating greasing system. It is a mineral oil based paste.
conditions found on machines. It contains an aluminium complex soap and solid
lubricants. It is suitable for use under water or in
Table 131. JCB Special high ambient temperatures. The specially designed
MPL-EP Grease Properties cartridges screw into the automatic greasing system
installed on the machine.
Description Data
Colour Brown The clear cartridge allows the operator to easily
Soap type Lithium monitor the grease usage from inside of the operator
Drop point 180°C (355.7°F) station.
Working temperature -20–130°C (-4.0– Table 134. JCB Autogrease
range 265.8°F)
Description Data
JCB Extreme Performance Moly Grease Colour Black
Soap type Aluminium complex, sol-
JCB Extreme Performance Moly grease is an id lubricants
advanced performance, multipurpose grease. It is Drop point 260°C (499.6°F)
recommended for heavily loaded bearing surfaces Working temperature -20–110°C (-4.0–
and in particular where limited or oscillating range 229.8°F)
motion causes fretting. The addition of molybdenum
disulphide provides extra protection against scoring
and wear. This grease is ideal for automotive, JCB EP Hammer Grease
industrial, agricultural and earthmoving equipment.
JCB EP Hammer grease is a unique formulation
Table 132. JCB Extreme aluminium complex grease for use where extremes
Performance Moly Grease Properties of pressure and temperature are likely to be
encountered. It is suitable for the hammer
Description Data applications where resistance to water washing and
Colour Grey Black migration may be critical.
Soap type Lithium
Drop point 185°C (364.7°F) Table 135. JCB EP Hammer Grease
Working temperature -20–120°C (-4.0– Description Data
range 247.8°F) Colour Black
Soap type Aluminium complex
JCB Special Slide Grease Drop point 250°C (481.6°F)
Working temperature -20–160°C (-4.0–
JCB Special Slide grease is formulated to provide range 319.8°F)
excellent protection under heavy load and extreme
pressure, where water and dirt are prevalent. It
maintains a film of lubrication on slow moving slides. JCB Special Hammer Grease
It has an excellent resistance to squeeze out and
superb corrosion resistance. JCB Special Hammer grease provides a highly
effective lubricant on slow moving slides and an
excellent corrosion resistant property. It combines
the self healing action of oils and the resistance to
drip of viscous compounds.
75 - 16 9813/8500-2 75 - 16
06 - Grease
00 - General
Table 136. JCB Special Hammer Grease

Description Data
Colour Dark grey
Soap type Lithium
Drop point 185°C (364.7°F)
Working temperature -15–120°C (5.0–
range 247.8°F)
JCB Special Slew Pinion Grease

JCB Special Slew Pinion grease is a soft, black and
tenacious grease. It is designed specifically for the
lubrication of large and heavy duty open gears. It has
an excellent corrosion protection and load carrying
properties throughout a large temperature range.
Table 137. JCB Special Slew Pinion Grease

Description Data
Colour Black
Soap type Organically modified
clay
Working temperature -40–100°C (-39.9–
range 211.9°F)
75 - 17 9813/8500-2 75 - 17
09 - Fluids
09 - Fluids
Contents Page No.
75-09-00 General ........................................................................................................................... 75-19

75-09-03 Antifreeze ....................................................................................................................... 75-20
75 - 18 9813/8500-2 75 - 18
09 - Fluids
00 - General
00 - General
Introduction
It is most important that you read and understand this

information and the publications referred to. Make
sure all your colleagues who are concerned with
lubricants read it too.
Hygiene
JCB lubricants are not a health risk when used
properly for their intended purposes.
However, excessive or prolonged skin contact can

remove the natural fats from your skin, causing
dryness and irritation.
Low viscosity oils are more likely to do this, so take

special care when handling used oils, which might be
diluted with fuel contamination.
Whenever you are handling oil products you should

maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued
by your local health authority, plus the following.
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled
containers.
Waste Disposal
All waste products should be disposed of in
accordance with all the relevant regulations.
The collection and disposal of used oil should be in

accordance with any local regulations. Never pour
used engine oil into sewers, drains or on the ground.
75 - 19 9813/8500-2 75 - 19
09 - Fluids
03 - Antifreeze
03 - Antifreeze Health and Safety

Health and Safety .......................................... 75-20 when the coolant is hot. When you remove the
Technical Data ............................................... 75-21 cap, hot coolant can spray out and burn you.
on the cooling system.
75 - 20 9813/8500-2 75 - 20
09 - Fluids
03 - Antifreeze
Technical Data
Check the strength of the coolant mixture at least

once a year, preferably at the start of the cold period.
Replace the coolant mixture according to the

intervals shown in the machine's Service Schedule.
You must dilute full strength antifreeze with clean

water before use. Use clean water of no more
than a moderate hardness (pH value 8.5). If this
cannot be obtained, use de-ionized water. For further
information advice on water hardness, contact your
local water authority.
The correct concentration of antifreeze protects the

engine against frost damage in winter and provides
year round protection against corrosion.
The protection provided by JCB High Performance

Antifreeze and Inhibitor is shown below.
Table 138.
Concentration Level of protection
50% (Standard) Protects against dam-
age down to -40°C
(-40°F)
60% (Extreme condi- Protects against dam-
tions only) age down to -56°C
(-69°F)
Do not exceed a 60% concentration, as the freezing

protection provided reduces beyond this point.
If you use any other brand of antifreeze:
• Make sure that the antifreeze complies with

International Specification ASTM D6210
• Always read and understand the
manufacturer's instructions
• Make sure that a corrosion inhibitor is included.
Serious damage to the cooling system can
occur if corrosion inhibitors are not used
• Make sure that the antifreeze is ethylene glycol
based and does not use OAT (Organic Acid
Technology).
For Aluminium Radiator in cooling system:
• For Top-up/replenishment, It is recommended

to use JCB ready to use coolant (Readymix
Antifreeze).
• Do not use hard water for any top ups.
• Do not do tamper / modify electrical system.
• For more clarification, Kindly contact your
nearest JCB Distributor.
75 - 21 9813/8500-2 75 - 21
10 - Locking Fluids
10 - Locking Fluids
Contents Page No.
75-10-00 General ........................................................................................................................... 75-23
75 - 22 9813/8500-2 75 - 22
10 - Locking Fluids
00 - General
Introduction .................................................... 75-23 All locking fluids should be used at all times in line
Technical Data ............................................... 75-24 with the manufacturer’s recommendations.
Locking fluids are used for the locking of threaded

fasteners and for the retention of ball & roller
bearings and similar cylindrical items on to shafts and
into housings. These fluids consist of an anaerobic
resin in a liquid form which hardens when confined
between closely fitting metal to metal and many
metal to non-metal surfaces.
The fluids available possess a wide span of

break-loose strengths, viscosities and gap filling
properties and are marketed for a variety of locking
and retaining purposes requiring different strength
grades. Some of the sealants in use in JCB are
also of anaerobic resin type and only differ from
the locking fluids in respect of viscosity and other
technical details.
Strength grades
Various strength grades of fluid are available,
the highest strength type for permanent locking
where disassembly is unlikely, medium strength
for permanent locking but allowing disassembly
with ordinary tools and low strength for locking
of components where frequent adjustment or easy
dismantling is required.
It is recommended that trials be carried out before

scheduling locking fluids for any new type of
application that has not been already proved as
satisfactory in production or when use at elevated
temperatures is intended.
Additional technical information is normally available

from the product manufacturers.
Approved locking fluids

The table shown in Technical Data shows the
approved locking fluids available to use on JCB
machines. The table also provides basic details to
help with selection of locking fluids. More up to
date information can be found on the manufacturer’s
website.
75 - 23 9813/8500-2 75 - 23
10 - Locking Fluids
00 - General
Technical Data
Table 139. Locking Fluids Approved Product Information

Subsec- Commer- Product Colour Shelf Strength Comments
tion cial name Number life
High Loctite 4101/0100 Green 365d 80–120bar For the retention of threads up to M20 di-
strength 270 fluores- (1,159.4– ameter where disassembly is unlikely and
R.A.S. cent 1,739.1psi) for locking bearings etc. onto shafts and
threadlock breakaway into housing. Has a maximum gap fill of
for studs strength 0.05mm.
(red)
High Loctite 4101/1400 Green, 365d More than Maximum gap fill of 0.25mm. Maximum
strength 638 UV fluo- 250bar strength at room temperature.
rescent (3,623.2psi)
compres-
sive shear
strength
High Per- 4101/0500 Red, flu- 365d 100–150bar Fast curing (10–15min) thread locking up
strength mabond ores- (1,449.3– to M20, especially for use on oily surfaces,
A115 cent 2,173.9psi) plated and clean parts.
prevailing
strength
High Loctite 4101/0600 Green, 365d More than Designed for holding gears and sprockets
strength 648 fluores- 250bar onto gearbox shafts and rotors on electric
Per- cent (3,623.2psi) motor shafts.
mabond compres-
A118 sive shear
strength
High Loctite 4101/1700 Green 365d 260–500bar Designed for permanent locking and seal-
strength 2701 (3,768.1– ing of threaded fasteners. Particularly suit-
7,246.3psi) ed for use on inactive substrates and/or
breakaway where maximum resistance to hot oil is re-
torque quired.
Medium Loctite 4101/1100 Blue 365d 140–340bar Suitable for all nuts, bolts, screws up to
to high 243 (2,029.0– M36.
4,927.5psi)
breakaway
torque
Medium Per- 4101/0900 Blue 365d 80–120bar Maximum gap fill of 0.25mm. Handling
strength mabond (1,159.4– strength in 10–15min.
A119 1,739.1psi)
static shear
strength
Medium Loctite 4101/1200 Green, 365d 150–330bar Product has a slow cure rate, used on parts
strength 640 fluores- (2,173.9– unlikely to be disassembled.
cent 4,782.6psi)
static shear
strength
Medium Loctite 4101/0200 Blue, 365d 80–120bar Suitable for all nuts, bolts and screws up to
strength 242 fluores- (1,159.4– M36 and hydraulic fittings up to 25mm in di-
Per- cent 1,739.1psi) ameter. Permabond A113 and A1042 are
mabond static shear the preferred choices. The difference be-
A1042 strength tween A113 and A1042 is timing for han-
dling and working strength. A113 handling
Per-
time 10–25min, working strength 1h. A1042
mabond
handling time 5–10min, working strength
A113
30min.
75 - 24 9813/8500-2 75 - 24
10 - Locking Fluids
00 - General
Subsec- Commer- Product Colour Shelf Strength Comments

tion cial name Number life
Low Loctite 4101/0300 Purple, 365d 15–40bar For screwed fasteners up to M20 that re-
strength 222 fluores- (217.4– quire easy disassembly or frequent ad-
cent 579.7psi) justment. Maximum gap fill of 0.05mm.
Achieves handling strength in 10–30min.
Low Per- 4101/1500 Blue 365d 120bar Allows dismantling of parts for mainte-
strength mabond (1,739.1psi) nance. Suitable for sealing small hydraulic
A1098 shear and pneumatic fittings. Handling strength in
strength 5–10min.
Low Loctite 4101/1600 Off- 365d 17bar For the locking and sealing of metal ta-
strength 567 white (246.4psi) pered threads and fittings. High lubricat-
breakaway ing properties prevent galling on stainless
torque steel, aluminium and all other metal pipe
threads and fittings.
Very low Loctite 4101/0400 Brown/ 365d 7–18bar Can be disassembled with hand tools. 10–
strength 932 red (101.4– 30min cure time for handling strength. Used
Per- 260.9psi) on large diameter screw threads bigger
mabond average than 50mm.
A011 shear
strength
75 - 25 9813/8500-2 75 - 25
14 - Solvents and Primers
Contents Page No.
75-14-00 General ........................................................................................................................... 75-27
75 - 26 9813/8500-2 75 - 26
00 - General
Introduction .................................................... 75-27 This section contains information on primers,
Technical Data ............................................... 75-28 solvents, cleaning solutions etc. that are in use at
JCB.
All primers and solvents should be used at all times

in line with the manufacturer’s recommendations.
Approved primers and solvents

The table shown in Technical Data shows the
approved primers and solvents available to use on
JCB machines. The table also provides basic details
to help with the selection of primers and solvents.
More up to date information can be found on the
manufacturer’s website.
75 - 27 9813/8500-2 75 - 27
00 - General
Technical Data
Table 140. Primers and Solvents Approved Product Information

Subsec- Commer- Product Colour Shelf Drying Comments
tion cial name Number life Time
Activa- Loctite 332/U7901 Colour- 365d Less than Used to make low energy surfaces suit-
tor/Primer 770 less 5s able for bonding with cyanocrylate adhe-
sives. It is recommended for polyethylene,
polypropylene, PTFE and thermoplastic
rubber materials. Can be used with Loctite
406 (332/U7899).
Activator Loctite 4104/1700 Clear 730d Apply and HIGHLY FLAMMABLE. Organic accelera-
7455 amber leave to dry tor, non CFC solvent based surface activa-
for 30s be- tor. Designed to promote the speed of cure
fore apply- of cyanoacrylic adhesives.
ing adhe-
sive
Activator Loctite 4104/0200 Colour- 365d 1–3min Used with anaerobic products it increases
7471 less cure speed. Recommended for inert sur-
Per- faces and large bond gaps.
mabond
A905
Water Loctite 4104/0500 - - - A water proofing solution for protecting
proofing water joints made using cyanoacrylate adhesive.
proofing Apply to Loctite 495 (4103/0900).
Solvent Loctite 4104/1500 Colour- 365d 1min at HIGHLY FLAMMABLE, cleaner and de-
7063 less 20°C greaser. Removes grease, oil and dirt from
(68.0°F) electrical parts, tools and precision equip-
ment.
Cleaning Loctite 4101/2200 Colour- 365d No wipe Cleaning treatment to remove most greas-
fluid 7070 less 5–10min, es, oils, lubrication fluids and metal cuttings
post wipe
1–2min
Cleaning Simple 332/E9240 Colour- 365d - An all purpose cleaner and degreaser used
fluid green ex- less diluted in water for direct, spray and dip
treme tank procedures.
Applica- A4GBCJCB4104/3300 Blue 730d - Vinyl labels application fluid for use with the
tion fluid insignia/livery labels.
Gasket Loctite 4104/3200 Colour- 730d Allow 10– This is a product to aid the removal of
cleaner 7200 less 15min for cured chemical gaskets. Apply for time
gasket, specified and remove gasket with soft
30min for scraper.
silicone
gasket.
Hand Loctite 4104/3100 Light 540d - Is a heavy duty hand cleaner, specially for-
cleaner 7855 grey mulated for the most difficult to remove
soils like polyurethane, paints, primers, ad-
hesives etc. The product is free from sil-
icone and harsh solvents. Can be used
without water.
Hand Sika hand 4104/1300 Off - - A non-abrasive hand cleaner for use when
cleaner cleaner white using direct glazing materials.
75 - 28 9813/8500-2 75 - 28
00 - General
Subsec- Commer- Product Colour Shelf Drying Comments

tion cial name Number life Time
Direct Sika acti- 4104/2100 Clear 365d 10min mini- HIGHLY FLAMMABLE. A cleaning and acti-
glazing vator mum drying vating agent specifically formulated for the
time treatment of bonded faces in direct glaz-
ing applications prior to applying the direct
glazing adhesive.
Direct Sika re- 4104/1900 Trans- - - A cleaning agent for removing contami-
glazing mover parent nates on painted surfaces and glass.
208 (use
4104/3600)
Direct Sika 4104/1200 Clear - - A cleaning agent for removing contami-
glazing cleaner nates on painted surfaces and glass.
205 (use
4104/3600)
Direct Sika 4104/2300 Black 270d Application Used to prime painted surfaces and plas-
glazing primer tempera- tic substrates prior to bonding with Sikaflex
209 (use ture 10– products.
4104/3500) 35°C (50.0–
95.0°F)
Direct Sika akti- 4104/2400 Clear 365d 10min Used to clean and give improved adhe-
glazing vator at more sion on glass, ceramic-coated glass, the cut
than 15°C face of old polyurethane adhesive beads,
(59.0°F) polyurethane coated windows glass and
or 30min paints.
at less
than 15°C
(59.0°F)
Active Tero- 4104/3400 Colour- 270d Minimum Applied with a clean cloth to the surface,
wipe for stat 8560 less 30s and the adhesive may then be applied after the
surface AC-25 maximum drying time. Applied to glass or ceramic
1h coating but only in the bonding area.
Direct Terostat 4102/3500 Black 0.1L Approx. Used to promote adhesion in direct glazing
glazing 8519 P bot- 2min to glass and glass ceramics.
tle =
365d.
0.01L
and
0.035L
bot-
tle =
540d
Cleaner Teroson 4104/3600 Clear 730d Depend- Used for degreasing and cleaning of sub-
FL cleaning on con- strates prior to application of adhesives and
er ditions be- sealants.
tween 2–
10min.
75 - 29 9813/8500-2 75 - 29
15 - Adhesive
15 - Adhesive
Contents Page No.
75-15-00 General ........................................................................................................................... 75-31
75 - 30 9813/8500-2 75 - 30
15 - Adhesive
00 - General
Introduction .................................................... 75-31 All adhesives should be used at all times in line with
Technical Data ............................................... 75-32 the manufacturer’s recommendations.
Adhesives are used for the bonding of a number

of engineering materials used in production at JCB.
Many types are available on the market but in the
interests of variety reduction and economy only a
limited selection is purchased for regular use.
Types of adhesive
Various types of adhesive are covered by JCB
Standards:
1. General purpose adhesives for bonding

laminated plastics, wood, rubber etc. to
themselves and to each other.
2. The more expensive cyanoacrylate adhesives
for use where high strength, resistance to many
chemicals and fast cure times are required.
3. Adhesives specially developed for bonding of
foam rubber to painted metal surfaces.
Additional health and safety for

cyanoacrylates
These adhesives require very careful handling on
account of their exceptional properties. They bond
together strongly and rapidly to most surfaces
including body tissue, the curing process being
initiated by surface moisture. For further information
on cyanoacrylates refer to the Manufacturer’s
recommendations.
Approved adhesives
The tables shown in Technical Data are the approved
adhesives available to use on JCB machines. The
tables also provide basic details to help with the
selection of adhesives. More up to date information
can be found on the manufacturer’s website.
75 - 31 9813/8500-2 75 - 31
15 - Adhesive
00 - General
Technical Data
Table 141. Adhesives Approved Product Information

Subsec- Commer- Product Colour Shelf Technical Comments
tion cial name Number life data
High Per- 4103/3100 Mixed 730d 3–5min for Two part adhesive mixed in equal parts. A
strength mabond grey handling toughened adhesive system which bonds
5002 strength metals, plastics, wood, glass, ceramics and
composites; even plated or coated surfaces
can be securely fastened.
High Loctite 4103/1000 Green 365d 16–30bar This product is a single component anaero-
strength 601 fluores- (231.9– bic adhesive. Used to bond cylindrical fitting
cent 434.8psi) parts, particularly where low viscosity is re-
static shear quired. Maximum gap fill is 0.15mm.
strength
Cyano- Loctite 4103/3500 Colour- - 18–26bar Suitable for most materials including plas-
acrylate 424 less to (260.9– tic and rubber. Takes 30s to cure to working
straw 376.8psi) strength.
shear
strength
Cyano- Loctite 4103/2300 Colour- 180d 18–26bar Designed for general purpose use. For use
acrylate 401 less (260.9– on acidic and porous surfaces, reaching
376.8psi) handling strength in seconds. Materials in-
tensile clude plated metals, composite materials,
strength wood, cork, foam, leather and paper.
Cyano- Loctite 332/U7899 Colour- 180d 18–26bar Designed for bonding of plastics and elas-
acrylate 406 less (260.9– tomeric materials where very fast fixturing
376.8psi) is required. Can be used with Loctite 770
lap shear as a primer (332/U7901)
strength
Cyano- Loctite 4103/2400 Black 120d 22bar 0.2mm, gap fill. A rubber toughened ethyl
acrylate 410 (318.8psi) cyanoacrylate adhesive with enhanced re-
lap shear sistance to peel and shock. Bonds rubber,
strength metals and plastics for use in difficult condi-
tions.
Cyano- Loctite 4103/3800 Black - 22–30bar A rubber toughened adhesive with in-
acrylate 480 (318.8– creased flexibility and peel strength along
434.8psi) with enhanced resistance to shock.
lap shear
strength
Cyano- Loctite 4103/0900 Colour- 270d 12h maxi- High speed bonding, suitable for rubber to
acrylate 495 less mum cure itself and other materials reaching handling
Per- time strength in a matter of seconds. Joint must
mabond be waterproofed with Loctite water proofing
C2 (4104/0500).
Low Dunlop 4103/1100 Clear 90d - Sprayable adhesive, non-structural appli-
strength 1727 to light cations. For the bonding of flexible foam
British vita straw to themselves, wood, painted metal, chip-
company board, fibreglass, hessian, felt etc.
VB 165
Acrylic 3M 4941P 4103/3900 Dark 730d Peel ad- High bond acrylic double sided foam tape.
foam grey hesion Its allows more complete bond contact area
strip ad- 350N/ when bonding rigid or irregular materials
hesive 100mm due to its conformability. Its core adhesive
composition makes the product well suited
to many paints and primers.
75 - 32 9813/8500-2 75 - 32
15 - Adhesive
00 - General

General Araldite 4103/1400 Clear / 730d 560bar Two part, equal parts by weight. Wear pad
purpose XD 580 cream (8,115.9psi)
fixing to castings and telescopic compo-
gap fill- flexural nents, alignments of fixings pads without
ing ma- strength expensive machining. This product is a
terial general purpose gap-filling material. Cure
time 2h at 25°C (77.0°F).
Methacry- Loctite 4103/3600 Cream - - This is a sag resistant, two component,
late Speed- to light equal parts, methacrylate adhesive system
bonder yellow formulated to bond automotive grade cold
H3151 rolled steel without the use of an external
primer. Suitable for bonding a wide variety
of plastic and metal substrates. Provides a
long open time (40–60min) for correct align-
ing of parts.
Methacry- Plexus 4103/3700 Off- 365d 186– Two part methacrylate adhesive for struc-
late MA420 white or 206bar tural bonding of thermoplastic, metal and
blue (2,695.6– composite assemblies. Combined at 10:1
2,985.5psi) ratio. It has a working time of 4–6min.
Structur- Scotch- 332/S7420 Black 180d - Two part acrylic based adhesive (10:1 ra-
al plastic weld tio by vol.) that can bond many low surface
structural energy plastics, including many grades of
plastic ad- polypropylene, polyethylene and TPO’s
hesive without special surface preparation.
Non-pre- Evo-Stick 4103/0800 None- 365d HIGHLY A thin even film of adhesive should be ap-
ferred 528 pre- FLAMMA- plied to both surfaces being bonded and al-
adhesive ferred BLE lowed to become touch dry. This is a con-
tact adhesive and coated surfaces can-
not therefore be slid into position since the
bond forms on contact. It is often conve-
nient to align the parts along an edge and
then bring the two areas into contact.
Direct Sika 4103/2100 Black - - A one component polyurethane pre-poly-
glazing 250PC mer based adhesive. A mastic adhesive
Sikat- which reacts with atmospheric moisture to
ack Ultra- form a rubber like solid.
fast (use
4103/4000
or
4102/4900)
Direct Sika 4103/2200 Black - - For bonding glass to cab frames. A mas-
glazing 255FC tic adhesive which reacts with atmospheric
(use moisture to form a rubber like solid. When
4102/5000) using this product ensure both surfaces
are clean and dry. Use Sika cleaner 205
(4104/1200).
Direct Sikaflex 4103/3200 Black - - A high performance, elastic, gap, filling one
glazing 552 (use part structural adhesive cures on exposure
4102/5000) to atmospheric moisture to form a durable
elastomer. Contains no isocyanate.
75 - 33 9813/8500-2 75 - 33
15 - Adhesive
00 - General

Industri- Loctite 333/Y7062 Light - 307bar Single component, heat activated formu-
al grade Hysol Grey (4,449.3psi) lation develops tough, strong, structur-
epoxy E-214 HP Paste tensile al bonds which provide excellent peel re-
adhesive strength sistance and impact strength. When ful-
ly cured, the product offers superior ther-
mal shock resistance, excellent mechan-
ical and electrical resistance properties
and withstands exposure to a wide vari-
ety of solvents and chemicals. Bonds to a
wide variety of materials, including metals,
glass, ceramics and plastics. Cure at 120°C
(247.8°F) or above until completely firm.
Heat up to 150°C (301.8°F) for 2h, to maxi-
mize properties.
Anaero- Scotch- 333/L9575 Green 365d - Single component anaerobic adhesives de-
bic ad- weld signed to secure cylindrical metal assem-
hesive RT-20 blies such as bearings on shafts, bush-
(Dimethacry- ings, sleeves, housings, and keyways.
late) Help prevent loosening, corrosion and leak-
age caused by shock and vibration. Full
cure time 24h. Temperature range = -54°C
(129.1°F) to 450°C (841.4°F). Not recom-
mended for use on most plastics due to po-
tential cracking of plastic parts.
Direct Terostat 4102/4900 Black 540d - Cure rate: approx. 3–4mm/24h. Glazing
glazing 8597 CT in time: maximum 20min (period of time be-
orig- tween beginning of material application until
inal inserting of the pane).
pack-
aging
Direct Teroson 4102/5000 Black, 365d - Skin formation time: approx. 10min. Cure
glazing 939CT / off- in rate: approx. 3mm/24h.
Terostat white, orig-
MS939 grey, inal
black pack-
aging
Direct Terostat 4103/4000 Black 180d 80bar One component, pumpable adhe-
glazing 8900 HV (1,159.4psi)sive/sealant based on polyurethane, which
tensile cures by reaction with moisture to an elas-
strength tic rubber. The skin formation and curing
time are dependent on humidity, tempera-
ture and depth of joint. High temperature
and high moisture reduces curing time.
Sag resistant, temperature range of -40°C
(103.9°F) to 90°C (193.9°F).
Direct Tero- 4103/4100 Black 270d 85bar Single component, moisture curing, ad-
glazing stat 8594 (1,231.9psi) hesive/sealant for repair. Product with
HMLC tensile high shear modulus and low conductivity.
strength Suitable for all applications that require very
high electrical insulation of the adhesive
used for the bonding of windows. Sag resis-
tant.
75 - 34 9813/8500-2 75 - 34
15 - Adhesive
00 - General

Direct Terostat 4103/4200 Black 365d 80bar One component, pumpable adhe-
glazing 8900 LV in (1,159.4psi) sive/sealant based on polyurethane, which
car- tensile cures by reaction with moisture to an elas-
tridges.strength tic rubber. The skin formation and curing
180d time are dependent on humidity, tempera-
in ture and depth of joint. High temperature
sausage and high moisture reduces curing time.
pack. Sag resistant, temperature range of -40°C
180d (103.9°F) to 90°C (193.9°F) short exposure
in (up to 1h) of 130°C (265.8°F).
hob-
bocks
and
drums
Direct Sika 295 4103/4300 Black, 365d - Direct glazing adhesive for plastic glaz-
glazing UV white ing panels. One component polyurethane
adhesive of paste like consistency. 60min
tack free time, 1d cure time (4mm at 23°C
(73.4°F)). Good UV, fresh water and sea-
water resistance. Do not apply below tem-
peratures of 10°C (50.0°F) or above 35°C
(95.0°F).
75 - 35 9813/8500-2 75 - 35
16 - Sealant
16 - Sealant
Contents Page No.
75-16-00 General ........................................................................................................................... 75-37
75 - 36 9813/8500-2 75 - 36
16 - Sealant
00 - General
Introduction .................................................... 75-37 All sealants should be used at all times in line
Technical Data ............................................... 75-38 with the manufacturer’s recommendations. Sealants
are used mainly for the sealing of screwed joints,
sealing flanges and flat surfaces and where gap
filling properties are required.
Types of Sealant
Various types of sealant are specified in JCB
Standards:
1. Those for the sealing of screwed joints.

2. Sealants for joining flanges and flat surfaces.
(Flange size and likelihood of dismantling
require consideration when selecting this type of
sealant).
3. Sealants for use where gap filling properties are
required. (The gap dimensions, joint movement
if any, type of materials being joined and
aesthetic appearance require consideration
when selecting this type of sealant).
Approved Sealants
The table shown in Technical Data are the approved
sealants available to use on JCB machines. The
table also provides basic details to help with selection
of sealants. More up to date information can be found
on the manufacturer’s website.
75 - 37 9813/8500-2 75 - 37
16 - Sealant
00 - General
Technical Data
Table 142. Sealants Approved Product Information

Subsec- Com- Product Colour Shelf Technical Comments
tion mercial Number life data
name
High Loctite 4102/0500 Green 730d 250bar Non drip formulation, used on larger fittings,
strength 275 (3,623.2psi) coarse threads.
Per- torque
mabond strength
A140 (on M8)
High Forge- 4102/3100 Yellow 270d 25bar Can be painted over with some 2 pack
strength way (362.3psi) paint. Maximum width of joint =35mm, min-
240FC breaking imum width =2mm, minimum depth =2mm.
strength Recommended depth of joint = width of
joint.
Medium Loctite 4102/3500 Green - 172bar Used for locating pins in radiator assem-
to high 620 (2,492.7psi) blies, sleeves into pump housings and
strength shear bearings in auto transmissions. Not suitable
strength for plastics.
Medium Loctite 4102/2000 Red, flu- 365d 90bar Typically used as form-in-place gasket on
strength 518 ores- (1,304.3psi) rigid flanged connections.
cent tensile
strength
Medium Loctite 4102/4100 Red gel, - 80bar It is manufactured to minimise air bubbles
strength 5182 fluores- (1,159.4psi) in the package. Used to seal gaskets, hous-
cent shear ings, cases and covers. It can also be used
strength to repair and replace cut gaskets (up to
0.08mm in thickness).
Medium Loctite 4102/2500 Clear 365d 6mm gap Formulated to withstand weathering and
strength 595 filling extreme temperature cycling. Used for pot-
ting, coating and sealing. Can be applied
horizontal, vertical and overhead.
Medium Loctite 4102/1900 Yellow 365d 170bar A fast curing thread sealant used on coarse
strength 577 (2,463.8psi) threads and pipe fittings up to 75mm thread
Per- breakaway size. Clearance for gap filling 0.8mm.
mabond torque
A1044
Medium Loctite 4102/2700 Blue 365d 140– Taper thread sealant, non-fluorescing to
strength 2431 340bar see oil leaks. Suitable for all taper fittings
(2,029.0– up to M36.
4,927.5psi)
breakaway
torque
Low Clayton 4102/2200 White 12h Maximum Seals pipes and plugs against leakage of
strength Dewan- opaque full seal pres- air, fuels, lubricants and coolants. Hardens
dre air cure sure 29bar to a tough seal resistant to shock and vibra-
brake (420.3psi) tion. Easily dismantled.
sealant
SC1252
Low Red 4102/0800 - - Resistant Non-hardening paste jointing for joints reg-
strength Her- to oil ularly opened for servicing.
metite
75 - 38 9813/8500-2 75 - 38
16 - Sealant
00 - General

name
Low Loctite 4102/1100 White 730d 40–100bar PTFE (Polytetrafluoroethylene) filler low
strength 572 opaque (579.7– strength sealant
1,449.3psi)
breakaway
torque
Gas- Loctite 4102/3200 Blue to 0.2mm 72h full Easy disassembly, used as form-in-place
keting 509 green gap strength on gasket.
medium filling steel
strength
Gas- Loctite 4102/1200 Red 730d 2h working Does not creep or relax after curing, no bolt
keting 574 strength re-tightening is required. Oil resistant. Ideal
medium Per- for formed in-situ gaskets.
strength mabond
A136
Gas- Bondloc 4102/4500 Clear/ - Full cure B555 is an anaerobic gasket sealant. It
keting B555 Opaque time 24h. seals close fitting joints between rigid metal
medium 50bar faces and flanges. Tensile strength to ISO
strength (724.6psi) 6922.
tensile
strength
Sealant Loctite 4102/2600 Black 365d Resists Used to dress new or worn gaskets. Dries
for gas- FAG 2 pres- slowly, sets to pliable film for easy disman-
kets sures up tling.
to 345bar
(5,000.0psi)
Rubber Dow 4102/0900 Clear or 270d 16.7bar A synthetic rubber joint sealant suitable for
jointing corning translu- (242.0psi) joints between non-porous surfaces such
com- 781 cent tensile as glass and metal, metal and metal where
pound Loc- strength relatively large gap filling properties are re-
tite su- quired. Suitable for vertical and overhead
perflex applications under normal atmospheric con-
clear ditions. Joint movement approx.+/-12.5%.
RTV3 Cure time to 6mm depth in 24h.
EVO-
stick
stan-
dard in-
dustri-
al clear
silicone
sealant
Dun-
lop high
modulus
silicone
sealant
DP2205
Epoxy Loc- 4102/2400 Slightly - - 0.05L container requires special bi-mixer
resin tite fast coloured / (gun) so it is mixed as dispensed, 0.024L is
epoxy trans- mixed by hand.
sealant parent
Room Loctite 4102/3400 Metal- - Dry to Designed for flange sealing, good resis-
tempera- 5910 lic black touch in tance to oils and allows high joint move-
ture vul- paste 40min ment.
canising
75 - 39 9813/8500-2 75 - 39
16 - Sealant
00 - General

name
Room Loctite 4102/4200 Black 730d 18bar Used for gaskets. Excellent resistance to
tempera- 5970 (260.9psi) engine oils. Typical applications include
ture vul- tensile stamped sheet metal covers (timing covers
canising strength and oil sumps) where good oil resistance
and the ability to withstand high joint-move-
ment are required.
Room Loc- 4102/2900 Black 270d 16bar Thixotropic allowing easy application, hori-
tempera- tite su- (231.9psi) zontal, vertical and overhead. Seals against
ture vul- perflex tensile water and many solvents.
canising black strength
silicone
Room Loctite 4102/3700 Grey 730d 14bar Designed specifically for on line, low pres-
tempera- 5901 (202.9psi) sure tests carried out before product be-
ture vul- shear gins to cure. Product exhibits excellent re-
canising strength sistance to automotive engine oils. Primari-
ly for flange sealing, it withstands high joint-
movement requirements.
Room Loctite 4102/3900 Black 730d 20bar Generally used for sealing applications, but
tempera- 5368 paste (289.9psi) also for bonding and for high temperature
ture vul- tensile protection.
canising strength
Room Loctite 4102/4000 Clear 730d 20bar Designed specifically for use as a bond-
tempera- 5366 paste (289.9psi) ing agent to ensure perfect sealing, as
ture vul- shear well as bonding and protection. Examples
canising strength are sealing side windows in trains, seal-
ing heat sources (heat exchangers and wa-
ter heaters) and for protection/insulation of
electrical boxes.
Room Hylomar 332/D5695 Black 540d 40bar A special purpose adhesive and sealant
tempera- 607 paste (579.7psi) that can be used for a variety of applica-
ture vul- tensile tions. It has good resistance to oils and
canising strength aqueous anti-freeze agents, and is particu-
larly suitable for high strength applications
in odour sensitive environments.
Joining Loctite 4102/3800 Black 730d 14bar JCB Service ONLY. Introduced for joining
oil pan to 5900 paste (202.9psi) the oil pan to the bedplate face during ser-
bedplate shear vice. High resistance to engine oils. The
strength joint should be clamped to spread the ad-
hesive and allowed to cure for 7d before
heavy service duty.
Direct Sikaflex 4102/2800 Yellow - - Direct glazing one component polyurethane
glazing 221 based adhesive and sealant compound.
(use Tack free time of 50min.
4102/4800)
Direct Sikaflex 4102/2300 Black - - A one component polyurethane pre-poly-
glazing 252 mer based sealant. For sealing glass to
(use frames. A mastic sealant which reacts with
4102/4700) atmospheric moisture to form a rubber like
solid.
Anti-cor- To mil- 4102/4300 Yellow - Type 1 Used to coat surfaces of dissimilar metals
rosive itary Class C prior to assembly to prevent corrosion. Zinc
spec chromate containing substance ideal for ap-
TT- plication to joints between aluminium and
P-1757B steel to prevent corrosion and seizure. FOR
1CY USE ON MILITARY VEHICLES ONLY.
75 - 40 9813/8500-2 75 - 40
16 - Sealant
00 - General

name
Seam Terolan 4102/4600 Light 90d - Serves as a seam sealant between sheet
sealant 3412 grey metal butt and overlap joints (interior
AA-25 seems) on vehicle bodies. Can be cured at
temperatures of minimum 140°C (283.8°F)
(effective metal temperature) for 15min.
The material is applied to electro-dip coated
steel sheets.
Direct 930 4102/4800 Yellow 365d - The substrates must be clean, dry, oil and
glazing JCB in grease free. It can be necessary to rough-
Branded orig- en the surface or to use a primer/adhe-
yellow inal sion promoter to provide optimum adhe-
CT pack- sion. When manufacturing of plastics, ex-
aging ternal release agents are often used; these
agents must be absolutely removed prior.
Skin formation time : approx. 20min Cure
rate : approx. 4mm/24h
Direct Teroson 4102/4700 - 365d - The substrates must be clean, dry, oil and
glazing PU92 in grease free. Skin formation time: approx.
CT orig- 20min Cure rate: approx. 4mm/24h
inal
pack-
aging
75 - 41 9813/8500-2 75 - 41
18 - Fuel
18 - Fuel
Contents Page No.
75-18-00 General ........................................................................................................................... 75-43
75 - 42 9813/8500-2 75 - 42
18 - Fuel
00 - General
00 - General
Introduction
Acceptable and unacceptable fuels

No warranty liability will be accepted for failure of fuel
injection equipment, where the failure is attributed to
the quality and grade of the fuel used.
Table 143.
Fuel specification Applicable engines Service requirements
EN590 diesel fuel types - Auto/C0/C1/C2/ All Dieselmax engines. Obey the usual routine maintenance
C3/C4 schedules and procedures
BS2869 class A2
ASTM D975-91 class 2, US DF1, US DF2,
US DFA
JIS K2204 (1992) grades 1, 2, 3 and spe-
cial grade 3
ASTM D975-91 Class 1DA All Dieselmax engines.
(1)
Obey the usual routine maintenance
MIL T38219 XF63 schedules and procedures. Fuel ad-
ditives are recommended for use
NATO F63
with low sulphur fuels.
French EN590 (RME5) with 5% maximum
AVTURFSII, NATO F34, JP8, MIL T83133, All Dieselmax engines.
(1)
Obey the usual routine maintenance
DERD 2463, DEF STAN 91-87 schedules and procedures. Fuel ad-
AVCAT FSII, NATO F44, JP5, MIL T5624, ditives must be used.
DERD 2452, AVTOR
NATO F35, JET A1, DEF STAN 91-91,
DERD 2494, JP7
AVCAT, NATO F43 (obsolete), JP5 without
additives
JET A (ASTM D1655)
ASTM D3699 kerosene
B20 Biodiesel - RME content blended with Dieselmax engines You must obey special routine main-
mineral derived diesel (20% maximum) - manufactured from tenance schedules and procedures.
ASTM D6751, DIN 51606, ISO 14214 2007 on only.
(2)
AVTAG (obsolete) These fuels are not ac-

AVTAG FSII (obsolete), NATO F40, JP4, ceptable with or with-
DERD 2454 out additives. Engines
must not be operated
JET B (ASTM D1655)
with these fuels.
BS MA100
JIS K2203 No.2
Unmodified vegetable oils
(1) Important: Engines operated with these fuels may have a reduced service life.
(2) The year of manufacture is part of the engine serial number. Refer to Typical Engine Identification Number.
Sulphur content Low sulphur fuels must have the appropriate fuel
lubricity additives, these lubricity improvers must not
High sulphur content can cause engine wear. (High create residual deposits that block the fuel system,
sulphur fuel is not normally found in North America, e.g. injectors, filters etc. Contact your fuel Supplier.
Europe or Australia.) If you have to use high sulphur
fuel you must change the engine oil more frequently.
75 - 43 9813/8500-2 75 - 43
18 - Fuel
00 - General
Table 144.
Sulphur in the fuel Oil change interval
Less than 0.5% Normal
0.5–1% 0.75 of normal
More than 1% 0.50 of normal
Effects of fuel contaminates

The effect of dirt, water and other contaminants in
diesel can be disastrous for injection equipment:
• Dirt - A severely damaging contaminant. Finely

machined and mated surfaces such as delivery
valves and distributor rotors are susceptible to
the abrasive nature of dirt particles - increased
wear will almost inevitably lead to greater
leakage, uneven running and poor fuel delivery.
• Water - Water can enter fuel through poor
storage or careless handling, and will almost
inevitably condense in fuel tanks. The smallest
amounts of water can result in effects that
are just as disastrous to the fuel injection
pump as dirt, causing rapid wear, corrosion
and in severe cases, even seizure. It is vitally
important that water is prevented from reaching
the fuel injection equipment. The filter/water
trap must be drained regularly.
• Wax - Wax is precipitated from diesel when
the ambient temperature falls below that of
the fuel's cloud point, causing a restriction in
fuel flow resulting in rough engine running.
Special winter fuels may be available for engine
operation at temperatures below0°C (32.0°F).
These fuels have a lower viscosity and limit wax
formation.
75 - 44 9813/8500-2 75 - 44
78 - After Sales
Contents Page No.
78-24 Maintenance Schedules

78-24-00 General ............................................................................................................................. 78-3
78-24-03 Maintenance Intervals ...................................................................................................... 78-4
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-5
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-8
78-81 Clothing and Personal Protective Equipment (PPE)
78-81-00 General ........................................................................................................................... 78-11
78-93 Special Tools
78-93-00 General ........................................................................................................................... 78-13
78-93-03 Parts List ........................................................................................................................ 78-14
78-96 Units of Measurement
78-96-00 General ........................................................................................................................... 78-33
9813/8500-2
2017-03-10
Notes:
9813/8500-2
2017-03-10
78 - After Sales
24 - Maintenance Schedules
Contents Page No.
78-24-00 General ............................................................................................................................. 78-3

78-24-03 Maintenance Intervals ...................................................................................................... 78-4
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-5
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-8
78 - 1 9813/8500-2 78 - 1
Notes:
78 - 2 9813/8500-2 78 - 2
78 - After Sales
00 - General
00 - General
Introduction
The schedules show the service tasks which must be

done and their intervals.
The services must be done at either the hourly

interval or the calendar equivalent, whichever occurs
first.
The intervals given in the schedules must not

be exceeded. If the machine is operated under
severe conditions (high temperature, dust, water,
etc.) shorten the intervals.
Table 145.
Service task can be completed by a
competent operator. Details of how to
complete the service task are given in
the Operator's Manual.
We recommend that a Service Engi-
neer completes the service task. De-
tails of how to complete the service
task are given in the Service Manual.
78 - 3 9813/8500-2 78 - 3
78 - After Sales
03 - Maintenance Intervals
03 - Maintenance Intervals
Introduction
General
Table 146.
Interval (h) Calendar Equivalent
Every 10h Daily
Every 50h Weekly
Every 500h Three months
Every 1,000h Six months
Every 2,000h Yearly
Services should be carried out at either the hourly or

calendar interval, whichever occurs first.
78 - 4 9813/8500-2 78 - 4
78 - After Sales
06 - Pre-start Cold Checks, Service Points and Fluid Levels
06 - Pre-start Cold Checks, Service

Points and Fluid Levels
Technical Data
Table 147. Engine

Description Operation 10 50 100
(1)
500 1000 1500 2000
Coolant Quality and Level - Check
Coolant
(6)
- Change
Oil Level - Check
Oil and Filter
(2, 3)
- Change
Pre-Cleaner - Clean
Air Cleaner Outer Element
(4)
- Change
Air Cleaner Inner Element
(4)
- Change
Fuel Sedimentor - Change
Fuel Sedimentor (Mud) - Drain
Engine Fuel Filter (Dual Filter) - Change
Drive Belt Tension/Condition - Check
All Hoses - Condition - Check
Radiator
(5)
- Clean
Engine Mounting Bolts - Tightness - Check
(1) First 100h Service only, to be completed by your JCB Distributor.
(2) If operating under arduous conditions, change the engine oil and filter every 200h.
(3) The oil service interval will be affected if there is a high sulphur content in the fuel. Refer to fuel system
for more information.
(4) If operating in dusty working environments, clean outer element two times when restriction indicator show
red signal. At third signal replace both inner and outer element.
(5) If operating in dusty working environment, frequent cleaning is required.
(6) Engine coolant change at 4,000h
Table 148. Transmission and Axles and Steering

(1)
500 1000 1500 2000
Transmission Oil Level - Check
Transmission Oil
(2)
- Change
Transmission Filter - Change
Transmission Strainer - Clean
Axle Oil Level (incl. Hubs when applicable) - Check
(Front and rear)
(3, 5)
Axle Oil - front and rear (incl. Hubs when - Change

applicable)
(4, 5)
Tyre Pressures and Condition - Check

Wheel Nut Security - Check
Front Hub Bearings - 2WD (ply) - Check
78 - 5 9813/8500-2 78 - 5
78 - After Sales

(1)
500 1000 1500 2000
Drive Shafts -Security and
grease
Front Axle (2WD), Main Pivot, King Pin, - Grease
Hub Bearing, Steering Rod
(2) After a major transmission repair, the new oil should be run to operating temperature and changed again
to remove any contamination which entered during the repair. Change the oil and filter after a further 100h
(3) Check for leaks every 50h, check level if leaking.
(4) After axle or hub repair, the new oil should be run to operating temperature and changed again to remove
any contamination which entered during the repair. Change the oil again after a further 100h to remove any
bedding-in wear. This is particularly important if new brake plates have been fitted.
(5) Front axle hub only for 4WD machine
Table 149. Hydraulics

(1)
500 1000 1500 2000
Hydraulic Oil Level
(2)
- Check
Hydraulic Oil (tank oil only)
(3)
- Sample, Change
Hydraulic Oil (complete system oil - Change
change)
(3)
Oil Filter - Change

Rams - Chrome Condition - Check
Hydraulic Oil Cooler and Transmis- - Check
sion Oil Cooler
Hydraulic Oil Strainer - Change
Hydraulic Tank Filler Cap (with inte- - Check
gral filter)
(2) Check the hydraulic fluid level with the loader and backhoe in the travel position.
(3) Hydraulic oil in tank: First replacement at 2,000h, Subsequent replacement at every 4,000h. Complete
system oil change (including tank oil): First replacement at 4,000h Subsequent replacement at every 4,000h
Table 150. Electrics

(1)
500 1000 1500 2000
Battery Electrolyte Level - Check
Wiring for Chaffing/Routing - Check
Battery Terminals for Condition and Tight- - Check
ness
Table 151. Bodywork and Cab

(1)
500 1000 1500 2000
All Pins and Bushes - Check and
grease
All Cables -Lubricate
Hydra clamp -Check and ad-
just
Cab Seat - Operation -Check
Boom Lock Engagement -Check
Condition of Paint work -Check
78 - 6 9813/8500-2 78 - 6
78 - After Sales

(1)
500 1000 1500 2000
Stabiliser Legs / Wear Pads -Check/Adjust
Machine Generally -Check and clean
Table 152. Brakes

(1)
500 1000 1500 2000
Brake System Fluid Level - Check
Brake System Fluid -Change
78 - 7 9813/8500-2 78 - 7
78 - After Sales
09 - Functional Tests and Final Inspection
09 - Functional Tests and Final

Inspection
Technical Data
Table 153. Engine

(1)
500 1000 1500 2000
Idle Speed
(2)
- Check/Adjust
Maximum No Load Speed - Check/Adjust
Exhaust System Security - Check
Air Inlet System Security - Check
Throttle System and Control - Check
Cable
(1) First 100h Service Only, to be completed by your JCB Distributor.
(2) Jobs which should only be done by a specialist.
Table 154. Brakes

(1)
500 1000 1500 2000
Foot Brake - Operation - Check
Park Brake - Operation - Check
Table 155. Transmission, Axles and Steering

(1)
500 1000 1500 2000
Forward/Reverse/Speed - Check
Range - Operation
Steer Circuit Pressure
(2)
- Check
Transmission Main Line Pres- - Check
sure
(2)
Transmission Dump Operation - Check

Neutral Start Operation - Check
Clutch Pack Pressures
(2)
- Check
Table 156. Hydraulics

(1)
500 1000 1500 2000
MRV/ Unloader Pressure
(2)
- Check and adjust
Operation All Services
(2)
- Check
Auxiliary Circuit & Pressures
(2)
- Check and adjust
78 - 8 9813/8500-2 78 - 8
78 - After Sales
09 - Functional Tests and Final Inspection
Table 157. Electrics

(1)
500 1000 1500 2000
Starter Motor - Check
Alternator - Output - Check
All Electrical Equipment Op- - Check
eration, (e.g. warning lights,
alarms, horn, wipers etc.)
Operation of Stop Control - Check
Table 158. Bodywork and Cab

(1)
500 1000 1500 2000
Teeth and Side Cutters - Check
Seat/Seat Belts - Check
78 - 9 9813/8500-2 78 - 9
78 - After Sales
81 - Clothing and Personal Protective Equipment (PPE)
Contents Page No.
78-81-00 General ........................................................................................................................... 78-11
78 - 10 9813/8500-2 78 - 10
78 - After Sales
00 - General
00 - General
Introduction
Do not wear loose clothing or jewellery that can get

caught on controls or moving parts. Wear protective
clothing and personal safety equipment issued or
called for by the job conditions, local regulations or
as specified by your employer.
78 - 11 9813/8500-2 78 - 11
78 - After Sales
93 - Special Tools
93 - Special Tools
Contents Page No.
78-93-00 General ........................................................................................................................... 78-13

78-93-03 Parts List ........................................................................................................................ 78-14
78 - 12 9813/8500-2 78 - 12
78 - After Sales
93 - Special Tools
00 - General
00 - General
Introduction
The tools shown are the special tools required for

completing the procedures described in this manual.
These tools are available from JCB Service or in
some instances can be manufactured locally.
The tools are divided into three categories:
• Special Tool = Only available from JCB.

• Recommended Tool = Available from JCB but
other tool manufacturers/suppliers may offer a
tool with the same characteristics.
• General Tool = A tool which is widely available.
Tools other than those listed will be required. It is

expected that such general tools will be available in
any well equipped workshop or be available locally
from any good tool supplier.
Before you start work, make sure that all safety

precautions are observed in accordance with the
information contained within the relevant support
documentation.
78 - 13 9813/8500-2 78 - 13
78 - After Sales
93 - Special Tools
03 - Parts List
03 - Parts List Introduction

Introduction .................................................... 78-14
Tool Category Part No. Description Qty. Comments

Special Tool 993/68100 Slide Hammer Kit 1

Special Tool 892/00842 Glass Lifter 2
Special Tool 892/00843 Folding Stand 1
Special Tool 892/00845 Cartridge Gun 1
Special Tool 892/00846 Glass Extractor 1
(Handles Only)
Special Tool 892/00847 Nylon Spatula 1
Special Tool 892/00848 Wire Starter 1
Special Tool 892/00849 Braided Cutting Wire 1
Special Tool 926/15500 Rubber Spacer Blocks 4
General Tool 992/12300 Mobile Oven (12V) 1
General Tool 992/12400 Static Oven (240V) 1
Special Tool 992/12800 Cut-Out Knife 1
Special Tool 992/12801 'L' Blades 1
24 - Brake System

Special Tool 892/00223 Hand Pump Pressure 1
Test
Special Tool 892/00346 Pressure Gauge (0-70 1
Bar)
Special Tool 992/04800 Flange Spanner 1

Special Tool 892/00279 Pressure Gauge (0-400 1
Bar)
27 - Driveline

Special Tool 445/04700 Shim Kit 1
Special Tool 459/70378 Spacer Kit 1
General Tool 892/00179 Bearing Press 1
Special Tool 892/00229 Flowmeter 1
78 - 14 9813/8500-2 78 - 14
78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool 892/00237 Flow Test Adaptor 1
Assembly
Special Tool 892/00270 Load Valve 1
General Tool 892/00333 Heavy Duty Socket 1
19mm A/F x 3/4 in
Drive
Special Tool 892/00812 Drive Coupling Spanner 1
General Tool 892/00822 Splined Bolt Socket 1
Special Tool 892/00918 Setting Tool Kit 1
Special Tool 892/01077 Selector Shaft Lock 1
Screw
Special Tool 892/01078 Main Shaft Adjuster 1
Special Tool 892/01092 Wheel Hub Service Kit 1
Special Tool 921/M0229 Shim Kit 1
Special Tool 990/00083 End Float Setting Tool 1
General Tool 993/70111 Torque Wrench 1
(10-100Nm)
Special Tool 997/11000 Support Bracket 1
Special Tool 998/11051 Digital Hydraulic 1
Pressure Test Kit
Special Tool 998/M1374 Reaction Plate M14 4
Studs
Special Tool 998/M1375 Reaction Plate 1

Special Tool 892/01255 Hydraulic Flushing Rig 1

General Tool 892/00349 Wiring Crimp Tool 1
General Tool 892/00350 Butane Heater 1

Special Tool 892/00913 Grease Gun 1
Attachment
General Tool 992/11300 Grease Gun 1
78 - 15 9813/8500-2 78 - 15
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 445/04700 - Shim Kit

After using a shim, obtain a replacement to keep the set
complete.
Item Part No. Description Qty.

1 445/04701 Shim 0.05mm thick 1
2 445/04702 Shim 0.1mm thick 1
3 445/04703 Shim 0.2mm thick 1
4 445/04704 Shim 0.5mm thick 1
5 445/04705 Shim 1.0mm thick 1
Special Tool - 459/70378 - Spacer Kit

After using a spacer, obtain a replacement to keep the
set complete.

1 823/10647 Spacer 17.8mm 1
thick
2 823/10648 Spacer 17.85mm 1
thick
3 823/10649 Spacer 17.9mm 1
thick
4 823/10650 Spacer 17.95mm 1
thick
5 823/10651 Spacer 18.0mm 1
thick
6 823/10652 Spacer 18.05mm 1
thick
7 823/10653 Spacer 18.1mm 1
thick
8 823/10654 Spacer 18.15mm 1
thick
9 823/10655 Spacer18.20mm 1
thick
10 823/10656 Spacer 18.25mm 1
thick
11 823/10657 Spacer 18.30mm 1
thick
12 823/10658 Spacer 18.35mm 1
thick
13 823/10659 Spacer 18.40mm 1
thick
14 823/10660 Spacer 18.45mm 1
thick
15 823/10661 Spacer 18.50mm 1
thick
16 823/10662 Spacer 18.55mm 1
thick
17 823/10663 Spacer 18.60mm 1
thick
18 823/10665 Spacer 18.65mm 1
thick
78 - 16 9813/8500-2 78 - 16
78 - After Sales
93 - Special Tools
03 - Parts List

19 823/10666 Spacer 18.70mm 1
thick
20 823/10667 Spacer 18.75mm 1
thick
21 823/10668 Spacer 18.80mm 1
thick
22 823/10669 Spacer 18.85mm 1
thick
23 823/10670 Spacer 18.90mm 1
thick
24 823/10671 Spacer 18.95mm 1
thick
25 823/10672 Spacer 19.00mm 1
thick
26 823/10673 Spacer 19.05mm 1
thick
27 823/10674 Spacer 19.10mm 1
thick
28 823/10675 Spacer 19.15mm 1
thick
29 823/10676 Spacer 19.20mm 1
thick

set complete.

1 823/10679 Spacer 2.20mm 1
thick
2 823/10680 Spacer 2.25mm 1
thick
3 823/10681 Spacer 2.30mm 1
thick
4 823/10682 Spacer 2.35mm 1
thick
5 823/10683 Spacer 2.40mm 1
thick
6 823/10684 Spacer 2.45mm 1
thick
7 823/10685 Spacer 2.50mm 1
thick
8 823/10686 Spacer 2.55mm 1
thick
9 823/10687 Spacer 2.60mm 1
thick
10 823/10688 Spacer 2.65mm 1
thick
11 823/10689 Spacer 2.70mm 1
thick
12 823/10690 Spacer 2.75mm 1
thick
13 823/10691 Spacer 2.80mm 1
thick
78 - 17 9813/8500-2 78 - 17
78 - After Sales
93 - Special Tools
03 - Parts List

14 823/10692 Spacer 2.85mm 1
thick
15 823/10693 Spacer 2.90mm 1
thick
16 823/10694 Spacer 2.95mm 1
thick
17 823/10695 Spacer 3.00mm 1
thick
18 823/10696 Spacer 3.05mm 1
thick
19 823/10697 Spacer 3.10mm 1
thick
20 823/10698 Spacer 3.15mm 1
thick
21 823/10699 Spacer 3.20mm 1
thick
General Tool - 892/00179 - Bearing Press
Special Tool - 892/00223 - Hand Pump Pressure Test
Special Tool - 892/00229 - Flowmeter
78 - 18 9813/8500-2 78 - 18
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00237 - Flow Test Adaptor Assembly

A 892/00304 Flow Test Adaptor 1
B 892/00301 Flow Test Adaptor 1
C 892/00302 Flow Test Adaptor 1
Special Tool - 892/00270 - Load Valve
Special Tool - 892/00279 - Pressure Gauge (0-400 Bar)
General Tool - 892/00333 - Heavy Duty Socket 19mm A/F x 3/4 in Drive
Special Tool - 892/00346 - Pressure Gauge (0-70 Bar)
General Tool - 892/00349 - Wiring Crimp Tool
General Tool - 892/00350 - Butane Heater
78 - 19 9813/8500-2 78 - 19
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00812 - Drive Coupling Spanner

PTO coupling spanner for yoke type couplings.
General Tool - 892/00822 - Splined Bolt Socket
Special Tool - 892/00842 - Glass Lifter

Essential for glass installation, 2 required to handle
large panes of glass. Ensure suction cups are protected
from damage during storage.
Special Tool - 892/00843 - Folding Stand

Essential for preparing new glass prior to installation.
Special Tool - 892/00845 - Cartridge Gun

Hand operated. Essential for the application of
sealants, polyurethane materials etc.
78 - 20 9813/8500-2 78 - 20
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00846 - Glass Extractor (Handles Only)

Used with braided cutting wire to cut out broken glass.
Refer to special tool 892/00849 (Braided Cutting Wire)
Special Tool - 892/00847 - Nylon Spatula

General tool used for smoothing sealants - also used
to re-install glass in rubber glazing because metal tools
will chip the glass edge.
Special Tool - 892/00848 - Wire Starter

Used to access braided cutting wire through original
polyurethane seal.
Refer to special tool 892/00849 (Braided Cutting Wire)
Special Tool - 892/00849 - Braided Cutting Wire

Consumable heavy duty cut-out wire used with the
glass extraction tool. Length: Approximately 25m.
Refer to special tool 892/00846 (Glass Extractor

(Handles Only))
Special Tool - 892/00913 - Grease Gun Attachment
78 - 21 9813/8500-2 78 - 21
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/00918 - Setting Tool Kit

1a 892/01164 Adaptor (PS760 - 1
1 1a 2004)
1b 892/01165 Sleeve (PS760 - 1
2004)
1c 892/01163 Support Bracket 1
(PS760 - 2004)
1b 1d 998/11350 Adaptor 1
1e 998/11351 Sleeve (40 series 1
drivehead - front
1c axles)
1e 998/11352 Sleeve (40 series 1
drivehead - rear
axles)
1d 1e
Special Tool - 892/01077 - Selector Shaft Lock Screw
Special Tool - 892/01078 - Main Shaft Adjuster
78 - 22 9813/8500-2 78 - 22
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 892/01092 - Wheel Hub Service Kit

A 5
1
6
8, 9
7
2 10
3
4
B
13,23 15
19,20
14
C 16
18
17
8
21
A Bearing Puller 1
B Bearing Press 1
C Seal Dolly - 1
comprises:
1 998/M5626 Puller Beam 1
2 998/1067 Clamp Plates 1
3 1315/3731Z Bolt M16 x 220mm 2
4 1370/0601Z Nut M16 2
5 998/10614 Reaction Tube 1
6 998/10624 Modified Wheel 2
Stud
7 1370/0701Z Puller Leg 2
8 1370/0701 Nut M20 4
9 1420/0012Z Washer M20 4
10 998/10610 Rod 2
11 1370/0401Z Nut M12 2
12 1420/0009Z Washer M12 2
13 998/10608 Bearing Centre 1
Puller
78 - 23 9813/8500-2 78 - 23
78 - After Sales
93 - Special Tools
03 - Parts List

14 1315/3414Z Bolt M10 1
15 1370/0301Z Nut M10 1
16 Reaction Tube 1
(same part as item
5)
17 998/10616 Handle Nut 1
18 1315/3833Z Bolt M20 2
19 445/12303 Washer 2
20 917/02800 Bearing 1
21 892/00891 Seal Dolly 1
22 998/10609 Bearing Installation 1
Tube
23 998/M5629 Bearing Centre 1
Puller (87 Series)
Special Tool - 892/01255 - Hydraulic Flushing Rig

set complete.

1 921/52628 Spacer 12.60mm 1
thick
2 921/52629 Spacer 12.65mm 1
thick
3 921/52630 Spacer 12.7mm 1
thick
4 921/52601 Spacer 12.75mm 1
thick
5 921/52602 Spacer 12.80mm 1
thick
6 921/52603 Spacer 12.85mm 1
thick
78 - 24 9813/8500-2 78 - 24
78 - After Sales
93 - Special Tools
03 - Parts List

7 921/52604 Spacer 12.9mm 1
thick
8 921/52605 Spacer 12.95mm 1
thick
9 921/52606 Spacer 13.00mm 1
thick
10 921/52607 Spacer 13.05mm 1
thick
11 921/52608 Spacer 13.10mm 1
thick
12 921/52609 Spacer 13.15mm 1
thick
13 921/52610 Spacer 13.20mm 1
thick
14 921/52611 Spacer 13.25mm 1
thick
15 921/52612 Spacer 13.30mm 1
thick
16 921/52613 Spacer 13.35mm 1
thick
17 921/52614 Spacer 13.40mm 1
thick
18 921/52615 Spacer 13.45mm 1
thick
19 921/52616 Spacer 13.50mm 1
thick
20 921/52617 Spacer 13.55mm 1
thick
21 921/52618 Spacer 13.60mm 1
thick
22 921/52619 Spacer 13.65mm 1
thick
23 921/52620 Spacer 13.70mm 1
thick
24 921/52621 Spacer 13.75mm 1
thick
25 921/52622 Spacer 13.80mm 1
thick
26 921/52623 Spacer 13.85mm 1
thick
27 921/52624 Spacer 13.90mm 1
thick
28 921/52625 Spacer 13.95mm 1
thick
29 921/52626 Spacer 14.00mm 1
thick
30 921/52627 Spacer 14.20mm 1
thick
78 - 25 9813/8500-2 78 - 25
78 - After Sales
93 - Special Tools
03 - Parts List

set complete.

1 921/53322 Spacer 13.55mm 1
thick
2 921/53323 Spacer 13.575mm 1
thick
3 921/53324 Spacer 13.6mm 1
thick
4 921/53325 Spacer 13.625mm 1
thick
5 921/53301 Spacer 13.65mm 1
thick
6 921/53302 Spacer 13.675mm 1
thick
7 921/53303 Spacer 13.7mm 1
thick
8 921/53304 Spacer 13.725mm 1
thick
9 921/53305 Spacer 13.75mm 1
thick
10 921/53306 Spacer 13.775mm 1
thick
11 921/53307 Spacer 13.80mm 1
thick
12 921/53308 Spacer 13.825mm 1
thick
13 921/53309 Spacer 13.850mm 1
thick
14 921/53310 Spacer 13.875mm 1
thick
15 921/53311 Spacer 13.90mm 1
thick
16 921/53312 Spacer 13.925mm 1
thick
17 921/53313 Spacer 13.950mm 1
thick
18 921/53314 Spacer 13.975mm 1
thick
19 921/53315 Spacer 14.00mm 1
thick
20 921/53316 Spacer 14.025mm 1
thick
78 - 26 9813/8500-2 78 - 26
78 - After Sales
93 - Special Tools
03 - Parts List

21 921/53317 Spacer 14.050mm 1
thick
22 921/53318 Spacer 14.075mm 1
thick
23 921/53319 Spacer 14.10mm 1
thick
24 921/53320 Spacer 14.125mm 1
thick
25 921/53321 Spacer 14.150mm 1
thick
Special Tool - 921/M0229 - Shim Kit

After using a shim, obtain a replacement to keep the set
complete.

1 921/M0230 Shim 0.15mm thick 1
2 921/M0231 Shim 0.2mm thick 1
3 921/M0232 Shim 0.25mm thick 1
Special Tool - 926/15500 - Rubber Spacer Blocks

Used to provide the correct set clearance between
glass edge and cab frame. Unit quantity: 500 off.
Special Tool - 990/00083 - End Float Setting Tool
78 - 27 9813/8500-2 78 - 27
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 992/04800 - Flange Spanner
General Tool - 992/11300 - Grease Gun
General Tool - 992/12300 - Mobile Oven (12V)

Required to pre-heat adhesive prior to use. It is fitted
with a male plug (703/23201) which fits into a female
socket (715/04300). Cartridge capacity: 1.
General Tool - 992/12400 - Static Oven (240V)

Required to pre-heat adhesive prior to use. No plug
supplied. Cartridge capacity: 2.
Special Tool - 992/12800 - Cut-Out Knife

Used to remove broken glass.
Refer to special tool 992/12801 ('L' Blades)
78 - 28 9813/8500-2 78 - 28
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 992/12801 - 'L' Blades

Refer to special tool 992/12800 (Cut-Out Knife)
25 mm (1 in.) cut. Replacement blades for cut-out knife.

Unit quantity = 5 off.
Special Tool - 993/68100 - Slide Hammer Kit

1 993/68101 Slide hammer 1
2 993/68102 End Stops 3
3 993/68103 Adaptor (M20 x 5/8" 1
UNF)
4 993/68104 Adaptor (M20 x 1" 1
UNF)
5 993/68105 Adaptor (M20 x 1
M20)
6 993/68106 Adaptor (M20 x 1
M24)
7 993/68107 Bar (M20 x M20 X 1
800mm)
8 993/68108 Adaptor (M20 x 7/8" 1
UNF)
9 993/68109 Adaptor (M20 x 1
M12)
10 993/68110 Adaptor (M20 x 5/8" 1
UNF - Shoulder)
11 993/68111 Adaptor (M20 x 1/2" 1
UNF)
General Tool - 993/70111 - Torque Wrench (10-100Nm)
78 - 29 9813/8500-2 78 - 29
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 997/11000 - Support Bracket
Special Tool - 998/11051 - Digital Hydraulic Pressure Test Kit

1 998/11052 Hand Held 1
4-Channel
ServiceMaster Unit
2 998/11053 SensoWin Software 1
Kit and PC Cable
3 998/11054 Equipment Case 1
4 998/11055 0-600 Bar Pressure 2
Transducer
5 998/11056 0-100 Bar 2
PressureTransducer
6 998/11057 RPM Tachometer 1
(includes fixed
cable, 2 metres)
7 998/11058 5 Metre Connecting 1
Cable
8 998/11059 M16 Metric 4
Adaptors for Test
Points
9 998/11060 400mm Test Hose 2
90° HSP to M16
10 998/11061 400mm Test Hose 2
Straight HSP to M16
Special Tool - 998/M1374 - Reaction Plate M14 Studs
78 - 30 9813/8500-2 78 - 30
78 - After Sales
93 - Special Tools
03 - Parts List
Special Tool - 998/M1375 - Reaction Plate
78 - 31 9813/8500-2 78 - 31
78 - After Sales
96 - Units of Measurement
Contents Page No.
78-96-00 General ........................................................................................................................... 78-33
78 - 32 9813/8500-2 78 - 32
78 - After Sales
00 - General
00 - General Table 164. Flow

Measurement Convert to Multiply by
Technical Data (unit)
Litre/Minute (L/ UK Gal- 0.220
m) lon/Minute
The standard units of measurement used by JCB are US Gal- 0.264
listed below together with the formula for conversion lon/Minute
for countries using non metric standards.
Table 165. Area
Standard Units Measurement Convert to Multiply by
(unit)
Table 159. Force Square Millime- Square Inch 0.0015
Measurement Convert to Multiply by tre (mm²) (in²)
(unit) Square Metre Square Foot 10.764
Newton (N) Kilogram force 0.102 (m²) (ft²)
(kgf) Square Yard 1.196
Pound force 0.225 (yd²)
(lbf)
Table 166. Torque
Table 160. Length Measurement Convert to Multiply by
(unit)
(unit) Newton metre Pound force 0.7376
(Nm) foot (lb f ft)
Millimetre (mm) Inch (in) 0.0394
Metre (m) Feet (ft) 3.281 Table 167. Pressure
Yard (yd) 1.094 Measurement Convert to Multiply by
Kilometre (km) Mile (mile) 0.621 (unit)
Bar Pound force/ 14.5
Table 161. Mass inch² (psi)
Measurement Convert to Multiply by Table 168. Fuel Consumption
(unit)
Gram (g) Ounce (oz) 0.035
(unit)
Kilogram (kg) Pound (lb) 2.205
Kilometre/Litre Miles/Gallon 2.825
Tonne Ton 0.984 (km/l) (mpg)
Miles/ US Gal- 2.352
Table 162. Speed lon
Measurement Convert to Multiply by Table 169. Temperature
(unit)
Kilometre/Hour mile/hour (mph) 0.621 Measurement Convert to Formula
(km/h) (unit)
Metre/Second feet/second (ft/ 3.281 Degrees Cel- Degrees Multiply by 9,
(m/s) s) sius (°C) Fahrenheit (°F) Divide by 5,
Add 32
Table 163. Volume Table 170. Power
Measurement Convert to Multiply by Measurement Convert to Multiply by
(unit) (unit)
Cubic Centime- Cubic Inch (in³) 0.061 KiloWatt (kW) Horsepower 1.341
tre (cm³) (hp)
Cubic Metre Cubic Foot (ft³) 35.315
(m³) Table 171. Time
Cubic Yard (yd³) 1.308
Millilitre (ml) Fluid ounce (fl 0.035 Measurement (unit)
oz) Second (s)
Litre (l) UK Gallon 0.220 Minute (min)
US Gallon 0.264 Hour (h)
78 - 33 9813/8500-2 78 - 33
78 - After Sales
00 - General
Table 172. Current

Measurement (unit)
Ampere (A)
Table 173. Voltage

Measurement (unit)
Volt (V)
Table 174. Noise Levels

Measurement (unit)
Sound pressure level (LpA)
Sound power level (LwA)
78 - 34 9813/8500-2 78 - 34

Service Manual: Foreword

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Foreword

The Operator's Manual

You and others can be killed or seriously injured

SERVICE MANUAL Do not operate the machine without an Operator's

Treat the Operator's Manual as part of the machine.

This manual contains original instructions, verified by

Copyright 2017 © JCB SERVICE

SERVICE MANUAL SERVICE MANUAL

SERVICE MANUAL SERVICE MANUAL

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

03 - Safety - Yours and Others

All machinery can be hazardous. When a machine

In this manual and on the machine you will find

Safety is not just a matter of responding to the

If you are not sure of anything, about the machine or

In this manual and on the machine, there are safety

The signal word 'DANGER' indicates a hazardous

The signal word 'WARNING' indicates a hazardous

The signal word 'CAUTION' indicates a hazardous

The signal word 'Notice' indicates a hazardous

The safety alert system (shown) also helps to identify

Figure 1. The safety alert system

09 - General Safety Lifting Equipment

12 - Maintenance Safety Hydraulic Pressure

Working Under the Machine

18 - Operating Safety Worksites

Electrical Power Cables Hands and Feet

21 - Worksite Safety An applicable worksite organisation is required in

24 - Risk Assessment Loading/Unloading Area

27 - Maintenance Positions Introduction

Lift Arm Lowered

Installing the Lift Arm Safety Strut 3. Release the strut.

A Fastener- unlock position B Fastener- lock position

Health and Safety

06 - About this Manual

Contents Page No.

01-06-03 Model and Serial Number .............................................................................................. 01-17

03 - Model and Serial Number

Contents Page No.

01-09-12 Main Component Locations ........................................................................................... 01-19

12 - Main Component Locations

A Loader arm B Canopy

Your machine might have a cab instead of canopy

15 - Service Point Locations

A Air filter assembly B Engine fuel filter

A Fuel filler point

A Hydraulic level indicator

Contents Page No.

01-33-00 General ........................................................................................................................... 01-23

Clean the product with water and/or steam. Do not

Before you do any service procedures that require

• The cleaning must be done either in the area

When you remove components, be aware of

Always obey the local regulations regarding the

Pressure Washing and Steam Cleaning

Notice: The engine and other components could Preparation

Use a pressure washer to remove soft dirt and oil.

The product must always be greased (if appropriate)